a727 a904 Transmission Manual

8/18/2019 a727 a904 Transmission Manual

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2/80

TORQU FLIGHT

A 727 A 904

We t bank

?heChrys ler Corp oration for the illustrations that have

made this imoklet possible. This booklet contains the general

description o f the lock up converter. A special tool section is

included.

The

teardown and assembly is fully covered. In car

service prom dures are outlined.

D LE ENGL ND

FIELD SERVICE CONSULT NT

W YNE COLONN

TECHNIC L SUPERVISOR

PETE

LUBlN

TECHNIC L CONSULT NT

A L TOiWTIC TRANSMISSION SERVICE GROUP

18639

S\rV

107

AVENUE

MIAMI, FLORIDA 33157

305) 670-4161


3/80

IN EX

PAGE

I N T R O D U C T I O N

3

D I A G N O S I S AN D T E S T S

9

A D J U S T M E N T S

20

S E R V I CE I N V E H I C L E 2 3

V A L V E B ODY

28

S E R V I C E O U T O F T H E V E H I C L E 33

S P E C I F I C A T I O N S

58

T E C H N I C A L S E R V I C E I N F O R M A T I O N

60

TQPQUE CONV E RT E R I N F O RM A T I ON

6 7

UTOM TIC

TR NSMISSION SERVICE GROUP


4/80

m

ITSG]

~ e c h n i c a l e r v i c e In fo rmat io

GENERAL IrVF09v:'-̂

- 9

Safety goggies

sh=

= .P

rz 2: zl?

i'mes when

working on tra-s-

ss z-r-

- .

he ident; '"

= .

- -

-

:

- - - - .

- . - - . -

3 Load-

. .

.

-. .. - - - - -

-

.

- -

. - -

l it e T r a n s ~ i s s , ; : : ~ : I : :: .-

:n-

ver te r lock-up .

Lock-up and non lock-up to rque conver te r . ; and

t r an s m i s s i o n s a r e not i n t e r m i x ab l e .

H Y D R A U L I C C O N T R O L S Y S T E M .

T h e h y d r au l i c co n t r o l c i r cu i t s d i ag r n m s s h o w the

posi t ion of the var ious valves wi th color coded pas-

s ag es t o i n d i ca t e t h o s e u n d e r h y d r au l i c p r e s s u r e f o r

a l l opera t ions o f the t r ansmis s ion .

T h e h y d r au l i c co n t r o l s y s t em m ak es

t h e

t r ansmis -

s i o n f u ll y au t o m a t i c , an d h a s f o u r i m p o r t an t f un c ti on s

t o p e r f o r m . I n a g en e r a l w ay , t h e co m p o n en t s of a n y

a u t o m a t i c tr a n s m i s s i o n c o n t r o l s y s t e m m a y be

group ed in to th e fo l lowing bas ic g roups :

T h e p r e s s u r e s u p p l y s y s t em . t h e p r e s s u r e r eg u la t-

ing va lves , the f low cont ro l va lves. th e c lu tches , and

band servos .

Tak ing ea ch of these bas ic g ro ups or sys tems in

t u r n . t h e co n t r o l s y s t em

may

be describe d a s follows:

AUTOMATIC TRANSMISSION SERVICE GROUP

3


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echnical S e r v i c e n f o r m a t i o n

L L T O M A T I C T R A N S W S S I O N S ER VIC E GROUP


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Technical Service nformat ion

UT O M T I C T R NS M I S S I ON S E RV ICE GROUP


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10/80

T e c h n i c a l S e rv i c e nformat ion

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 require

heavy throttle for 1/2 mile or more. This reduces

possibility of overheating the transmission a nd torque

converter under these conditions.

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 i n N (ncut.ra1)wi1.h rear whccls on

t h e

ground at

~

specd not to cxcced

30

mph

48 k n i / h ) .

If

the vehicle

s

to be towed for extended distances, it

should be done with

a

rear end pickup or the

propeller shaft removed. Because the transmission

receives lubrication only when the engine is running,

it is good practice to always tow

a

disabled vehicle

with

a rear end

pickup or remove the propeller shaft.

DIAGNOSIS AND TESTS

DIAGNOSIS GENERAL

Automatic transmission malfunctions may be

caused by four general conditions: poor engine per-

formance, improper adjustments, hydraulic malfunc-

tions, and mechanical malfunctions. Diagnosis of

these problems should always begin by checking the

easily accessible variables: fluid level and condition,

manual linkage adjustment, and throttle linkage ad-

justment. Then perform a road test to determine

whether th e problem has been corrected or tha t more

diagnosis

s

necessary.

f

the problem exists after the

preliminary tests and corrections are completed,

hydraulic pressure tests should be performed.

Fluid Level and ondition

If a failure of any kind has contaminated the

transmission fluid, the oil cooler and cooler tubes

must be rever se flushed (see Oil Cooler an d Cooler

Tubes Flushing. )

Before removing th e dipstick, wipe al l dir t off of th e

protective cap and top of th e filler tube.

Since the torque converter fills more slowly in the

P Pa rk position, place the selector lever in N

Neutral to be sure that the fluid level check is

accurate. The vehicle must be on level ground. The

.engine should be runn ing a t idle speed. Th e fluid

should be a t normal operating tempe ratu re (approxi-

mately

175

F). The fluid level is correct if it is

between the Full and Add mar ks on th e dipstick.

Low fluid level can cause

a

variety of conditions

because it allows the pump to take in air along with

the fluid.

As

in any hydraulic system, air bubbles

make th e fluid spongy, ther efor e, pressures will be

low and build up slowly.

Improper filling can also raise the fluid level too

high. When the transmission has too much fluid, the

gears churn up foam and cause the same conditions

which occur with a low fluid level.

In ei ther case, the ai r bubbles can cause overheat-

ing, fluid oxidation, and varnishing, which can inter-

fere with normal valve, clutch, and servo operation.

Foaming can also result in fluid escaping from the

transmission vent where it may be mistaken for a

leak.

Along with fluid level, it is important to check the

condition of the fluid. When the fluid smells burned,

and is contaminated with metal or friction material

particles, a complete transmission overhaul is needed

and because the t orque converter canno t.be flushed, it

should be replaced. Be sure to examine the fluid on

the dipstick closely. If there is any doubt about its

condition, drain out a sample for a double check.

After the fluid has been checked, seat the dipstick

fully to seal out water an d dirt.

OIL COOLERS AND TUBES.FLUSHING

When a transmission or lock-up clutch failure has

contaminate d the fluid, th e oil cooler(s) should be

reverse flushed to insure that metal particles or

sludged oil are not later transferred back into the

reconditioned transmission.

1)

Disconnect both cooler lines a t radiat or.

(2) Dislodge a ny foreign ma teri al a t the inlet side of

the cooler with a small screwdriver.

3)

Reverse flush the cooler with a combination of

mineral spirits and pulsating air und er pressure (shop

air).

4)

Tre at the cooler lines separately and insure they

are clear by flowing mineral spirits or automatic

transmission fluid throu gh th em.

5 )

Remove leftover mineral s piri ts from cooler and

cooler lines by flowing automatic transmission fluid

through them.

6 ) Cooler flow should now be checked by connect-


11/80

T e c h n i c a l S e r v i ce l n f o r m a t i o n

ELEMENTS

IN USE AT EACH POSITION OF THE SELECTOR LEVER

Clutches Bands

Lever Standard Wide Start Parking

Position Ratio Ratio Safety Sprag

. .

I

I I

R-REVERSE 2.21 2.21

N-NEUTRAL

D-DRIVE

First

2.45

2.74

Test Ona Selector in

Irr)

(1)

Attach gauges to line and rear servo ports.

(2) Operate engine a t 1000 rpm for tests.

(3) Move selector lever on transmission al l t he way

forward ( 1 position).

(4) Read pressures on both gauges as throttle lever

on transmission is moved from full forward position to

full rea rward position.

(5) Line pressure should read 54 to 60 psi (372 to

414 kPa) with throttle lever forward and gradually

increase, as lever is moved rearward, to 90 to 96 psi

(621 to

662

kPa).

(6) Rear servo pressure should read the sa me as line

pressure within 3 psi.

7) This tests pump output, pressure regulation, and

condition of rear clutch and rea r servo hydraulic

circuits.

P-PARK l X l X

I

Front

Second 1.45 1.54

Direct

1 OO 1 OO

2-SECOND

First

2.45

2.74

Second 1.45 1.54

1-LOW First) 2.45 2.74

Tort Two Solactor in ff2pr)

1)

Attach gauge to line pressure port and

tee

into rear cooler line fitting to read lubrication

1 x 1

X

APPLY PORT FRONT SERVO RELEASE PORT RHW)

X

X

pressure.

(2) Operate engine a t 1000 rpm for test.

3)

Move the selector lever on transmissio

detent rearward from full forward position.

T

selector 2 position.

(4) Read pressures on both gauges as throttle

on transmission is moved from full forward p o s

full rearward position.

(5) Line pressure should read 54 to 60 psi

414 kPa) with throttle lever forward and gra

increase, as lever

is

moved rearward, to 90

to

(621

to

662 kPa).

(6) Lubrication pressure should be 5 to 15

psi

103 kPa) with lever forward and 10 to 30 psi (68

kPa) with lever rearward.

(7) This tests pump output, pressure regulatio

condition of rear clutch and lubrication hyd

circuits.

Kickdown) (LowW

Front

Re

Rear

X

Test Three Selector in dfD l

1) Attach gauges

to

line and front sem

X

X

X

X

X

X

lease ports.

(2) Opera te engine a t 1600'rpm for test.

3)

Move the selector lever on transmission

detents rearward from full forward position. T

selector D osition.

Over-

running

LUBRICATION

PRESSURE PORT

COOLER RETURN GOVERNOR

FITTING) PRESSURE PORT REAR S

Lock-up

X

Fig. l Pressure Test Locations .

Fig. 2 Pressure Test Locations

UTOM TIC TR NSMISSION

SERVI E GROUP

10

X

X

X

X


12/80

Techn ica l Serv ice l nforrnat ion

4) Read pressures on both gauges as throttle lever

ssion is moved from full forward position to

earward position.

5 )

Line pressure should read 54 to 60 psi (372 to

kPa) with throttle lever forward and gradually

as lever is moved rearward.

(6)

Front servo release is pressurized only in direct

d should be same

as

line pressure within 3 psi

kPa), up

to

downshift point.

(7) This tests pump output, pressure regulation, and

circuits.

Four Sekc tor in Reverse)

1)

Attach

300

psi gauge to rear servo apply port.

(2) Operate engine at 1600 rpm for test.

(3) Move the selector lever on transmission four

rearward from full forward position. This is

R

position.

(4)

Rear servo pressure should read

145

to

175

psi

psi as throttle lever is moved rearward.

(5)

This tests pump output, pressure regulation, and

circuits.

(6)Move selector lever on transmission to D osi-

tion to check t ha t rear servo pressure drops to zero.

(7) This tests for leakage into rear servo, due

to

case

porosity, which can cause reverse band burn out.

Test Result Indications

1) If proper line pressure, minimum to maximum,

is found in any one test, the pump and pressure

regulator are working properly.

(2) ow pressure in

D,

1 and 2 . but correct pres-

sure in R ndicates rear clutch circuit leakage.

3) Low pressure in

D

nd

R

but correct pressure

in 1 indicates front clutch circuit leakage.

4) Low pressure in R and 1 but correct pressure

in 2 indicates rear servo circuit leakage.

(5) Low line pressure in all positions indicates a

defective pump, a clogged transmission oil filter, or a

stuck pressure regulator valve.

Governor Pressure

Test only if transmission shifts at wrong vehicle

speeds when throt tle rod

is

correctly adjusted.

(1)

Connect a 0-100 psi pressure gauge, to governor

AUTOMATIC SHIFT SPEEDS AND GOVERNOR PRESSURE CHART

APPROXIMATE MILES PER HOUR AT ROAD LOAD)

kmlh = kilometers per

hour)

1.5

psi at sfandstill or downshift may not occur.

Figures given are typical for the axle ratio and tire size combination. Changes in tire size or axle ratio will

C.I.D.)

.

. . . .

.

.

.

. . .

Upshift

.

Upshift .

Upshift

. .

Upshift

Downshift

Downshift

5 psi

. . . .

psi . .

5 psi

150

3.2 1

P195/75R15

rnph km/h

8-10 13-16

11-14 18-23

8-10 13-16

29-36 46-57

55-61 89-98

50-57 80-92

25-27 40-43

16-18 26-29

36-41 58-66

54-59 87-95

5

250

3.54

P235/75R15XL

mph km/h

8-10 13-16

11-14 18-23

8-10 13-16

29-36 46-57

55-61 89-98

50-57 80-92

25-27 40-43

16-18 26-29

36-41 58-66

54-59 87-95

150

2.71

P195/75R15

rnph km/h

10-12 16-19

13-17 21-27

10-12 16-19

34-42 55-68

65-73 105-118

60-68 97-109

30-32 48-52

19-21 31-34

43-49 69-79

64-70 103-113

3181360

250

3.2

1

P235/75R15XL

rnph km/h

9-11 14-19

12-16 19-26

9-11 14-19

36-43 58-69

63-70 101-113

58-65 93-101

27-35 43-56

17-20 27-32

43-49 69-79

62-68 100-110

150

2.94

P195/75R15

mph krn/h

9-11 14-19

12-15 19-24

9-11 14-19

31-39 50-63

60-67 97-108

55-63 89-101

28-30 45-48

17-19 27-31

40-45 64-72

59-65 95-105

350

3.54

8.75x16.5-E

rnph krn/h

8-11 13-18

12-16 19-26

8-11 13-18

34-41 55-66

60-67 97-108

55-62 89-100

26-33 42-53

16-19 26-31

41-47 66-76

59-65 95-105


13/80

T e c h n i c a l S e r v ic e I n f o r m a t i o n

pressure take-off point, located at lower left side of

extension near the mounting flange (Fig.

2).

2) Operate transmission in third gear to read pres-

sures and compare speeds shown in chart.

If governor pressures are incorrect at the given

vehicle speeds, the governor valve and/or weights are

probably sticking. The governor pressure should re-

spond smoothly to changes in mph and should return

to 0 to 1-1/2 psi (10kPa) when vehicle is stopped. High

pressure (above 2 psi) when vehicle is stopped will

prevent the transmission from downshifting.

Throttle Pressure

No gauge port is provided for throttle pressure.

Incorrect throttle pressure should only be suspected if

part throttle upshift speeds are either delayed or

occur too early in relation to vehicle speeds. Engine

runaway on either upshifts or downshifts can also be

an indicator of incorrect (low) thrott le pressure

setting.

In no case should throttle pressure be adjusted until

the transmission throttle linkage adjustment has been

verified to be correct.

TORQU E CONVERTER ST LL TEST

WARNING: DO NOT LET ANYONE STAND IN FRONT

OF VEHICLE D URING TEST

The stal l tes t consists of determining t he engine

speed obtained a t full throt tle in D position only. This

test checks the torque converter stator clutch oper-

ation, and th e holding ability of th e transmission

clutches. The transmission oil level should be checked

and t he engine brought to normal operating tempera-

ture before stall operation. Both the parking and

service brakes must be fully applied and front

wheels blocked while making this test

Do not hold the throttle open any longer than is

necessary to obtain a maximum engine speed reading,

and never longer than five seconds at a- time.If more

tha n one stall check is required, operate the engine at

approximately

1,000

rpm in neutral for 20 seconds to

cool the transmission fluid between runs. If engine

speed exceeds th e maximum limits shown, release the

accelerator immediately since transmission clutch

slippage is indicated.

Stall Speed Above Specification

If sta ll speed exceeds the maximum spec :'-:

chart by more than 200 rpm, transmission

slippage is indicated. Follow the transmission c?i:

sure and air pressure checks outlined in this

sec:

determine the cause of slippage.

Stall Speed Below Specification

Low stall speeds, with a properly tuned e

indicate torque converter stator clutch probler

road test will be necessary to identify the

problem.

If stall speeds are 250-350 rpm below s p e c i 5

and the vehicle operates properly at highway

s

but has poor through-gear acceleration, the x

overrunning clutch is slipping (lock-up and nor

up torque converters).

If stall speed and acceleration are norm<

abnormally high throttle opening is required to

r

tain highway speeds, the sta tor clutch has sei&

lock-up torque converter only).

Both of these stator defects require replaceme

the torque converter.

Noise

whining or siren-like noise due to fluid f

normal during stall operation with some torque

verters; however, loud metallic noises from loose

or interference within the 'assembly indicate a

:

tive torque converter. To confirm that the noise

nates within the torque converter, operate the

YE

at light throttle in D nd "N" on a hoist and 1

under the transmission bell housing.

CLUTCH ND SERVO IR PRESSURE TESTS

A

NO DRIVE" condition might exist ever_

correct fluid pressure, because of inoperative clc

or bands. The inoperative units, clutches, bands

servos can be located through a series of te? :

substituting air pressure for fluid pressure (Fig.

The front and rear clutches, kickdown senc

low-reverse servo may be tested by applying

air

sure to their respective passages after the valve

assembly has been removed. To make air pre

tests, proceed as follows:

LOADFLITE TRANSMISSION STALL

SPEED

CHART

A U TOMA TI C TR A N S MI S S I ON S E R V IC E

GROUP

Torque Engine

Engine Carburetor

Converter

Stall Speed

C I D BBLS

Diameter

rPm

1800-2100

1700-2000

1700-2000

10 -3 /4 inch

10 -3 /4 inch

10 -3 /4 inch

25

3 1 8

360

1

2


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T e c h n i c a l Se r v i c e

n fo rmat ion

F L U I D L E A K A G E T R A N S M I S S I O N T O R Q U E

C O N V ER T ER H O U S I N G A R E A

(1)

Check for Source of Leakage.

Since fluid leakage a t or around the torque con-

verter area may originate from an engine oil leak, the

area should be examined closely. Factory

f i l l

fluid is

dyed red and, therefore, can be distinguished fro::]

engine oil.

2)

Prior to removing the transmission, perform the

following checks:

When leakage is determined to originate from the

transmission, check fluid level prior to removal of the

transmission and torque converter.

High oil level can result in oil leakage out t he vent

located a t the top of th e front pump housing. If the

fluid level is high, adjust to proper level.

After performing this operation, inspect for leak-

age. If a leak persists, perform the following operation

on the vehicle to determine whether

it

is the torque

converter or transmission that is leaking.

Compressed-air supply must be free of all

dirt

or

Leakage Test Probe

moisture. Use

a

pressure

of 30

psi.

1)

Remove torque converter housing dust shield.

(2) Position vehicle with front lower than back so

Front Clutch

that accumulated fluid in torque converter housing

Apply air pressure to front clutch apply passage

will drain out. Wipe inside of torque converter hous-

ing as dry as possible. solvent spray followed by

and listen for a dull thud which indicates th at front

air drying is

recommended.

clutch is operating. Hold air pressure on for a few

seconds and inspect system for excessive oil leaks.

3)

Fabricate a nd fasten test probe (Fig.

4

securely

to convenient dust shield bolt hole. Make certain

Rear Clutch

Apply ai r pressure to re ar clutch apply passage

and listen for a dull thud which indicates th a t rea r

clutch is operating. Also inspect for excessive oil

leaks. If a dull thud cannot be heard in the clutches,

place finger tips on clutch housing and again apply ai r

pressure. Movement of piston can be felt as th e clutch

is applied.

torque converter is cleared by test probe.

ool

must be

clean and dry.

(4) Run engine a t approximately 2,500 rpm with

transmission in neutral, for about 2 minutes. Trans-

mission must

be

a t operating temperature.

(5)

Stop engine and carefully remove tool.

(6)

If upper surface of test probe

is

dry, there is no

torque converter leak. A path of-fluid across probe

indicates a torque converter leak. Oil leaking under

Kickdown Servo Front)

the probe is coming from the transmission pump

Direct ai r pressure into front servo apply passage.

Operation of servo is indicated by a tighten ing of front

band. Spring tension on servo piston should release

the band.

Low Reverse Servo Rear)

Direct ai r pressure into rea r servo apply passage.

Operation of servo is indicated by a tightening of rear

band. Spr ing tension on servo piston should release

the band.

If clutches and servos operate properly, no upshift

DUST

CONVERTER HOUSING

or erratic shift conditions indicate that malfunctions

SHIELD MATERIAL: 5-112'' X 1-112 X

exist in the valve body.

BOLT

1 /3 2 SHEET METAL PY300

m

Fig

4 Leak Locating Test Probe Tool

UTO M TIC TR NSM ISSION SERVICE GROUP

3


15/80


16/80

Techn ica l

S e r v i c e

I n fo rmat ion

-

I

..

WELD

OR

BRAZE

4-21/32 RADIUS

l+-Y-

5 RADIUS

. - -

i

MATERIAL: 3/16 STEEL STOCK PY307

Fig. 10-A-727 Vent Plug Retainer

The transmission should be prepared for pressure

test a s follows after removal of the torque converter:

1)

Install filler tube bore plug, propeller shaft yoke

tie in with cord or wire), flared tube fitting cap on

front cooler line fitting), and a short piece of tubing,

flared at one end, on the rear cooler line fitting Figs.

12 and 13).

2) Remove necessary front pump housing bolts.

Install vent plug rubber stopper), and vent plug

retainer preferably using longer bolts than those

removed.

3) With rotary motion. install torque converter

13/32 DRILL 2 HOLES

WELD

OR

3-314

RADIUS

rn

MATERIAL /16 STEEL STOCK PY30B

Fig. I-A-904T and A-999 Vent Plug Retainer

Fig. 12-Transmission Prepared for Test

hub seal cup over input shaft, and through the torque

converter hub seal until the cup bottoms against the

pump gear lugs. Secure with cup retainer st rap Fig.

9 ,

using torque converter housing to engine block

retain ing bolts.

4)

Attach and clamp hose from nozzle of Tool

C4080 to tubing which is on the rear cooler line

fitting Fig. 13).

5)

Pressurize the transmission using Tool C-4080

until the pressure gauge reads 8 psi. Position trans-

mission so that pump housing and case front may be

covered with soapy solution or water. Leaks are some-

times caused by porosity in the case or pump housing.

CAUTION

Do not under any circumstances

pres-

surize a transmission to more than

10

psi.

If a leak source is located, th at par t and all associ-

ated seals and gaskets should be replaced with new

parts.

FLA R ED

T U E

ON

COOLER LINE Fl'ITlNG RY2 54

Fig. 13-Pressurizing Transmission


17/80

T e c h n i c a l

S e r v i c e

I n fo rmat ion

INSPECT AND CORRECT THE TRANSMISSION

FLUID LEVEL, ROAD TEST TO VERIFY THAT

A N AB NO RM AL N OISE EXISTS, IDENTIFY

THE TYPE OF NOISE, DRIVING RANGES, AND

CONDITIONS WHEN THE NOISE OCCURS.

GEAR NOISE

R GRINDING BUZZ NOISE SCRAPE N O l U

TRANSMISSION AND

CONVERTER ASSEMBLY

DISASSEMBLE. CLEAN AND

INSPECT ALL PARTS: CLEAN

THE VALVE BODY INSTALL

ALL NEW SEALS. RINGS.

A N D GASKETS; REPLACE

WORN OR

LISTEN TO TRANSMISSION

A N D

CONVERTER FOR SOURCE

OF NOISE.

REMOVE T O

CONVERTER AND

FOR LOOSE OR CR

CONVERTER DRIVE_

INSPECT FOR CON

THE STARTER DRIVE

THE STARTING RING

AUTOMATIC TRANSMjSSION SERVICE GROUP

TRANSMISSION MAS

BUZZ OR

WMIN

REMOVE THE

CONVERTER HAS

BUZZ OR WH

L-

N O D E IR IS

PRlSLNT

REMOVE VALVE BODY,

REPLACE TORQUE

CONVERTER

J

TRANSMISSION PAN;

INSPECT FOR DEBRIS

INDICATING WORN OR

FAILED PARTS.

DEBRIS PR S W

REMOVE TR ANS M

AND CONVERTER AS

DISASSEMBLE. CLEAN AN D

INSPECT PARTS.

REASSEMBLE, INSTALL,

CHKK OPERATION AND

PRESSURES

ASSEMBLY: DISASSE

CLEAN A ND INSPEf

PARTS. CLEAN THE

BODY INSTALL l l

SEALS. RINGS A h

GASKETS: REPLACE

OR DEFECTIVE PA


18/80

Technica l S e r v i c e i n format ion

NO

ABNORMAL NOISE

MOVE THE SELECTOR TO A FORWARD

DRIVE RANGE AND OBSERVE THE

PROPELLER SHAFT FOR TURNING.

DO NOT TURN, INSPECT

FOR BROKEN REAR

PROPELLER SHAFT DOES

NO T TURN.

REMOVE THE

TRANSMlSSlON OIL PAN.

I

ABNORMAL NOISE.

STOP ENGINE IMMEDIATELY.

REMOVE TRANSMISSION

AND CONVERTER AS AN ASSEMBLY;

DISASSEMBLE, CLEAN AND INSPECT

ARTS; CLEAN THE VALVE BODY. INSTAL

ALL

NEW

SEALS, RINGS, AND GASKETS;

REPLACE WORN OR DEFECTIVE PARTS.

DIAGNOSIS GUIDE

NO DEBRIS

REMOVE VALVE BODY.

DISASSEMBLE CLEAN AND

INSPECT ALL PARTS.

REASSEMBLE, INSTALL AND

CHECK PRESSURES AND

OPERATION.

I

EAK.IF THE SOURCE OF LEAK

CANNOT BE READILY DETERMINED,

CLEAN THE EXTERIOR OF THE

TRANSMISSION. CHECK TRANSMISSION

FLUI

LEVEL. ORRECT

I

NECESSARY

I

DEBRIS IS PRESE

REMOVE THETRANwIs N AND

CONVERTER AS AN ASSEMBLY.

DISASSEMBLE, CLEAN AND INSPECT

ALL PARTS. CLEAN VALVE BODY;

INSTALL ALL NEW SEALS, RINGS

AND GASKETS; REPLACE WORN OR

DEFECTIVE PARTS.

PU567

THE FOLLOWING LEAKS MAY BE CORRECTED

WITHOUT REMOVING THE TRANSMISSION:

MANUAL LEVER SHAFT OIL SEAL

FILLER TUBE 0 ING

PRESSURE GAUGE PLUG

NEUTRAL START SWITCH

PAN GASKET

OIL COOLER FI ll INGS

EXTENSION HOUSING TO CASE GASKET

EXTENSION HOUSING TO CASE BOLTS

EXTENSION HOUSING YOKE SEAL

SPEEDOMETER ADAPTER 0 RlNG

FRONT BAND ADJUSTING SCREW

1

THE FOLLQWING LEAKS

REQUIRE REMOVAL OF THE TRANSMISSION

AND TORQUE CONVERTER FOR

CORRECTION.

TRANSMISSION FLUID LEAKING FROM THE LOWER

EDGE OF THECONVERTER HOUSING; CAUSED BY

FRONT PUMP SEAL, PUMP TO CASE SEAL, OR TORQUE

CONVERTER WELD.

CRACKED OR

POROUS TRANSMISSION CASE.

Q

PUMB


17


19/80

Faulty lock-up clutch.

Overrunning clutch inner

race damaged.

Overrunning clutch worn.

broken or seized.

Planetary gear sets broken

or seized.

Rear cluth dragging.

Worn or faulty rear clutch.

Insufficient clutch plate

clearance.

Faulty cooling system.

Kickdown band adjustment

too tight.

Hydraulic pressure too

high.

Breather clogged.

High fluid level.

Worn or faulty front clutch.

Kickdown servo band or

linkage malfunction.

Governor malfunction.

Worn or broken reaction

shaft support seal rings.

Governor support seal rings

broken or worn.

Output shaft bearing

and/or bushing damaged.

Overrunning clutch not

holding.

Kickdown band out of

adjustment.

lncorrect throttle linkage

adjustment.

Engine idle speed too low.

Aerated fluid.

Worn or broken input shaft

seal rings.

Faulty oil pump.

Oil filter clogged.

lncorrect gearshift control

linkage adjustment.

Low fluid level.

Low-reverse servo band or

linkage malfunction.

Valve body malfunction

or leakage.

Low-reverse band out of

adjustment.

Hydraulic pressures

too low.

Engine idle speed too high.

Stuck lock-up valve.

Stuck switch valve.

T e c h n i c a l e r v i c e

Informat ion

LOADFLltE DIAGNOSIS CHAM GENERAL

UTO M TIC TR NSM ISSION SERVICE GROUP

8


20/80

Technical Service In format ion

DIAGNOSIS CHART LOCK UP TORQUE CONVERTER

POSSIBLE

C USE

UTOM TIC TR NSMISSION

SERVICE GROUP

9

TUNE ENGINE

F ULTY INPUT SH FT OR SE L RING

THROTTLE LINK GE MIS DJUSTED

I

'

; z

W

X X

X


21/80

T e c h n i c a l S e r v i c e I n f o r m a t i o n

LUBRIC TION

Inspect fluid level on dipstick every six months with

engine idling and transmission in ne utr al position a nd

vehicle on

level

ground.

A

properly filled transmission

will read near the add mark when fluid tempera-

ture is 70 degree fahrenheit (21 degrees Celsius) and

near (but not over) the full mar k a t 180 degrees

fahrenheit (82 degrees Celsius) (average operating

temperaturej.

lever momentarily to each position, endir.,

neutral position.

(8) Add sufficient fluid to bring level to t t s

mark.

Recheck fluid level after transmission is

:

-

operating temperature. The level should

be F

the "FULL" mark and "ADD" mark with ve

level ground.

To prevent dirt from entering transmissic-

certain t ha t dipstick cap is fully seated ontc

I-

tube.

Fluid and Filter hanges

Refer to Lubrication and Maintenance Group

for mileage intervals.

Severe usage as defined below, requires that fluid

and filter

be

changed and bands adjusted every 12,OOG

miles

(19

000 kilometers).

l j More than 50% operation in heavy city traffic

dur ing hot wea ther iabove 90°F.) (32°C.).

(2) Police, Taxi, Limousine, Commercial Type Oper-

ation, and Trailer Tow.

NOTES:

(1) When the factory fill fluid is changed as recom-

mended above, MOPAR ATF PLUS (Automatic Trans-

mission Fluid) Type 7176 should be used. A band

adjustment and filter change should be made a t the

time of the oil change.

(2) If the transmission is disassembled for any rea-

son, the fluid and filter should be changed, and the

bands adjusted.

Drain and

Refill

(1)

Raise vehicle on a hoise. Place a drain container

with a large opening, under transmission oil pan.

(2) Loosen pan bolts and tap the pan at one corner

to break it loose allowing fluid to drai n, then remove

the oil pan.

3 )

If necessary, adjust the reverse band.

(4) Install a new filter on bottom of the valve body

and tighten retaining screws to 35 in. lbs. (4 N.m).

5)

Clean the oil pan. Make sure the round magnet

is located over the bump in the front, right hand

corner of the oil pan. Install oil pan using a new

gasket. Tighten oil pan bolts to 150 in. lbs. (17 N.m).

(6) Pour four quarts of MOPAR ATF PLUS (Auto-

matic Transmission Fluid ) Type 7176 through t he

filler tube.

(7) St ar t engine and allow to idle for a t least two

minutes. Then, with parking brake on, move selector

GE RSHIFT LINK GE DJUSTM ENT

(Column Shift) (Fig. 1

When it is necessary

to

disassemble linka

from levers which use plastic grommets

as

ers, the grommets should be replaced wi

ones. Use a prying tool to force rod from grc:

lever (pry only where grommet and rod at=:--

on the rod itself), then cut away old gron?r:-

pliers to snap new grommet into lever and

grommet.

1) To insure proper adjustment, make s u r ~

able swivel block is free to tu rn on shi ft rod.C-

ble and clean or repair parts to assure free zr

necessary.

(2) Place gearshift lever in

P

park) posi ~

(3) With all linkage assembled and the at.r

swivel lock bolt loose, move shift lever on trar::.

all the way to re ar detent (park) position.

GROMMET

FRONT ROD

ASSEMBLY

:.

TyHtF

BUSHING

A

WASHER.

1~~

RONT

ASHER

(2)\\\ \

BUSHING

WASHER -F

.

.

e ETAINER

..

Fig.

I--Column earshift Linkage

Adju

AUTOMATIC TRANSMISSION S E R V I C E GROUP

20


22/80

Technical S e r v i c e In format ion

4 ) Tigh ten a dju stm ent swivel lock bolt to 90 in. lbs.

10

N.mr.

5) Check ad justm ent as fol lows:

(a ) Detent posi tion for neut ra l a nd drive should

be wi thin l imi ts of ha nd lever gate stops.

(b) Key s t a r t m ust occur on ly when sh i f t l ever is

in park or neu tral posit ions.

THROTTLE ROD ADJUSTMENT

W i t h eng i ne a t ope ra t ing t em p era t u re and ca rbu-

retor off fast idle cam, adjust idle speed of engine

using

a

t achometer . Refer t o Fuel Sys tem Group 14,

for idle speed Speci ficat ions and carburetor l inkage

adjus tment .

ADJUSTMENT PROCEDURE

Figs.

2 or

3)

1 ) Perform t ransmiss ion thro t t l e rod ad jus tment

whi le engine is a t normal opera t ing t empera ture

o the lwi se make sure carbure tor i s no t on fas t i d l e

cam.

(21 Raise vehicle on hoist to m ak e adjus tmen t a t

t ransmission thro t t l e l ever .

(31 Loosen a dju stm ent swivel lock screw.

4 ) To insure proper ad jus tment , swive l must be

free to sl ide along flat end of throt t le rod so that

preload spring act ion i s not rest r icted. Disassemble

and c l ean or repa i r par t s t o assure f ree ac t ion , i f

necessary.

(5) Hold t ransmission lever f i rmly forward against

i t s interna l s top and t ighten swivel lock screw to 100

in. Ibs. 11 N.m).

6) he ad jus tment i s f i n ished an d l i nkage backlash

was automat ical ly removed by th e preload spring .

7) If lubricat ion i s required, refer to Lubricat ion

Group 0 .

(8) Lower vehicle, reconnect choke if disconnected,

and test l inkage freedom of operat ion by moving

thro t t le rod rearw ard, s lowly releasing i t to conf irm i t

wi ll r etu rn ful ly forward.

B ND

ADJUSTMENTS

Kickdown Band

Front)

The kickdown band adjust ing screw is located on

left s ide of th e t ransm ission case (Fig. 4).

1) Loosen l x k nu t and back off lock n ut approxi-

mate ly f ive tu rns . Tes t ad jus t ing screw for f ree tu rn -

ing in th e t ransmiss ion case .

(2) Using wre nch , Tool C 3380 A w i t h a d a p t e r

C-3705, t ighten ban d adjust ing screw

47

t o 50 in. Ibs.

(5 N.m). If ada pte r G3 70 5 is not used, t ighten adjust -

ing screw to 72 in. lbs. (8 N.m) which i s the t rue

torque.

3) Back off ad jus t ing screw the num ber of t u r ns

listed in Specifications . Hold adjusting scre w in th is

posit ion and t ighten lock nut to 30 ft . Ibs. 41 N.m).

RETURN SPRING

FRONT

I

WASHER

THROTTL

LEVER

RO ADJUSTABLE SWIVEL

\

SPRING

~ J A

Fig. 2-Throttle Rod Adjustment 6 Cylinder Models

UTOM TIC TR NSMfSSION

SERVI E

GROUP

2


23/80

A - -

ical S e r v i c e

In format ion

Fig. 3-Throttle Rod Adjustment 8 Cylinder odes

Low Rmversa mama

~ s s r

(I) Raise vex::?.

? TL .

' r~smission fluid from

loosened oil par.

2 ?

Z=Y CX pan.

.

(2) Loosen

a 1 5 i . ~ - :xs

nut and back off

lock nut

approdzx e ~

EII

~ ~

ig.

5).

Test adjust-

ing screw for free z r l r g

-ever.

3) Using wrenc: .. 7:r. C-?-:?-.4. righten band ad-

..

-

justing screw to 73

k x

5 . r .

4) Back off ac sg

5e number of turns

listed in

"SpeciScz5cz~".

Ec:C e2justing screw in this

position and tighre: x3

r x : 1r2

5 ft lbs.

(34

Nem).

5 )

Reinstall

oC

2 g z e a gasket. Tighten oil

pan bolts

to

132 LY.

1 Y.=

.

Flg. H x t e m a i

wd

Ad,irstments

- -

(6) Fill transrck-r:

r . r

(Automatic Trans== r

=

I PLUS

HYDRAULIC CONlRC:

ADJUSTMENTS

Line Pressure

--

An incorrect t z e =-- ._.-

=--

cause

incorrect line

p=cC-:

c= Y

- . .-,?Iine

ressure adjustme-: x - . ~ i ~ end

correct throttle press r -

=

?i:-sting

the line pressure.

-

The approximex z= LT = r -

---

. meas-

-

ig. 5 - - L o w - R m ST t

.

--

* * * -

-

.

- - ;NSMISSION SERVICE

GROL


24/80

T e c h n i c a l S e r v i c e

In format ion

l T L

ER

SPACING TOOL

RH259

Fig 6-Line Pressure Adjustment

Fig.

7-Thro ttle Pressure Adjustment

ured from valve body to inner edge of adjusting nut

(Fig. 6). However, due to manufacturing tolerances,

the adjustment can be varied to obtain specified line

pressure.

The adjusting screw may be turned with n Allen

wrench. One complete turn of the adjusting screw

changes closed throttle line pressure approximately

1 2/3 psi. Turning adjust'ing screw counterclockwise

increases pressure, and clockwise decreases pressure.

Throttle Pressure

Throttle pressures cannot be tested accurately;

therefore, the adjustment should be measured if a

malfunction is evident.

1)

Insert gauge pin of Tool C-3763 between the

throttle lever cam and kickdown valve (Fig. 7).

2)

By pushing in on tool, compress kickdown valve

against its spring so throttle valve is completely

bottomed inside the valve body.

3) As force is being exerted to compress spring,

turn throttle lever stop screw with allen wrench until

head of screw touches the throttle lever tang with

throt tle lever cam touching tool and t he throttle valve

bottomed. Be sure adjustment is made with spring

fully compressed and valve bottomed in the valve

body.

SERVICE

IN

VEHICLE

G E N ER L I N F O R M T I O N

Various transmission components can be removed

for repairs without removing the transmission from

the vehicle. The removal, reconditioning, and installa-

tion procedures for these components are covered

here.

S P E E DO M E T E R P I N I O N G E R

Any time the speedometer pinion adapter is re-

moved, a N W 0

ing

black in color must be

installed on the outside diameter of the adapter.

Removal and nstallation

Rear axle gear ra tio and t ire size determines pinion

gear requirements.

1)Place drain pan under speedometer adapter.

2) Remove bolt and reta iner securing speedometer

pinion adapter in the extension housing (Fig.

1).

(3) With cab e housing connected, carefully work

adapter and pinion out of the extension housing.

4)

If transmission fluid is found in cable housing,

replace seal in the adapter (Fig.

2).

Start seal and

retainer ring in the adapter, then push them into

adap ter with Tool

C 4004

until tool bottoms (Fig. 3).

UT OM T I C T R NS M I S S I ON S E RVICE

G R O U P

23


25/80

T e c h n i c a l S e r v i c e Informat ion

011

SEAL

RH

6 O CLOCK

POSITION

Rti260 Fig

3-Install Speedometer Pinion Seal

Fig. I-Speedometer Pinion and Adapter

Before installing pinion and adapter assembly,

make sure adapter flange and its mating area on

extension housing

re

perfectly clean. Dirt

or

sand

will cause misalignment resulting in speedometer

pinion gear noise.

(5) Note number of gear teeth a nd instal l speedome-

ter pinion gear into adapter.

6)

Rotate the speedometer pinion gear and adapter

assembly so that the number on the adapter, corre-

sponding to the number of teeth on the gear, is in the

o clock position as the assembly is installed (Fig. 1 .

7) Install retainer and bolt, with retainer tangs in

adapter positioning slots. Tap adapter firmly into the

extension housing and tighten retainer bolt to 100 in.

Ibs. 11 N.m). Refill transmission.

NEUTRAL STARTING AND BACK-UP LAMP

SWITCH

(Fig. 4)

eplacement

nd

Test

The neutral starting switch is the center terminal

of the

3

terminal switch. It provides ground for the

starter solenoid circuit through the selector lever in

only Park and Neutral positions.

1) To test switch, remove wiring connector from

switch and test for continuity between center pin of

switch and transmission case. Continuity should exist

TER

RETAINER RING

RATIO ADAPTER

(REQUIRED

ON

SOME MODELS

RH261

Fig.

2-Speedometer Drive

only when transmission is in Park or Neutral.

2)

Check gearshift linkage adjustment be

replacing a switch that tests bad.

3) Unscrew switch from transmission case allow

fluid to dra in into a container. Move selector leve

Park

and then to

Neutral

positions, and inspect to

that the switch operating lever fingers are centere

switch opening in the case.

4) Screw switch with new seal into transmis

case and tighten to 25 ft. lbs.

34

N-m). Retest sw

with the test lamp.

5) Add automatic transmission fluid to transm

sion to bring up to proper level.

6) The back-up lamp switch circuit is through

two outside terminal s of th e 3 terminal switch.

(7) To test switch, remove wiring connector f

switch and test for continuity between t he two out

pins.

8) Continuity should exist only with transmiss

in Reverse position.

9)

No

continuity should exist from either pin

to

case.

EXTENSION HOUSING YOK SEAL

eplacement

1)Mark parts for reassembly then disconnect

propeller shaft at rear univefial joint. Carefully p

Fig.

4-Start and

Back-Up

Lamp Switch

SlO

S E R V I E

GROUP


26/80

Technica l Serv ice In format ion

shaft yoke out of the transmission extension housing.

SPECIAL

TOOL

Be

careful

not

to scratch or nick ground surface

on sliding spline yoke during removal and installa

t ion of the shaft assembly. I

t?

2)

Remove oil sea l with Tool C-3985 Fig.

5).

. ,

..

3) To install a new seal, position seal in opening of

extension housing and drive i t into th e housing with

Tool 2-3995 or C-3972 Fig. 6).

RH 8

4) Carefully guide front universal joint yoke into

Fig.

6-Install Extension Housing Yo ke Seal

extension housing a nd on th e mainshaft splines. Align

marks made

at

removal and connect propeller sha ft to

bearing from th e shaft Fig. 8).

rea r axle pinion sha ft yoke.

2)

Install a new bearing on shaft with outer race

ring groove toward front, then install rea r sn ap ring.

EXTENSION HOUSING BUSHING

A-727 has a snap ring in front of bearing; A-904T and

AND

OUTPUT

SHAFT

BEARING

A-999 do not.

Extension Removal

1)

Mark parts for reassembly then disconnect pro-

peller shaft a t rear universal joint. Carefully pull

shaf t assembly out of the extension housing.

2)

Remove speedometer pinion a nd adapter assem-

bly Fig. 1).Drain approximately two quarts of fluid

from the transmission.

3) Remove bolts securing extension housing to the

crossmember. Raise transmission slightly with service

jack, then remove center crossmember and support

assembly.

4) Remove extension housing to transmission bolts.

When removing or installing extension housing

step 6 , the gearshift lever must be in 1 low)

position. Thi s positions parking lock control rod rear-

ward so it can be disengaged or engaged with the

parking lock sprag.

5)

Remove screws, plate, a nd gasket from bottom of

extension housing mounting pad. Spread large snap

ring from output shaft bearing Fig

7).

With snap ring spread as far as possible, carefully

tap extension hosuing off the output shaft bearing.

Carefully pull extension housing rearward, to allow

parking lock control rod knob to clear park ing sprag,

then remove the housing.

earing Replacement

1) Using heavy-duty snap ring pliers, remove the

output shaft bearing rear snap ring and remove

SPECIAL \

\

ushing Replacement

1) Remove oil seal with Tool C-3985 Fig. 5 .

2)

A-904T

and

A 999:

Press or drive out bushing

with Tool C-3996 Fig. 9).

A-727: Remove bushing in the same manner with

Tool C-3974.

(3) A-904T and A-999:

Slide a new bushing on

installing end of Tool C-3996. Align oil hole in bushing

with oil slot in the housing, then press or drive

bushing into place Fig. 9).

A-727: Using Tool C-3974, install a new bushing in

same manner.

4) A-904T and A-999: Drive a new oil seal into

housing with Tool 2-3995 Fig.

6).

A-727:

Using Tool C-3972, install a new oil seal in

same manner.

Extension Ins tallation

1)Place a new extension housing gasket on the

transmission case. Position the output shaft bearing

retaining sna p ring in extension housing. Slide exten-

sion housing on output shaf t guiding the parking lock

..

Fig. 5--Remove Extension Housing Yok e Seal

Fig. 7-Remove or Install Extension Housing

UTOM TIC TR NSfVllSSION SERVICE GROUP

2 5


27/80

T e c h n i c a l S e rv ic e ' - ' z - l a t i o n

BEARING SNAP RlNG

RH268 RING CONTROL ROD

Fig. 8--Output Shaft Bearing

control rod knob past the parking sprag. While

spreading large snap ring in housing Fig.7), carefully

tap housing into place, then release the snap ring.

Make sure snap ring is fully seated in bearing outer

race ring groove.

2 --

2) Install and tighten extension housing bolts to 32

ft. Ibs. 43 N-m). Fig.

10--Governor S zz =-

3)

Install gasket, plate, and screws on bottom of

the extension housing mounting pad.

4)

Install the center crossmember and rear mount

assembly, tighten retaining bolts. Lower transmission

to install extension housing to support bolts and

tighten to 50 ft. lbs.

68

N.m .

5) Install the speedometer pinion and adapter.

weight. Figure 11 shows a

CIET

;

;

* 3

governor assembly.

5) Remove snap ring fro-

+--: I 7

?-c

.

-

.

hen slide governor and

s - 2 2 ~ - 2

I

.

-

- O

-7-I-=:e

utput shaft. Remove the

:;-

:

r

governor body and screen f r c :r T

:..:

6)Carefully guide front universal joint yoke into

extension housing and on the output shaft splines.

Cleaning and Inspectien

Figure shows

2 ei==r --- -

2--

.---

a.

-=--

.

-.

Align marks made at removal and connect propeller

nor assembly.

shaft to rear axle pinion shaft yoke.

- -

VTL . :

Insepct all par> f:r I ; -.

-

SF

. - - -

7) Add automatic transmission fluid to transmis-

_--

weight for

free Z L

---

- FT- .

- .

-

er

sion to bring up to proper level. -

---

----

w e i a h t f o r f + z T - ~ -

;

t . . - 1 - - - - -

G O V E R N O R A N D P A R K I N G G E A R

Removal

1)

Remove extension housing and output

shaft

bearing as previously described.

(2)

Carefully pry snap ring from weight e ~ bi

governor valve shaf t Fig.

10).

Slide valve an?

s 32?

assembly out of governor body.

3)

Remove large snap ring from weight

e r i

governor body, lift out governor weight

as,se~l?:y.

4) Remove snap ring from inside governor =eicl-.:-

remove inner weight and spring from r 5 o r. : :e-

v

u : .


28/80


29/80

T e c h n i c a l S e rv i c e I n f o r m a t i o n

2) Remove top and bot tom screws f rom spr ing

re ta ine r a nd ad jus tm ent sc rew bracke t .

3) Hold spr ing re ta iner f i rmly agains t spr ing force

while rem oving las t re ta inin g screw from s ide of va lve

body.

(4) Remove spr in g re ta ine r , w i th l ine and thro t t l e

pre s sure ad jus t ing sc rews (do not d i s turb se t t ing) and

the l ine pressure and switch va lve regula tor spr ings .

5 ) Slide switch va lve and regula tor va lve out of

the ir bores .

6)

Remove screws f rom lock-up mo dule (or s t i f fener

pla te) and careful ly remove tube and lock-up module

(or s t i f fener p la te) . Disassemble lock-up mod ule , tag-

ging springs. Nonlock-up A-904T, for California mod-

e ls , use a n em pty lock-up body ins tead of a stiffener

pla te .

7) Remove t r ans fe r p la te r e ta in ing sc rews and l i ft

off t r ans fe r p la te an d sepa ra to r p la te a s sembly .

8)

Remove lock-up solenoid re ta ining screw and

pull solenoid f rom i ts bore in t ransfer pla te , i f so

PRESSURE REGULATOR

FILTER SCREEN f - -

1

. I-

._ T

3

---x

Fig. 4-Transfer

p a r o

C

3

equipped. .

2) Remove lock-up rrr.r;

x

r

(9) Remove thre e sc rews f rom sepa ra tor p la te an d

3) R~~~~~ fail-saft

vdr5

7 r

sep ara t e pa r ts for c leaning (Fig. 4) .

Z-m-

ag these spr ings

as t:?e?

.-

7 z

(10) Remove r ear c lutch ba l l check, reverse servo

ly identification.

ba l l check, and l ine pressure regula tor va lve screen

from separa tor pla te for c leaning (Fig.

4).

Shuttle Valve and

Governor P7 r

(11) Remove t he seven ba l ls f rom valve body as

1)

Tu rn va lve

body 0: er z-.i x

: =

-.-a ve

shown in F igure 5.

cover pla te .

LOCK-UP MODULE Fig.

3)

2) Remove g0verr.x

r : q

F

and

.

l ide out the

snu- r :e

-.-


30/80

Technica l Service n format ion

lT AYzTR

PLATE SPRING RETAINER

AN D SH AFT LEVER ASSEMBLY

PU5

Fig.

I-Valve Body Assembly

2) Drive a new sea l into th e case with a

15/16

inch

socket and ham mer F ig . 13 .

This sea l can be rep laced wi thout r emoving the

valve body from transmission by using a small screw-

dr iver to pry sea l out of i ts bore . Be careful not to

s c r a tc h m a n u a l l e ve r s h a f t o r t h e s e a l b or e i n

transmission.

VALVE ODY DISASSEMBLY

Tag all springs as they are removed for reassem-

bly identification.

Do not c lam p an y por t ion of va lve body or t ran sfer

pla te in a vise . Any s l ight dis tor tion of th e a lum inu m

body or t ransfer pla te wil l resul t in s t icking va lves ,

excessive leakage or both.

When removing or install-

ing valves or plugs, slide them in or out carefully. Do

not use force.

Remove E cl ip and pa rk control rod f rom man ual

lever.

Filter, Transfer Plate,

and

Pressure

Regulators

(1) Place va lve body assembly on repair s t an d Tool

C 3749 Fig. 1 .Remove three screws f rom the f luid

filter a nd lift off fil ter.

ER WASHER

E

CLIP

MANUAL VALVE

SWITCH VALVE

SWITCH VALVE SPRING

LlNE PRESSURE

REGULATOR VALVE

LlNE PRESSURE ADJUSTING

SCREW ASSEMBLY

THROllLE PRESSURE

SPRING RETAINER AN D

ADJUSTING SCREW BRACKET

PU8A

Fig.

2-Pressure Regulators and Manual Control

UT O M T I C T R NS M I S S I ON S E RVI CE G R O U P

29


31/80

Technical Se r .

- -

-

1/4 INCH D I A M E T E R ~

/

11/32

INCH DIAMETER BALL

1/4 INCH DIAMETER BALLS

P u l l

Fig. 5--Steel Ball Loca tions

valve governor

plug.

3) Remove shutt le valve

E

clip and slide shuttle

GOVERNOR

- =

-c-ove th e secondary

v = ~

-ain ed by

E

clip.

1 1 1 m -

~p r r

C

e

Lever

-

-

- ; - .

-

... ~

. -~

-

- -

. - I r from throttle lever

. - ~

rom shaft, then

1

-

~-

-

- - - - - -

.

5all and spring in

- - - - -

. - T

s'milar

tool, slide

-

ar-,LL

- - -

- .

- - -

-

-

- - :._-3ve the det ent

ball a r f 5 ; -,

2) sli?E 2--z

- :_-= -

-

. - - - -

- -

3)

q.:;;

- - - - -.- - . --

.

.

- . . - - -

-

. -

.

- r czTidown

valve, + - - +

7 - r

- - - 2 - - - = .--

- . . .

-

.=.i-e.

Shift Valves a

we

r e

Sensing PI s

1 ) Rerr?c-;~ ?

. ~ - ?

r 7 I-_-

- - - -.-._'.P

end

plate Fig.

-

~ r f

5

r -.-+ T 1.: Z:T

s:eeve,

line

presscre

=:-:g.

: - - 5 F

:

-; : ?ring.

2) Remcve : f . I

:-+

I l

-

~ -

--. -

~ i n g

assembly.

3) Renr

. -?

- ----

- -

-- - -

--

.

.

. - -

.

.

- -

-

zr :

7.

1-2 SHIFT VALVE

GOVERNOR PLUG

SHU?TLE VALVE

PLUG

END

PL TE

\:.um

VALVE

'E?~oR PLUG

VL--E

V A L E

PRIMARY SPRING

d

Y L R X E VAL-

THROTTLE PLUG

SCREW61

Fig.

+Shuttle Valve and Governor Plugs

A UT O MA T I C T RA N S MI S S I ON S E RVICE GROUP

3


32/80

Techn ica l Se rvi ce n fo rm a t ion

Fig. 7 Shift Valves and Pressure Regulator Valve Plugs

4)

Slide retainer from housing and remove limit

valve and spring.

5)

Remove the three springs and shift valves from

the valve body.

leaning nd

Inspection

Allow all parts to soak a few minutes in

a

suitable

clean solvent. Wash thoroughly and blow dry with

compressed a ir. Make s ure all passages ar e clean and

free from obstructions.

Inspect manual and throttle valve operating levers

and shafts for being bent worn or loose. If

a

lever is

loose on its shaft the lever and shaf t assembly should

be replaced.

Do not attempt to straighten bent

levers.

Inspect lock-up solenoid assembly for cut or broken

wire melted or distorted coil cut or nicked O-rings

etc. Shake solenoid to verify that plunger is free to

travel. Replace solenoid if plunger is stuck. Check

orifice in solenoid nozzle an d drilled crosshole a t

solenoid bore in transfer plate for dirt or foreign

material. To check solenoid operation hold solenoid

with nozzle pointing up and apply 12 volts between

solenoid wire and solenoid fr ame a t screw hole.

Plunger should travel up and down when 2 volts

power is turned on and off.

a

Inspect all matin g surfaces for burrs nicks and

scratches. Minor blemishes may be removed with

crocus cloth using only a very light pressure. Using a

straightedge inspect all mating surfaces for warpage

or distortion. Slight distortion may

be

corrected using

a surface plate. Make sure all metering holes in steel

plate and valve body are open. Using a pen light

inspect bores in valve body for scores scratches pits

and irregularities.

Make sure orifice referred to in iFig. 5) is open by

inserting a 1 32 inch diameter drill through it into

the

1 2 shift control valve bore.

Inspect all valve springs for distortion and collapsed

coils. Inspect all valves and plugs for burrs nicks and

scores. Small nicks and scores may be removed with

crocus cloth providing extreme care is take n not to

round off sharp edges. The sharpness of these edges is

vitally important because it prevents foreign matter

from lodging between valve and valve body th us

reducing possibility of sticking. Inspect all valves and

plugs for freedom of operation in valve body bores.

When bores valves and plugs are clean and dry

the valves and plugs should fall freely in the bores.

The valve body bores do not change dimensionally

with use. Therefore a valve body assembly that was

functioning properly when vehicle was new will oper-

U T O M T I C T R N S M I S S IO N S E R V I C E G R O U P


33/80

- -

Techn icz

5:-

-

- - c V - p -

.

- -

a t e c or re c t ly

i f

i t is proper ly and thorous? :- - r

i z t r

There is no need to replace va lve k:;

51- i -

unle s s i t is da ma ge d in ha nd l ing .

V LVE

BO DY RE SSEM BL Y

Tighten

all valve

body screws to 35

i n c h - p o w i r

4

Newton-meters).

Shift Valves and Regulator Valve ressure

Sensing Plugs Fig.

7 )

(1)

S l i d e s h i f t v a lv e s a n d s p r i n g s i n t o p r c T -

. 1 5

body bores.

(2) Subassemble the 3-2 l imit va lve hot is icg

z- --

bly as follows:

(a ) Inse r t l im i t va lve a nd sp r ing in to

i?rx~::,

(b ) S l ide sp r ing re ta in e r in to g roove

n

+r:s

;

( c ) Inse r t th ro t t l e p lug in hous ing bore

25 .

:

a s se mbly a ga in s t th e sh i f t va lve sp r ings .

Omit step

(2)

when no 3-2 limit valve housing as s en

bly is used.

(3 ) Ins ta l l e nd p la te a nd t igh te n sc re ws .

4) Ins ta l l th ro t t l e p re s sure sp r ing a r? d

~ : x g . :r

pre s sure p lug a nd s le e ve , the n fa s te n e nd ? E P

:I

valve body.

Shuttle Valve and Governor Plugs

Fig . 6 )

(1 ) P la c e 1 -2 a nd 2 -3 sh i f t va lve gove rnor

in

the ir respec t ive bores .

(2)

Ins ta l l shut t le va lve and hold i t in bore

\\ irk

index f inger while ins ta l l ing the secondar? : spr ing

w i t h g u i d e s a n d r e t a i n in g "E" clip.

( 3 ) I n s ta l l p r i m a r y s h u t t l e v al v e s p r i n g a n d t h r o t t l e

plug.

(4 ) Ins ta l l gove rnor p lug e nd p la te a nd t igh te n t he

re ta in ing sc re ws .

5 ) Ins ta l l shu t t l e va lve c ove r p la te a nd t igh te n the

re ta in ing sc re ws .

Manual Lever and Throttle Lever Fig. 2 )

(1) ns ta l l th ro t t l e va lve , th ro t t l e va lve sp r ing , k ick-

down va lve , and kickdown de tent s leeve .

(2 ) S lide ma n ua l va lve in to i t s bore .

(3 ) Ins ta l l th ro t t l e l e ve r a nd sha f t on va lve body .

Inse r t de te n t s p r in g a nd ba l l in i t s bore in va lve body .

Depress ba l l and sp r in g with Tool (2-3765 (Fig.

8)

o r

s imi la r tool a nd s l ide ma n ua l l e ve r ove r th ro t t l e sha f t

s o t h a t i t e n g a g e s m a n u a l v a l v e a n d d e t e n t b a l l .

Ins ta l l s e a l, r e ta in ing wa she r , a nd "E" c l ip on th ro t t l e

sha f t .

Filter, Transfer Plate, Lock-up Solenoid, and

Pressure Regulators

(1)

Ins ta l l th e 7 ba l l s in va lve body a s shown in

F i g u r e 5 .

(2) Ins ta l l rea r c lutch ba l l check an d low -reverse-

servo ba l l check (Fig. 4 i n t r a n s f e r p l a t e a n d r e g u l a -

to r va lve s c re e n in s e p a ra to r p la te (F ig . 4).

Fig.

8-Install Det ent Spring and Ball

e

low-reverse servo ball check is used

ONLY

wit

A-904T

and A-999 transmissions.

3

Ins ra l l 3 s c re ws in s e pa ra to r p la te .

4

Place t ransfe r pla te assembly on va lve body. Be

~ 2 r e i ~ Io a l ign f i l t e r s c re en a s the

17

sho r te r s c rews

zre ins ta l le d f inge r t igh t ( the th re e longe r s c re ws a r e

f ~ ril f ilter).

(5)

S t a r t i n g a t t h e c e n t e r a n d w o r k i n g o u tw a r d ,

r igh te n sc re ws to

35

in. lbs. (4 N.m).

(6': S l ide swi tc h va lve a nd l ine p re s sure va lves a n d

spr ings in to the i r bore s (F ig . 2).

7 ) Ins ta l l p re s sure a d jus t ing sc re w a nd b ra c ke t

a s se mbly on th e sp r ings a nd fa s te n wi th one sc rew fo r

now. Use sc rew which goes into s ide of va lve body.

This s c re w i s to be t igh te ne d f i r s t, a f te r s ta r t ing t he

top a n d bo t tom sc rews .

(8)

Ins ta l l o il f i l te r an d t ig hten sc rews to 35 in . lbs.

(4 N.m).

(9)

Ins ta l l loc k-up va lve a nd sp r ing , the n ins ta l l

fa i l -sa fe spr in g and va lve int f - th e lock-up module (Fig.

3 .

Ins ta l l loc k-up module to t r a ns fe r a nd se pa ra to r

p la te a s se mbly wi th th re e s c re ws . ( Ins ta l l s t i f f e ne r

pla te on nonlock-up va lve body).

10)

nse r t lock-up solenoid nozzle (with O-r ing) into

bore in t r a ns fe r p la te a nd ins ta l l r e ta in ing sc re w.

Ro ute lock-up solenoid wi re be tween solenoid and

l imi t va lve hous ing c ove r, a nd und e rne a th e dge of o il

f i l te r .

Correct wire routing is

VERY

IMPORTANT. The

wire must

be

routed away from the low-reverse

band lever.

11) After va lve body has been se rviced and com-

p le te ly a s se mble d , me a sure th ro t t l e a nd l ine p re ssure

a d j u st m e n ts ( se e " M a in t en a nc e a d A d ju st m en ts ") .

However , if pressures w ere

sari~ ector?.

prior to disas-

semb ly, use or igina l

~ i c

. .

.

(12) Insta DET. : : ?~

v

:+: 2nd

"E"

c l ip r e ta ine r

to m a n ~ a 5 - : ~ -

- - -

- - - - - -

AUTOMAT IC

TRANS ."'CS

1 -

- -

-

- - -

- -

-


34/80

T e c h n i c a l S e r v i ce I n f o r m a t i o n

VALVE

O DY

AND ACCUMULATOR

PISTON INSTALLATION

1)Make sure combination back-up lamp/neutral

start switch is not installed in transmission case.

2)

Place valve body manual lever in manual low

position to move parking rod to rear position.

3) Use a screwdriver to push the park sprag into

engagement with parking gear, turni ng output shaft

to verify engagement. This will allow knob on end

of park ing rod to move past th e sprag as valve body is

installed.

(4) Install accumulator piston in the transmission

case.

(5) Position accumulator spring between piston and

valve body.

(6)

Place valve body in position, working park rod

through opening and past sprag. Install retaining

bolts finger tight.

7) With neutral starting switch installed, place

manual lever in th e neutral position. Shift valve

body if necessary, to center neutral finger over the

neutr al switch plunger. Snu g bolts down evenly, th en

tighten to 105 in. lbs. (12 N-m).

8)

Conned lock-up solenoid wire to wiring connec-

tor pin a t rear of t~.ansmissioncase, if so equipped.

(9) Install gearshift lever and tighten cl amp bolt.

Check lever shaft for binding in the case by moving

lever through all detent positions. If binding exists,

loosen valve body bolts and realign.

10)

Make sure throttle shaft seal is in place, then

install flat washer and throttle lever and tighten the

clamp bolt. Connect throttl e and gearshift linkage and

adjust as required.

(11) Install oil pan, with a new gasket. Add trans-

mission fluid to bring it up to proper level.

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, or equivalent . Essentially; th is

repair consists of drilling out the worn or damaged

threads, tapping the hole with a special Heli-Coil tap,

or equivalent, and

installing a Heli-Coil insert, or

equivalent into the tapped hole. This brings the hole

back to its original thread size.

Heli-Coil, or equivalent, tools and inserts are

readily available from most automotive parts

suppliers.

SERVI E

OUT

OF VEHI LE

TRANSMISSION AND CONVERTER REMOVAL

Remove Transfer Case (if so equipped). Refer to

Transfer Case Removal for procedure.

(1)- The transmission and torque converter must be

removed as an assembly; otherwise, the torque con-

verter drive plate. pump bushing, or oil seal may be

damaged. The drive plate will not support a load;

therefore, none of the weight of the transmission

should be allowed to rest on t he

plat,e during removal.

2) Disconnect negative (ground) cable from th e

battery for safety.

3) Some models require th at th e exhaust system be

dropped for clearance, (see Group 11).

4) Remove engine to transmission struts, if so

equipped.

5)

Remove cooler lines at Transmission.

61 Remove sta rt er motor a nd cooler line bracket.

7) Remove torque converter access cover.

8) Loosen oil pan bolts, tap the pan to break it

loose allowing fluid to drain.

(9) Reinstall pan.

(10) Mark torque converter and drive plate to aid in

reassembly. The crankshaft flange bolt circle, inner

and outer circle of holes in t he drive plate, and th e

four tapped holes in front face of the torque converter

all have one hole offset so these p art s will be installed

in the original position. This maintains balance of the

engine and torque converter.

(11) Rotate engine clockwise with socket wrench on

vibration dampener bolt to position the bolts attach-

ing torque converter to drive plate, and remove bolts.



35/80

12)Mark parts for reassembly then discnn-e:

propeller sha ft a t rea r universal joint. Careful:-

?

sha ft assembly out of th e extension housing.

(13) Disconnect wire connector from the back-z=

lamp and neutr al start ing switch and lock-up sol en o~ i

wiring connector, if so equipped.

14) Disconnect gearshift rod and torque shafc

assembly from transmission.

When it is necessary to disassemble linkage rods

from levers that use plastic grommets as retainers,

the grommets should be replaced with new ones.

Use

a prying tool to force rod from grommet in lever,

then cut away old grommet. Use pliers to snap new

grommet into lever and rod into grommet.

15) Disconnect throttle rod from lever at the left

side of transmission. Remove linkage bellcrank from

transmission, if so equipped.

(16) Remove oil filler tube and speedometer cable.

17) Install engine support fixture, Tool G3487-A

with frame hooks or a suitable substitute, that will

support rear of the engine Fig. 1 .

(18)

Raise transmission slightly with service jack to

relieve load on the supports.

19) Remove bolts securing transmission mount to

crossmember and crossmember to frame, then remove

crossmember.

20) Remove all bell housing bolts.

21) Carefully work t ransmission and torque con-

verter assembly rearward off engine block dowels and

disengage torque converter hub from end of crank-

shaft. Attach a small "C" clamp to edge of bell

housing to hold torque converter in place during

transmission removal.

22) Lower transmission and remove assembly f ron

under the vehicle.

23) To remove torque converter assembly; remove

C clamp from edge of bell housing, then carefully

slide assembly out of th e transmission.

TOOL ASSEMBLY

RH 74

YCT : 1

m l= 7 1m e r s ,

with starte r

- - - ---- = . = -

- - -

r I

-

.

.

z?rr.ent,

should be

r f 1 1 7 2 - 5 - E -

zsqrnbly. This is

to

--.-E ,: ;,: . _

=-

. . .

.;age while weld-

- c : =?~ =--

... .

-

-

- - - -

HO

2

..

er--.=

FA

converters,

with

rsrsr

-I-; = r

2 7

: z z : z ~ ~ e n tan have

the gezr

: - z - - z c

z T --.~-._-rr::r.s 'ke sw.

Tks

T-Z-F- _ r

~ 2 7 r2xx:

directly on outer

diamerer

7

r :

_I?

Yc r e te r front cover. With

torque

r r - ; ? - e - =z: ;e i

fx tm vehicle, replacement

of the

gez- ::l :q:

Removal

1)

Cut thy-2~: z -2:eT1:2 at rear side of ring

gear with a h a c i

SZT 7

=7.r.j:3g

wheel

Fig. 2). Be

careful not to

cu: r r g-:f

:r:c

5 3 :

cover stamping.

2)

Scribe a heav.~

:ne

r: : t c

?on

cover next

to

front face of ring g- ..:z 13 :m:ing rhe new gear.

(3)

Support torque

crr .wrer

r

f~r.:

cover, next to

the lugs with blocks of acoi

o

prevert altering lug

position. The torque converJr

EZ not

rest on the

front cover hub during

this o p e r a 5 ~ . -sing

a blunt

chisel, or drift and hammer,

x p

dcwwarc on ring

gear near welded areas to break

an remaining

weld

material Fig. 2). Tap around

ring

gear mril

it

comes

off the torque converter.

4) Smooth off weld areas on the cover

w1th

a file.

nstallation

Any of the following methods may

be

used

to

heat

a d

xpand starter ring gear for installation on the

torque converter:

Oven Place ring gear in Oven and set temperature

a: 11

degrees F.

93 degrees Celsius). Allow ring gea r

Cr_

r m Starter Ring Gear

Fig. 1 4ng ine Support Fixture (Typical)

+

= ~

-Up Only)

AUTOMATIC TRANSMISSIC ;

SEz

- -

^

- -

-- -

34


36/80

Techn ica l Serv ice n fo rmat i on

to remain in oven for 1 5 to 20 minutes.

Boiling Water: Place ring gear in a shallow con-

tainer, add water, and heat for approximately eight

minutes after water has come to a boil.

Steam:

Place ring gear on a flat surface and direct

flow around gear for approximately two minutes.

Flame: Place ring gear squarely on a flat surface.

Using a medium-size tip, direct a slow flame evenly

around inner rim of the gear. DO not apply flame to

the gear teeth.

Place a few drops of water on face of

gear a t intervals du ring heating process. When gear is

hot enough to just boil th e water, installation of gear

on the torque converter can be made.

1)After ring gear is expanded by heating, place

the gear in position on torque converter front cover.

Ta p gear on the cover evenly with a plastic or rawhide

malle t until face .of gear is even wi th scribed line

Fig. 3 Remove

Pump

Seal

made during On the

Make

sure inward). Using Tool C-4193 and handle Tool C-4171,

gear is even with scribed line around full circumfer-

drive seal into housing unti l tool bottoms Fig. 4).

ence of t he front cover.

A 727:

Using Tool C-3860-A and handle Tool C-4171,

2) Reweld ring gear to torque converter front

install new seal in the same manner

cover, being careful to place, as nearly as possible,

same amount of weld material in exactly same loca-

DISASSEMBL~ SUBASSEMBL~

R E M O V A L

tion

as

was used in original weld. This is necessary in

order to maintain proper balance of the unit. Place

welds alternately on opposite sides of torque converter

to minimize distortion.

3) The following suggestions are offered as an aid

in making the weld:

a. Do not g s weld.

b. Use

a

D.C. welder tha t is se t at s traight polarity

or an

A C

welder if the proper electrode is available.

c. Use a 1 /8 inch diam eter welding rod, and a

welding curr ent of 80 to

125

amps.

d. Direct the arc a t intersection of th e gear and

front cover from an angle of 45 degrees from rear face

of the gear.

4) Inspect gear teeth and remove all nicks where

metal is raised, weld metal splatter, etc., in order to

insure quiet starter operation.

O I L COOLER

AND

T UBES FLUSHING

(See Diagnosis and Tests )

P U M P O I L S EA L

Replacement

he

pump oil seal can be replaced wi thout removing

pump and reaction shaft support assembly from the

transmission case.

1)

A 904T and A 999: Screw seal remover Tool

C-3981 into seal iFig. 31, then tighten screw portion of

tool to withdraw the seal.

A 727: Using Tool C-3861, remove seal in the same

manner.

2)

A 904T and A 999:

To install a new seal, place.

seal in opening of the pump housing lip side facing

Prior to removing any transmission subassemblies.

plug all openings and thoroughly clean exterior of the

unit , preferably by steam. Cleanliness through ent ire

disassembly and assembly cannot be overemphasized.

When disassembling, each p art should be washed in a

suitable solvent, then dried by compressed air.

Do

not

wipe parts with shop towels. All mating surfaces in

the transmission are accurately machined; therefore,

careful handling of parts must be exercised to avoid

nicks or burrs.

Input Shaft nd Play

Measuring input shaft end play before disassembly

will usually indicate when a thrust washer change is

required, except when major parts a re replaced). The

Fig. 4 Install Pump Seal

U T O M T I C T R N S M I S S I O N S E R VI CE

G R O U P

5


37/80

T e c h n i c a l S e r v i c ~

I

- -

thrust washer is :mared between reaction shaft sup-

port and front c u:ch ret ainer on A-727 transmissions.

The thrust washer is located between input and out-

put sha fts on A-904T and A-999 transmissions.

- .

1)

Attach a dial indicator to transmission bell

housing with its plunger seated against end of input

sha ft (Fig. 5 .

Move input shaft in and out to obtain end play

.

-

5

reading. End play specifications are .022 to .091 inch

A

for A-904T and A-999 transmission, and .034 to

OM

- :

inch for A-727 transmissions.

:/

(2) Record indicator reading for reference wher.

reassembling t he transmission.

=-

-

Oil Pan

1) Place transmission assembly in repair stan6.

Tool C-3750-A (Fig. 6).

2)

Remove oil pan bolts and remove oil pan art

7

gasket.

Valve Body Assembly

(1) Loosen clamp bolts and remove th rot tle an?

gearshift levers from the transmission.

(2) Remove back-up lamplneutral start switch.

3) Disconnect lock-up solenoid wire from u i f c ?

connector a t rea r of transmissionas n t x - ~ x e r

(4) Remove the

10

hex-head valve ' y

r

r= =1

sion bolts. Remove

E

clip

securing ;z \ g

:< -

3:

to th e valve body manua l lever

5 ) While lifting valve

body

u?wa+ -.::

7 :

:= ==L

sion case, disconnect parking

:cr r

rcrl : 5

5-5-

P A I R

STAND

, /

-

C -

,

srr Uepair

Stand

.

- - -

- . . -.

-.

- -

--.-- -

-- ~d sprag to permit

.

- - -

--

---

-

.

. .

.

- .- 1 z

=

he sprag.

- -

- - - -- -.--on and adapte r

- - - - - - -

2 -

- -

- =-

-

,= -- -

-

.- - -

-

...

.

.

. -

-

.

. ,

.

:n

:ransmission bolts.

- -

- - -

.

. - -

- - - -

- -

- ---

-

.

y

-

=. = - ,,-iet from bottom of

- -=- r - - - - -

- -

- - - - - - -

r . . .

- .

.

---

.

_

. - . - Spread large snap

- - - - - - -

- .

--.

-

+

-. - .-. - . -

.

- .

- . .

+ a 1-2

sna p ring spread

-

-

-

- = -

^

-

-= - ---- -

- - = -

- .

.

-

-

.

*

---

er: ~3s ion housing off

Accumulator

Piston and

Spring

.

-

.

-

- -

-

.

^

*,.--..-

< - - . -

- - -

- - - - - -

-..

. d .

- - . - -

---

1)

Lift spring off ac cumulator piston and withdram-

.

, i , b

Usi2g

ea\-;-=::-.- F.E= - - z

-.:en, remove out-

piston from the case.

-

-

put shaft bearir-g rez r r = 7 y ~ .3emove bearing

from shaft, then remove irzr.: s r . ~ ?

ing

(A-727). The

Extension Housing or Adapter on 4-W-D)

A-904T and A-999 transmisio~r rve no front snap

Before removing extension housing, pull parking

ring.

lock rod forward out of the case. Rotate output shaft,

( 5 ) On 4-W-D vehicles, use. Tool L4450 inverted

TRANSMISSION

with Handle C-4171 to drive out bearing from adapter,

if necessary.

Governor and Support

1)Carefully pry snap ring from weight end of

governor valve shaft. Slide valve and shaft assembly

out of the governor body.

(2) Remove snap ring from behind governor body,

the n slide governor body an d support assembly off th e

output shaft.

Oil Pump and Reaction Shaft Support

(1) Tighten front band adjust ing screw until band is

tight on front clutch retainer. This prevents clutch

retainer from coming out

with

pump which might

cause unnecessary damage

to

th e clutches.

Fig.

Measuring Input Shaft

End

Play

2) Remove oil pump housing reta ining bolts.

AUTOMAT IC TRANSM I SS ION SERV ICE GROUP

36


38/80

Technical Service nforma t ion

3) Attach Tool C-3752 to pump housing flange,

(Fig. 7 . in threaded holes in t he flange.

4) Bump outward evenly with the two knocker

weights to withdraw oil pump and reaction shaft

support assembly from the case.

Front Band and Front Clutch

1)

Loosen front band adjuster, remove band strut

(and A-727 anchor) and slide band out of t he case.

(2) Slide front clutch assembly out of the case.

input Shaft and Rear Clutch

1)

Grasp input shaft, and slide input shaft an d rear

clutch assembly out of the case.

Be

careful not t o lose th rus t washer located between

rear end of input shaft and forward end of the output

shaft.

Planetary Gear Assemblies, sun Gear, and

Driving Shell

1)

While supporting output shaft and driving shell,

carefully slide assembly forward and out through the

case.

Be very careful not to damage ground surfaces.on

outpu t shaft during removal.

Rear Band and low-Reverse Drum

1)Remove low-reverse drum, loosen rear band

adjuster, remove band strut and link, remove band

from the case.

Double-Wrap

Band): Loosen band adjusting screw,

then remove band and low-reverse drum.

Overrunning Clutch

(2) Carefully slide out clutch

hub

and remove roll-

ers and springs.

Kickdown Servo Front)

1) Compress kickdown servo spring by using

engine valve spring compressor Tool C-3422A.

remove snap ring (Fig.

8 .

(2) Remove rod guide, spring and piston assembly

from the case. Be careful not

to

damage piston rod or

guide during removal.

(3) Withdraw piston from the transmission case.

Low-Reverse Servo Rear)

1)Compress low and reverse servo piston spring by

using engine valve spring compressor Tool C-3422A,

then remove t he sn ap ring.

(2) Remove spring retainer, spring, and servo piston

a727 a904 Transmission Manual

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Transcript of a727 a904 Transmission Manual