CHECK HOLE SIZE! A paperclip should NOT fitthru hole! A feed hole .035" or larger floods EPCsolenoid, causing rough shifts and excess bindup dur-ing 2-3 shift (not enough psi DROP when TCU pulsesEPC solenoid). If paperclip fits thru hole, replace jetwith extra alum plug provided in kit. Remove jet, in-sert plug' in hole and smack with hammer to spreadtight. Drill a new .031-.033" hole in center of plug(fractional size 1/32"). NOTE: 1/32" drill not provided.

FITS Al1L KM electronic OverDriveThe VB mmodels with trans on driver side are tJ..eMIRROR IMAGE of~th1tshown in the instrUctions: ~

You're gonna love this product!The large high rez pictures and clear instructionsmake it nearly fool proof. I have to say nearlysince there will always be that one rocket scientistto prove me wrong. But for most of you DSM' ergand rice rocket fans.. take your time, payattention, don't get careless, and success. is justaround the comer. Hundreds of nonprofessionalshave installed this kit without complications.

Please follow the installation exactly as shownand do not /week our recommendations andsettings trying to get "fimler shifts" before you'veeven roadtested it. This kit provides fast, firm,high quality shifts right outa the box!

Dean MasonTransLab Product S\;lpport2740 W. Ball Rd. / uirit D2

Anaheim, California USA [92804]

HOTLINE 714-484-6657FAX 714-484-6697

email = deanmason@juno.com

1998 all rights reserved I revision 07-01-04ALL CONTENTS PRODUCED BY TRANSLAB C DEAN MASON I TRANS LAB MAR.

#42 = .093"Use FIVE DRILL BITS SUPPLIEDIN KIT [ 4 numbered / 1 fractional]

to enlarge holes shown above!! #35 = .110"

3/16" = .1"87"

page 3Hi tensUe strength ...won't push thru the holeLow speclflc gravity... won't beat up or rifle thru the plateUPPER

VALVEBODY

2-3 /4-3 shift

Iill1UillW11-2 shift

~ -:~ >: fJTJTJmnJ

rear clutch exhaust PURPLEfj,AAMA,wJ

-A- -B- stop A stopB

J~

hole/

plug A

1.I.lll.lJ.lllllll.lI!I~1 =shift control

large GRAY pressure regulator,.. (lllAAAAI ~

TC controlORANGE

U_11~11_1- UJJPR adjustment:1/2 - 1 threadsticking out atinner end ofadjuster

IFACES0 U T ! \

flat sides

- -N~D control \,IrmI.-1 I. r

! SILVER; SHIM SPRING-

, PUSH ONTO INNEREND OF N-D VALVE.Valve will NOT moveafter two screw retainer

bracket is mounted on.

~sure controlc'/:/inner

~

-~ - - -PRESSURE REGULATOR VALVE

/ CONVERTER LAND

bevel onangle if

nub isgone

wronggear

starts...commonassemblyerror...

valve stopincorrectlyinstalled

here\

~ softerrt

4

ORIGINAL RED BLACK

ALL PERFORMANCE APPLICA nONS INSTALLBLACK SPRING FOR FIRMEST SHIFTS.

(you will be IbIe k> feci ~t downshifts )

IF YOU...HA VB AN UNMODIFIED CONVERTER.

DO NORMAL STREET DRIVING(use your car to and from work) .PREFER LESS FIRM SHIFTS

(more comfortable coast downshifts) .USE RED SPRING

NOTE: upshifts with red spripg arestill much firmer than Stock.

SHIFf CONTROL VALVE ASSEMBLY

- ~ r ~ shift wI vlv ;.

IF TRANS HAs NEVER BEEN WORKED ON YOU CANSKIP THIS PORTION. IT'S A REPAIR TIP FORINCORRECfL Y MODIFIED PR VALVE.A tiny bevel ( 1/32" max) on one side of the converter landis ok. but land must close completely when PR valve isbottomed in it's bore. View land at notch in casting (seewhite circle/arrow above). ,:t!:CAUTION: If land is ground all the way'aroUnd and is openwhen bottomed, replace valve. End clutch damage and coastdownshift neuttaling could occur. If land is only slightlyope.n it may be repairable by grinding off some of the nubon inner (right) end to let PR valve sink deeper into the bar::.If nub is completely ground off, bevel end on angle shownabove to allow balance pressure under inner end of valve.

lilLUl,!,I,!,U1U-W-lj

Plugs must go outside the valve stops. Outer ends of shift conuol valvemust be able to go thru legs of valve stops when moving left and right.

plugB

tX

/in valve

LOWER VALVE BODY

Yellow

JmrtiYfffTTn

END clutch

LightBrownMWm

damper clutch control

«

N-R engagement control

reducing

MATCH VALVE TOCORRECT SPRING

MEASURE REDUCINGVAL VB LAND DIAMETERS

If a valve with lands thatdiffer by more than +/-

.001" is found USEORIGINAL SPRINGand please contact uswith vehicle VIN # .

tADJUST AS SHOWN BEWW.ADD 1 ADDITIONAL 1URN

CLOCKWISE FOR m-po USETYPE 1 TYPE 2

W\AAAAAAtLight Blue .393" .393".393" .493"

ADJUSTMENT - adjuster flush with casting ADJUSTMENT - Use .125"a feeler guage betweenadjuster and valve body

(1/8") drill bit likethe bottom of theca~ting

.

light or darkBlue

NON-LOCKUP MODELS:NO SPRING INSTALLED

Factory replaced damper clutchcontrol valve and spring witha one piece non-moving plug.

I LINE\PRESSURE

RELIEF

ATTENTION!Examine ball seat in plate and area of alumcasting in lower channel plate that guidesball & spring. If beginning to show damagefrom ball bouncing around, line pressurerelief been very active. Replace steel ballwith hi tension ball furnished, and reuse a 11

steel at one of the other locations that ! ~shows NO WEAR mark in plate. ~ ~

0./ ~REEN/,

1/4- STEELCHECKBALL

ACTUAL SIZE SHOWN

{~_. .385"

SAMPLE VAL VB BODY SHOWN IS KM175-177.W4A321 F4A33 I A4EFI MAY VARY SLlGHTL Y

G)

Late W4A33,F4A33, &A4AFIUSE LONGERBOLTS IN 2

PLACES

~ .745"

@ .855"

@ 1 . 1 75"

@ 1.330"

. Lay middle casting on upper VB. Install the #3 bolts fingertight.

. Place lower VB on middle casting, gently push down to

compress relief valve spring and install #6 with washer.. Insert alignment pins in holes as shown.

. Install all others shown except solenoid mounting bolts but donot tighten.

. Check seperator plate alignment thru VB to CASE ( lOmm

bolt) holes around outer edge.. SNUG bolts in this order: #6 with washer, two #7's, all #6's,

all #5's, two #2's, then all #3's.. TORQUE bolts to 55-60 inch Ibs in same order.

(70+ inch lbs will strip threads). . @ 1.570"

IMPORT ANT: Insert scribe through cover plate hole andstroke damper clutch valve. It must move freely! Stuckdamper valve can cause planetary bum out (no cooler flow).

CAREFUL not to overtighten & strip threads.2 lower VB mounting bolts don't thread deep.Torque 40-45 inch Ibs.

lower VB mounting bolt #6 with washeror#3

ALIGNMENTPINS

~WARNING:Filter boltstoo long willdamage VB!( bottom incasting anddistort lowerVB, bindingdamper valveor break thecasting atinner end ofreducingvalve causingneutraling,slips, flares,and irraticshifts. )

attachEPC

groundwirehere

lower VB mounting bolt

cover plate has hole here

view damper valve movement through openingpage 6

measure length 1

Early type flat bottom shift solenoids EARLY TYPE SOLENOm O-RINGS should have some press.

A That is, there should be a slight gap between solenoid and alum0 / / body that closes up when screws are tightened. With screws

removed there is a very slight "spring" feel when squeezing o-rings.

LATE PUSH-IN TYPE SHIFT SOLENOmS, use original or new -- -,from overhaul kit, whichever has fit tighter. Oiled rings must have ~

slight drag (press fit in bore).0r7 Rubber gaskets must compress to seal when solenoids are tightened. Replace if

<D e flattened out. Remove screens before blowing out solenoids. They'll go sailingacross the room never to be found. Reinstall after solenoids are cleaned and tested.

IN ",". '

lock-up

First design EPC uses TWO orings! ~~~/t

screens

J.&

IEPC

enlarge hole for plug in this portion only!

LOCATE PLUG HEREDOWN INSmE VALVE

t

1. Drill hole in cup plug furnished.Installing plug without drilling hole causes reverse bindshortly after engagement.

2. Push plug flush with end of valve with thumb.WARNING: forcing plug can break end of valve.Ifplug won't push flush with only thumb pressure, removesharp bevel inside enu of valve. Easiest is witt. high speedrotary file (carbide "burr") in drill or die grinder.

3. Stand valve on end on vise or hard surface.4. Carefully tap plug into position shown with a

hammer and small punch (approx 3/16" diameter).

INSERTPLUGHERE

1---,

l:

BLUE-EPC[ 2-4 ohms]

RED - lockup [ early 2-4 ohms][ late 13 ohms]

ORANGE - shift A [ 20-30 ohms]

YELLOW - shift B [ 20-30 ohms)

page 7 ground lead goes between shift solenoids and attaches here with #2 screv.

page 8 BAND ADJUSTMENT CRITICALno tighterthan 2 turns,

no looser than 2112 turns.

Here's how to check it...Insert .062" (1/16") drill bit in gap so servo pincushion can't compress. Air check through theband apply hole and measure pin travel. Withcushion blocked, total servo travel shouldbe .065" - .085" .

(at least 1/16", but less than 3/32")r

~;; ~ Only teflon is available for large servo wide band units (W4A33/ F4A33).When using poly seals scotchbrite the servo bore before washing case.

USE POLY "D" RINGS (rubber) ONSERVO PISTON whenever available

cushion

~t

Please always useFACTORY ORiGINALservo release spring[tension = 75-85Ib. @ 1"]

cushion gapin end ofservo pin

Without this kit a weaker servo sprin~may reduce 2-3 flare but caus~ coast3-2 bump & part-throttle 3-2 bang.

TCCrelease

TOOapply

pumpsuction

pumppr~ssure.

/ forward clutch(drum with shaft)reducing PSI cooler -

3rd 'reverse(front) clutchband release

...'1-~~ .band apply

'" "SERVO SWITCH TEST

Adjust band and installservo cover. Attach onevolt meter test probe toservo switch connectorand the other meterprobe to trans case...Select OHMS and aircheck the servo

'\

...., ..

CORRECT READINGS:With band released...

.1 - .3 OHMSWid1 band applied...

"OL" (out of limit)i.e., OPEN circuit

..(

adjustment--locknut

-SOLENoms MUST BE CLEANED WELL

\ Submerge in solvent until air bubbles stop. Swisht them around. Remove and blow lots of air into every':' hole and seam for 20-30 seconds each solenoid, then'" back in solvent. Repeat 1 0 times or until no more~ black soot (carbon/metal particles) deposit on your, hand after each air blast. The contamination content

! inside is surprising.

i TESTING TRANS (remote shift control)

-rmns stuck in failsafe? (full-time 3rd gear / no powerto\SOlenoids). Shift functions can be checked easily.

i Get two 12v DC toggle switches, some small 14"alligator clip leads, a large alligator for the battery +post, and a roll of 16 gauge wire (all Radio Shackitems). Fabricate test leads to supply battery voltagethru two toggle switches, which output to two smallalligator clip leads. Trans solenoid connector isusually clipped to air box mounting bracket. Unplugit and attach the small clip leads directly to trans shiftsolenoids (YELLOW and ORANGE wire pins). Shifttrans with toggles following the application shownbelow!

t

I IN-CAR ADJUSTMENTS I

Reducing Valve adjustment{ use 4mm socket or wrench}

~ COUNTER-CLOCKWISE for softershifts\(1 <J { higher reducing pressure = lower shift psi}

~ CLOCKWISE for firmershiftsV' 01 { lower reducing pressure = higher shift psi}

-.,'--:'.;::; , '.~- ,~ . '1

This kit ~ been t~sted and- proven in almost every ~

make and model car with every variation of the KMtrans. It provides adjustable shift feel and componenttiming for variations in engine size, performance, orTCU software. This kit plus corrected end play fixesall the problems listed front page of install portion.

1 week (200 mile) check is strongly recommend.Roadt~1eakcheck, and look over install. Catching

y ""

leaks earl~1especially axle seals) reduces costlycome;;.backs. A good hot road test reveals ~hat thecustomer has experienced during the break-inperiod.COMPLETELY STRIP AND CLEAN THE VBIt's usually..Joadcd v.ith-carbon.and mctal [lu!l! 3(&" J

or END clutch. Empty VB castings must bethorou~y" flushed and blown dry to remove alldeb~ ~~.. valve sticking. This requires a goodhi pre~i/:W4'olume blow gun Everything neededfor error-free assembly is included, No worries!

If,. turn small but noticable differenceI turn makes obvious difference1 If,. turns make a big difference

Valve sticking? Here's the bestway in the universe to unstick itlLay thick steel plate on VB casting oversticking valve and give it a good smack!

Restores bore clearance with valveinstalled. Shown is a ST300 VB spacer

plate stiffener. A 604 solenoid body plate

works. A THM350 front plate will work

but bends easier. Thicker is Better! Bestis to bum a piece of 1/4" plate from local

machine shop.

I REPAIR TIPS, TRICKS, CORRECTIONS

DELAYED REVERSE / NO REVERSE / NO ENGAGE FROM PARKTO REVERSE, BUT WILL ENGAGE AFTER P-N-R! UNPLUG theSOLENOID CONNECTOR and TRY AGAIN! If R engages now the transis ok. Problem is external electrical, possibly induced by INHffiITOR SW(no R position signal to TCU), or SPEED SENSOR malfunction. All KM'shave reverse inhibit safety function. EPC is pulsed to hold N-R engagementcontrol valve closed, blocking low/rev clutch feed from manual valve. Thisis done when TCU detects forward motion (speed sensor signal) or someother condition that could cause hazardous or damaging operation.

CONNECTOR LEAKS.. The secret for a goodseal is clean dry connector and case area. Installo-ring dry and put a bead of silicon all the wayaround. Slowly push connector through case justfar enough to install the horseshoe clip. A snugfit clip supports the connector. Let silicon drybefore adding A TF. New Horseshoe clips areavailable: Chrysler/Mitsu pt# MD728163

PREVENT PUMP BUSHING FAILURE DURING INITIAL START-UP & FILL... During trans install,Prelube converter hub & bushing with lots of petroleum jelly. Pull converter flush with flywheel, install bolt insnug, then back out 1 turn. Install ALL converter bolts BEFORE llOHTENINO. This allows converter to centerand align with crank pilot and pump bushing. After rebuild... add 5 quarts before starting engine. Have another 4ready to pour. AL WAYS fill and check level in NEUTRAL, not park. FRONT SEAL LEAK.. Drill drainbackhole (behind front seal) with 1/4" bit. Pump bushing to cOnverter hub clearance should be .0015 - .003".

-ELECTRICAL CONNECTIONS- Use non-corrosive, non-residue electrical contact cleaner: CRC Lectra-MotiveClean ( product# 05018 - lib 3 oz can) ...or Radio Shack Tuner Cleaner. Spray into harness connectors and blow dry with compressed air. Measurepins, find comparable drill bit, 8;J)d check female side of connectors with drill for sufficient installed tension. CRC cleaner also good toflush solenoids! Silicon di-electric compound keeps corrosion and moisture out!

2-1 DOWNSHIFT CLUNK TPS & accelerator peddle/closed throttle switch out of adjustment. Lift completelyoff gas when stopping. Closed throttle switch function is checked with PSI guage on band apply port (right sideof servo). In D at a stop, pressure should read 0-25-0-25 when lightly touching on-off-on-offgas peddle.

ALL CONTENTS PRODUCED BY TRANsLAB C DEAN MASON / TRANSLAB MAR 1998 all rights reserved I revision 09-24-03