AUTO TRANS OVERHAUL - ZF 4HP 18Article Text

1991 Eagle PremierFor Dan's Transmission Service 10 Jefferson Place Fort Walton Beach FL 32548

© 1997 Mitchell Repair Information Company, All Rights Reserved.Tuesday, April 06, 2004 02:52AM

ARTICLE BEGINNING

AUTOMATIC TRANSMISSIONS ZF 4HP 18

* PLEASE READ THIS FIRST *

NOTE: This article is based on information for Saab vehicles. Procedures for Monaco/Premier are similar. Complete information for Monaco/Premier models was not available at time of publication.

APPLICATION

APPLICATION & LABOR TIMESÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄVehicle Labor Times Trans.Application (1) R & I (2) Overhaul Model

Dodge Monaco .............. 7.0 ....... 9.1 ..... ZF 4HP 18Eagle Premier ............. 7.0 ....... 9.1 ..... ZF 4HP 18Saab 9000 Series .......... 8.2 ....... 9.1 ..... ZF 4HP 18

(1) - Removal and installation of transmission from vehicle chassis.(2) - Bench overhaul time for transmission and differential. DOES NOT include removal and installation.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

IDENTIFICATION

Automatic Transaxle (A/T) can be identified in 2 ways. A/Tsequence number and type is shown on transaxle identification platewhich is located on the left side of the case just above oil pan. SeeFig. 1. The 7th position of the VIN identifies the transmission type(8 = ZF 4-Speed Automatic).

Fig. 1: Locating Transaxle Identification TagCourtesy of Chrysler Corp.

DESCRIPTION

The ZF 4HP 18 Automatic Transaxle (A/T) has 4 speeds,providing an overdrive ratio of .74:1. A/T shifting is controlled by agovernor valve, line pressure valve, throttle pressure regulator valveand a modulator valve. Valve operation is dependent on shift leverposition, vehicle speed and throttle position. The A/T features alock-up type torque converter and a planetary gear set, consisting ofa total of 6 planetary pinions. Ignition TDC sensor is activated by astamped steel trigger wheel attached to the torque converter driveplate. Two types of one-way clutches are used: roller and sprag.Roller type clutch operates in 4th gear, and a sprag type clutch in2nd gear.

LUBRICATION & ADJUSTMENTS

NOTE: For lubrication services, refer to the appropriate TRANSMISSION SERVICING - A/T article in the AUTOMATIC TRANS SERVICING section.

NOTE: Transmission and differential sections are not integral in the ZF 4HP 18 transaxle. They are separate and require different lubricants. A/T uses Dexron II/Mercon ATF, while the differential section requires a synthetic SAE grade 75W-140 gear lube.

BAND ADJUSTMENT

1) Loosen band adjustment screw lock nut. Tighten bandadjustment screw to 89 INCH lbs. (10 N.m). Place reference marks onadjuster screw and A/T case. 2) Back off adjusting screw 2 turns. Hold adjusting screwwhile tightening lock nut to 59 ft. lbs. (80 N.m).

THROTTLE VALVE CABLE

Ensure throttle lever is at curb idle position. Using verniercalipers or a fabricated gauge that can be slipped over the throttlecable wire, set cable travel to 1.55" (39mm) for the Monaco andPremier and .079-.098" (2.0-2.5 mm) for the 9000. See Fig. 4.

TROUBLE SHOOTING

NOTE: Always check fluid level and shift linkage before trouble shooting any component.

Park Does Not Engage Gear selector cable misadjusted, excessive play at parkingpawl washer, segment fitted incorrectly, parking pawl mechanismbinding or excessively worn.

Engine Will Not Start Start inhibitor switch faulty, excessive play at gearselector shaft.

Reverse Will Not Engage Gear selector control or selector cable misadjusted, oilfilter clogged, clutch "B" damaged, brake "D" damaged (engine will notdecelerate in 1st gear), governor sticking, or first and reverseinhibitor valve sticking.

Slips Or Vibrates When Accelerating From A Stop Clutch "B" or brake "D" damaged. Turbine shaft "O" ring orpump stator malfunction, or fluid pressure leaking into reverse clutchor piston.

Harsh Engagement From "P" To "R" Or From "N" To "R" Accumu-lator inoperative, shift cable misadjusted.

Lack Of Power, Poor Acceleration Torque converter malfunction, oil screen plugged, shiftlinkage out of adjustment, throttle or shift valve sticking.

No Reverse Lights; No Electrical Faults Inhibitor switch defective.

Vehicle Creeps In Neutral Shift cable misadjusted.

Harsh Engagement Shifting From "N" To "D" Accumulator "D" sticking or spring broken.

No 1-2 Upshift Or 2-1 Downshift Governor sticking or 1-2 shift valve binding.

No 1-2 Shift Brake "C" or band "C" malfunction.

No 2-3 Upshift Or 3-2 Downshift Governor sticking or 2-3 shift valve binding.

No 2-3 Shift Clutch "E" damaged or oil supply for clutch "E" leaking.

No 3-4 Upshift Or 4-3 Downshift Governor sticking or 3-4 shift valve sticking.

No 3-4 Shift Brake band "C" inoperative or loose, 2-3-4 upshift valvesticking or position 3 valve sticks.

Shifting Points Incorrect Throttle cable misadjusted, governor sticking, shift valvesbinding.

Vehicle Takes Off In 2nd Gear (No Downshift To 1st) Governor piston binding, 1-2 shift valve sticking or band "C"not releasing (adjusted too tight).

Vehicle Takes Off In 3rd Gear (No Downshift To 1st Or 2nd) Governor malfunction, 1-2 and 2-3 shift valves sticking orclosing gap in center plate leaking fluid pressure (reverse clutchstays applied).

A/T Shifts From 1st To 3rd 2-3 shift valve sticking, 2-3-4 shift valve sticking or 1-2-3shift valve sticking.

A/T Shifts From 1st To 4th Valve body malfunction.

No Kickdown Throttle valve cable misadjusted. Governor sticking orleaking, or shift valve binding.

A/T Noisy; Will Not Move In "D" Or "R" Converter drive plate damaged or oil pump gears worn ordamaged.

No Overrun Braking Brake band "C" defective.

TESTING

Preliminary Checks Begin diagnosis by checking easily accessible items such asfluid level and condition and cable adjustments. Check and adjustfluid level with A/T at normal operating temperature, parking brakeset and engine at curb idle speed. Correct fluid level is between ADDand FULL HOT marks. Perform appropriate basic procedure. One procedureis for vehicles that are driveable, and an alternate procedure is fordisabled vehicles.

Vehicle Is Driveable Check fluid level and condition. Adjust throttle and shiftcables if complaint was based on delayed, erratic or harsh shifting.Road test and note transmission operating characteristics. Refer todiagnostic charts and tables.

Vehicle Is Disabled Check for broken or disconnected throttle or shift cables.Check for cracked or leaking cooler lines. Raise vehicle, startengine, shift A/T into gear and check the following: If axle shafts donot turn and A/T is noisy, stop engine and remove oil pan forinspection. If no debris is found in pan, remove A/T and checkconverter drive plate, converter, oil pump, input shaft ordifferential. If axle shafts do not turn and A/T is not noisy, removeand repair or replace unit.

ROAD TEST

1) Operate A/T in all gear ranges while checking for slippageand shift variations. Note when shifts are harsh, spongy, delayed,early or if downshifts are sensitive. 2) Check closely for engine flare during shifts. Engine flareusually indicates clutch, band or overrunning clutch malfunctions.

Road Test Results Refer to specifications in the CLUTCH & BAND APPLICATIONtable and the SHIFT SPEED SPECIFICATIONS charts to provide a basis foranalyzing road test results.

CLUTCH & BAND APPLICATIONÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄGear Position Elements In Use

1st Gear ..................... Clutch "A", Brake "D", 1st Gear One-Way Clutch

2nd Gear ............ Clutch "A", Brake "C", Band "C" 2nd Gear One-Way Clutch3rd Gear ..................... Clutch "A", Clutch "E"4th Gear ....................... Band "C", Clutch "E"Reverse ....................... Clutch "B", Brake "D"ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

SHIFT SPEED SPECIFICATIONS TABLES

NOTE: Shift speed specifications not available for Dodge Monaco and Eagle Premier.

SHIFT SPEED SPECIFICATIONS (9000 TURBO, 2-STAGE)ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication MPH

Upshifts Light Throttle 1-2 Upshift ............................... 16-24 2-3 Upshift ............................... 27-34 3-4 Upshift ............................... 40-48 Wide-Open Throttle (1) 1-2 Upshift ............................... 35-42 2-3 Upshift ............................... 68-75 3-4 Upshift .............................. 98-105 Kickdown (Wide-Open Throttle, Maximum Speed) 4-3 Downshift ............................ 86-94 3-2 Downshift ............................ 68-75 2-1 Downshift ............................ 34-40

(1) - RPM should be between 5100-5700 for pre-1988 models and 4800-5400 for 1988 and later models.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

SHIFT SPEED SPECIFICATIONS (9000 TURBO, 3-STAGE)ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication MPH

Upshifts Light Throttle 1-2 Upshift ............................... 12-15 2-3 Upshift ............................... 25-31 3-4 Upshift ............................... 34-45 Wide-Open Throttle (1) 1-2 Upshift ............................... 34-41 2-3 Upshift ............................... 67-74 3-4 Upshift ............................... 87-97 Kickdown (Wide-Open Throttle, Maximum Speed)

4-3 Downshift ........................... 86-94 3-2 Downshift ........................... 56-62 2-1 Downshift ........................... 28-34

(1) - RPM should be between 5100-5700 for pre-1988 models and 4800-5400 for 1988 and later models.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

SHIFT SPEED SPECIFICATIONS (9000/9000i/s, 2-STAGE)ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication MPH

Upshifts Light Throttle 1-2 Upshift ............................... 11-17 2-3 Upshift ............................... 24-30 3-4 Upshift ............................... 36-44 Wide-Open Throttle (1) 1-2 Upshift ............................... 32-38 2-3 Upshift ............................... 63-70 3-4 Upshift ............................... 86-93 Kickdown (Wide-Open Throttle, Maximum Speed) 4-3 Downshift ............................ 78-84 3-2 Downshift ............................ 51-57 2-1 Downshift ............................ 28-34

(1) - RPM should be between 5100-5700 for pre-1988 models and 4800-5400 for 1988 and later models.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

SHIFT SPEED SPECIFICATIONS (9000/9000i/s, 3-STAGE)ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication MPH

Upshifts Light Throttle 1-2 Upshift ............................... 11-15 2-3 Upshift ............................... 23-29 3-4 Upshift ............................... 33-42 Wide-Open Throttle (1) 1-2 Upshift ............................... 32-38 2-3 Upshift ............................... 62-69 3-4 Upshift ............................... 81-91 Kickdown (Wide-Open Throttle, Maximum Speed) 4-3 Downshift ............................ 78-84 3-2 Downshift ............................ 51-57 2-1 Downshift ............................ 25-31

(1) - RPM should be between 5100-5700 for pre-1988 models and 4800-5400 for 1988 and later models.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

LINE PRESSURE & STALL SPEED TESTS

Line Pressure Test 1) Perform line pressure test after A/T has reached operatingtemperature of 176øF (80øC). Ensure fluid level and condition havebeen checked and are acceptable. 2) Measure line pressure with gear selector in "N" and engineidling. Measure kickdown line pressure with throttle valve cablewithdrawn fully and engine speed at 2000 RPM. 3) Connect Oil Pressure Gauge to pressure port in A/Thousing. Use appropriate adapter for vehicles equipped with eitherfuel injected engines or with turbocharged engines. See Fig. 2. Startengine, obtain pressure readings and refer to specifications. Seeappropriate LINE PRESSURE & STALL SPEED SPECIFICATIONS table.

Fig. 2: Locating Pressure Test PortsCourtesy of Saab-Scania of America, Inc.

LINE PRESSURE & STALL SPEED SPECIFICATIONS

NOTE: Line pressure and stall speed specifications not available for Dodge Monaco, Eagle Premier and Saab 9000 Non-Turbo.

LINE PRESSURE & STALL SPEED SPECIFICATIONS (9000 TURBO) (1)ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

Pressure Pressure StallGear Engine @ Idle @ Kickdown SpeedPosition RPM psi (kg/cmý) psi (kg/cmý) RPM

"R" ... 900-950 ..... 150-179 .......... ..... ......... ..... (10.3-12.3)"N" ..... 875 ....... 103-115 ......... 178-198 ........ ..... (7.1-7.5) (12.3-13.7)"D" ... 900-950 ..... 103-115 .......... ..... ..... 2600-3100 (7.1-7.5)"1" ... 900-950 ..... 103-115 .......... ..... ..... 2600-3100 (7.1-7.5)

(1) - Test At normal operating temperature.ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

Stall Speed Test 1) Perform stall speed test with A/T at operatingtemperature. Check engine and A/T fluid to ensure proper levels andcondition. 2) Stall speeds are measured with gear selector in "D" and"1" positions. Parking brake and service brake must be applied fullywhile performing stall test. Connect an engine tachometer visible todriver. 3) Start engine, apply parking brake and service brake fully,then shift gear selector to "D" position. Ensure no one is in front orbehind vehicle and depress accelerator pedal to floor. Obtain engineRPM reading and release accelerator pedal immediately. 4) Allow ATF to cool, then repeat test with gear selector in"1" position. To prevent internal damage to A/T, DO NOT hold stallspeed any longer than 10 seconds. See LINE PRESSURE & STALL SPEEDSPECIFICATIONS table.

ON-VEHICLE SERVICE

SPEEDOMETER DRIVE/SPEEDOMETER SENSOR

Removal & Installation With a small hammer and pin punch, remove locking pin fromA/T case. Pull speedometer cable from A/T case. If equipped withelectronic sensor, remove retaining bracket and drive.

SERVO PISTON

Removal 1) Remove transmission fluid cooler. Compress piston andcover and remove cover snap ring. 2) Remove piston cover and band piston assembly. Remove anddiscard "O" rings from piston and cover. Clean piston and cover.Inspect for signs of wear or damage.

Installation 1) Install new "O" rings on band piston and piston cover.Install piston assembly and cover in case bore and ensure piston rodis seated in band. 2) Compress piston and cover and install cover snap ring.Remove tool and install transmission fluid cooler. Tighten cooler boltto 37 ft. lbs. (50 N.m).

NEUTRAL SWITCH REPLACEMENT

Removal 1) Disconnect neutral switch harness connector in enginecompartment. Raise vehicle and remove splash shield. 2) Remove bolt attaching switch bracket to A/T case andremove switch from case.

Installation 1) While under vehicle, feed switch harness up into enginecompartment. Install new "O" ring on neutral switch. 2) Insert neutral switch into A/T case, install switchbracket and tighten bolt to 89 INCH lbs. (10 N.m). 3) Install splash shield and lower vehicle. Connect neutralswitch harness connector in engine compartment.

VALVE BODY ASSEMBLY

Removal Shift A/T to manual 1st gear position. Remove oil pan boltsand oil pan. Remove larger valve body bolts. Remove valve bodyassembly and oil screen and cover.

Installation 1) Move gear selector lever counterclockwise to manual 1stgear position (last detent in counterclockwise direction). Pullthrottle cable to wide open throttle position to avoid jammingthrottle cam and piston during installation. 2) Set manual valve all the way into manual 1st gearposition. Align and install valve body assembly into A/T case. 3) Tighten valve body bolts to 89 INCH lbs. (10 N.m). Tightensmall (5mm) oil screen bolts to 44 INCH lbs. (5 N.m) and the larger(6mm) oil screen bolts to 71 INCH lbs. (8 N.m). 4) Install oil pan and tighten clamp nuts to 53 INCH lbs. (6N.m). Install splash shield, and lower vehicle. Install ATF and adjustthrottle cable.

THROTTLE VALVE CABLE REPLACEMENT

Removal 1) Loosen lock nuts securing throttle valve cable in bracketat throttle body. Disconnect cable from throttle lever and remove from

AUTO TRANS OVERHAUL - ZF 4HP 18

bracket. 2) Remove valve body. See VALVE BODY ASSEMBLY. Disconnectthrottle valve cable from pin on throttle cam. 3) Using a 10-mm socket and extension, push throttle valvecable out of A/T case. See Fig. 3. Remove cable.

Installation & Adjustment 1) Install new "O" ring on cable and lubricate with ATF orpetroleum jelly. Insert cable into A/T case. 2) Connect cable to throttle cam. Install valve body. SeeVALVE BODY ASSEMBLY. Install splash shield. 3) To set throttle valve cable adjustment, ensure throttlelever is at curb idle position. Using vernier calipers or a fabricatedgauge that can be slipped over the throttle cable wire, set cabletravel to 1.55" (39mm) for the Monaco and Premier and .079-.098" (2.0-2.5 mm) for the 9000. See Fig. 4.

Fig. 3: Removing Throttle Valve Cable From CaseCourtesy of Chrysler Corp.

Fig. 4: Checking Throttle Valve Cable Adjustment

GOVERNOR

Removal 1) Raise vehicle and remove left front wheel. Removereduction gear cover bolts and cover. Ensure transmission is in park.Remove bolt on driven gear and remove gear with taper roller bearing. 2) Use a heat gun to heat outer race of taper roller bearing.Remove outer race (use a jaw type puller if necessary). Removegovernor with governor housing. Thoroughly clean governor if reusing.

Installation Apply petroleum jelly to governor seals and install governor(ensure governor is fully seated). Heat case with a heat gun beforeouter race installation. Install outer race. install clamping sleeveand driven gear. Tighten driven gear bolt to 110 ft. lbs. (150 N.m).

Governor Disassembly Remove governor cover and governor valve assembly. Separategovernor valves from governor body, and remove seal rings fromgovernor body. See Fig. 5.

AUTO TRANS OVERHAUL - ZF 4HP 18Article Text (p. 13)1991 Eagle PremierFor Dan's Transmission Service 10 Jefferson Place Fort Walton Beach FL 32548

Fig. 5: Removing & Installing Governor (Typical)Courtesy of Chrysler Corp.

Governor Reassembly 1) Install new oil seals in governor support. Seal positionis important. Install small diameter seal with seal lip toward therear of governor support. 2) Install large diameter seal with seal lip facing out.Install new "O" rings on governor support. Lubricate with petroleumjelly. Install governor valves on governor body and tighten bolts to89 INCH lbs. (10 N.m).

AXLE SHAFTS

Removal & Disassembly (Left Side) 1) Remove left front wheel. Remove drive axle from left axleshaft. Remove 5 bolts from bearing housing. Pull output shaft withbearing assembly from case. 2) To disassemble, remove tappet and compression spring frominside of shaft. Remove "O" ring from bearing housing. Remove snapring from shaft. Separate drive shaft from bearing housing using aplastic mallet. Remove seal and bearing from housing.

Assembly & Installation (Left Side) Press new bearing assembly into housing and install seal.Install axle shaft and snap ring. Install "O" ring, spring and tappet.See Fig. 12. Start shaft into housing and install 5 bolts. Tightenbolts to 17 ft. lbs. (23 N.m).

Removal (Right Side) Remove right front wheel. Remove drive axle from right axleshaft. Remove dust cover and "O" ring. Remove snap ring. Using a slidehammer and adapter, remove axle shaft.

Installation (Right Side) Press axle shaft into case using appropriate driver. Installsnap ring, "O" ring and dust cover.

PARKING PAWL COMPONENTS

Removal & Disassembly 1) With the valve body and reduction gear cover removed,disconnect the throttle valve cable from the throttle cam. Remove thethrottle cam assembly. Refer to VALVE BODY ASSEMBLY and GOVERNOR underON-VEHICLE SERVICE. 2) Disconnect and remove A/T shift lever, and discard shiftlever nut (nut is not reusable). Press detent spring to one side witha screwdriver, then remove stop plate with rotating motion. SeeFig. 15. 3) Remove clamp and connecting rod from A/T case. Removedetent spring attaching screws and remove spring. Spring positioningpin will normally remain in case, if not, remove pin with pliers andset aside for reassembly. 4) Remove parking pawl pressure spring, parking pawl pin andparking pawl. Disassemble gear selector assembly if necessary.

Reassembly & Installation 1) Install parking pawl and pin in A/T case. Reassemble gearselector if necessary. Hook ends of retainer spring in slots oflocking cam and selector disc and seat cam on disc. Set gear selectorassembly aside; DO NOT install at this time. 2) Install Detent Spring Alignment Tool (6155) in gearselector shaft hole. Install positioning pin (if removed), and installdetent spring on positioning pin. Press and hold spring against

alignment tool and install screws. Tighten screws to 89 INCH lbs. (10N.m) and remove alignment tool. 3) Install gear selector assembly while pushing detent springaside with screwdriver. Install connecting rod and pawl pressurespring. Place spring on pawl slot pin and install rod. See Fig. 13. 4) Install connecting rod clamp and push into place using ascrewdriver. Install throttle cam and tighten bolt to 44 INCH lbs. (5N.m). Connect cable to throttle cam. 5) Install A/T shift lever and tighten new lever retainingnut to 12 ft. lbs. (17 N.m). Install reduction gear cover and valvebody. See VALVE BODY ASSEMBLY and GOVERNOR under ON-VEHICLE SERVICE.

REMOVAL & INSTALLATION

See the TRANSMISSION REMOVAL & INSTALLATION - A/T article inthe AUTOMATIC TRANS SERVICING section.

TORQUE CONVERTER

Torque converters used with ZF 4HP 18 transaxles are notserviceable. If damaged in any way or contaminated, converter must bereplaced. The transaxle assembly must be removed to access torqueconverter.

TRANSAXLE DISASSEMBLY

1) Mount transmission on work bench and secure with oil panfacing upward. Remove torque converter, oil filter cover and oildipstick. Remove oil pan and valve body assembly. Remove 18 bolts andtorque converter housing on input shaft. Lift out differentialassembly. 2) Remove tappet and compression spring from input shaft.Remove intermediate plate with oil pump and clutch "C". Remove anglewasher and shims from turbine shaft. Turn turbine shaft back and forthwhile removing clutch "A", clutch "B" and 2nd gear one-way clutchassembly. 3) Remove brake band and engine shaft with clutch "E". Removeintermediate shaft with 2 axial washers and axial needle bearing.Remove sun gear shaft with axial bearings, washer and angle washer.Remove pot with axial bearing, axial washer, angle washer and sungear. Lift out planetary spider assembly with axial bearing, washerand angle washer. 4) Turn transmission over, remove spur gear cover and engageparking pawl. Loosen spur gear bolts, but DO NOT remove. Turntransmission over with oil pan side facing upward. Release parkingpawl and remove spur gear bolts. Remove spur gear and output shaft. 5) Remove spider pot. Remove hexagon bolt, spur gear andadjusting washer. Remove countershaft. Remove inner race from spurgear (output shaft).

6) Remove tapered roller bearing inner shaft of spur gear(countershaft). Tapered roller bearing inner ring on countershaft canbe pressed off. Turn transmission housing on end and remove bearingouter race with 2 jaw bearing puller. Remove sleeve and governorassembly. 7) Turn transmission with pan facing upward and removeslotted nut. Remove bearing ring with 1st gear assembly and retainerwasher. Depress brake "C" servo cover. Remove retaining ring andpiston "C" assembly. Remove adjusting bolt and pin. 8) Lift out brake "D" clutch discs and plate spring. Usecompressed air to remove piston "D". Release snap ring and removediscs from clutch "B". Remove clutch "A" and "E" assembly, outputshaft and 1st gear one-way clutch. Remove governor and differentialassembly. Remove input shaft speedometer from converter housing.Remove selector mechanism and parking interlock from transmissionhousing. For further information on individual components, seeCOMPONENT DISASSEMBLY & REASSEMBLY below.

COMPONENT DISASSEMBLY & REASSEMBLY

BAND SERVO, BRAKE "C" & OIL PUMP

Disassembly 1) Press down on servo piston cover and release snap ringwith a screwdriver. Remove cover and servo piston "C" assembly.Disassemble piston by removing snap ring and separating plate springs.Remove piston "C" pin from housing by loosening adjusting pin. Removeband from housing. See Fig. 6. 2) Remove intermediate plate bolts and separate pump fromintermediate plate. It may be necessary to tap with plastic hammer toremove pump. Rectangular plates and locating pin remain inintermediate plate. Disassemble pump by removing pump gears. Removecom-pression spring and valve with cap from intermediate plate. SeeFig. 7. 3) Remove snap ring from groove and remove all clutch discs.Using press and brake "C" together with plate spring. Press out piston"C" by screwing in 2 bolts from pump side.

AUTO TRANS OVERHAUL - ZF 4HP 18Article Text (p. 17)1991 Eagle PremierFor Dan's Transmission Service 10 Jefferson Place Fort Walton Beach FL 32548

Fig. 6: Exploded View Of Band "C" & ServoCourtesy of ZF Getriebe GMBH Saarbrucken

Fig. 7: Exploded View Of Brake "C" With Intermediate Plate & Oil PumpCourtesy of ZF Getriebe GMBH Saarbrucken

Cleaning & Inspection Clean all parts with solvent and dry with compressed air.Inspect all parts for excessive wear and damage. Replace parts (asnecessary). Replace all seals and "O" rings.

Reassembly

1) Install new "O" ring on band anchor pin and insert intohousing. Install adjusting bolt with wave washer partially intohousing. If piston was disassembled from pin, install thicker washeragainst collar of pin. See Fig. 14. Install sleeve into servo cylinderhousing using appropriate mandrel. 2) Lubricate and install new "O" ring on servo piston.Install springs over piston shaft and slide into housing. Installservo cover. Insert snap ring, remove mounting device and installscrew plug. Install brake band. Fit flush with shoulder intransmission housing. 3) Install pump gears into pump housing. Ensure mark at topof pump housing and outer pump gear are visible. Install 2 straightpins into intermediate plate using a plastic hammer. Install assembledtorque converter pressure relief valve into intermediate plate. 4) Insert compression spring into pump opening and installintermediate plate onto pump housing. Install intermediate plate andpump housing. Tighten 6 Torx bolts to 89 INCH lbs. (10 N.m). Spin pumpshaft to ensure smooth rotation. Install rectangular rings onto hub. 5) Fit "O" ring on clutch piston "C", lubricate piston withpetroleum jelly and press piston into intermediate plate. Insertcomplete set of clutch discs. Install end disc and secure with snapring. 6) Install measuring bar and dial indicator, position tip onend disc and zero gauge. Manually lift complete set of discs andrecord readings. Release clearance should be .05-.06" (1.3-1.6 mm). Ifreadings differ from these readings, install correct size snap ring.

BRAKE "D"

Disassembly Remove snap ring and remove complete set of brake "D" discsand plate spring. Use compressed air to remove piston "D" out oftransmission housing oil passage. See Fig. 8.

Cleaning & Inspection Clean all parts with solvent and dry with compressed air.Inspect for excessive wear and damage. Replace disc set as a unit.

Reassembly 1) Install new "O" rings into piston and insert piston intohousing with raised face up. Insert plate spring with convex surfacefacing plate spring. Insert complete set of brake "D" discs. Beginwith spring disc followed by outer disc and lined disc, end with enddisc.

NOTE: Manufacturer does not provide snap ring thickness information.

2) Install .04" (1.0 mm) snap ring. Install measuring bar anddial indicator and zero dial. Manually lift complete set of discs and

record clearance. Release clearance for 5 pairs of discs should be .07-.09" (1.7-2.2 mm) and clearance for 6 pairs of discs should be .09-.10" (2.0-2.5 mm). If readings differ from these readings, installcorrect size snap ring.

Fig. 8: Exploded View Of Brake "D" With 1st Gear One-Way ClutchCourtesy of ZF Getriebe GMBH Saarbrucken

CLUTCH "B"

Removal Remove snap ring from clutch and clutch discs. Using pressand adapter, compress plate spring and release split retaining ring.Remove plate spring. Use compressed air to remove piston out of oilfeed bore. Remove piston intermediate ring. Press out overrun clutchinner ring and separate 2 cover washers from outer ring. See Fig. 9.

Cleaning & Inspection Clean all parts with solvent and dry with compressed air.Inspect all parts for excessive wear and damage. Replace parts (asnecessary).

Reassembly 1) Install new "O" ring on hub and lubricate with petroleumjelly. Install intermediate ring with chamfer facing inward. Installnew "O" ring on piston, lubricate and install into clutch drum. 2) Using centering ring, insert plate spring. Using press and

mounting device, depress plate spring, install thrust washer andsecure with split retaining ring. Install clutch discs and secure withsnap ring.

Fig. 9: Exploded View Of Clutch "B"Courtesy of ZF Getriebe GMBH Saarbrucken

CLUTCH "A"

Disassembly Use snap ring pliers to remove snap ring and turbine shaftfrom clutch "A". Remove snap ring from cylinder. Remove complete setof discs and spring disc. Use press and adapter to press down baffleplate and release snap ring. Remove baffle plate and 2 plate springs.Place compressed air gun against one of 2 oil feed bores and, usingcare, remove piston with compressed air. See Fig. 10.

Cleaning & Inspection Clean all parts with solvent and dry with compressed air.Inspect for excessive wear or damage. Replace parts (as necessary).

Reassembly 1) Install new "O" rings onto clutch piston and installpiston into cylinder. Insert plate spring and plate spring with curvedface pointing up. Fit "O" ring into baffle plate and apply petroleumjelly prior to seating baffle plate into clutch housing. See Fig. 10. 2) Install snap ring and insert clutch discs. Begin withspring disc, followed alternately by steel discs and lined discs.Install end disc and secure with snap ring. Install 2 rectangularrings onto turbine shaft and engage hook. Press turbine shaft ontoclutch "A" and install locking ring. Ensure turbine shaft seats withsnap ring, otherwise axial reading will be false. 3) Insert clutch "A" assembly, turning back and forth untilteeth of discs engage. Ensure plastic thrust washer is centered onengine shaft. If correctly installed, engine shaft projects

approximately .9" (22 mm) over turbine shaft.

Fig. 10: Exploded View Of Clutch "A"Courtesy of ZF Getriebe GMBH Saarbrucken

CLUTCH "E"

Disassembly 1) Remove thrust washer off engine shaft. Remove snap ringand lift out complete set of discs. Press down plate spring "E" andremove split retaining ring. 2) Remove plate spring and use compressed air gun to forcepiston out. Rectangular rings remain on engine shaft. White plasticrings have chamfered ends. See Fig. 11.

Cleaning & Inspection Clean all parts with cleaning solvent and dry with compressedair. Inspect all parts for excessive wear or damage. Replace parts asnecessary.

Reassembly 1) Install new "O" ring onto piston and apply a light coatingof petroleum jelly. Press assembled piston onto cylinder of engineshaft. Using press and adapter, compress 2 plate springs. Secure withsplit retaining ring. 2) Insert clutch discs beginning with steel disc followedalternately by lined disc and steel disc. On models with 5 pairs ofdiscs, end disc is installed with recess to outside. Secure disc setswith snap ring. 3) Install 2 rectangular rings onto engine shaft and engagehook. Coat rings with petroleum jelly. Install thrust washer. Install

engine shaft while turning back and forth. If installed correctly,shoulder of clutch "E" is flush with edge of disc carrier on sun gearshaft.

Fig. 11: Exploded View Of Clutch "E" With Engine ShaftCourtesy of ZF Getriebe GMBH Saarbrucken

OUTPUT SHAFT & 1ST GEAR ONE-WAY CLUTCH

Disassembly Remove snap ring from housing and separate hollow gear fromoutput shaft. Remove tapered roller bearing with inner race. Pulloverrun clutch inner race from assembly. Remove snap ring from outerrace and disassemble.

Cleaning & Inspection Clean all parts in solvent and dry with compressed air.Inspect all parts for excessive wear and damage. Replace parts (asnecessary).

Reassembly Install plate springs and install snap ring. Press in one-wayclutch inner race in clutch housing. Press on tapered roller bearingwith race. Install hollow shaft into overrun clutch housing and securewith snap ring.

GOVERNOR

Disassembly Remove bolts and separate 1st and 2nd stage valve assembliesfrom hub. Pull piston cover plate and remove piston of 1st stage.Using a screwdriver to press down on compression spring, removeretaining plate, compression spring and piston of 2nd stage.

Cleaning & Inspection Clean all parts with cleaning solvent and dry with compressedair. Replace complete governor housing if damaged. Stop plate andretaining plate may be replaced separately. Replace parts (asnecessary).

Reassembly 1) Insert governor piston into valve housing and secure witha washer in 1st stage housing. To assemble 2nd stage, insert governorpiston, install 2 compression springs into piston and secure withretaining plate. 2) Install 1st stage and 2nd stage of governor housing intogovernor flange with each stage covering one straight and one angledoil feed passage. Tighten Torx bolts to 89 INCH lbs. (10 N.m). Fitrectangular ring onto first governor flange and secure hook. Insert 2rubber rings into middle and rear annular groove. DO NOT distortrubber ring excessively. Lubricate rubber rings with petroleum jellywhen installing into transmission housing.

DIFFERENTIAL

Disassembly Press 2 axle bevel gears and thrust washers out ofdifferential cage. Install differential into soft jaw vise and removering gear from differential. Pull tapered roller bearing and race offdifferential and remove speedometer worm gear.

Cleaning & Inspection Clean all parts with solvent and dry with compressed air.Inspect all parts for damage and excessive wear. Replace differentialhousing if damaged or worn.

Reassembly 1) Insert 2 axle bevel gears into differential housing,ensuring both axle bores are aligned. Press tapered roller bearing andrace onto housing. Turn differential over. Install tension pin intospeedometer worm gear until seated. Install worm gear intodifferential with tension pin fitting into notch in housing. 2) Press on tapered roller bearing and race using press andadapter. Place differential housing into soft jawed vise. Install ringgear and tighten bolts to 57 ft. lbs. (77 N.m) in a crisscrosspattern.

AXLE SHAFTS

Disassembly 1) Remove retainer speedometer drive sleeve and shaft. Remove"O" ring, seal and snap ring from right axle shaft. Remove right axleshaft and shaft seal with a plastic hammer. Remove shaft seal. Presslocking ring and roller bearing from axle shaft. See Fig. 12. 2) Using a punch and drift, remove shaft seal from converter

housing. Remove bearing race from converter housing. Remove left axleshaft by removing bearing cover bolts. Remove shaft from case with aplastic hammer. 3) Remove snap ring from left axle shaft. Using press andadapter, press shaft out of bearing housing and remove shaft seal.Using centering tool, press roller bearing out of bearing housing.

Fig. 12: Exploded View Of Final Drive ComponentsCourtesy of ZF Getriebe GMBH Saarbrucken

Cleaning & Inspection Clean all parts in cleaning solvent and dry with compressedair. Inspect all parts for excessive wear or damage. Replace parts (as

necessary).

Reassembly 1) Press outer bearing race into converter housing. Pressroller bearing onto right axle shaft and secure with snap ring. Insertaxle shaft into converter housing and press shaft seal in place.Secure assembled right axle shaft with snap ring. Slip on "O" ring andinstall seal until seated. 2) Insert assembled speedometer into converter housing,ensuring hexagon of speedometer sleeve meshes with cast contour ofspeedometer bore. Press on a new retaining ring. 3) Using a press and adapter, press axle bearing into leftaxle bearing housing. Turn bearing housing over and press axle shaftseal into housing with adapter. Press left axle shaft into bearinghousing using adapter. Secure axle shaft with snap ring.

NOTE: Differential preload should be checked when replacing any final drive components including axle shafts or bearings. For preload procedures, see steps 33)-35) under TRANSAXLE REASSEMBLY.

SELECTOR MECHANISM & PARKING PAWL

Disassembly 1) Detach throttle valve cable from cam and pry out housingwith 2 screwdrivers. Remove retaining bolt and remove accel-erator camaxle together with leg spring and accelerator spring. Remove bolts andremove detent spring and pin. See Fig. 13. 2) Remove screw plug and withdraw support shaft. Use punch tomove tension pin enough to remove selector shaft. Remove segment withlocking cam and adjusting washer by pressing pawl down slightly. 3) Remove pin at annular groove and remove pawl with legspring. Remove 2 bearings outer races. Remove shaft seal and selectorshaft. Remove dipstick tube and oil tubes. DO NOT damage sealingsurface of housing or reuse oil tubes. Remove all screw plugs to cleanhousing. Leave locating pin and outer turbo feed tube intransmissionhousing.

Cleaning & Inspection Clean all parts with cleaning solvent and dry with compressedair. Replace all seals and "O" rings. Inspect all parts for excessivewear and damage. Replace parts (as necessary).

Reassembly 1) Coat new selector shaft seal and install in case. Installparking pawl, spring and insert pawl pin. See Fig. 13. Tightensecuring bolt to 23 ft. lbs. (32 N.m). Install detent spring andtighten bolts to 89 INCH lbs. (10 N.m). 2) Install selector mechanism gears and shaft. Ensureselector gear teeth mesh. Install assembled accelerator cam axle and

tighten bolts to 89 INCH lbs. (10 N.m). Install new accelerator cableinto transmission housing and pretension accelerator cam by rotatingone revolution and inserting accelerator cam nipple.

Fig. 13: Exploded View Of Linkage ComponentsCourtesy of ZF Getriebe GMBH Saarbrucken

TRANSAXLE REASSEMBLY

1) On turbo model, install turbo pressure feed tube intotransmission housing with a plastic hammer (if removed). Install plugsinto housing. Tighten plugs to 11 ft. lbs. (15 N.m). Screw 2 plasticplugs into housing oil cooler line connection hole. Install dowel intotransmission housing using a plastic hammer. 2) With a heat gun, heat transmission housing to 158øF (70øC)and install countershaft tapered roller bearing outer ring. Installshaft seal into transmission housing. Assemble pawl and spring andpress pin into housing, securing pin with Torx bolt. Tighten bolt to89 INCH lbs. (10 N.m). Assemble locking cam and install into housing,tightening Torx bolt to 23 ft. lbs. (32 N.m). 3) Insert Detent Adjustment Tool (5P89002021) and installdetent spring. See Fig. 13. Tighten detent spring bolt to 89 INCH lbs.(10 N.m). Install assembled selector mechanism into housing. Usefollowing formula to determine thickness of washer used on selectorassembly.

S = X - .40" (.10 mm) S = Thickness of washer X = Value to be measured .40" (.10 mm) = Standard clearance

Insert correct size washer to meet standard clearance byremoving stop plate and withdrawing selector shaft enough to installwasher. 4) Assemble and install throttle cam and throttle cable intotransmission housing and pretension throttle cam by rotating onerevolution and inserting nipple of cable in cam. Install brake "C"band anchor pin into housing and hold in place with adjusting bolt.Assemble piston "C" according to version being used. See Fig. 14.

Fig. 14: Identifying Band Servo Piston VariationsCourtesy of ZF Getriebe GMBH Saarbrucken

NOTE: Certain transmission versions require a sleeve to be inserted with servo piston "C".

5) Install piston "C" into transmission housing. Withmounting device, press piston cover slightly and install snap ring tosecure piston "C". Turn transmission over and install brake band intohousing. Fit lugs of brake band into 2 pins. Ensure brake band seatsinto transmission housing shoulder. 6) Assemble and install brake "D" clutch discs intotransmission housing and secure with snap ring. Install measuring barand dial indicator. Manually lift complete set of clutch discs andread clearance of discs. Clearance for 5 pairs of clutches should be .07-.09" (1.7-2.2 mm). Clearance for 6 pairs of clutches should be .08-.10" (2.0-2.5 mm). Remove brake "D" disc set and insert 1st gear one-

way clutch into gearing in transmission housing. Ensure inner ring ofone-way clutch does not fall out. Turn transmission over while holdingfree-wheel in place. 7) Set tab washer with locking lug into transmission housing.Install slotted nut and tighten to 68 ft. lbs. (50 N.m). Bend lock tabinto nut seat. Ensure free-wheel turns freely in clockwise direction.Reinstall brake "D" disc set and secure with correct washers. Installspider bowl into one-way clutch inner ring. Press tapered rollerbearing inner ring onto output shaft. Insert output shaft into hollowgear and secure with snap ring. See Fig. 15.

Fig. 15: Exploded View Of Planetary Gears & Related ComponentsCourtesy of ZF Getriebe GMBH Saarbrucken

8) Install output shaft/hollow gear assembly intotransmission case. Install needle bearing assembly along with flatwasher and angle washer in output shaft assembly. Install planetarycarrier into hollow gear. Install sun gear into planetary carrier. Fitsun gear pot onto teeth of sun gear. 9) Install needle bearing assembly along with flat washer andangle washer into sun gear pot. Insert sun gear shaft into sun gearpot. Ensure when rotated, sun gear pot rotates in opposite direction

from sun gear shaft. Install needle bearing assembly along with flatwasher and angle washer over the end of the intermediate shaft. Insertintermediate shaft into sun gear shaft. 10) Fit rectangular rings and thrust washer on engine shaft.Install assembled clutch "E" and engine shaft assembly into case.Ensure shoulder of cylinder "E" is flush with edge of disc carrier onsun gear shaft. 11) Assemble clutch "A" and install 2 rectangular rings ontoturbine shaft and engage hook. Press turbine shaft into clutch "A"cylinder and engage locking ring with snap ring pliers. Pull onturbine shaft until it seats with snap ring, otherwise axial clearancewill be incorrect. Insert assembled clutch "A", rotating until teethof discs engage. Plastic thrust washer must be centered on engineshaft. If correctly installed, engine shaft will project approximately.8" (22 mm) over turbine shaft. 12) Assemble clutch "B" and install into case by turninguntil discs fully engage. Clutch "B" must engage in recesses of potfor a gap of .04" (1.0 mm) to be still visible. 13) Assemble pump housing and torque converter pressurerelief valve, and install on intermediate plate. Insert compressionspring into opening in pump, place intermediate plate onto pumphousing and align. Bolt intermediate plate to pump housing; tightenbolts to 89 INCH lbs. (10 N.m). Inspect torque converter relief valveto ensure it operates freely. Ensure pump operates freely. Install 3rectangular rings onto hub of intermediate plate. 14) Assemble one-way clutch by inserting cage of one-wayclutch into collar with collar facing down. If not installed properly,clamping direction will not be correct. Install cover rings on one-wayclutch collar. Insert one-way clutch inner race by turning itclockwise. One-way clutch inner race must rotate freely in clockwisedirection with collar pointing out. 15) Install .04" (1.0 mm) selective adjusting washer andangle washer onto shaft. DO NOT install 2nd gear one-way clutch duringmeasurement process. Insert assembled pump and intermediate plate.Rotate back and forth until fully engaged. Hold in place with 2opposing bolts. Tighten bolts to 89 INCH lbs. (10 N.m). Installmeasuring tool onto turbine shaft and secure tightly. 16) Measuring tip of dial indicator must rest on impellershaft. Pull on measuring device to obtain reading. Axial clearanceshould be .004-.012" (.10-.30 mm). If reading differs from thisclearance, select correct washer. Remove intermediate plate assembly.Install angle washer and adjusting washer onto hub of intermediateplate. 17) Install 2nd gear one-way clutch into lined discs of brake"C" with inner teeth seated on washer. Ensure all lined discs meshwith one-way clutch inner race. Do this by rotating outer race; lineddiscs must also turn. 18) Tighten adjusting washer of brake band in order to securecylinder "B" in place. Insert assembled pump, intermediate plate and2nd gear one-way clutch into transmission. Rotate back and forth to

seat unit. When inserting unit, hold one-way clutch to avoid discsslipping out. When properly installed, plate springs seat intotransmission housing when pressure is applied against pump housing. 19) Install 8 bolts into intermediate plate and tighten boltsto 89 INCH lbs. (10 N.m). Loosen brake band and check axial clearance.Assemble governor housing on governor hub. Tighten retaining bolts to89 INCH lbs. (10 N.m). Install rectangular ring on end groove ofgovernor hub and snap hook. Insert 2 rubber rings into middle and reargroove. DO NOT stretch rings unnecessarily. 20) Coat rubber rings and rectangular ring with petroleumjelly. Carefully insert assembled governor unit into transmissionhousing. Use care installing rubber rings into annular groove. Installtapered roller bearing inner race onto countershaft. Insertcountershaft into engaging gears of governor flange while rotatingshaft and holding flange in position to prevent it from falling out. 21) Install retaining tool to hold countershaft in placewhile turning transmission over. Slip spacer sleeve over countershafton governor unit. Install outer race of tapered roller bearing withplastic hammer until seated. Outer ring must be seated with noclearance to ensure correct adjustment. 22) Press tapered roller bearing inner race onto spur gear.Install .07" (1.9 mm) washer and spur gear onto countershaft andsnugly tighten bolt. See Fig. 16. Drive the 3 tension pins ofadjusting ring until they protrude. Install adjusting ring ontotapered roller bearing inner race of output shaft with tension pinsfacing up and install on spur gear.

Fig. 16: Exploded View Of Spur Gears, Countershaft & Governor

Courtesy of ZF Getriebe GMBH Saarbrucken

23) Engage parking pawl. Tighten countershaft nut to 44 INCHlbs. (5 N.m) to ensure tapered roller bearings are seated. Releaseparking interlock, rotate spur gears several times, tightencountershaft nut to 44 INCH lbs. (5 N.m) and rotate again. 24) Loosen nut, remove spur gear and use micrometer tomeasure thickness of washer at 3 tension pins of adjusting sleeve.Average 3 readings and install correct washer.

NOTE: See manufacturer's parts list for correct size washers.

25) Insert correct washer and spur gear onto countershaft.Loosely tighten countershaft bolt. Install Pretension Device(5P95000300) on differential side of countershaft.

NOTE: Always insert thickest washer to assure proper clearance. Engage parking interlock and tighten nut to 110 ft. lbs. (150 N.m).

26) Attach measuring tool with dial indicator. Turn adjustingscrew down for gauge pointer to move. Set gauge scale to zero; rotatespur gears several times while doing this. If pointer deflects to endof scale, record readings to determine average reading. Loosenpretensioning device on bottom of transmission. Tighten adjustingscrew one turn. 27) Rotate spur gears several times until pointer of dialindicator has settled. Record readings and obtain an average. Usefollowing formula to obtain correct washer thickness.

S = Specific thickness of washer X = Reading on dial indicator .03" = Clearance of washer selected S = .07" - .03" S = .04" (1.02 mm) washer is correct size of washer to install.

NOTE: If it is necessary to install a washer of different thickness, it is recommended to repeat measurement steps. Nut must be tightened to 110 ft. lbs. (150 N.m).

28) Install spur gears and washer, and tighten bolt to 110ft. lbs. (150 N.m). DO NOT install end cover and gasket at this time;differential housing must be rotated over countershaft to seatbearings. This step must be repeated for subsequent adjusting ofpreload. 29) Install shaft seal into converter bellhousing and coatseal with petroleum jelly. Turn over converter bellhousing and installbearing race until it is seated. Press roller bearing onto right axleshaft and secure with snap ring.

30) Insert axle shaft into converter bellhousing. Install newshaft seal and assembled right axle shaft. Secure assembled right axleshaft with snap ring. Slip new "O" ring on shaft and install axleseal. Install "O" ring on speedometer sleeve. Insert speedometerpinion into speedometer sleeve and install sleeve. 31) Insert assembled speedometer drive into converter housingensuring speedometer seats properly into speedometer bore. Install newretaining ring. Install converter housing gasket and converterhousing. Tighten bolts to 17 ft. lbs. (23 N.m). 32) Press left axle shaft bearing into bearing housing. Pressaxle shaft seal into other end of bearing housing. Press left axleshaft into bearing housing and secure axle shaft with locking ring.Install differential bearing race into transmission housing. Ifnecessary, preheat housing with heat gun. 33) Measure shoulder of axle shaft bearing housing andrecord, this is distance "B". Measure distance "A" between machinedsurface of converter housing (where axle bearing housing mates) anddifferential bearing race. Use following formula to determine washerthickness: "A" - "B" = Clearance. Insert correct washer and fit anadditional .02" (.5 mm) washer to preload bearing. Use followingformula: "A" - "B" + .02" (.5 mm) = X clearance. 34) Bolt axle shaft housing with "O" ring removed to allowaxle shaft to fit better. Tighten bolts to 16 ft. lbs. (23 N.m). Turncountershaft nut several times to seat tapered roller bearings. Removeaxle bearing housing bolts and measure gap between axle bearinghousing and mating surface of converter housing (clearance "H"). Usefollowing formula to find clearance "S".

"S" = Thickness of washer required "X" = Distance "A" - distance "B" + .5 mm "H" = Size of gap determined with feeler gauge "V" = Preload selected within specified limits

Example:

"S" = .04" "X" = .05" (.79" - .76" + .02" = .05") "H" = .01" (determined with feeler gauge) "V" = .004" (preload selected within specified limits)

Round up or down numerical size of washer to install washerof closest size needed. 35) Insert selected washer into bearing housing. Install "O"ring on bearing housing and install compression spring and tappet intoaxle shaft. Tighten bolts to 89 INCH lbs. (10 N.m). Install assembledleft axle shaft and tighten bolts to 16 ft. lbs. (23 N.m). Installspur gear cover and gasket. Brake band must be adjusted. 36) Apply a light coat of ATF to cylinder "B". Tighten brakeband bolt to 89 INCH lbs. (10 N.m). Turn cylinder "B" duringtightening operation to ensure brake band is not twisted. Loosen

adjusting bolt 2 turns. Mark adjusting bolt and housing to ensurescrew does not turn. Tighten lock nut to 59 ft. lbs. (80 N.m). 37) Insert oil tubes into mounting aid and install withplastic hammer until seated. Install dipstick tube into transmissionhousing and secure with a clamp. Tighten clamp bolt to 44 INCH lbs. (5N.m). Turn transmission on side to prevent bolt from falling intohousing. Set gear selector to position 1. 38) Pull accelerator cam, with accelerator cable, far enoughto prevent accelerator cam from jamming with throttle piston. Setselector valve (push in) in valve body to position 1. Install valvebody, with accelerator cable pulled out, ensuring selector valve isinserted in pin of stop plate. Tighten all bolts to 71 INCH lbs. (8 N.m).

NOTE: It is recommended to immediately adjust accelerator cable following installation of valve body to prevent cable from coming off cam.

39) Pull out accelerator cable, with sleeve extended, topoint of kickdown (noticeable resistance). Clamp lead seal 1.51-1.55"(38.5-39.5 mm) from end of sleeve. Check operation of acceleratorcable and selector mechanism. 40) On turbo version, install a new tube for charge airpressure feed to valve body together with new "O" rings and seat tubewith plastic hammer. Install new oil pan gasket and oil pan. Tightenbolts to 53 INCH lbs. (6 N.m). Install oil pan drain plug and tightenplug to 59 ft. lbs. (80 N.m). Install "O" ring and oil filter ontotransmission housing. 41) Install filter cover, with magnet. Install bolt andtighten to 71 INCH lbs. (8 N.m). Install torque converter and securewith retaining clamp. Install new "O" ring on dipstick and installdipstick.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONSÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄApplication Ft. Lbs. (N.m)

Brake Band "C" Lock Nut ......................... 59 (80)Converter Bell Housing Bolt ..................... 17 (23)Countershaft Lock Nut ......................... 111 (150)Differential Cover Bolts ........................ 17 (23)Differential Drain Plug ......................... 18 (25)Differential Fill Plug .......................... 37 (50)Exhaust Bracket-To-Rear A/T Bracket Bolt ........ 20 (27)Exhaust Pipe-To-Manifold Nuts ................... 23 (31)Exhaust Pipe-To-Pipe Bracket Nut ................ 23 (31)Fill Tube Bracket-To-Differential Cover Bolt .... 18 (25)Fill Tube-To-Oil Pan Nut ....................... 74 (100)

Front Pipe-To-Catalytic Converter Nuts .......... 25 (34)Governor Support Retainer Bolt .................. 17 (23)Input Shaft Housing ............................. 17 (23)Oil Pan Drain Plug .............................. 59 (80)Output Shaft Center Bolt ........................ 18 (25)Rear A/T Bracket Bolts .......................... 30 (40)Rear Cushion-To-Rear Bracket Bolt ............... 49 (67)Reduction Gear Case-To-A/T Case Bolts ........... 17 (23)Reduction Gear Case-To-Bearing Plate Bolts ...... 17 (23)Shift Cable Bracket-To-A/T Case Bolt ............ 15 (21)Shift Lever Nut (Non-Reusable) .................. 13 (17)Starter Bolts ................................... 31 (42)Throttle Cable Jam Nuts ......................... 11 (15)Transaxle Cooler Bolt ........................... 37 (50)

INCH Lbs. (N.m)

Detent Spring Bolt .............................. 89 (10)Detent Spring Screws ............................ 89 (10)Dipstick Oil Tube Bolt ........................... 44 (5)Dust Cover Bolts ............................... 106 (12)Engine Timing Sensor Bolts ....................... 71 (8)Governor Housing Bolts .......................... 89 (10)Governor Valve-To-Governor Body Bolts ........... 89 (10)Intermediate Pump Bolts ......................... 89 (10)Neutral Start Switch Bracket Bolts .............. 89 (10)Oil Pan Bolts .................................... 53 (6)Oil Pan Retaining Clamp Nuts ..................... 53 (6)Oil Screen Cover ................................. 71 (8)Oil Screen & Valve Body Bolts M5 Bolts ....................................... 44 (5) M6 Bolts ....................................... 71 (8)Speedometer Sensor Bolt ......................... 89 (10)Spur Gear Cover ................................. 89 (10)Throttle Cam Bolt ................................ 44 (5)Valve Body Bolts ................................. 71 (8)ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

END OF ARTICLE