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P. 1
Group 7 Automatic Transmissions

Group 7 Automatic Transmissions

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7 -'
P A R T
7 -1
P A G E
G E N E R A LT R A N S M IS S IO N S E R V IC E . .7 -
1
P A R T 7 -2
C 4
A U T O M A T IC D U A L R A N G E
T R A N S M IS S IO N
7 -1 5
P A R T
7 -3
P A G E
C 6
A U T O M A T IC
DUAL RANGE
T R A N S M IS S IO N
7 -5 3
P A R T 7 -4
S P E C IF IC A T IO N S
7 -8 2
G E N E R A L T R A N S M IS S IO N
S E R V IC E
S e c tio n
P a g e
S h iftP o in tC h e c k s
7- 7
A irP re s s u re C h e c k s
7- 7
D ia g n o s is G u id e
C 4 A u to m a tic D u a l R a n g e D ia g n o s is G u id e . .7 - 9
C 6 A u to m a tic D u a l R a n g e D ia g n o s is G u id e .. 7 -1 0
2 C o m m o n A d ju s tm e n ts a n d R e p a irs
T r a n s m is s io n
F lu id
D ra in
a n d
R e fill
. . . . . . .7 -
8
O il C o o le r
F lu s h in g
P ro c e d u re
7 -1 1
O il C o o le r T u b e R e p la c e m e n t. . . . . . . . . . . . . . . . 7 - 1 1
3 C le a n in g a n d In s p e c tio n
C le a n in g
7 -1 1
In s p e c tio n
7 -1 2
S e c tio n
P a g e
1 D ia g n o s is a n d T e s tin g
7 -1
T r a n s m is s io n F lu id
LevelCheck. . . . . . . . . . . . . .7- 1
F lu id A e r a tio n C h e c k
7- 1
T r a n s m is s io n F lu id
LeakageChecks... . . . . . . . .7- 1
F lu id
L e a k a g e C o n v e rte r A re a. . .
. . . . . . . . . . . . .7- 2
C o n v e rte r L e a k a g e C h e c k. . . . . . . . . . . . . . . . . . . . 7 - 3
E n g in e Id le S p e e d C h e c k
7- 3
A n ti-S ta ll D a s h p o t C le a ra n c e C h e c k. . . . . . . . . . . 7 - 3
M a n u a IL in k a g e C h e c k s
7- 4
C o n tro l p re s s u re a n d V a c u u m D ia p h ra g m
U n it
C heck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S ta IIT e s t
In itia l
E ngagem ent
C hecks.
. . . . . . . . . . . . . . . ..
7- 4
7- 7
7- 7
D IA G N O S IS
A N D
T E S T IN G
F L U ID
A E R A n O N
C H E C K
A
flu id
le v e l th a t is to o h ig h
w ill
c a u s e th e
flu id
t o
b e c o m e a e ra te d .
A e ra te d
flu id
w ill
c a u s e lo w
c o n tro l
p re s s u re , a n d th e a e ra te d flu id
m ay
b e fo rc e d o u t th e v e n t.
C h e c k th e tra n s m is s io n flu id
le v e l.
L o w
flu id
le v e l c a n a ffe c t th e o p e r-
a tio n
o f
th e
tra n s m is s io n , a n d m a y
in d ic a te flu id
le a k s th a t c o u ld
c a u s e
tra n s m is s io n d a m a g e .
T R A N S M IS S IO N
F L U ID
L E A K A G E
C H E C K S
C heck
th e
s p e e d o m e te r
c a b le
c o n -
n e c tio n
a t th e
tra n s m is s io n .
L e a k a g e
a t
th e
o il
p a n
g a s k e t
o fte n
c a n
b e
s to p p e d
b y
tig h te n in g
th e
a tta c h in g
b o lts
t o
th e
p ro p e r
to rq u e .
I f
n e c e s -
s a ry ,
re p la c e
th e
g a s k e t.
C heck
th e
flu id
fille r
tu b e
c o n n e c tio n
a t
th e
tra n s m is s io n .
I f
th e
fille r
tu b e
O ;'rin g
s e a l
is
le a k in g ,
re p la c e
th e
s e a l.
2 . R u n th e e n g in e a t n o r m a l id le
s p e e d . If
th e
tra n s m is s io n
flu id
is
c o ld , r u n th e e n g in e a t fa s t id le s p e e d
(a b o u t
1 2 0 0
rpm )
u n til
th e
flu id
re a c h e s its
n o rm a l
o p e ra tin g
te m -
p e ra tu re . W h e n th e
flu id
is
w a rm ,
s lo w th e e n g in e d o w n to n o r m a l id le
s p e e d .
3 . S h ift th e s e le c to r le v e r th ro u g h
a ll p o s itio n s , a n d p la c e th e
le v e r a t
P. Do
n o t tu rn o ff th e e n g in e d u rin g
th e flu id
le v e l c h e c k s .
4 . C le a n a ll d irt fro m

th e tra n s m is - s io n flu id d ip s tic k c a p b e fo re re m o v - in g th e d ip s tic k

fro m
th e fille r tu b e .
5 .
P u ll
th e
d ip s tic k
o u t
o f
th e
tu b e , w ip e
it
c le a n , a n d
p u s h
it all
th e w a y
b a c k
in to
th e
tu b e .
6 .
P u ll
th e
d ip s tic k
o u t
o f
th e
tu b e a g a in , a n d c h e c k th e flu id
le v e l.
I f
necessary, add
e n o u g h
flu id
t o
th e
tra n s m is s io n
th ro u g h
th e
fille r
tu b e to
ra is e
th e
flu id
le v e l to
th e
F
(fu ll)
m ark
o n
th e
d ip s tic k . D o
n o t o v e rfill
th e
tra n s m is s io n .
W
h e n
d ia g n o s in g
tra n s m is s io n
p ro b le m s , firs t re fe r to th e d ia g n o s is
g u id e fo r d e ta ile d in fo rm a tio n

o n th e ite m s th a t c o u ld b e c a u s in g th e p ro b - le m .

T h e
fo llo w in g
p re lim in a ry
c h e c k s s h o u ld b e m a d e in
th e o rd e r
g iv e n :
1 . C h e c k th e flu id
le v e l. C h e c k th e
flu id
fo r
a b u rn t
c lu tc h
p la te
o d o r.
2 . C h e c k th e e n g in e id le s p e e d a n d
d a s h p o t a d ju s tm e n ts .
3 . C h e c k th e
m a n u a l lin k a g e
a d -
ju s tm e n t.
4 .
C heck
th e
a c c e le ra to r
p e d a l
h e ig h t a n d
d o w n s h ift
lin k a g e .
S . C h e c k th e
th ro ttle
lin k a g e
t o
a s s u re w id e
o p e n th ro ttle
o p e ra tio n .
6 .
C heck
th e
e n g in e
fo r
p ro p e r
o p e ra tio n .
T R A N S M IS S IO N
F L U ID
L E V E L
C H E C K
1. M ake
s u re th a t
th e
v e h ic le
is
s ta n d in g le v e l. T h e n fir m ly
a p p ly th e
p a rk in .\t b ra k e .
,
F L U ID
L E A K A G E
C O N V E R T E R
A R E A
In d ia g n o s in g a n d c o rre c tin g
flu id
le a k s
in
th e
fro n t
pum p
and con-
v e rte r
a re a , u s e th e
fo llo w in g
p ro -
c e d u re s
t o
fa c ilita te
lo c a tin g
th e
e x a c t c a u s e o f th e le a k a g e . L e a k a g e
a t th e
fro n t
o f
th e tra n s m is s io n , a s
e v id e n c e d b y
flu id
a ro u n d
th e
c o n -
v e rte r
h o u s in g ,
m ay
h a v e
s e v e ra l
s o u rc e s . }J y
c a re fu l
o b ~ e rv a tio n , it
is
p o s s ib le , in
m any
in s ta n c e s , to
p in p o in t
th e
s o u rc e o f
th e
le a k
b e -
fo re re m o v in g th e tra n s m is s io n fro m
th e
c a r. T h e
p a th s w h ic h
th e
flu id
ta k e s
t o
re a c h
th e
b o tto m
o f

th e c o n v e rte r h o u s in g a re s h o w n in F ig . 1 .

1 .
F lu id
le a k in g
b y
th e
fro n t
pum p
s e a l lip
w ill
te n d
t o
m ove
a lo n g
th e
d riv e
h u b
a n d
o n to
th e
b a c k
o f
th e
im p e lle r
h o u s in g . E x -
c e p t in
th e
c a s e o f a to ta l s e a l fa il-
u re , flu id
le a k a g e b y
th e
lip
o f
th e
s e a l w ill
b e d e p o s ite d o n
th e
in s id e
o f
th e
c o n v e rte r h o u s in g
o n ly , n e a r
th e o u ts id e d ia m e te r o f th e h o u s in g .
2 .
F lu id
le a k a g e b y
th e
o u ts id e
d ia m e te r o f th e s e a l a n d fro n t p u m p
b o d y
w ill
fo llo w
th e
s a m e p a th
a s
le a k s b y th e fro n t p u m p
sealor m ay
ru n d o w n th e fa c e o f th e fro n t p u m p .
3 .
F lu id
th a t
le a k s
b y
a
fro n t
p u m p a n d c o n v e rte r h o u s in g to c a s e
b o lts w ill
b e d e p o s ite d o n th e in s id e
o f th e c o n v e r te r h o u s in g o n ly . F lu id
w ill
n o t
b e d e p o s ite d
o n
th e
b a c k
o f th e c o n v e rte r.
4. Leakage by
th e fro n t
pum p
t o
c a s e a n d a -rin g
s e a l m a y c a u s e flu id
~ ,,~
~ ,{$ ~ ;:2 ,
~ ~ ~ ~ ~;"f;,~ ,;i~ .:~
':":'C ;"';"""
,
~ ,< i~ ~ ~ :
~~
j,~ I~ ~ ~ ~ g f;\~ ~ ~ :4 ~ ~ it~ ;
i
T h e
tra n s m is s io n
flu id
is
w a te r
c o o le d ; c h e c k th e flu id
lin e s a n d fit-
tin g s b e tw e e n
th e
tra n s m is s io n a n d
th e
c o o le r
in
th e ra d ia to r
ta n k
fo r
lo o s e n e s s ,
w e a r,
o r
dam age.
I f
le a k a g e c a n n o t b e s to p p e d b y
tig h t-
e n in g a fittin g ,
re p la c e th e d e fe c tiv e
p a rts .
C heck
th e
e n g in e c o o la n t
in
th e
ra d ia to r.
I f
tra n s m is s io n
flu id
is
p re s e n t in
th e
c o o la n t,
th e
c o o le r
in th e ra d ia to r ta n k is p ro b a b ly le a k -
in g .
T h e c o o le r c a n b e fu rth e r c h e c k e d
fo r
le a k s b y d is c o n n e c tin g
th e
lin e s
a t
th e
c o o le r
fittin g s
a n d

a p p ly in g 5 p s i a ir p re s s u re to th e fittin g s . T h e ra d ia to r c a p m u s t b e re m o v e d w h e n m a k in g

th is
c h e c k
t o
r e lie v e
th e
p re s s u re o n
th e e x te rio r
s id e o f th e
c o o le r. If
th e
c o o le r is le a k in g
a n d
w ill n o t h o ld
th is p re s s u re , th e ra d i-
a to r
must be
re p la c e d . T h e
c o o le r
c a n n o t b e re p la c e d s e p a ra te ly .
. I f
le a k a g e is fo u n d
a t e ith e r th e
th ro ttle
le v e r s h a ft
o r
th e
m anual
le v e r
s h a ft,
re p la c e
e ith e r
o r
b o th
s e a ls .
In s p e c t th e p ip e p lu g
in
th e c a s e .
I f
th e
p lu g
show s
le a k a g e , to rq u e
th e p lu g
t o
s p e c ific a tio n . If
tig h te n -
in g
d o e s n o t. s to p th e
le a k s , r e p la c e
th e p lu g .
O n
a
C 6
tra n s m is s io r.
th e
T V
p re s s u re p o rt p lu g
o n th e rig h t
re a r
s id e
o f
th e
case m ust
a ls o
b e
in -
s p e c te d .
W hen
c o n v e rte r d ra in
p lu g s le a k ,
re m o v e th e
tw o
d ra in
p lu g s w ith
a
s ix - p o in t
w re n c h . C o a t
th e
th re a d s
w ith
F o M o C o
P e rfe c t
s e a lin g
C o m p o u n d o r its e q u iv a le n t, a n d in :'
s ta ll
th e
p lu g s .
T o rq u e
th e
d ra in
p lu g s to
s p e c ific a tio n . F lu id
le a k a g e
fro m
th e
c o n v e rte r h o u s in g m a y b e
caused by
e n g in e
o il
le a k in g
p a s t
th e
re a r
m a in
b e a rin g o r
fro m
o il
g a lle r y
p lu g s . B e s u re to
d e te rm in e
th e
e x a c t c a u s e o f th e
le a k .
O il- s o lu b le . a n ilin e
o r
flu o re s c e n t
d y e s
p re m ix e d
a t
th e
ra tio
o f
1 ;7 -
te a s p o o n o f
d y e p o w d e r to
1 /2 p in t
o f
tra n s m is s io n
flu id
h a v e
p ro v e d
h e lp fu l
in
lo c a tin g
th e
s o u rc e
o f
th e
flu id
le a k a g e . S u c h
d y e s
m ay
b e
u s e d
t o
d e te rm in e
w h e th e r a n
e n g in e o il o r tr a n s m is s io n flu id
le a k
is p re s e n t, o r if
th e
flu id
in
th e
o il
c o o le r le a k s in to
th e e n g in e c o o la n t
s y s te m . A
b la c k lig h t, h o w e v e r , m u s t
b e
u s e d w ith
th e
flu o re s c e n t
d y e
s o lu tio n .
: \ \ '
.F R O N T P U M P
F R O N TP U M P
A N D
C O N V E R T E R
H O U S IN G
T O
C A S E
B O L T
L E A K
C R A N K :
SEAL I
~ (
G A S K E T
C O N V E R T E R
A S S E M B L Y
. ~
C A S E
C O N V E R T E R
}-7 "7 7 4 -r~ -:;
~~
C O N V E R T E R
D R A IN
P L U G
L E A K
7 -2
G R O U P 7 -
A U T O M A T ICT R A N S M IS S IO N
,
" -
C O N V E R T E R
H O U S IN G
FLYW HEEL
/
D 1 S 1 J -A
F IG .
1 - T y p ic a l C o n v e rte rA re a L e a k a ~ eC h e c k s
" " ,.',,~ '"
P A R T
7 -1
G E N E R A LT R A N S M IS S IO N S E R V IC E
7 -3
fro m
th e
e n g in e
o r
tra n s m is s io n .
U n le s s
a
c o n s id e r a b le
am ount
o f
m a k e -u p
flu id
h a s
b e e n
a d d e d
o r
th e flu id
h a s b e e n c h a n g e d , th e re d
c o lo r s h o u ld a s s is t in p in p o in tin g
th e
le a k .

S in c e ro a d d ra ft m a y c a u s e le a k in g v a lle y c o v e r o il to b e p re s e n t o n th e tra n s m is s io n , th is le a k a g e , if p re s e n t, s h o u ld

b e
e lim in a te d
b e fo re
p e r-
fo rm in g
w o rk
o n
th e
tra n s m is s io n .
(b )
R em ove
th e
c o n v e rte r
lo w e r
h o u s in g
c o v e r. C le a n o ff
a n y
flu id
fro m
th e to p
a n d b o tto m
o f th e c o n -
v e rte r
h o u s in g , fro n t
o f
th e
tra n s -
m is s io n
case, and
re a r fa c e
o f
th e
e n g in e
a n d
e n g in e
o il
p a n .
C le a n
th e c o n v e rte r a re a b y
w a s h in g w ith
s u ita b le n o n ~ fla m m a b le s o lv e n t, a n d
b lo w d ry w ith c o m p re s s e d a ir.
(c ) W a s h o u t th e
c o n v e rte r h o u s -
in g , th e
fro n t
o f
th e
fly w h e e l,
a n d
th e c o n v e rte r d ra in
p lu g s . T h e
c o n -
v e rte r
h o u s in g
may be
washed out
u s in g c le a n in g s o lv e n t a n d
a s q u irt-
ty p e
o il c a n . B lo w
a ll w a s h e d a re a s
d ry
w ith
c o m p re s s e d a ir.
(d ) S ta rt a n d ru n
th e e n g in e u n til
th e
tra n s m is s io n re a c h e s its
n o rm a l
o p e ra tin g
te m p e ra tu re . O b s e rv e th e
b a c k
o f
th e
b lo c k
a n d
to p
o f
th e
c o n v e rte r
h o u s in g
fo r
e v id e n c e
o f
flu id
le a k a g e . R a is e
th e
c a r
o n
a
h o is t a n d r u n th e e n g in e a t fa s t id le ,
th e n
a t
e n g in e
id le ,
o c c a s io n a lly
s h iftin g
t o
th e
d riv e
a n d
re v e rs e
ra n g e s
t o
in c re a s e p re s s u re s w ith in
th e
tra n s m is s io n . O b s e rv e th e
fro n t
to b e d e p o s ite d o n th e o u ts id e lo w e r
p a rt
o f
th e
c o n v e rte r
h o u s in g
a s
s h o w n in F ig . 1 .
5 .
F lu id
le a k a g e
fro m
th e
c o n -
v e r te r d r a in p lu g s w ill
a p p e a r a t th e
o u ts id e d ia m e te r o f th e c o n v e rte r.
E n g in e
o il
le a k s
a re
s o m e tim e s
im p ro p e rly
d ia g n o s e d a s fro n t
pum p
s e a l le a k s . T h e
fo llo w in g
a re a s o f
p o s s ib le
le a k a g e
s h o u ld
a ls o
b e
c h e c k e d to
d e te rm in e
if
e n g in e o il
le a k a g e is c a u s in g th e p r o b le m :
(a )
L e a k a g e
a t
th e
ro c k e r
a rm
c o v e r ( v a lle y
c o v e r) m a y
a llo w
o il
t o
flo w
o v e r th e
c o n v e rte r
h o u s in g
o r
s e e p
dow n
b e tw e e n
th e
c o n -
v e rte r
h o u s in g
a n d
c y lin d e r
b lo c k
c a u s in g
o il
t o
b e
p re s e n t in
o r
a t
th e b o tto m
o f th e c o n v e rte r h o u s in g .
(b ) O il g a lle ry
p lu g
le a k s w ill
a l-
lo w
oil to
flo w
d o w n 'th e
re a r fa c e
o f
th e
b lo c k
t o
th e
b o tto m
o f
th e
c o n v e rte r h o u s in g .
(c ) L e a k a g e b y th e c ra n k s h a ft s e a l
w ill
w o rk
b a c k to
th e fly w h e e l, a n d
th e n in to
th e
c o n v e rte r h o u s in g .
F lu id
le a k a g e
fro m
o th e r
a re a s ,
fo rw a rd
o f
th e
tra n s m is s io n
c o u ld
c a u s e flu id
t o
b e p re s e n t a ro u n d th e
c o n v e rte r h o u s in g d u e to
b lo w -b a c k
o r ro a d d ra ft.
T h e fo llo w in g

p ro c e d u re s h o u ld b e u s e d to d e te rm in e th e c a u s e o f le a k - a g e b e fo re

a n y re p a irs a re m a d e :
(a ) R e m o v e th e

tr a n s m is s io n d ip - s tic k a n d n o te th e c o lo r o f th e flu id . O rig in a l fa c to ry

fill fluid
is d y e d re d
t o
a id
in
d e te rm in in g
if
le a k a g e is
HEX.HEAD SCREW
% "-2 4
X
\1 2
3 h 2 "STEEL PLATE
0 /8 "X
1 3 /8 ",
D IS H E D O R
D R IL LT O
S U IT
FLAT W ASHER
,~ ::~ ::~
1 3 /4 " O .D ., 1 7 1 3 2 "
'~ ~ # ,,~ ~
H E X .N U T 3 /8 "-2 4
W ELD
T O G E T H E R
o f
th e
fly w h e e l,
b a c k
o f
th e
b lo c k
( in
a s fa r
a s p o s s ib le ) , a n d
in s id e
th e
c o n v e rte r h o u s in g (F ig . 1 ). R u n
th e e n g in e u n til
flu id

le a k a g e is e v i- d e n t a n d th e p ro b a b le s o u rc e o f le a k - a g e c a n b e d e te rm in e d .

C O N V E R T E R
L E A K A G E
C H E C K
D u rin g
th e
a b o v e
flu id
le a k a g e
c h e c k s , if
th e re

a re in d ic a tio n s th a t th e w e ld s o n th e to rq u e c o n v e rte r a re le a k in g ,

th e
c o n v e rte r
w ill
h a v e to
b e re m o v e d a n d th e fo llo w in g
c h e c k
m a d e b e fo re th e u n it is re p la c e d :
A
le a k
c h e c k in g
to o l
(F ig .
2 ),
c a n
b e
m ade
fro m
s ta n d a rd
p a rts .
1 . In s ta ll
th e
p lu g
in
th e
c o n -
v e rte r
(F ig .
3 )
a n d
e x p a n d
it
b y
tig h te n in g
th e
w in g
n u t. A tta c h
th e
s a fe ty c h a in s .
2 . In s ta ll th e a ir v a lv e in o n e o f th e
d ra in
p lu g
h o le s .
3 . In tro d u c e
a ir p re s s u re in to
th e
c o n v e rte r h o u s in g . C h e c k
th e
p re s -
s u re
w ith
a
t ir e
gauge and
a d ju s t
it to 2 0 p s i.
4 . P la c e
th e
c o n v e rte r in
a
ta n k
o f
w a te r.
O b s e rv e th e
w e ld
a re a s
fo r
b u b b le s . If
n o
b u b b le s a re
o b -
s e rv e d , it m a y b e a s s u m e d th a t th e
w e ld s a r e n o t le a k in g .
E N G IN E
ID L E
SPEED CHECK
C heck
a n d ,
if

n e c e s s a ry , a d ju s t th e e n g in e id le s p e e d , u s in g th e p r o - c e d u r e g iv e n in

G ro u p
1 0 .
I f
th e
id le
s p e e d is to o
lo w ,
th e
e n g in e
w ill
ru n
ro u g h ly .
A n
id le
s p e e d
th a t
is
to o
h ig h
w ill
c a u s e
th e
c a r
t o
c re e p w h e n
th e
tra n s -
m is s io n is s h ifte d
in to
g e a r a n d w ill
c a u s e
ro u g h
tra n s m is s io n
e n g a g e -
m e n t.
A N T I-S T A L L
D A S H P O T
C L E A R A N C E
C H E C K
A fte r
th e
e n g in e
id le
speed has
b e e n
p ro p e rly
a d ju s te d ,
c h e c k th e
~
( ( ) )
'( 0
'IJ /
. ,,'
J ""
FLAT W ASHER
R U B B E RP L U G
13 fs " O .D .
1 V 2 " D IA . X 2 "
LO N G
V 2 "
"S P A C E R -
H O L E T H R U
,
8 2 Q .9 4 3 8 .A
A P P R O X IM A T E L Y S T A N D A R D B O L T
~
4 0
D U R O M E T E R
V 2 "-1 3
X
4 V 2 "
~
P L U G
LO N G
S Q U A R E
T H R E A DE N D
S T A N D A R D
,W ELD TOGETHER
R E M O V E H E A D
T I R EV A L V E
S E C U R E L Y -M U S T
A N D W E L DT O
N O T L E A K
W ASHER
FLAT W ASHER
1 3 fa " C .D .
W IN G
N U T
1 f2 "- 1 3 T H R E A D
~
I @
I
C H A IN , 1 0 " L O N G
7 -',..
'"
" \
'- - -
T ire
In fla tin g
C huck
T ire P re s s u re G a u g e
S T A N D A R D
F IT T IN G -
8 7 9 7 1 -8
-
D 1 5 1 4 -A
F IG .
3 -T y p ic a l C o n v e rte r
le a k
C h e c k in g T o o l
D 1 0 6 7 -A
V A L V E
F IG .
2 - C o n v e r le r le a k C h e c k in gT o o l

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