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I~AT561

INTRODUCTION
THM 700-R4 (4L60)
1987 -1993

We wish to thank GENERAL MOTORS CORPORATION for the information and illustrations that have made this booklet possible. The 1987 - 1993 THM 700-R4 transmission was produced with many major engineering design changes, which include an added auxiliary valve body, reverse apply package, and three different checkballlocations , depending on design levels. This booklet contains general description and the overhaul procedures necessary to repair, overhaul, or service the 1987 -1993 THM 700-R4 transmissions and includes all design levels. The 1987 -1993 THM 700-R4 transmission is a fully automatic unit consisting of a three element torque converter with the addition of a converter clutch. Five multiple disc clutch packs, one roller clutch, one sprag, and one band provide the friction elements required to obtain the desired function of the compound planetary gear set. The combination of the compound planetary gear set and friction elements provides four forward speeds, including overdrive, and reverse. Changing of the gear ratios is fully automatic in relation to vehicle speed and engine torque. Vehicle speed and engine torque signals are constantly fed to the transmission to provide the proper gear ratio for maximum efficiency and performance at all throttle openings. "Portions of material contained herein have been reprinted with permission of General Motors Corp., Service Technology Group" The information and part numbers contained in this booklet have been carefully compiled from industry sources known for there reliability, but ATSG does not guarantee its accuracy Copyright
© ATSG 1994

ROBERT D. CHERRNAY
TECHNICAL DIRECTOR

FIELD SERVICE CONSULTANT

DALE ENGLAND

TECHNICAL CONSULTANT

FRANK MIETUS

TECHNICAL SUPERVISOR

WAYNE COLONNA

ED KRUSE
LAYOUT

TECHNICAL CONSULTANT

PETE LUBAN

AUTOMATIC TRANSMISSION

SERVICE GROUP

9200 S. DADELAND BLVD. SUITE 720 MIAMI, FL 33156 (305) 670-4161

Technical
HYDRA·MATIC FIRST SECOND THIRD 4L60

Service
• GEAR 3.06 1.62 1.00 RATIOS

Information

FOURTH REVERSE

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Z-4 BAND REVERSE INPUT CLUTCH OVERRUN CLUTCH fORWARO CLUTCH fORWARO SPRAG CL. ASSEMBLY 3-4 CLUTCH LO.flOLLER CLUTCH LO·REV. CLUTCH

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ht 2nd 3rd 41h hI APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED HOLDING HOLDING HOLDING HOLDING HOLDING HOLDING HOLDING APPLIED APPLIED APPLIED HOLDING HOLDING HOLDING HOLDING APPLIED APPlIEO HOLDING HOLDING

D

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2nd 31d

111

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2nd hI REVERSE

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R

APPLICATION

CHART

Figure 1

AUTOMA TIC TRANSMISSION
2

SERVICE GROUP

ATS6
THM 700-R4 (4L60) 1987 -1993
GENERAL DESCRIPTION LINE PRESSURE CHECK DIAGNOSTIC CHARTS INTERNAL WIRING HARNESS SCHEMATICS OIL PRESSURE PASSAGE IDENTIFICATION SPACER PLATE IDENTIFICATION CHARTS TRANSMISSION DISASSEMBLY COMPONENT REPAIR AND RE-ASSEMBLY L/R SUPPORT AND L/R PISTON IDENTIFICATION LOW/REVERSE SELECTIVE PLATE IDENTIFICATION OUTPUT SHAFT IDENTIFICATION INPUT HOUSING IDENTIFICATION TURBINE SHAFT IDENTIFICATION DIFFERENT 3-4 CLUTCH STACK-UPS REVERSE INPUT HOUSING IDENTIFICATION PUMP COVER IDENTIFICATION VALVE BODY CHECKBALL LOCATIONS CASE CHECKBALL LOCATIONS ACCUMULATOR ORIENTATION CHARTS AUXILIARY VALVE BODY CHECKBALL LOCATION TORQUE SPECIFICATIONS SPECIAL TOOLS
4 6

INDEX

7 17 22 30 36 50 52 56 62 63 64 79 84 90 98 99 103 105 119 120

"Portionsof material contained herein have been reprinted with , permission of General Motors Corp" Service Technology Group"

AUTOMATIC TRANSMISSION SERVICE GROUP 9200 S. DADELAND BLVD. STE 720 MIAMI, FLORIDA 33156 (305) 670-4161
3

Copyright

(g

ATSG 1994

One Roller Clutch. Valve Body Assembly. 9. Torque Converter Clutch Assembly. 5. Auxiliary Valve Body Assembly. Five Multiple-Disc Clutch Packs. The major components of this transmission are: 1.I~RT5GI Technical Service Information HYDRA·MATIC 4L60 2·4 BAND GENERAL DESCRIPTION Figure 2 The THM 700-R4 is a fully automatic transmission for rear wheel drive vehicles which provides four forward speeds and a reverse range. 8. AUTOMATIC TRANSMISSION 4 SERVICE GROUP . 2-4 Band Assembly 4. 2. The oil pressure and shift points a~e controlled by throttle opening via a throttle valve cable. 6. The transmission can be operated in any of seven different modes shown on the shift quadrant (See Figure 3). Two Planetary Gear Sets. One Sprag Clutch. 10 Vane Type Oil Pump 3. 7.

MANUAL 2 RANGE: While in 3rd gear range. shift to manual second. and Figure 3 1? . (In some vehicles it may be possible to obtain a 1-2 upshift while in this gear range). Downshifts are available for safe passing by depressing the accelerator pedal. but will only downshift below Approx.REVERSE allows the vehicle ated in a rearward direction. position the range selector lever in the O. manually shift the transmission to Drive Range. 1) :2 . REVERSE RANGE: Position the selector lever in Reverse check reverse operation. Shift points will vary with different throttle positions. (]3) .MANUAL SECOND is used to provide acceleration and engine braking. and 3-4 upshift. Again. the converter clutch may apply in 2nd or 3rd gear depending on calibration. and trailer towing. AUTOMATIC TRANSMISSION 5 SERVICE GROUP .OVERDRIVE is used for all normal ~iving conditions. This range may also be selected at any vehicle speed. to be oper- ~ . 1 . Check for a 2-1 detent downshift. or :3 . Check for part throttle and detent downshifts. DRIVE RANGE: At road speed in fourth gear (Overdrive Range). It provides three gear ratios plus torque converter clutch operation. Check for a 1-2.PARK position prevents the vehicle from rolling either forward or backward. the downshifts are available by depressing the accelerator pedal.DRIVE position is used for city traffic. (For safety reasons the parking brake should be used in addition to the Park position). the transmission should downshift immediately.(~RT5G] Technical Service Information ROAD TEST PROCEDURE OVERDRIVE RANGE: While stopped. hilly terain. This range may be selected at any vehicle speed. Check for part throttle downshifts by depressing the throttle to a 3/4 open position. 2-3. MANUAL LO RANGE: Position the selector lever in Lo Range and check operation.D. Also. Check for detent downshifts by depressing the accelerator to wide open position at various vehicle speeds. 's should increase and a braking effect should be noticed. The transmission should shift back to 3rd gear. OVERRUN BRAKING: Overrun braking can be checked by manually downshifting to a lower gear range. If necessary this position may be selected if the engine must be re-started with the vehicle moving. Engine R.M.MANUAL LO is used to provide maximum engine braking. ~ .P. 40 MPH.NEUTRAL allows the engine to be started and operated without driving the vehicle. It provides four gear ratios plus converter clutch operation. range and accelerate.

LDM. NEUTRAL. CBM.V. MJM. LBM. cable. Intermediate and Reverse positions of the selector lever.V. IlPa PII 483-622 70·90 451·515 65·75 451·515 65·75 451·515 65·75 65-75 451·515 451·515 65·75 65·75 451·515 483-622 70·90 451·515 65·75 451·515 65·75 793·1023 115-148 742-847 108·123 108·123 742-847 742-847 108·123 84-96 580-862 106-123 742-847 741·845 107·123 793·1023 115-148 84-98 580-882 742-847 108·123 1127·1286 1205·1554 1191·1359 163·186 175·226 173·197 NORMAL PRESSURE AT FUU T. TLM.V. FZM LAM. OVERDRIVE& MANUAL 3RD CZ» 1000 RPM @ REVERSE 1000 RPM MANUAL 2ND & MANUAL LO @ 1000 RPM BBM CAM. CFM. MJM.. In the Neutral. LFM MSM SAM SHM. indicated in the chart below. WCM FBM FTM. KBM. LCM. CFM. WBM CHM. FBM. RAM. Full T. FUM.V. FUM. KCM. SHM. TLM BBM CAM. Second and Lo by the reverse boost valve. WBM CHM.V. LDM. take the line pressure readings in the ranges and at the engine r.V. KAM. TLM CAM. KAM. CJM. cable to the full extent of its travel. MSM LAM. Pr . cable to specification. as well as the control valve assembly. KCM. KAM. link. CBM. and with the brakes applied. 1991 HYDRA-MATIC RAIGE MODEL 4L60 TRANSMISSION PRESSURES NORMAL PREIIURE AT MIIIMUM T. FZM. take the line pressure readings in the ranges and at the engine r. Brakes must be applied at all times. KCM. CHM.m. FZM LAM. and with the brakes applied. FTM. LFM Line pressure is basically controlled by pump output and the pressure regulator valve. In addition. Lin. MNM. CJM.p. WCM 88M. MNM.WAM CCM. MJM. CCM. MNM. FUM. system.(~~T5GI Technical Service Information LINE PRESSURE CHECK PROCEDURE • CHECK TRANSMISSION FLUID LEVEL • CHECK AND ADJUST T. line pressure readings are obtained by tying or holding the T. the line pressure should increase with throttle opening because of the T. CJM. Pr ••• Check Set the T. WAM CCM. Figure 4 AUTOMATIC TRANSMISSION 6 SERVICE GROUP . SAM. Drive. Full T. LFM MSM SAM SHM. RAM. KBM. indicated in the chart below. liP.. CABLE • CHECK OUTSIDE MANUAL LINKAGE AND CORRECT • CHECK ENGINE TUNE • INSTALL PRESSURE GAGE • CONNECT TACHOMETER TO ENGINE • CHECK PRESSURE AS FOLLOWS: fA) ATTACH PRESSURE GAGE Minimum T.V. The main line pressure tap plug Is located on the left side of the transmission above the outside manual lever. line pressure is boosted in Reverse. WCM FBM FTM. KBM. Check *NOTICE CAUTION Total running time for this combination not to exceed 2 minutes.V. WBM. Un. LBM. w. WAM. LCM. The pressure is controlled by the T. w.V. CFM. Also. V. CBM. RAM. LDM. PII 866-1146 125·166 851·1063 123·154 947·1185 137·172 914-1149 133·167 918·1146 133·166 1073·1354 155·196 899-1134 130·164 797·1079 116-157 845-1068 123·155 969-1231 141·179 1424-1883 206-273 1400·1747 203·253 1556-1948 226-283 1503·1889 218·274 1180·1472 171·214 1783·2225 256-323 1474·1880 214-270 1311·1773 190-257 1085·1372 157·199 1593·2023 231·293 " 27·1286 1205·1554 1191-1359 163·186 175·226 173-197 PARK.V. LCM. LBM.p. the throttle lever and bracket asaembly and the T.m.

T. Throttle valve (326) sticking. Excessive rotor clearance. binding or damaged.V. Manual valve (340) scored or damaged. binding or damaged. Case to valve body face not flat. Porosity in pump cover or body. reverse boost valve (220) or sleeve (221) stuck. Rotor guide (213) omitted or misassembled. Sticking slide (206) or excessive rotor clearance. • Case (10) - HIGH OR LOW SHIFT POINTS • T. Cable • T. Modulated downshift valve (301) stuck. Exhaust Ball (91) • Throttle Lever & Bracket Assembly (65) • Throttle Link (64) • Valve Body (67) - - Misassembled. Rotor (214) cracked or broken. damaged or incorrectly assembled.Technical CONDITION OIL PRESSURE HIGH OR LOW (Verify With Gage-Refer To Line Pressure Check Procedure) Service Information FOR CAUSE Pressure regulator valve (218) stuck. boost valve (222). Face not flat. Cracks in filter body or intake pipe.V. Orifice hole in pressure regulator valve (218) plugged. Exhaust Ball (91) • Throttle Lever & Bracket Assembly (65) - Binding or not correctly adjusted. Spacer plate (56) or gaskets (88 & 89) incorrect.V. 2-3 Shift valve (316) stuck. limit valve (332) sticking.V. Checkballs omitted or misassembled. binding or damaged. "0" ring seal (70) missing. Pressure regulator valve spring (219) damaged. ALL ILLUSTRATION NUMBERS REFERENCEHYDRA-MATIC 4L60 UNIT REPAIR Figure 5 AUTOMATIC TRANSMISSION 7 SERVICE GROUP . INSPECT COMPONENT • Oil Pump Assembly (7) • Oil Filter (71) • T. misassembled or damaged. Misassembled. Wrong grease used on rebuild. T. Line bias valve (336) stuck. Misassembled. Stuck or damaged.V. Wrong pump cover. Pump faces not flat. cut or damaged. Stuck or damaged. Pressure relief ball (231) not seated or damaged. Intake pipe restricted by casting flash.

2-4 Band Assembly (602) a. Governor filter (47 A) restricted or. b. Wear on bottom of gear indicates pin is not pressed in deep enough. Burned. limit valve (332) sticking.NO UPSHIFT • Governor Assembly (45) - • Valve Body (67) Governor valve (107) sticking.V. damaged or incorrect. Porous or damaged valve body pad. Governor weights (108 & 109) or springs ( 110 & 111) missing. Apply pin damaged or improper length. or there is a burr on the output shaft. up or down valves (301 & 303) sticking. Case to valve body face not flat or damaged. Damaged servo piston seals. Anchor pin not engaged. Line bias valve (336) sticking. Spacer plate (56) or gaskets (88 & 89) mispositioned or damaged. 1-2 Shift valve (322) sticking. 2-4 accumulator porosity. Sticking throttle valve (326) or plunger (324). T. Nicks or burrs on governor sleeve (106) or case bore. b. boost valve (222). Governor support pin in case too long or short. Modulated T. Wear of corner of gear indicates pin is missing. - - • Case (10) - ALL ILLUSTRATION NUMBERS REFERENCEHYDRA-MATIC 4L60 UNIT REPAIR Figure 6 AUTOMATIC TRANSMISSION 8 SERVICE GROUP . damaged. c.V. Sticking pump slide (206).V. Wear on one side of gear indicates output shaft snap ring is missing or the governor has seized in the bore. Governor driven gear retaining pin (82) missing. • Valve Body Assembly (67) • Case (10) - 1ST GEAR RANGE ONLY . Governor filter (47 A) restricted or damaged. binding or damaged. c. Spacer plate (56) or gaskets (88 & 89) misassembled. Governor driven gear (83) loose or damaged: a.Technical CONDITION HIGH OR LOW SHIFT POINTS (Continued) Service Information FOR CAUSE INSPECT COMPONENT • Oil Pump Assembly (7) - Stuck pressure regulator valve (218) or T. Nicks or burrs on output shaft (687). b. 2-4 Servo Assembly (13-31) a. Wear resembles an apple core if wrong gear is used. d.

Technical CONDITION 1ST GEAR RANGE ONLY . Spacer plate (56) or gaskets (88 & 89) incorrect. Piston (367) out of its bore. Piston seal (369) missing. Band anchor pin not engaged. 1-2 Accumulator valve (333) stuck. 2-4 Band (602) worn or damaged. Damaged forward clutch housing (628). • Forward Clutch Accumulator - • Oil Pump (7) - • Input Housing & Shaft Assembly (621) • Valve Body (67) - - • T. damaged lands or interconnected passages.NO UPSHIFTS (Continued) Service Information FOR CAUSE Restricted or blocked apply passages in case. Nicks or burrs on servo pin (29) or pin bore in case. Cable • Low Roller Clutch (678) - • Torque Converter (1) ALL ILLUSTRATION NUMBERS REFERENCEHYDRA-MATIC 4L60 UNIT REPAIR Figure 7 AUTOMATIC TRANSMISSION 9 SERVICE GROUP . Stator roiler clutch not holding. Turbine shaft seals (619) missing. Auxiliary accumulator valve tube (96) leaks. Porosity in the piston or auxiliary valve body (377). Forward clutch piston inner and outer seals (629) missing. cut or damaged. Porosity or damage in forward clutch piston (630). Forward clutch housing retainer and bail assembly (627) not sealing or damaged. mispositioned or damaged. Lube passage plugged. Stuck abuse valve (360). Roilers not free moving. INSPECT COMPONENT • 2-4 Servo Assembly (13-31 ) • 2-4 Band Assembly (602) - SLIPS IN 1ST GEAR • Forward Clutch Assembly - Clutch plates (649) worn.V. Face not flat. Inadequate spring tension Damage to inner splines. Damage to lugs or inner ramps. 4th Servo piston (16) in backwards. cut or damaged. not seated in pump cover or missing. cut or damaged. cut or damaged. Input housing to forward clutch housing "0" ring seal (622) missing. Binding or broken.

Nicks or burrs in 1-2 accumulator housing. 1-2 Shift valve train (317-322) stuck. T. Not correctly adjusted.HIGH OR LOW • T.) Misassembled. cut or damaged. INSPECT COMPONENT • 1-2 Accumulator Assembly (59-63) • Oil Pressure • 2-4 Servo Assembly (13-31 ) - 1-2 SHIFT SPEED . limit valve (332) stuck.(~~T5G) CONDITION SLIPS IN 1ST GEAR (Continued) Technical Service Information FOR CAUSE Porosity in piston (61) or 1-2 accumulator cover and pin assembly (62). Porosity in 1-2 accumulator housing (62) or piston (61). cut or damaged. • 2-4 Servo Assembly (13-31 ) - • 2nd Accumulator (59-63) - ALL ILLUSTRATION NUMBERS REFERENCEHYDRA-MATIC 4L60 UNIT REPAIR Figure 8 AUTOMATIC TRANSMISSION 10 SERVICE GROUP . plunger (324) sticking. link missing. (See 1st Gear Range Only . Leak between piston and pin. Cable • Governor Assembly (45) • Throttle Lever & Bracket Assembly (65) • Valve Body (67) - Binding or broken. T.V. cable broken or binding. Missing or restricted oil passage. Face not flat. Line bias valve (336) stuck. T. binding or damaged.) 4th Servo piston (16) in backwards.V. missing or damaged.V. mispositioned or damaged. Valve body to spacer plate gasket (89) at 1-2 Accumulator cover.No Upshift. Damaged ring grooves on piston. Piston seal (60) missing. 1-2 Accumulator valve (333) stuck. Face not flat. exhaust checkball (91) stuck. Gaskets (88 & 89) or spacer plate (56) incorrect. Servo bore in case damaged.V. Throttle valve (326) sticking. T. Face not flat. Restricted or missing oil passages. 2nd servo apply piston seal missing. • Oil Pump Assembly (71) or Case (10) SLIPPING OR ROUGH 1-2 SHIFT • Throttle Lever & Bracket Assembly (65) • Valve Body Assembly (67) - Incorrectly installed or damaged. T. binding or damaged. (See Causes of High or Low Oil Pressure. Apply pin (29) too long or too short.V. Broken 1-2 accumulator spring (59).V. Piston seal or groove damaged.

Forward clutch piston retainer and ball assembly (627) not seating. mispositioned or damaged. Governor driven gear retaining pin (82) missing or loose. Governor valve (107) stuck. Spacer plate (56) or gaskets (88 & 89) incorrect. limit valve (332) stuck.(~~TSG) CONDITION Technical Service Information FOR CAUSE INSPECT COMPONENT • 2-4 Band (602) (7) or SLIPPING OR ROUGH 1-2 SHIFT (Continued) - Worn or mispositioned. Governor driven gear (83) damaged. Excessive clutch plate travel. • Oil Pump Assembly Case (10) NO 2-3 SHIFT OR 2-3 SHIFT SLIPPING. 2nd Apply piston seals (23 & 24) missing. Valve (107) stuck. Faces not flat. Sealing balls loose or missing. Stator shaft (216) sleeve scored or off location. Throttle valve (326) stuck. 3rd Accumulator retainer and ball assembly (80) not seating. cut or damaged. Clutch plates worn (3-4 (654) or forward (649)J. T. damaged or not sealing. Governor support pin in case too long or too short. Restricted apply passages. Governor weights (108 & 109) binding. Porosity in input clutch housing (621) or piston (623). Drive gear retaining pin (82) missing or loose. 2-3 Valve train (313-316) stuck. Cut or damaged piston seals (3-4 (624) or forward (629)].V. 3-4 Piston checkball (620) stuck. • Governor Assembly • Oil Pump (7) - • Valve Body (67) - • Input Housing Assembly (621 ) - • Case (10) - • 2-4 Servo Assembly (13-31 ) NO 3-4 SHIFT/SLIPPING OR ROUGH 3-4 SHIFT • Governor (45) - ALL ILLUSTRATION Governor weights (108 & 109) binding. Accumulator valve (333) stuck. 4L60 UNIT REPAIR NUMBERS REFERENCE HYDRA-MATIC Figure 9 AUTOMATIC TRANSMISSION 11 SERVICE GROUP . Governor driven gear (83) damaged. Governor support pin in case too long or too short. ROUGH OR HUNTING • Converter (1) (45) - Internal damage.

Technical
CONDITION NO 3-4 SHIFT/SLIPPING OR ROUGH 3-4 SHIFT (Continued)

Service

Information
FOR CAUSE Faces not flat. - Pump cover retainer omitted or damaged. -

INSPECT COMPONENT • Oil Pump Assembly (7)

and ball assembly

• Valve Body Assembly

(67)

• 2-4 Servo Assembly (13-31 ) • Input Housing Assembly (621) • 2-4 Band Assembly (602) -

Valves stuck. • 2-3 Shift valve (313-316) train. • Accumulator valve (333). • Throttle valve (326). • T.V. limit valve (332). • 1-2 Shift valve train (317-322). • 3-2 Control valve (339). Manual valve link (64) bent or damaged. Spacer plate (56) or gaskets (88 & 89) incorrect, mispositioned or damaged. Incorrect band apply pin (29). Missing or damaged servo seals (14 & 17). Porosity in pistons, cover or case. Damaged piston seal grooves. Plugged or missing orifice cup plug (86). 3rd Accumulator retainer and ball assembly (80) leaking. Porosity in 3-4 accumulator piston (52) or bore. 3-4 Accumulator piston seal (53) or seal grooves damaged. Plugged or missing orifice cup plug (81). Restricted oil passage. Refer to Slipping 2-3 Shift. Worn or misassembled.

• Case (10)

NO REVERSE OR SLIPS IN REVERSE

• Input Housing Assembly (621)

-

3-4 Apply ring (625) stuck in applied position. Forward clutch not releasing. Turbine shaft seals (619) missing, cut or damaged. Disconnected. Retainer and ball assembly missing or damaged. Stator shaft seal rings (233) or ring grooves damaged. Stator shaft sleeve scored or damaged. Reverse boost valve (220) stuck, damaged or misassembled. Cup plug missing. Restricted oil passage. Faces not flat. Converter clutch valve (227) stuck.

• Manual Valve Link (705) • Oil Pump Assembly (7)

-

ALL ILLUSTRATION NUMBERS REFERENCE HYDRA-MATIC

4L60 UNIT REPAIR

F1gure 10

AUTOMATIC

TRANSMISSION
12

SERVICE GROUP

(~~T5G)
CONDITION NO REVERSEOR SLIPS IN REVERSE (Continued)

Technical

Service

Information
FOR CAUSE 2-3 Shift valve (316) stuck. Manual linkage (64) not adjusted. Spacer plate (56) and gaskets (88 & 89) incorrect, mispositioned or damaged. Clutch plate (612) worn. Reverse input housing and drum assembly (605) cracked at weld. Clutch plate retaining ring out of groove. Return spring assembly retaining ring (610) out of groove. Seals (608) cut or damaged. Restricted apply passage. Porosity in piston (607). Belleville plate (611) installed incorrectly. Excessive clutch plate travel. Lo overrun valve (364) stuck. Orificed cup plug (359) restricted, missing or damaged. Clutch plates (682) worn. Porosity in piston (695). Seals (696) damaged. Return spring assembly retaining (693) mispositioned. Restricted apply passage.

INSPECT COMPONENT • Valve Body Assembly (67)

• Reverse Input Clutch Assembly (605)

• Auxiliary Valve Body (377)

• Lo And Reverse Clutch

ring

NO PART THROTILE OR DELAYED DOWNSHIFTS

• T.V. Cable • T.V. Bracket Assembly (65) • 2-4 Servo Assembly (13-31)

Loose or incorrectly installed. Bent. Servo cover retaining ring (13) omitted or misassembled. 4th Apply piston (16) damaged or misassembled. Servo inner housing (22) damaged or misassembled. Governor weights (108 & 109) binding. Governor valve (107) stuck. Valves stuck. • Throttle valve (326) • 3-2 Control valve (339) • T.V. modulated downshift (301) 4-3 Sequence valve body channel blocked.

• Governor Assembly (45)

• Valve Body Assembly (67)

ALL ILLUSTRATION NUMBERS REFERENCEHYDRA-MATIC 4L60 UNIT REPAIR

Figure

11

AUTOMATIC

TRANSMISSION
13

SERVICE GROUP

r~~T5GJ
CONDITION NO OVERRUN BRAKING - MANUAL 3-2-1

Technical

Service

Information
FOR CAUSE Not adjusted properly. Valves stuck. • 4-3 Sequence valve (329) • Throttle valve (326) Checkball #3 mispositioned. Spacer plate (56) and gaskets (88 & 89) incorrect, damaged or mispositioned. Turbine shaft oil passages plugged or not drilled. Turbine shaft seal rings (619) damaged .. Turbine shaft sealing balls loose or missing. Porosity in forward (630) or overrun clutch piston (632). Overrun piston seals (631) cut or damaged. Overrun piston checkball (633) not sealing.

INSPECT COMPONENT • External Linkage • Valve Body Assembly (67)

• Input Clutch Assembly (621)

-

NO CONVERTER CLUTCH APPLY

• Electrical

-

12 Volts not supplied to transrmsston. Outside electrical connector damaged. Inside electrical connector, wiring harness or solenoid damaged. Electrical short (pinched solenoid wire). Solenoid not grounded. Incorrect or damaged pressure switches. Temperature switch damaged. Internal damage. Converter clutch valve (227) stuck or assembled backwards. Converter clutch valve retaining ring (225) mispositioned. Pump to case gasket (9) mispositioned. Orifice cup plug (240) restricted or damaged. Solenoid "0" ring seal (49) cut or damaged. High or uneven bolt torque (pump body to cover). Turbine shaft "0" ring seal (618) cut or damaged. Turbine shaft retainer and ball assembly (617) restricted or damaged. TCC shift valve stuck. TCC apply valve stuck. Solenoid o-ring leaking. Blocked.

• Converter (1) • Oil Pump Assembly (7)

-

• Input Housing and Shaft (621 )

-

• Valve Body Assembly (67)

• Solenoid Screen (47B)

ALL ILLUSTRATION NUMBERS REFERENCEHYDRA-MATIC 4L60 UNIT REPAIR

Figure 12

AUTOMATIC

TRANSMISSION
14

SERVICE GROUP

Sprag assembly installed backwards. Converter clutch apply position. Actuator rod spring binding or improperly crimped. Parking lock bracket (710) damaged or not torqued properly. Flash restricting filter neck. Converter apply valve stuck in (45) • Valve Body Assembly • Oil Pump Assembly • ECM DRIVES IN NEUTRAL • Forward Clutch clutch valve (227) stuck. NO PARK • Parking Linkage (701-715) - - Actuator rod assembly (701) bent or damaged. Converter clutch valve (227) stuck. 4L60 UNIT REPAIR ALL ILLUSTRATION NUMBERS REFERENCE HYDRA-MATIC Figure 13 AUTOMATIC TRANSMISSION 15 SERVICE GROUP . Turbine shaft retainer and ball assembly (617) restricted or damaged. - • Miscellaneous • Input Housing and Shaft Assembly (621) . - Clogged exhaust orifice. Internal damage. • Manua! Valve Link (705) • Case (10) 2ND GEAR START (DRIVE RANGE) • Governor Assembly - Valve (107) stuck.Turbine shaft "0" NO CONVERTER CLUTCH RELEASE • Solenoid • Converter (1) (67) (7) .External ground. • Forward Clutch Sprag Assembly (642) . "0" ring seal (70) cut or damaged. ring (618) cut or damaged. Face not flat. Actuator rod not attached to inside detent lever (703). Disconnected. Engine not tuned properly. Not releasing. Internal leakage. Crack in filter body. Low oil pressure. Governor support pin too long or missing. External ground. Restricted oil passage.(~~T5G) CONDITION CONVERTER SHUDDER Technical Service Information FOR CAUSE INSPECT COMPONENT • Torque Converter Assembly (1) • Oil Pump Assembly • Oil Filter (71) (7) - Internal damage.

ALL ILLUSTRATION NUMBERS REFERENCE HYDRA-MATIC 4L60 UNIT REPAIR Figure 14 AUTOMATIC TRANSMISSION 16 SERVICE GROUP . • Torque Converter Seal (2) DELAY IN DRIVE AND REVERSE • Torque Converter (1) - Converter drainback. OIL OUT THE VENT • Oil Pump (7) • Valve Body (67) • Miscellaneous - Chamfer in pump body rotor pocket too large.1~~T5GJ CONDITION NO PARK (Continued) Technical Service Information FOR CAUSE Inside detent lever (703) not torqued properly. Converter not bolted to flex plate. limit valve (332) stuck. NO DRIVE IN ALL RANGES • Torque Converter (1) - Converter to flex plate bolts missing. damaged or misassembled. NO DRIVE IN DRIVE RANGE • Torque Converter (1) - Stator roller clutch not holding. T. Damaged converter hub.overfilled. Missing garter spring. Fluid level . INSPECT COMPONENT • Parking Linkage (Cont. VIBRATION IN REVERSE AND WHINING NOISE IN PARK • Oil Pump (7) - Broken vane rings (212). FRONT OIL LEAK • Torque Converter (1) - Welded seam leaking.V.) RATCHETING NOISE • Parking Pawl (711) - Parking pawl return spring (714) weak. Detent roller and spring assembly (709) mispositioned or not torqued properly. Parking pawl (711) binding or damaged. Damaged seal assembly.

' I :4-3 : 4TH DISCREET SW(N.C.C.C. B TO 14TH CLUTCH SWITCH (COLOR ID-WHITE) SHIFT TERMINAL (COLOR ID. OIL PATH) 0.010 AMPS ...lII.) NORMALLY NORMALLY OPEN (N.C. MM. T J. yp.) TYPE 3 T..) TYPE 4 MODELS: POS. SOL TERMINAL TO 4-3 SWITCH (COLOR ID-RED) FA.~i-TERMINAL A TO 4-3 DOWNSHIFT SW (COLOR ID-RED) 4-3 SW TERMINALS (COLOR ID-YELLOW) 1.5 AMPS .-_-rVV"'\+ 12V .O.. MH...O. -i~-'__' B . YT TYPE Figure 16 4 AUTOMATIC TRANSMISSION 17 SERVICE GROUP . YL. SOLENOID ASSEMBLY (COLOR ID-BLACK) POS. TN/If< TYPE Figure 15 3 TERMINAL A TO 4-3 DOWNSHIFT SW (COLOR ID-RED) 4-3 PULSE (N.C..) T.YELLOW) 0. SOL (N.C.:~~:-4-3 DOWNSHIFT SW (COLOR ID-BLACK BODY) 2 TERMINALS NORMALLY NORMALLY OPEN (N.C.) CLOSED (N.. SOL TERMINAL TO 4-3 DOWNSHIFT SW (COLOR ID-RED) MODELS: TS.~~: i ' TERMINAL . YF. -.) CLOSED (N..O.• cA""_. MA.C.>" + 12V 0. YN. YK.1~~T5G) Technical Service Information IW~___".

C. SOLENOID (COLOR ID·DK GREEN) MODELS: MP.) 4TH CL TERMINAL (COLOR ID-BLUE) 4TH CLUTCH SW (COLOR ID-MET ALLIC AND WHITE) 1 TERMINAL OPTIONAL 4TH CL SW (COLOR ID-MET ALLIC & BLACK) NEG. YO. PL. TA. SIDE (COLOR ID-RED) TERMINAL B TO 4TH CLUTCH SWITCH (COLOR ID-WHITE) 4TH DISCREET SW(N. YX.C.) CLOSED (N. SOL TERMINAL TO TERMINAL 0 (CCC GROUND) (COLOR ID·BLACK) TYPE 9 MODELS: YZ. SOL (N.O.O.) NORMALLY NORMALLY OPEN (N. TYPE Figure 18 9 AUTOMATIC TRANSMISSION SERVICE GROUP 18 .Technical Service Information T.C.5 AMPS A +}'2V ~~----{ B GROUNDrD~--------~ NORMALLY NORMALLY OPEN (N.C.O. SOL (N.C.C. OIL PATH) TERMINAL A TO SOL POS. YA.C. YR. YW.) TYPE 6 T.C. YS YC. TB TYPE Figure 17 6 T. OIL PATH) 0.O.) CLOSED (N.C.

. SOL TERMINAL TO 4-3 DOWNSHIFT SW (COLOR ID-REDI NEG.. MWM. SOL TERMINAL TO 4TH CLUTCH SW (COLOR ID-BLACKI 4·3 SHIFT (N. MLM. MRM. MFM.M. MPM.. OIL PATH) TERMINAL A TO 4·3 DOWNSHIFT SW (COLOR ID·RED) J~~M~~t~c~ ~~ (COLOR ID·BLACK) 4·3 DOWNSHIFT SW (COLOR ID·BLACK) 2 TERMINALS 4·3 SW TERMINALS (COLOR ID·YELLOW) 4TH CL TERMINAL (COLOR ID·BLUE) 4TH CLUTCH SW (COLOR ID·BLACK) 1 TERMINAL POS.) E. SOL TERMINAL TO 4-3 SWITCH (COLOR IO-RED) TUM. TYPE Figure 20 15 AUTOMATIC TRANSMISSION 19 SERVICE GROUP .~nl : .C.C. SOL (N. GRD-+~:>=D~-L..O..C. MUM. MAM. MMM.. MXM. POS.O.--. MOM.) . MICM. . -""-L_-"'"-H' .. ..J NORMALLY NORMALLY OPEN (N. SWTTCH ASM.4-3 DOWNSHIFT SW : (COLOR ID-BLACK BODY) 2 TERMINALS TYPe 16 1987 MODELS: FAM. TJM. . .(~~TSGJ Technical Service Information T.) TYPE 10 MODELS: MW. MZM..C...C. CONNECTOR BODY (COLOR IO-BLACK) : 3 SHIFT TERMINAL (COLOR 10-YELLOW) .--. TlCM.O.. TXM..0 ~ 0.) CLOSED (N.. TW TYPE Figure 19 10 TERMINAL A TO 4-3 DOWNSHIFT SW (COLOR IO-RED) TERMINAL B TO \ 4TH CLUTCH SWITCH ~ (COLOR IO-WHITE) 'rtMP.' • ir@'-~\~-.t-- 4TH CL (N.

M. GREEN) NEGATIVE SOLENOID TERMINAL TO TEMP SWITCH (COLOR 1. ASM. BLUE) TYPE 18 1993 MODELS: MM. AFM.0. BBM.C. BWM.C.:=-==:p. BLACK) TYPE Figure 21 18 POSITIVE SOLENOID TERMINAL (COLOR 1. RED) PIPE PLUG:'=::~=F=-=-==::..j 4TH CL.I POSITIVE SOLENOID TERMINAL (COLOR 1. BLACK) 4TH CLUTCH SWITCH SIGNAL TERMINAL (COLOR 1.6 AMPS IA : TEMP __'-:--(N.) TRANSM1SSION +12V~~ E.0.C. FDM. I I T.. COMPLETE (COLOR 1.t: '3 REQ'D SOLENOID ASM. LGT. COMPLETE (COLOR 1. BFM. LT. REDI 1 C:lt~R1~_~_Ll1_. BLACK) TYPE 19 1993 MODEL: SAM TYPE Figure 22 19 AUTOMATIC TRANSMISSION SERVICE GROUP 20 .0. FAM.=::. BAM. BROWN) NEGATIVE SOLENOID TERMINAL TO TEMP SWITCH (COLOR 1. I I 0.0. I I i 4TH CLUTCH TERMINAL (COLOR 1.:!=.O.O. (N. BHM.0. ADM. FRM. SOL OIL PATHI---. CPM.BRM.0.0.0. BLACK) 4TH CLUTCH SWITCH SIGNAL TERMINAL (COLOR 1. ~ GROUND D .O. BCM.(~RT5GI Technical CCC PATTERN SHIFT 4TH CLUTCH SIGNAL • Service Information r--·(N. FXM.0..SFM SOLENOID ASM.

. YCM. FMM. BLACK a TEMP.0. HOM.0.H II { 4TH COLOR 1. METALLIC & BLACK 4TH CL._ TEMP.C. SWITCH COLOR 1. METALLIC & WHITE TYPE Figure 23 TllAHIMISIION 22 :------.0. SWITCH ASM.. __ _~ a --_'/ TYPE 22 1993 MODELS: HBM. 10~N IN 2NDI : J : SOLENOID ASM. HLM CL.YAM. SWITCH COLOR 1. YOM TYPE Figure 24 23 AUTOMATIC TRANSMISSION 21 SERVICE GROUP . TERMINAL COLOR 1.C. SWITCH N. _ . (OPIiN IN 31101 : • . SWITCH COLOR 1. COLOR 1.(~~T5[iJ Technical Service Information 1_. SWITCH ASM. SWITCH COLOR 1.~C~C. '---___________ ~ _____________________ 7j 'T:E. I: I rh' : 2ND CL. BLACK NEGATIVE SOLENOID TERMINAL TO TEMP.0. CONNECTOR COLOR 1.~~~-------.0.12V -4-----1 A' TOECM 3110GEAII D1SCIIET£IN'UT TO ECM 2ND GEAII DISCRETE IN'UT C: I : 3110tL..0. CONNECTOR COLOR 1. BLACK SOLENOID ASM. BLACK 2ND CL. COLOR 1. SWITCH N. METALLIC & BLACK TYPE 23 1993 MODELS: FFM. BLUE __ .0.0.~~!.0.0. HJM. PURPLE PIPE PLUG OPTIONAL 4TH CL.

17 OVERRUN CLUTCH 18 T. EXHAUST 47 4TH FEED 48 1-2 ACCUMULATOR ILL. 24 MOD. UP 25 MOD. DESCRIPTION 1 LINE 2 D4 3 D2 4 LO 5 REVERSE 6 GOVERNOR 7 LO . NO. DOWN 26 DETENT 27 3-4 CLUTCH 29 RND4-3 30 3RD CLUTCH ILL.V.V. 11 M. EX.V. Figure 25 AUTOMATIC TRANSMISSION 22 SERVICE GROUP . SIG. DESCRIPTION 16 T. DESCRIPTION 31 IDENTIFICATION 32 VOID 33 EXHAUST 34 SF 35 4-3 42 04 ABUSE 43 3RD FEED 44 3-2 HIGH SPEED 45 2ND FEED 46 3RD CL.1ST FEED 9 3RD ACCUMULATOR 10 T.(~RT5G) Technical VALVE Service BODY Information PASSAGES ILL. 12 ACCUMULATOR 13 4TH SIGNAL 14 2ND CLUTCH 15 3-4 ACCUMULATOR NO. 19 D3/PART THROTTLE 20 PART THROTTLE 21 03 22 4TH CLUTCH 23 C.C. NO.T.F.V.

. NO. SIG.C. 19 D3/PART THROTTLE 20 PART THROTTLE 21 03 22 4TH CLUTCH 23 C. DESCRIPTION 2 04 3 02 8 7 8 9 10 11 12 13 1 LINE 4 LO 5 REVERSE GOVERNOR LO· 1ST FEED LO/REVERSE 3RD ACCUMULATOR T.(~~T5GI Technical TYPICAL Service SPACER Information PLATE THERE IS AN ADDED ORIFICE HOLE IN THE 1993 SPACER PLATE THAT THE 1987-1992 SPACER PLATE DOES NOT HAVE.V.4 00 27 10 0 26 13 028 0 ~O 0 6 • 0 15 11 0 28 o 11 16 ~. THIS HOLE IS TO ACCOMODATE THE ADDED CHECKBALL IN 1993 MODELS. UP 25 MOO. EXHAUST 47 4TH FEED 48 1·2 ACCUMULATOR Figure 26 AUTOMATIC TRANSMISSION 23 SERVICE GROUP .V. 24 MOO. M. ° 2 •o 5 08 50 07 0~ 30 14 0 0 08 90 08 4~ 011 110 017 17 •. NO.0 o 10 0 27 26 0 0 .. DOWN 28 DETENT ILL.T.V. ADDED ORIFICE HOLE FOR ADDED CHECK BALL.12 0 ILL. ~ ~ 0. DESCRIPTION 14 2ND CLUTCH 15 3·4 ACCUMULATOR 16 T.0 3 3 @o o 10 o 280 44 0 28 • 1 290 43 0 0 . o 17 cJ:: 00 1 16 o 23 • a 10 • 10 0 10 0 18 00 20 0 19 180 lb' IDENTIFICATION 120 00 12 13 • • 80 . DESCRIPTION 27 3·4 CLUTCH 29 RND4·3 30 3RD CLUTCH 31 IDENTIFICATION 42 04 ABUSE 43 3RD FEED 44 3·2 HIGH SPEED 45 2ND FEED 48 3RD CL.V.F. 17 OVERRUN CLUTCH 18 T. 5 07 08 • 017 • ·24 ~O24 09 23 o• () 22 01 14 O. EX. ACCUMULATOR 4TH SIGNAL ILL.12 •• •o 0. o 12 012 20 . NO.48 045 (:).

0 ) G6") . 15 o 15 o SPACER PLATE TO CASE GASKET Figure 27 AUTOMATIC TRANSMISSION 24 SERVICE GROUP .0 23 22 lEJ r:..024 230 0"00 • 25 09 0.14 o 012 09 CJ1 o 23 10 o oB 10 100 • 14 14 OGQ 1 o o °0 I 0 12 12 o.:. 0 26 ~\) o 10 13 02 11 o 26 "0010 o 26 24 CJ 2 0 026 0 6 o0 11 2 CJ L..------ • 1 03 29r=:J 0• ~0 • 9 CJ '----Do 26 0 7 30 40 09 14 010 27 10 • 06 0" 170 • 02 'Y.. -----"" ~ 027 . 80 017 .__ 12 •• -' 500 o? 08 ----.l o 22 o 10 16 o 14 01 __ ----0-.Technical Service Information ROUND OR SQUARE HOLE 1987-1992 1993 VALVE BODY GASKETS VALVE BODY GASKETS 50 05 .

LJ 05 40 10 02 <:» 09 ~ 00 30 • 9 0 06 011 11 c::::J 0 c::J17 17 • 10 SJ() o 26 '"'00 t:l14 100 ~ 0 06 0 10 o 02 o 23 o 20 O· 6 011 14 G @] EJ 0 0 c:J 7 05 • ~8 O. O~ 3 0r. c:::l'9 19 o BODY TO SPACER PLATE GASKET Figure 28 AUTOMATIC TRANSMISSION 25 SERVICE GROUP . 0 16 cr::-o 16 10~ 15 ~ 0• ~G 00 12 ~ 07 08 0 05 0 12 12 15 0 '--.~ ~O \J 10 0 09 24. 23 10 o 26 22 O0 15 o o @).Technical Service Information ADDED TEAR DROP HOLE 1987-1992 1993 VALVE BODY GASKETS c::J6 06 43 VALVE BODY GASKETS ~[!j----~ o 10 ---rj"QP i'6 40 0 30 • 1 WOO 29 1. O.J ~. 42 5 11 0 11 13 . o. 0 13 o 8 o~ 12n o• 0 VALVE O 140 U 000 10 10 10 0 16 ~.

UP 25 MOO. 3RD ACCUM. 27 32 391. 1 9 D3/PART THROTTLE 20 PART THROTTLE 21 03 22 4TH CLUTCH 23 C. CL.(~RT5GJ Technical Service Information MSSAGES . 1 UNE 3 DR-2 15 REVERSE . 7 O.T.V. LINE 2 04 3 02 4 LO 5 REVERSE 6 GOVERNOR 7 LO . CASE SERVO o CASE Figure 30 SERVO PASSAGES Figure 31 AUTOMATIC TRANSMISSION 26 SERVICE GROUP .V. 11 M.T.V.V. &IG. PRESSURE TAP PASSAGE 80 RETAINER & BALL ASSEMBLY.) 48 1 -2 ACCUMULATOR SSF 18 CHECK BALL (2ND/'-2) SSG I' CHECK BALL (4TH ACCUMULATORI 47A 106 55H 106 *3 CHECK BALL (PART THROTTLE/DRIVE 3) RETAINER & BALL ASM. EX. EXHAUST 47B CONVERTER CLUTCH FILTER LOCATION 47 4TH FEED SSE 14 CHECK BALL (3-4 CLUTCH/3-2 EX. 17 OVERRUN CLUTCH 18 T.R. CLUTCH 23 CONV. DOWN 26 DETENT 27 3-4 CLUTCH (3-2 EX) 29 RND4-3 42 04 ABUSE 43 3RD FEED 44 3-2 HIGH SPEED COMPONENTS 4S 2ND FEED 47 A GOVERNOR FILTER LOCATION 46 3RD CL.V. 12 ACCUMULATOR (4TH) 13 4TH SIGNAL 14 2ND CLUTCH 15 3-4 ACCUMULATOR 16 T. 24 MOO.) 39(b) 49 315 3-4 CLUTCH VOID VENT LUBE TO COOLER LUBE FROM COOLER PRESSURE TAP A 2-4 SERVO BORE B SERVO EXHAUST HOLE C 2ND & 4TH BAND APPLY PASSAGE 3RD ACCUM. .C.F.1ST FEED 8 LO/REVERSE 9 3RD ACCUMULATOR 10 T. (DOUBLE-ORIFICE) Figure 29 CASE PUMP PASSAGES A B CM! OIL 'MUGE. 86 PLUG. 1 M. SIG.

2ND APPLY 26 SPRING. SERVO RETURN 80 RETAINER & BALL ASSEMBLY. SERVO CUSHION 27 RETAINER. 2·4 SERVO PISTON. CASE SERVO 2-4 Figure 32 SERVO ASSEMBLY AUTOMATIC TRANSMISSION 27 SERVICE GROUP . "0" RING 22 HOUSING. SERVO APPLY PIN 20 SPRING. OIL SEAL (2ND APPLY PISTON) (OUTER) 25 PISTON.• 1~~T5[iJ Technical A B C Service F Information 80 17 4TH OIL 3RD ACCUMULATOR OIL VALVE BODY FACE OIL PAN FLANGE EXHAUST 2ND OIL SEAL. OIL SEAL (4TH APPLY PISTON) (OUTER) 18 RING. SERVO CUSHION SPRING 28 RING. RETAINER (APPLY PIN) 1S WASHER. 3RD ACCUM. "0" RING (2·4 SERVO COVER) COVER. 4TH APPLY RING. OIL SEAL (2ND APPLY PISTON) (INNER) 24 RING. 2ND APPLY PISTON 31 SPRING. SERVO PISTON (INNER) 23 RING. 86 PLUG. RETAINER (2ND APPLY PISTON) 29 PIN. SERVO APPLY PIN A B C D E F 14 16 18 17 21 SEAL.

) 36 VENT 37 DECREASE 38 SEAL DRAIN 39 LUBE 39(.C. 17 OVERRUN CLUTCH 23 CONVERTER CLUTCH SIGNAL 27 3-4 CLUTCH 32 VOID 33 EXHAUST 33(a) EXHAUST (T. RELEASE) 33(b) EXHAUST (PRESS.C.(~RT5G) Technical PUMP Service Information 36 COVER PASSAGES 3 1 LINE 02 5 REVERSE 11 MODULATED T.V.) LUBE TO COOLER 39(b) LUBE FROM COOLER 40 CONVERTER CLUTCH RELEASE 41 CONVERTER CLUTCH FEED 3 1 02 LINE 33 Figure 34 AUTOMATIC TRANSMISSION 28 SERVICE GROUP . REG. REG. 17 OVERRUN CLUTCH 23 CONVERTER CLUTCH SIGNAL 23(a) CONVERTER CLUTCH SIGNAL (ORIFICE CUP PLUG) 27 3-4 CLUTCH 41 32 VOID 33 EXHAUST 33(. V.) 36 VENT 37 DECREASE 37(a) DECREASE AIR BLEED (ORIFICE CUP PLUG) 38 SEAL DRAIN 39 LUBE 39(a) LUBE TO COOLER 39(b) LUBE FROM COOLER 40 CONVERTER CLUTCH RELEASE 41 CONVERTER CLUTCH FEED 41 (a) CONVERTER CLUTCH FEED TO COOLER (ORIFICE CUP PLUG) 27 Figure 33 PUMP BODY PASSAGES 6 REVERSE 11 MODULATED T. RELEASE) 33(b) EXHAUST (PRESS.C.C.) EXHAUST (T.

(~~T5G) Technical Service Information REAR CASE PASSAGES ORIFICED CUP PLUG GOVERNOR SUPPORT PIN 10 45 46 83 CASE GOVERNOR ASSEMBLY GOVERNOR COVER (USE LOCTITE ON FLANGE) GOVERNOR GEAR Figure 35 - 83 AUTOMATIC TRANSMISSION 29 SERVICE GROUP .

.._=--== 8663764 8667525 AJ YLM ... F--········-.. CODE 8667367 FITS THESE MODELS 8667704 ========== "'========== :a========= F========= 8667825 TAM TBM BO YPM a ••••••••••••••• BZ YWM BS THM TLM Figure 36 ••••••••••••••• FITS THESE MODELS ==•••=.D.. I.. CODE ~ -••• =--===== 8663592 8663585 ======--=-== ==_===ms==== 8667703 8663590 MFM MXM . I...D. ••••••••••• .. ..__ ...... .=••==a=z==. PART NO. CODE FITS THESE MODELS 1988 PART NO.-----_ .a •• AB YTM AZ YWM AG YKM AO YPM AU YNM .D.D.-.. I.=____=....MLM MKM TUM TXM MZM MPM FAM MRM PART NO. "-==== =" SERVICE GROUP AUTOMATIC TRANSMISSION 30 ..(~RT5G) 1987 PART NO.. ========== 8663594 8667063 AT TAM TBM AL YOM AA YZM YMM AS YSM AH PAM PBM PCM YAM SPACER 8667355 AE PRM MTM MCM PLATE 8667356 YXM THM 8667353 700-R4 8667354 CHART 8667358 8667357 BH PAM PBM PCM BE MCM PRM MTM BD HAM BF MKM BM MWM BA YZM FAM MDM MPM MHM MXM ... CODE FITS THESE MODELS FITS THESE MODELS 8663584 ==___ =_ ~----=-===-====-======... I.. CODE FITS THESE MODELS Technical THM 8663589 Service Information PLATE 8663587 700-R4 8667064 SPACER 8663595 AM MWM CHART 8663593 8663763 AF TJM TKM MDM MUM AP TNM TRM MIDi AD MMM HAM AN TSM AK YFM .D........... ....------PART NO. I.........=--====-= ===a===_== 1=========== ==-••--=== ========== TNM MFM FMM MRM MLM TJM TKM TUM TXM MZM PART NO. CODE 8667359 8667360 8667363 8667364 8667475 8667700 BL YOM BG YKM ___ =UiI:====== BT YXM BB YTM BU YNM BX YMM ..F========-= 8667061 8663591 8663588 =..D.--_.. +....-....---._-----=. -=-.......

..-------.••.. CODE -.. 1..(~RT5G) 1989 Technical THM 8673053 Service Information PLATE BS THM TLM CHART 8673135 700-R4 8673136 SPACER 8673137 PART NO.. _= .: =_====a==== 8673238 =-======"'== ========== 1="========= F== ... 8673138 8673165 •• =-=-=... 1. PART NO..---=-. CODE FITS THESE MODELS =_:......0.0. PART NO. ====== ============ 8673206 8673352 8673353 8673499 8673500 CK YNM CL HDM CM FXM CO YZM CW HCM CX HFM Figure 37 AUTOMATIC TRANSMISSION 31 SERVICE GROUP .-----8673166 8673163 MXM MFM MRM BY MHM PAM PBM PCM TNM CB FKM CC YDM CD YTM CG YXM CH YPM FITS THESE MODELS 1:.. -----= ---_ ..-..-: . 1.. CODE FITS THESE MODELS 8667825 8673139 BC HBM HHM BN MeM PRM BP MDM MKM MLM TJM TKM BV MPM MZM TUM TXM MWM BW HAM FMM ~ ..0.•••• 8673160 ____ K ____ •• 8673164 ..~._. ~.

====-. == p:.._=_==K3===p:====z===== . .. 1. CODE 8673633 8673440 FITS THESE MODELS DA LAM DB DBM FITS THESE MODELS LBM LCM LDM LFM Figure 38 AUTOMATIC TRANSMISSION 32 SERVICE GROUP .. . 1..D...D. CL HDM CM FUM CN MSM CS FBM ~•••••___==_5=.. 8673511 8673499 8673500 8673645 CT YDM CU FIM CV FZM CW HCM CX HLM CZ HJM ~:C_=..== = ===== = = PART NO. I.Fa======--=-= PART NO...=== ===... CODE FITS THESE MODELS Technical 1990 THM 8673053 Service Information PLATE BS SHM SPM TLM CHART 8673135 700-R4 8673136 SPACER 8673137 8667825 8673139 BC HBM BN MBM SAM BP CCM CFM KLM WBM =========-= BV CHM CJM KCM BW CAM CBM K.D. == p========== ~========== p"========= = PART NO.===~.I~RTSG) PART NO. = ======= ..RM RAM MJM WAM MNM KMM ==... 1..D....:-====".. CODE 8673509 FITS THESE MODELS 8673510 =====. CK BPM _ . ==-=====-= ~. == =====... ==== =========== = = 8673352 8673401 8673441 WCM CD BAM 11. CODE 8673164 ========== 8673238 8673206 ======= . ==:0:============= ...

. CODE FITS THESE MODELS 8677720 1=========== 8677704 -==-==-=== 8678207 ~=====.. . = = 8678328 8678567 8679298 8680144 ===..== F=-========= ========== 1=========== ~=======.. 8673500 8673655 8673653 8673654 I. I.(~AT5G) 1991 PART NO.D.1==== ==_8= 8676591 8676590 PART NO..----=.. = = ~••---=--==-=== 1=======.. ===== ~=====:z_== 8673510 8673551 8673499 CN MSM CS FBM CT YHM CU FTM CV FZM CW HCM .D. ===== = DT LlIM DU LAM DV AAM EA CNM CYM KWH RCM RDM EB AMM •.._. CODE FITS THESE MODELS 1===========. ====== ========== F========== .D.D.... CODE FITS THESE MODELS Technical THM 8673053 Service Information PLATE 8673165 700-R4 8667825 SPACER 8673135 CHART 8673352 8673238 BC HBM BS SlIM TLM 8673441 BW MJM MNM CB FYM CK BJM CM FUM p••••• =a:======== PART NO.==========: 8673401 ========== WAM 8673509 = F========== ==-.-----==-= =====------=--=---== AUTOMATIC TRANSMISSION 33 SERVICE GROUP . I. CX HLM DC CCM CFM KLM WBM DD CAM CBM KMM ========== DG SAM DH DAM DJ BCM ~.•_= •••••• -- LBM LCM LDM LFM --=====---= Figure 39 APM ===-====--~.••••• ======= F========== =========== 8677426 8677719 I.... CODE FITS THESE MODELS F··==-========= PART NO.. I. CODE FITS THESE MODELS PART NO.....=== 8678042 DK DBM DM HDM DN HJM DO SFM DP 2DDM 92 MODEL ========== 8680371 DS BBM BlIM !a====== = =..D....

CODE 8678042 8678328 8678567 8679298 8679492 8680144 FITS THESE MODELS DS BBM BHM DT LHM DU LBM LCM LDM LFM DV AAM DY TAM TBM EA CJM CHM KJM WCM FITS THESE MODELS PART NO. I.D.. CODE FITS THESE MODELS 8673441 BC HBM BS SHM TLM 8673500 CB FUM CK BFM CS FBM CD FTM ==.======= =========== =========== F====================== ==========: ========== PART NO. CODE EK CPM FITS THESE MODELS FITS THESE MODELS MSM ============= =========== =========================================== Figure 40 ========== AUTOMATIC TRANSMISSION 34 SERVICE GROUP .D.===================== 1=========='========== 8680678 8680677 8680502 8680503 8680770 8680828 EC YAM YCM 8681061 ED YDM EE BAM EG BWM EH ADM AKM EJ MMM ~=.D. CODE 8673511 8673655 8673653 8673654 8676590 CV FZM CX HLM DC CCM CFM KHM WBM DD CAM CBM KMM MJM MNM WAM DG SAM DH ACM FITS THESE MODELS F========================= :===========~========== =========== =========== ========== PART NO.. =========== =========== =========== =========== ========== ========== PART NO. I. CODE "'============:=========== =========== ..D.D. I. =========== =========== !=========== ========== 1====================== ========== PART NO. I. CODE 8676591 8679435 8677719 8677720 8677704 8678207 DJ BCM DL TWM DM HDM DN HJM DO SFM DP DDM ====••=======. I.D. I.==.(~RT5G) 1992 Technical THM 8673053 Service Information PLATE 8673238 700-R4 8667825 SPACER 8673165 CHART 8673510 PART NO.

..D.D. I.--====== 1===========1===========~========== 1===========1::========== F========== PART NO. CODE 8681277 8681280 8681285 8681259 FITS THESE MODELS GH BFH GJ SAM GL CPM GS LHM GW SFM GX BRM ~==.. -======== 1===========1===========F========== 1===========F========== 1=========== PART NO.D. I. CODE 8681262 8681264 8681265 8681266 SPACER ET ADM AFM 8681270 8681267 EP AAM ES BWM EV HBM EW HDM ~============ =========== =========== 1::========== =========== =========== F========== PART NO. =========== F========== F========== 1===========F========== F========== ===== PART NO. I. CODE 8684466 HA FITS THESE MODELS i:::===_=======:==========::=========:============================================ Figure 41 FITS THESE MODELS ASH AUTOMATIC TRANSMISSION 35 SERVICE GROUP . I..(~~T5G) 1993 Technical THM 700-R4 8681263 Service Information PLATE EU FAM FDM CHART ~============~==========~==========F==========~==========F==========F========== PART NO.D. CODE 8681271 8681272 8681273 8681274 8681275 8681276 FITS THESE MODELS GA HLH GB YAM YCH 8681278 GC YDM GD BAM GE BBH BliM 8681289 GG BCM ~---=== .. CODE 8681268 8681269 FITS THESE MODELS EX FFH EY FMM EZ HJM ~=..D. I.

3. Install J-22269-01 compressor on the second apply piston. 5. Remove the servo return spring. Install J-33037 with the apply pin as shown in Figure 45. AUTOMATIC TRANSMISSION 36 SERVICE GROUP . as shown Figure 42. Remove second apply piston snap ring as shown in Figure 44. 11. Rotate the transmission with extension housing down. 13. 6. Pull the "0" ring up thru the slot in case and cut. remove the "0" ring. Figure 43 Figure 42 2-4 SERVO ASSEMBLY 1. Apply 100 in. Remove the servo cover. Remove the 2nd apply piston assembly from the servo pin.(~RT5G) TRANSMISSION Technical Service Information 15 2·4 SERVO COVER DISASSEMBLY GENERAL INFORMATION 1. Install transmission into the fixture base on work bench. and the apply pin spring. Use the servo pin selection chart in Figure 45 to determine the correct pin length. 8. Remove "E" clip.lbs. Remove the 4th apply piston. Thoroughly clean the exterior of the transmission before disassembly. Figure 44 SERVICE NOTE: As a diagnostic aid. Install holding fixture. 9. be certain to inspect the 2-4 band and reverse input housing for wear. 7. as shown in Figure 44. 2. 3. Remove the 2-4 servo assembly. Use Figure 47 as a guide for the disassembly of the 2-4 servo parts. and drain the fluid. pin length is correct. BAND PIN SELECTION 1. 3. 5. Install J-29714 servo cover compressor. 25 SECOND APPLY PISTON ASM. If the servo pin length is not proper. 4. Remove cushion spring retainer and the cushion spring. 2. Length can be measured as shown in Figure 46. 2. 12. in Figure 45. 5. 4. Remove servo cover retaining ring. 10. Remove the torque converter. If white line appears in the window of J-33037 tool. of torque as shown. on transmission case. washer. 4. as shown in Figure 43. as shown in Figure 42. the servo pin length should now be checked for proper selection.

53 68. SERVO CUSHION SPRING RING. SERVO CUSHION SPRING. 17 Figure 45 MEASURE THIS DISTANCE \ FOR SERVO PIN LENGTH n. SERVO CUSHION ASSIST (CORVETTE ONLY) RETAINER.64-68. SERVO RETURN J Figure 47 AUTOMATIC TRANSMISSION 37 SERVICE GROUP . SERVO COVER RETAINING SEAL.94 INCH 2. OIL SEAL (2ND APPLY PISTON -INNER) RING.0. OIL SEAL (2ND APPLY PISTON .(~~TSGI Technical Service Information 14 A WHITE LINE B GAGE SLOT PIN IS PRESET AT FACTORY AND MUST NOT BE READJUSTED 2.12 67.60 2. RETAINER (2ND APPLY PISTON) PIN.59-2. 4TH APPLY RING. OIL SEAL (4TH APPLY PISTON . SERVO PISTON (INNER) RING.23-67. 2ND APPLY PISTON SPRING.66 2. ·0·RING (2·4 SERVO COVER) COVER. RETAINER (APPLY PIN) WASHER. SERVO APPLY PIN SPRING. ·0· RING HOUSING.OUTER) PISTON.4 SERVO PIN SELECTION PIN LENGTH MM 65. 2·4 SERVO PISTON.70-2.82-66. 2ND APPLY SPRING.--_u~i --~tu ~I IDENTIFICATI~ Figure 46 13 14 15 16 17 18 19 20 21 22 23 24 25 26 26A 27 28 29 31 RING..65-2. SERVO APPLY PIN SEAL.OUTER) RING.71 1 GROOVE 2 GROOVES NO GROOVE PIN 1.

Remove four extension housing bolts and the extension housing. INTERNAL TRANSMISSION SPEED SENSOR Figure 50 8. NO. INTERNAL TRANSMISSION BOLT. Remove the output shaft sleeve (690) if so equipped (Figure 50). DESCRIPTION CASE. Remove the output speed sensor from extension housing bore. CASE EXTENSION TO CASE EXTENSION. Remove the bolt. 9. Remove and discard the extension housing "0" ring (Figure 50). and inspect the case bore for wear or damage. using tool J-38417. Tap around the governor cover flange with a punch to remove the governor cover. Some models have plastic speedometer gear. Refer to Figure 50. TRANSMISSION SEAL. OUTPUT SHAFT ALL MODELS ROTOR. SPEEDO DRIVEN GEAR GEAR. and inspect for damage and/or wear. 2. as shown in Figure 48. AUTOMATIC TRANSMISSION SERVICE GROUP 38 . SPEEDO DRIVE SLEEVE. CASE EXTENSION TO CASE SEAL ASSEMBLY.Technical Service Information 100 '~ 99 100 SPEED SENSOR. CASE EXTENSION OIL RETAINER. Remove speed sensor rotor from the output shaft with puller. SPEEDO DRIVEN GEAR FITTING BOLT & WASHER ASSEMBLY SEAL. INTERNAL TRANSMISSION BOLT. 7. O-RING (SPEEDO FITTING TO CASE EXTENSION) FITTING ASSEMBLY. as shown in Figure 50. SPEEDO SENSOR RETAINING ~9 Figure 48 45~ 46 'L44~~j2 ~ 43~ _!)_OMEMODELS __ -. 10 35 36 37 39 40 41 42 43 44 45 46 99 100 687 688 689 690 691 699 SPEED SENSOR Figure 49 EXTENSION HOUSING AND GOVERNOR 1. ILL. CASE BOLT. 4. Great care must be used so as not to damage the governor cover. 5. and some models have speed sensor rotor in this location (See Figure 51). SPEEDO SENSOR RETAINING SHAF~ OUTPUT CLIP. GOVERNOR SPEED SENSOR. OUTPUT SHAFT NOT USED ON SEAL. SPEEDO DRIVEN GOVERNOR ASSEMBLY COVER. SPEEDO DRIVE GEAR GEAR. (Used some models only). 3. and tap speedometer gear off of the output shaft using care not to damage the speedo gear (Figure 51). Push down on tab of speedometer gear clip. Remove the governor from the case bore with a twisting motion. 6. (Used on some models only). adapter retainer and speedometer adapter housing.

(~~TSGI Technical Service Information 687 688 689 699 SHAFT. SPEED SENSOR Figure 51 OUTPUT SHAFT IDENTIFICATION CORVETTE IJ LONG SPLINE SYCLONE Figure 52 AUTOMATIC TRANSMISSION 39 SERVICE GROUP . SPEEDO DRIVE GEAR GEAR. SPEEDO DRIVE ROTOR. OUTPUT CLIP.

Remove the main oil filter and open the filter by prying the metal crimping away from the top of the filter (Black Part) and pull apart. ACCUMULATOR COVER CLIP. 6. TRANSMISSION OIL PAN PAN. CHIP COLLECTOR Figure 53 IJ. TRANSMISSION OIL SCREW. HEX HEAD (MB X 1 X 45) Figure 54 AUTOMATIC TRANSMISSION 40 SERVICE GROUP .IItlI"flV""n/ 97 376 64 65 69 LINK. AUXILIARY TUBE BOLT. DETENT (INNER) LINK. The filter may contain important evidence for diagnosis. MANUAL DETENT SPRING CONDUIT. CONTROL VALVE ASSEMBLY -t~~~~~~~~~~~~~~375 Figure 56 BOTTOM PAN AND VALVE BODY COMPONENTS 1. SPEC. Remove solenoid bolts (51). Remove remaining pan bolts using a 13mm socket and speed handle. ELECTRICAL WIRE BOLT. HEX WASHER HEAD (M6 X 1 X 18) BOLT. HEX WASHER HEAD (PAN) MAGNET. 5. Remove and discard the filter seal that is stuck in the pump cover bore with a pair of snap ring pliers. MANUAL VALVE SPRING ASSEMBLY.(~~T5G) Technical Service Information 73 72 71 10 340 703 705 709 VALVE. SPEC. Rotate transmission so that bottom pan is facing up and lock fixture. THROTTLE BOLTS. THROTILE LEVER TO CABLE LEVER 81 BRACKET ASSEMBLY. 51 50 A 50 51 63 66 69 75 92 97 374 376 376 WASHER WIRE RETAINER SOLENOID ASSEMBLY BOLT. SOLENOID WIRE CLAMP. HEX HEAD (M8 X 1 X 35) BOLT. and harness assembly. MANUAL DETENT Figure 55 70 71 72 73 74 93 10 CASE. 3. TRANSMISSION SEAL. Remove the bottom oil pan and discard the oil pan gasket. lock-up solenoid (50). MANUAL LEVER. VALVE BODY BOLT. wiring harness from the switches. FILTER FILTER ASSEMBLY. 4. HEX WASHER HEAD (SOLENOID) BOLT. 2. TRANSMISSION OIL GASKET.

See the wiring schematics on Pages 17 thru 21 for specific wiring types for various applications. Ill. 14. Remove the case connector and the "0" ring seal. VALVE BODY ASM. Remove bolt (75) and remove the manual detent spring (See Figure 54). Remove the three remaining auxiliary valve body bolts and remove auxiliary valve body and set aside.SPECIAL HEX HEAD (M6 X 1 X 16) BOLT. and remove auxiliary valve body tube by prying carefully with screwdriver (See Figure 58). AUXILIARY TUBE BOLT. 13. 9. There may be two check balls or three checkballs depending on model. On some models it will be retained in the auxiliary valve body by a retaining clip.PARKING LOCK BOLT. 12. Remove the T. 8.HEX HEAD (M6 X 1 X 45) AUXILIARY ACCUM. and on some models you will find it on the spacer plate.PARKING LOCK BRACKET Figure 57 Figure 58 AUTOMATIC TRANSMISSION 41 SERVICE GROUP . and set valve body aside. See "Checkball Locations" in the assembly section of this manual. ELECTRICAL TUBE. AUXILIARY ACCUMULATOR VALVE CLAMP. lever and bracket assembly (See Figure 56). WIRE RETAINING CONNECTOR. Remove the checkballs from top of the spacer plate. BRACKET.Technical Service Information 7. NO.V. and discard "0" ring seal. Remove the remaining main valve body bolts.HEX HEAD (M6 X 1 X 35) BOLT. 11. 10. lift valve body straight up and off of manual valve link. NOTE: There is one checkball located under the auxiliary valve body. A 33 96 97 374 375 376 377 710 715 DESCRIPTION WASHER. Remove the auxiliary valve body tube bolts and clamps.

FMM 61 PISTON. 63 BOLT. NOTE: In the 1993 model year the accumulator pistons and springs could be installed in different directions depending on the model you are working on. VALVE BODY SPACER 59 SPRING. BRM r~" _jf::: r~ . FFM. OIL SEAL (3·4 ACCUMULATOR PISTON) 54 SPRING. ALL S. OIL SEAL '1·2 ACCUM. . Remove the spacer plate. and spring. 5. ACCUMULATOR COVER 77 PIN.OL CARS AND s. both valve body gaskets. _ FAM. Remove the three accumulator housing retaining bolts and remove the 1-2 accumulator housing (See Figure 59) 2.Technical Service Information Figure 59 ACCUMULATOR HOUSING ASSEMBLY 1.n. Make note of the spring so that it can be put back in the same position. Remove the 1-2 accumulator piston. 3·4 ACCUMULATOR 56 PLATE. AFM. FOM BFM. 1993 MODELS BCM. r--------~----------------I 82 I 81 60 59'1 59 60 61 t-z AND 3·' ACCUMULATOR ASSEMBLY. seal. SPACER PLATE TO VALVE BODY YAM. BWM SAM SFM HBM. CPM 1·2 ACCUMULATOR SPRING COLOR DARK GREEN YELLOW YELLOW NO PAINT DARK GREEN VIOLET DARK GREEN YELLOW NO PAINT ACCUMULATOR SPRING COLOR 3·4 NOT USED NOT USED RED DARK GREEN YELLOW YELLOW VIOLET NO PAINT VIOLET VIOLET Figure 60 AUTOMATIC TRANSMISSION 42 SERVICE GROUP . YCM. and discard the valve body gaskets. Refer to Figure 60 for identification. LHM YELLOW NO PAINT NO PAINT J. SPACER PLATE TO CASE 89 GASKET. 1·2 ACCUMULATOR 62 COVER AND PIN ASSEMBLY. Remove the 3-4 accumulator spring and piston from the case bore.ASM. ACCUMULATOR PISTON 88 GASKET. HLM HJM HOM BAM. 3. PISTON) AAM. BBM. '·2 ACCUMULATOR 60 RING.7L POLICE CAR L 52 PISTON. BHM. NOTE: Record the spacer plate code. 3·4 ACCUMULATOR 53 RING. 4. B CAR AND D CAR ·EXCEPT S.ADM. YOM. I 1·2 ACCUM. NOTE: The 1-2 accumulator spring may "Conical" shape and may not on the different models.

The checkball locations are different for different model years. Figure 63 5. 7. Lift up on pump remover and record the transmission end play observed. Remove the remaining oil pump bolts.015" minimum to . 6. 7. CHECKING TRANSMISSION END PLAY 1. 3. See "Checkball Locations" in the assembly section of this manual for the model year you are working on.036" maximum. Remove a front pump bolt and install a 11" bolt and lock nut (See Figure 62). Rotate the transmission so that the pump is facing up. to check transmission end play. as shown in Figure 62 and set to zero. as shown in Figure 63. IMPORTANT: As a diagnostic aid. or J-34725 adapter (Figure 61) onto the turbine shaft as shown in Figure 61. NOTE: THE SOLENOID AND WIRING HARNESS ASM. AND OIL FILTER MUST BE REMOVED BEFORE OIL PUMP REMOVAL. 10. transmission end play should be checked BEFORE pump is removed. Install J-25022 adapter. Remove and inspect the converter clutch and the governor screens. 8. 8. Remove the checkballs from the case passages. and remove oil pump. Install pump remover J-24773-A shown in Figure 62. Remove the dial indicator set-up. Install pump remover J-37789 and the adapter J-39119 as shown in Figure 63. AUTOMATIC TRANSMISSION 43 SERVICE GROUP . AND OIL FILTER MUST BE REMOVED BEFORE OIL PUMP REMOVAL. 9. Turn the handle clockwise to remove the oil pump from the case bore. 4. End play should be .Technical Service Information A DIAL INDICATOR B 278mm (11") BOLT C LOCK NUT Figure 62 A 8 298mm 245mm TUR81NE SHAFT TURBINE SHAFT Figure 61 6. Install dial indicator. 2. THE SOLENOID ASM.

Remove reaction sun gear. Use care so as not to over-expand the snap ring. 6 6 7 8 9 10 48 601 602 605 621 668 ILL. OIL (PUMP TO CASE) GASKET. if fixture is not used. Remove the input carrier. BAND ANCHOR WASHER. DESCRIPTION BOLT. removing the input housing and reverse input drum together (See Figure 64). TRANSMISSION PIN. 6. 2. OIL SEAL. Remove the input carrier to output shaft snap ring using snap ring pliers as shown in Figure 66. AND INPUT GEAR SET. 7. 4. PUMP TO CASE O-RING. Remove the 2-4 band assembly from case. PUMP COVER TO CASE CASE. 9. 8. INPUT HOUSING. INPUT SUN Figure 64 AUTOMATIC TRANSMISSION 44 SERVICE GROUP . 10.Technical Service Information 10 CASE. and sun gear shell (Figure 68). NO. and thrust washer on top of low roller clutch inner race (See Figure 68). as shown in Figure 65. and input ring gear and support as an assembly. 2-4 BAND. NOTE: Output shaft may fallout when input carrier snap ring is removed. PUMP TO CASE BOLT PUMP ASSEMBLY. THRUST (PUMP TO DRUM) BAND ASSEMBLY. Refer to Figure 68. 1_ Remove the band anchor pin from the case bore (See Figure 67). Grasp the turbine shaft and lift straight up. Remove the low roller clutch inner race (See Figure 68). 5. 2-4 HOUSING & DRUM ASM. REVERSE INPUT CLUTCH HOUSING & SHAFT ASSEM8LY. OUTPUT Figure 65 REVERSE INPUT DRUM. Install J-29837 output shaft support fixture. 3.. Remove the input sun gear as shown in Figure 64. INPUT GEAR. Remove ring gear support thrust washer. TRANSMISSION 687 SHAFT.

the Lo/Reverse clutches. as we can use it to remove the reaction carrier. The manufacturer assembles the output shaft and reaction ring gear with adhesive for ease of assembly. all at one time. center support. ~ )'/ Figure 66 2-4 BAND ANCHOR PIN Figure 67 AUTOMATIC TRANSMISSION 45 SERVICE GROUP . leave it in place.Technical IMPORTANT! Service Information If the output shaft has not yet fallen from the reaction ring gear.

9. 14. INPUT RING GEAR INPUT CARRIER INPUT CARRIER SNAP RING 2-4 BAND ASSEMBLY INPUT SUN GEAR INPUT CARRIER THRUST WASHER INPUT CARRIER BEARING 8. 6. 4. 2. 7. 13. 3. 10.[~~TSG) Technical Service Information I ~ 8 3 2 I 9 10 _ _j 1. GEAR WASHER SUN GEAR SHELL/RING SUN GEAR SHELL REACTION SUN GEAR SNAP RING REACTION SUN GEAR SUN GEAR/INNER RACE WASHER LOW ROLLER CLUTCH INNER RACE CASE TRANSMISSION Figure 68 AUTOMATIC TRANSMISSION 46 SERVICE GROUP . 5. II. 12.

4. Remove inside detent lever and the parking lock rod (Figure 69). __ 7 8 14 1 1. 9. D. Remove parking pawl shaft cup plug from case with #4 screw extractor. Remove the bolts and parking lock bracket from the case. Remove parking pawl pivot shaft with a pencil magnet. C. 10. 13. 2. B. 9. 10. 11. 6. Remove manual shaft seal by prying out carefully with a screwdriver. CUP PLUG PARKING PAWL SHAFT PARKING PAWL RETURN SPRING PARKING PAWL CASE BRACKET PARKING PAWL Figure 70 AUTOMATIC TRANSMISSION 47 SERVICE GROUP .. E. PARKING LOCK ROD INSIDE HEX NUT MANUAL VALVE LINK INSIDE DETENT LEVER MANUAL SHAFT RETAINER MANUAL SHAFT SEAL MANUAL SHAFT 8. 8. 4. Remove parking pawl and the parking pawl return spring. 7. Remove the manual shaft. Figure 69 MANUAL DETENT SPRING PARKING BRACKET BOLT (2) PARKING LOCK BRACKET CUP PLUG (CASE) PARKING PAWL SHAFT PARKING PAWL RETURN SPRING PARKING PAWL PARKING LINKAGE COMPONENTS 1. See Figure 70. 12. 5. 6. Remove inside manual shaft nut. 3. Remove the manual shaft retainer. 2. Refer to Figures 69 and 70. 7. 14. A..Technical Service Information 5 r ~6 . 3. 5.

4. 10/reverse clutch plates. E. and reaction ring gear all at one time. Remove the low roller support snap ring from the case as shown in Figure 73. and then remove the spring compressor. 3. NOTE: If the output shaft has not yet been seperated from the reaction ring gear. C. G. Remove the 10/reverse piston and seals by blowing compressed air into the 10/ reverse apply passage (See Figure 72). B.(~J:lT5G) ~~~~----------~ Technical Service Information o o o (A) APPLY AIR PRESSURE HERE TO REMOVE LO & REVERSE PISTON FROM THE CASE Figure 72 LOW/REVERSE CLUTCH PLATES AND REACTION GEAR SET 1. reaction carrier. Remove the 10/reverse return spring assembly from the case (Figure 76). LOW-REVERSE CLUTCH PLATES OIL DEFLECTOR (USED ON HIGH PERFORMANCE MODELS ONLY) H. Remove "Anti-Clunk" spring from between the support and case (See Figure 75). TRANSMISSION CASE REACTION RING GEAR/CASE BRG. 5. Remove the Lo/Reverse clutch plates. Figure 71 AUTOMATIC TRANSMISSION SERVICE GROUP 48 . Remove parking lock from the case. REACTION RING GEAR SUPPORT REACTION RING GEAR REACTION CARRIER/SUPPORT BRG. Compress the return spring and remove 10/reverse retainer snap ring. D. Remove the reaction ring gear and the thrust bearing. 2. A A. REACTION CARRIER ASSEMBLY LOW/REVERSE CLUTCH PISTON 1. NOTE: The parking pawl may have to be removed before removing the 10/reverse piston. 4. as shown in Figure 74. Remove the reaction carrier (Figure 71). 6. 2. 5. F. Install clutch spring compressor. Remove the low roller support from the case (Center Support). grasp the output shaft and lift up to the low roller support. 3. due to interference.

LO & REVERSE CLUTCH Figure 74 A. LO & REVERSE CLUTCH. SNAP RING Figure 76 AUTOMATIC TRANSMISSION 49 SERVICE GROUP . E. Figure 73 693 10 693 694 695 CASE. PISTON. TRANSMISSION LOW/REVERSE LOW/REVERSE LOW/REVERSE LOW/REVERSE CASE ASSEMBLY CLUTCH SEALS PISTON RETAINER ASSY.1~~T5G) \ Technical Service Information '/\ -. RING. D. B. C. LO & REVERSE CLUTCH RETAINER SPRING ASSEMBLY.

Thoroughly clean all parts and dry with compressed air. Torque nut to 23 ft. NOTE: It may be necessary to install the parking pawl after installing the Lo/Reverse piston into case. 3. and through the parking pawl and spring. refering to Figures 69 and 70. 5. MANUAL SHAFT 2. Inspect parking pawl and all components for wear and/or damage. Install parking pawl and parking pawl return spring into case. park rod. 6.(~~T5GI MANUAL SHAFT SEAL BE FULLY SEATED CASE BORE 1 Technical Service Information A B GOV.71mm (3. • Speedometer or speed sensor bore for any damage. 2. 5. clutch plate lugs worn. COMPONENT REPAIR AND RE-ASSEMBLY 1. • Orifice cup plug in the 3-4 accumulator bore for debris. and proper torque. Refer to Figure 69. inside detent lever. wear or porosity. • Vent assembly for damage. • All bolt holes for thread damage. Install parking pawl pivot shaft into case.30 in. AUTOMATIC TRANSMISSION 50 SERVICE GROUP . COVER FACE SURFACE DOWEL 2 B4. • 2-4 servo bore for damage. interconnected oil passages.lbs. • Governor support pin installation depth (See Figure 78). Inspect the transmission case for the following: • Exterior for cracks. 4. and straightedge this surface. • Air check all oil passages to insure that they are open. • 3rd accumulator ball capsule for missing. Install manual shaft retainer onto the manual shaft by snapping into place. porosity and/or damage. and case bushing for wear. • Case interior for damaged snap ring grooves. PARKING PAWL 1. Install the manual shaft. BEFORE nut is tightened. sticking or leaking. • Valve body surface for any damage. 2. Install cup plug into the case with sealer to prevent leakage. • Cooler line fittings for damage. Make certain that flats of inside detent lever are engaged on the flats of manual shaft. 3. Install new manual shaft seal into the case using a 9/16" deep socket. and inside manual shaft nut. • Orifice cup plug in servo bore for debris or damage. TRANSMISSION CASE Figure 77 4. and Heli-Coil if necessary. Check parking linkage for the proper operation. and fully seat seal (See Figure 77).) 1.

Install the 2-4 servo assembly into the case servo bore. as shown in Figure 80. 3RD ACCUMULATOR PASSAGE CAPSULE ASSY. 2. Oil feed slots in the ball capsule MUST line up with oil passage in the servo bore. 3RD ACCUMULATOR C. refer to "D" in illustration. 3. 4. Remove the defective ball capsule assembly with a #4 screw extractor. Install the servo cover and snap ring. FOR HERE A. seat end first (Figure 79). Using a 3/8" diameter steel rod. Watch for leakage inside the barrel of the case (See Figure 79). 2. from the valve body side (See Figure 79). 2-4 SERVO BORE B. 5. 4. LEAK CHECKING PROCEDURE 1. If leakage is seen from the exhaust hole in the case bore. 3.(~~TSG) Technical Service Information 3RD ACCUMULATOR BALL CAPSULE. Pour a suitable solvent into passage that feed 3rd accumulator. Install new ball capsule assembly into case. drive the ball capsule assembly down into the case untill it is 1 5/8" below the worm track surface. replace the 3rd accumulator ball capsule assembly with part number 8634400. A A B C D E F SERVO EXHAUST HOLE 2ND APPLY PASSAGE 3RD PRESSURE TAP PASSAGE 3RD ACCUMULATOR BALL CAPSULE ORIFICED CUP PLUG FILLER TUBE SEAL Figure 80 AUTOMATIC TRANSMISSION 51 SERVICE GROUP . Figure 79 REPLACEMENT PROCEDURE FOR 3RD ACCUMULATOR BALL CAPSULE ASSEMBLY 1.

905" 2.243"-.(~~TSG) Technical Service Information LOW/REVERSE CLUTCH SUPPORT AND LOW/REVERSE PISTON IDENTIFICATION "A" YEAR MODEL ALL 1993 MODELS 90 (PARTIAL)-1992 1987-90 (PARTIAL) THESE PARTS SUPPORT DIMENSION "A" .845" 2.845" INTERCHANGEABLE! "B " "" LOW/REVERSE CLUTCH PISTON Figure 81 AUTOMATIC TRANSMISSION 52 SERVICE GROUP .302"-.249" .309" .262"-.272" ARE NOT L/R PISTON CASTING NO. 8681725 OR 8685550 8663888 8663888 L/R PISTON DIMENSION "B" 2.

6. THEY WILL NOT INTERCHANGE BETWEEN MODEL YEARS. LO 3& REVERSE CLUTCH PISTON. LO & REVERSE CLUTCH RETAINER SPRING ASM . Install return spring assembly on top of the low/reverse piston (Figure 82). LO & REVERSE CLUTCH RETAINER SPRING ASSEMBLY. AND THE LOW/REVERSE SUPPORT BE MATCHED. LO 3& REVERSE CLUTCH Figure 83 A UTOMATIC TRANSMISSION 53 SERVICE GROUP . "~_. Remove the spring compressor. Compress the return spring assembly by turning clockwise.M~~" 10 693 694 695 696 CASE. Install the low/reverse piston into the case so that alignment tab goes into the slot in case. and install the snap ring onto case hub. Inspect the low/reverse piston for cracks and/or damage. LO & REVERSE CLUTCH SEALS. 3.(~~T5GJ Technical Service Information 693~ 694-. Install three new seals on low/reverse piston and coat seals with a light coat of Trans-Jel lubricant. LOW AND REVERSE PISTON ASSEMBLY 1. 5. LO & REVERSE CLUTCH Figure 82 69 10 693 694 695 CASE. RING. 4. 7. TRANSMISSION RING. Install J-23327 spring compressor as shown in Figure 83. IT IS MANDATORY THAT THE LOW/REVERSE PISTON. 8. REFER TO FIGURE 81 TO IDENTIFY PARTS FOR PROPER BUILD CONTENT BEFORE THE LOW/REVERSE PISTON IS INSTALLED 2.• LO & REVERSE CLUTCH PISTON. and psrking pawl window is aligned for parking pawl.

024" Figure 84 OUTPUT SHAFT -~ SLEEVE A. PINION END PLAY .008" .. INPUT CARRIER ASSEMBLY Figure 85 AUTOMATIC TRANSMISSION 54 SERVICE GROUP .I~~TSG) Technical Service Information A A A.

024" (See Figure 84). Install the thrust bearing in front side of reaction ring gear support. OIL (HIGH OUTPUT MODELS ONLY) Figure 86 AUTOMATIC TRANSMISSION 55 SERVICE GROUP . TRANSMISSION 681 CARRIER ASSEMBLY.008"-. Carefully inspect the following: • Reaction ring gear and ring gear support for cracks. Pinion end play should be between . Install the entire reaction planetary gear set into the case. peening on the clutch lugs. and/or wear. 5. REACTION GEAR SUPPORT TO CASE 697 DEFLECTOR. and for excessive pinion washer wear. • To check the trapped thrust bearings in the carriers for wear. INTERNAL REACTION GEAR 692 BRG. proper pinion pin staking. in the direction shown in Figure 86. stripped splines. as shown in Figure 85. and retain with Trans-Jel. • Reaction carrier assembly for p1n10n gear damage. • Thrust bearing assemblies for damage. stripped splines. any imperfections will be felt through the sleeve. 10 CASE. Turn it with the palm of your hand.. 4. Install the thrust bearing on back side of reaction ring gear support. in the direction shown in Figure 86. (Do not contact the pinion gears). 3. and retain with Trans-Jel. REACTION 683 BEARING ASSEMBLY. 2. and teeth or park lug damage. Install reaction carrier into reaction ring gear with a twisting motion until seated fully on thrust bearing. THRUST (REACTION CARRIER/SUPPORT) 685 SUPPORT.I~RT5GI Technical Service Information REACTION PLANETARY GEAR SET 1. place a bushing or output shaft sleeve on the bearing race.

122"-.249".066"-.Technical Service Information SUPPORT AND IDENTIFICATION LOW/REVERSE CLUTCH L/R CLUTCH SELECTIVE ff A ff IF LOW/REVERSE SUPPORT MEASURES . REQUIRES LOW/REVERSE PISTON 8681725 OR 8685550 (SEE FIGURE 81).066"-.100" .262"-.072" . USE CHART "A".272". THESE PARTS WILL NOT INTERCHANGE' "A" CHART LOW/REVERSE SELECTIVE PLATE 90 (PARTIAL)-1993 PART NUMBER 8673548 6261120 8673549 THICKNESS .072" .309".046"-.092" CHART "B" LOW/REVERSE SELECTIVE PLATE 1987-90 (PARTIAL) PART NUMBER 6261120 8667584 8667585 THICKNESS .243"-. USE CHART "A".128" Figure 87 IDENTIFICATION NONE (REGULAR STEEL PLATE) STAMPED "4" STAMPED "5" IDENTIFICATION STAMPED "8" NONE (REGULAR STEEL PLATE) STAMPED "9" - AUTOMATIC TRANSMISSION 56 SERVICE GROUP . REQUIRES LOW/REVERSE PISTON 8663888 (SEE FIGURE 81).302"-.052" .094"-.086"-. USE CHART "B" REQUIRES LOW/REVERSE PISTON 8663888 (SEE FIGURE 81). IF LOW/REVERSE SUPPORT MEASURES . IF LOW/REVERSE SUPPORT MEASURES .

four steel plates. C.(~J:lTSG I Technical Service Information r----INSTALL THE APPROPRIATE SELECTIVE SPACER PLATE TO THE FINAL ASSEMBLY AFTER DIMENSION "0" IS OBTAINED. Refer to Figure 88 for proper order. One "Waved" plate (682B). Change the selective plate as necessary to obtain the proper dimension "D" using the proper chart in Figure 87. (SELECTIVE) WAVE PLATE. 7. stack the low/reverse clutchs on a flat work surface in the following order: A. The overall height for dimension "D" with the selective spacer plate included should be 1. REFER TO FIGURE 87 TO DETERMINE PROPER BUILD CONTENT BEFORE THE LOW/REVERSE CLUTCHES ARE INSTALLED. 6.240". AUTOMATIC TRANSMISSION 57 SERVICE GROUP .) on the support will provide the correct dimension for measurement. starting with one lined plate and alternating with steel plates.200"-1. Low/Reverse Clutch Support on top of the clutch pack. B. MEASURING FOR L/R SELECTIVE PLATE 1. as shown in Figure 88. Measure the Low/Reverse support as shown in Figure 87 to determine which selective plates to use. IDENTIFICATION SIDE UP. One "Selective" plate (682A). SIbs. THEY WILL NOT INTERCHANGE BETWEEN MODEL YEARS. Use chart "A" or chart "B" to make your selection based on low/reverse support thickness (See Figure 87). Measure the height of the clutch pack from the work surface to the top of the Low/Reverse clutch support (Dimension "D"). 8. LO & REVERSE CLUTCH PLATE ASSEMBLY. S. 679 682 682(A) 682(B) SUPPORT ASSEMBLY. LO & REVERSE CL. 4.240". 2. Apply an evenly distributed load to the top of the low/reverse support assembly with your hand. Light pressure (Approx. All models 1987-1993 use five friction plates. 6820 682C 682(A) WITH THE SELECTIVE PLATE INSTALLED THE OVERALL HEIGHT AT DIMENSION "D" SHOULD BE 1. LO & REVERSE CLUTCH SPACER PLATE.200" TO 1. To measure for the proper selective plate. one "Waved" plate and one selective plate. Five lined and four steel plates. D. LO & REVERSE CLUTCH STACK UP FOR MEASURING Figure 88 IT IS MANDATORY THAT THE LOW/REVERSE SUPPORT AND THE LOW/REVERSE SELECTIVE PLATE BE A MATCHED SET. 3. AND THEY MUST ALSO BE COMPATABLE WITH THE LOW/REVERSE PISTON THAT YOU HAVE ALREADY INSTALLED.

and retain with Trans-JeI. LO & REVERSE CLUTCH PLATE. 5. LO & REVERSE CL. • Cam and support assembly for loose cam. OIL (HIGH OUTPUT MODELS ONLY) Figure 89 10 CASE.(~~TS6) Technical Service Information LOW/REVERSE CLUTCH PLATES 1. 3. LOW/REVERSE SUPPORT ASSEMBLY 1. 7. 6. 3. 2. TRANSMISSION 682 PLATE ASSEMBLY. 2. 4. REACTION GEAR SUPPORT TO CASE DEFLECTOR. as shown in Figure 93. INTERNAL REACTION SUPPORT. Rotate the low roller clutch inner race clockwise and push down until the inner race is fully engaged on the tangs of the reaction carrier. The gap on the snap ring should be placed as shown in Figure 92. Install the Low/Reverse support snap ring into the case snap ring groove. INTERNAL REACTION GEAR BRG. and alternating with steel plates until five friction plates and four steel plates have been placed into the case (See Figure 89). 4. TRANSMISSION CARRIER ASSEMBLY. LO & REVERSE CLUTCH (WAVED) PLATE. surface finish for damage. Install the low roller inner race thrust washer onto the inner race. LO & REVERSE CLUTCH Figure 90 AUTOMA TIC TRANSMISSION 58 SERVICE GROUP . Install the Low/Reverse selective plate (682B) from the selection procedure. 10 681 682 682A 682B 683 684 685 692 697 CASE. THRUST (REACTION CARRIER/SUPPORT) GEAR. Install the "Anti-Clunk" spring in the position shown in Figure 91. Install the Low/Reverse support assembly into the case lugs by aligning the wide notch in the support with the wide case lug (See Figure 92). Install low roller clutch inner race into low roller clutch by rotating clockwise into position (Figure 93). Install the Low/Reverse clutch plates beginning with a friction plate on top of the selective. 6. and for cracked or damaged lugs. (SELECTIVE) BEARING ASSEMBLY. • Low roller clutch assembly for damaged rollers or broken springs. Carefully inspect the following: • Low roller clutch inner race for any damage to the surface finish. Align the teeth of the friction plates onto the reaction carrier as they are installed. Align the steel plates with the notch in the case lug as shown in Figure 90. Install the Low/Reverse clutch "Waved" plate into the case (See Figure 89). 5.. The inside tangs of thrust washer should engage in four slots of the inner race when it is properly installed. REACTION PLATE ASSEMBLY. A friction plate should be the last plate installed (See Figure 89). Install low roller clutch assembly into support and install snap rings (677). 7.

Technical Service Information Figure 91 Figure 92 680 "J--- A B 675 677 678 679 680 LOCKED UP FREE WHEELS RACE. LO & REVERSE ROLLER CLUTCH RING. LO & REVERSE ROLLER SUPPORT ASSEMBLY. LO & REVERSE RETAINER (ROLLER ASSEMBLY ICAM) CLUTCH ASSEMBLY. LO & REVERSE CLUTCH SPRING. TRANSMISSION LO & REVERSE CLUTCH SUPPORT RETAINER Figure 93 AUTOMATIC TRANSMISSION 59 SERVICE GROUP .

Install reaction sun gear with snap ring in place. o Damaged splines and/or teeth. 2. Install the reaction sun gear shell thrust washer onto the reaction sun gear shell (Figure 96). into the reaction carrier by rotating into the pinions. and cracked shaft. REACTION SUN GEAR RETAINER 673 GEAR. broken hub or bent tangs. o Input carrier to ring gear thrust bearing for wear or damage (Figure 94). INPUT CARRIER/RING GEAR SUPPORT BEARING C. TRANSMISSION 669 WASHER. REACTION SUN 674 WASHER. THRUST (REACTION SHAFTI SHELL) 670 SHELL. Refer to Figure 96. scored.Technical Service Information A B C A. INPUT CARRIER ASSEMBLY B. LO & REVERSE ROLLER CLUTCH 676 RING. Install the reaction sun shell and thrust washer by rotating onto the reaction sun gear splines. o Loose or weak snap ring. Inspect the following: o Reaction sun gear for nicked. REACTION SUN 671 RING. damaged splines or gear teeth. 10 CASE. LO & REVERSE SUPPORT TO CASE RETAINER INPUT GEAR SET AND OUTPUT SHAFT 1. INPUT RING GEAR AND SUPPORT ASSEMBLY Figure 94 REACTION SUN GEAR AND SHELL 1. 3. o Sun gear shell for stripped or worn splines. Figure 95 AUTOMATIC TRANSMISSION SERVICE GROUP 60 . 4. and retain wi th Trans -JeI. Inspect the following: o Input ring gear and support for worn or damaged bushings. This snap ring should never be removed unless replacement is necessary. or worn bushing. THRUST (RACE/REACTION SHELL) 675 RACE.

NOTE: 1987-1993 model transmissions DO NOT use the black thrust washer on top of input carrier. Install input sun gear as shown in Figure 99. 9. 6. Identify output shaft using Figure 100 and install output shaft into transmission by rotating to index the shaft splines with the mating parts. Pinion end play should be . o ~ )/ Figure 98 Figure 99 AUTOMATIC TRANSMISSION 61 SERVICE GROUP . Install input carrier into input ring gear by rotating into position. Install J-29837 output shaft holding fixture if necessary. Install input carrier snap ring using care not to over-expand the snap ring.024" as shown in Figure 84. Remove the output shaft holding tool. on Page 54. 10. 7. Polish with crocus as necessary.Technical Service Information O Figure 96 ~. 2. damage or burrs to the front of shaft at lube seal area. Install thrust bearing into input ring gear and retain with Trans-Jel (See Figure 94 for bearing direction). Install entire assembly into the transmission by rotating into position as shown in Figure 97. 5. 4.008"-.~ •. II Figure 97 o Input carrier trapped thrust bearing as shown in Figure 85. 8.. 3. as shown in Figure 102. This snap ring should be replaced on all units.l. by rotating into the carrier pinions.. on Page 54. damaged splines or governor teeth. o Output shaft for plugged or restricted lube oil passages. Input carrier for worn thrust washer.

lf °11I1 II o · '. -r .Technical Service Information CAN SERVICE 1982 .1 J °li:rm:JIII]JIII=oOIII :JII"I~ 1i0 IJ 11 4 WHEEL DRIVE SYCLONE II~ LONG SPLINE SHORT SPLINE 100 J 29837 687 699 SHAFT.1"[_>1. TRANSMISSION 687 SHAFT. INTERNAL TRANSMISSION SENSOR 10 CASE.II11 °0]11 illi CORVETTE o O. OUTPUT ROTOR.]IQIIrn Figure REMOVAL INSTALLATION .1 o r °1.1991 HYDRA-MATIC 4L60 TRANSMISSIONS CAN SERVICE ALL HYDRA-MATIC 4L60 TRANSMISSIONS PREVIOUS SHAFT USE SEAL #8642178 NEW SHAFT USE SEAL #8677268 o "1. OUTPUT SPEED Figure 101 Figure 102 AUTOMATIC TRANSMISSION 62 SERVICE GROUP .

INPUT HOUSING WITH ALUMINUM IN LATE 1987 THRU 1993 MODELS.I~RTSG) INPUT Technical CLUTCH Service HOUSING Information IDENTIFICATION INPUT HOUSING "A" = USED WITH REVERSE PISTON} AND FOUND INPUT HOUSING "B" = USED WITH REVERSE PISTON} AND FOUND INPUT HOUSING THAT HAS STEEL IN EARLY 1987 MODELS QNLY. AS THE FIT WILL BE VERY LOOSE AND CAN CAUSE A RATTLING NOISE IN PARK AND NEUTRAL. HOWEVER. DO NOT INSTALL A NEW DESIGN BACKING PLATE INTO AN EARLY DESIGN INPUT HOUSING. Figure 103 AUTOMATIC TRANSMISSION 63 SERVICE GROUP . THE EARLY DESIGN BACKING PLATE IS TOO LARGE TO FIT INTO THE NEW DESIGN INPUT HOUSING. DIFFERENT DESIGN DIFFERENT DIFFERENT FORWARD CLUTCH BACKING PLATE SMALLER DIAMETER WHERE PLATE SPLINES INTO THE INPUT HOUSING AND SHAFT ASSEMBLY EARLY AND LATE MODEL FORWARD CLUTCH BACKING PLATES ARE NOT INTERCHANGEABLE. THE NEW DESIGN BACKING PLATE WILL FIT INTO AN EARLY DESIGN INPUT HOUSING.

ONLY (COMES IN BOTH HOLE SIZES). TURBINE SHAFT "0" RING A.Technical TURBINE Service Information SHAFT IDENTIFICATION INSPECT WITH FLASHLIGHT 6mm FEED HOLE 1987 MODELS WITHOUT AUX. IT IS MOST DIFFICULT TO TELL WHICH HOLE IS THE NEW DESIGN. FITS 298mm CONVERTER B. VALVE BODY NOTE: USE CARE WHEN DETERMINING HOLE SIZE. VALVE BODY 1987-1993 WITH AUX. FITS 245mm CONVERTER B. Figure 104 AUTOMATIC TRANSMISSION 64 SERVICE GROUP . ONLY (COMES IN BOTH HOLE SIZES). A. WITHOUT REMOVING THE TURBINE SHAFT FROM THE INPUT HOUSING.

ORIFICED CUP Figure 105 AUTOMATIC TRANSMISSION 65 SERVICE GROUP . 3RD & 4TH CLUTCH BACKING PLATE RETAINER 698 PLUG. 600 615 ILL. OVERRUN CL. 3RD & 4TH CLUTCH (FLAT STEEL) 654C PLATE. DESCRIPTION NO. SPRAG 642 FORWARD SPRAG ASSEMBLY 643 RETAINER RINGS. OVERRUN CLUTCH 635 SNAP RING.l 651 RING. STATOR SHAFTI SELECTIVE WASHER 616 WASHER. OVERRUN CLUTCH 641 RETAINER" RACE ASSEMBLY. 3RD & 4TH CLUTCH BACKING (SELECTIVE) 656 RING. INPUT HOUSING TO OUTPUT SHAFT 645A PLATE ASSEMBLY. 3RD & 4TH CLUTCH APPLY 626 SPRING ASSEMBLY. 3RD & 4TH CLUTCH APPLY (STEPPED) 654A PLATE ASSEMBLY. OVERRUN CLUTCH (STEEL) A FORWARD CLUTCH SPRAG ASSEMBLY 837 BEARING ASSEMBLY. 3-4 CLUTCH BOOST (5) BEARING ASSEMBLY. OVERRUN CLUTCH SPRING RETAINER 636 SEAL.(~~T5G) INPUT 615 616 617 Technical CLUTCH Service HOUSING 623 625 Information EXPLODED VIEW 648 649B 649A 651 A DESCRIPTION SPRING ASM. HUB RET. FORWARD CLUTCH 632 PISTON. THRUST (SELECTIVE) 617 RETAINER & BALL ASSEMBLY. FORWARD CLUTCH BACKING PLATE RETAINER 652 PLATE. FORWARD CLUTCH (WAVED) 649A PLATE ASSEMBLY. FORWARD CLUTCH (STEEl) 650 PLATE. 3RD & 4TH CLUTCH (FIBER) 654B PLATE. FORWARD CLUTCH BACKING (SEL.. NO. 3RD & 4TH CLUTCH RING RETAINER 653 PLATE. 646 PLATE. 639 HUB. 3RD & 4TH CLUTCH 627 RETAINER & BALL ASSEMBLY. CHECK VALVE 620 RETAINER & CHECK BALL ASSEMBLY 621 HOUSING & SHAFT ASSEMBLY. 3RD & 4TH CLUTCH 625 RING. FORWARD CLUTCH APPLY 648 PLATE. FORWARD CLUTCH (OUTER) ILL. FORWARD CLUTCH 630 PISTON. FORWARD CLUTCH HOUSING 628 HOUSING. OVERRUN CLUTCH 634 SPRING ASSEMBLY. INPUT 623 PISTON. OVERRUN CLUTCH 633 BALL. 3RD & 4TH CLUTCH (STEEL) 655 PLATE. INPUT SUN GEAR 638 SNAP RING. OVERRUN CLUTCH (FIBER) 645B PLATE. SPRAG ASSEMBLY 644 RACE. FORWARD CLUTCH (FIBER) 649B PLATE.

Technical Service Information 621 INPUT HOUSING & SHAFT ASSEMBLY Figure 106 Figure 108 Figure 107 Figure 109 AUTOMATIC TRANSMISSION 66 SERVICE GROUP .

Technical Service Information T-1574 INSTALLATION TOOL SOLID SEALING RING T-1574 RESIZING TOOL • OVERRUN CLUTCH PASSAGE TURBINE SHAFT SOLID TEFLON SEALING RINGS Figure 112 AUTOMATIC TRANSMISSION 68 SERVICE GROUP .

as shown in Figure 105. 15. and remove and discard both lip seals. 17. 14. 5. S. Remove the forward clutch piston. Use CAUTION when removing these clutch packs. Remove the forward clutch housing to input housing "0" ring seal from the groove down inside the input housing. 12. USE CAUTION WHEN REMOVING THE SNAP RING AS IT IS EXTREMELY STIFF. Remove the thrust bearing assembly(615) and the selective thrust washer (616) from the turbine shaft. Remove and discard the four turbine shaft sealing rings from the turbine shaft (See Figure 112). Remove the 3-4 clutch piston. 6. Remove the overrun clutch return spring assembly from the input housing. Place the input housing assembly on the bench. 10. Remove the overrun clutch piston. 2. Refer to Figure 105 for exploded view of the input housing assembly. ALWAYS REPLACE THESE SEALING RINGS WITH THE SOLID TEFLON SEALS. 4.(~~T5GJ Technical Service Information INPUT CLUTCH HOUSING DISASSEMBLY 1. Remove the forward clutch snap ring using a screwdriver (See Figure 110). remove and discard both lip seals. as shown in Figure 109. Refer to Figure 105 for disassembly. and remove and discard both lip seals. Remove the forward clutch housing. as the forward sprag assembly will come out at the same time. as shown in Figure lOS. Remove the 3-4 clutch apply ring from the input housing assembly. 7. 3. Remove the overrun clutch return spring snap ring with snap ring pliers. as shown in Figure 106. IS. Turn the input housing upside down to remove the forward clutch pack. and the overrun clutch pack. Figure 110 Figure 111 AUTOMATIC TRANSMISSION 67 SERVICE GROUP . 13. with the turbine shaft through a hole in the bench (See Figure 107). Remove the 3-4 clutch snap ring using a screwdriver. Install the proper spring compressor. 16. 11. 9. and' compress the overrun clutch return spring. Remove the entire 3-4 clutch pack.

715mm (1/4'" DIA. 3. AUTOMATIC TRANSMISSION 69 SERVICE GROUP . INSTALLATION A 620 621 698 ROD STOCK/DRIFT.5mm (3/8'" METAL ROD CHECK VALVE RETAINER 81 BALL ASSEMBLY Figure 113 REMOVAL TURBINE SHAFT CAPSULE REPLACEMENT 1. Straighten the inside tangs of capsule and remove the ball from capsule. Leak check the ball capsule with solvent. 2. ORIFICED CUP Figure 114 INPUT HOUSING BALL CAPSULE REPLACEMENT 1. 7. can be left out of the retainer. OEM part number for the input housing ball capsule is 8654438 (Figure 114). use a 1/4" drift punch and hammer to remove and replace the capsule assembly. as shown in Figure 114. OEM part number for the 245mm converter is 8647037 (See Figure 104). for a firmer converter clutch apply. DO NOT leave the retainer out of the turbine shaft. 6. If replacement is necessary. Install the new ball capsule assembly using a 3/8" drift punch and seat the retainer 1/8" below the top surface of turbine shaft (See Figure 113).L 'rQDP INSTALL Technical Service Information 620 A B C 617 14 EASY OUT TURBINE SHAFT 9.7 . 5. 5. For HEAVY DUTY APPLICATIONS ONLY. the BALL ONLY.. Be certain that the ball is still loose in the retainer after installation. 4. the BALL ONLY can be omited. Remove the ball capsule retainer using a #4 screw extractor (See Figure 113). 3. 2.(~~TSGI . INPUT PLUG. OEM part number for the 298mm converter is 8639284 (See Figure 104). RETAINER 81 CHECK BALL ASSEMBLY HOUSING 81 SHAFT ASSEMBLY.

(~RTSG)

Technical

Service

Information
"0" RING
621---..... 624

621

INPUT HOUSING & SHAFT ASSEMBLY

Figure

115

621 623 624

HOUSING 3& SHAFT ASSEMBLY. INPUT PISTON. 3RD 3& 4TH CLUTCH SEALS. 3RD 3& 4TH CL. (INNER 3& OUTER)

Figure

117

621 622 623 626 626 628 629 630

HOUSING 3& SHAFT ASSEMBLY, INPUT SEAL. "0" RING INPUT TO FORWARD HSG. PISTON. 3RD & 4TH CLUTCH RING. 3RD & 4TH CLUTCH APPLY SPRING ASSEMBLY. 3RD 3& 4TH CLUTCH HOUSING. FORWARD CLUTCH SEALS. FORWARD CLUTCH (INNER & OUTER) PISTON. FORWARD CLUTCH

621 623 625 626 628 630 631 632

HOUSING 3& SHAFT ASSEMBLY. INPUT PISTON. 3RD & 4TH CLUTCH RING. 3RD & 4TH CLUTCH APPLY SPRING ASSEM8LY. 3RD & 4TH CLUTCH HOUSING. FORWARD CLUTCH PISTON. FORWARD CLUTCH SEAL. OVERRUN CLUTCH (INNER & OUTER) PISTON, OVERRUN CLUTCH

Figure

116

Figure

118

AUTOMATIC

TRANSMISSION
70

SERVICE GROUP

(~~TS[i)

Technical

Service

Information

INPUT HOUSING ASSEMBLY 1. Thoroughly clean and inspect all parts and dry with compressed air. 2. Position the input housing on bench with the turbine shaft through a hole in the bench (See Figure 107). 3. Install the inner and outer lip seals on the 3-4 clutch piston in direction shown in Figure 117, with the lips facing down. ALWAYS USE LONG LIP SEALS IN THE OUTER LIP SEAL LOCATIONS. 4. Lubricate the lip seals with Trans-Jel, and install the 3-4 clutch piston into the input housing with a rotating motion, as shown in Figure 117. 5. Install a new "0" ring into the input housing groove as shown in Figure 117, and lubricate with Trans-Jel. 6. Install the 3-4 clutch apply ring on top of the 3-4 clutch piston. Refer to Figure 116, item (625). 7. Install the 3-4 clutch return spring (626) on top of the 3-4 clutch apply ring (See Figure 116). 8. Lubricate both inside diameters of the forward clutch housing (628), and then install it into the input housing, as shown in Figure 116. 9. Install the inner and outer lip seals on the forward clutch piston in the direction shown in Figure 116, with the lips facing down. ALWAYS USE LONG LIP SEALS IN THE OUTER LIP SEAL LOCATIONS. 10. Install the forward clutch piston into forward clutch housing using the tool J-29883, as shown in Figure 116. NOTE: The forward clutch apply legs must be indexed with the 3-4 apply ring legs. 11. Firmly seat the assembly. 12. Install the inner and outer lip seals on the overrun clutch piston in the direction shown in Figure 118, with the lips facing down. ALWAYS USE LONG LIP SEALS IN THE OUTER LIP SEAL LOCATIONS. 13. Install the overrun clutch piston into the housing using tool J-29882, shown in Figure 118. 14. If all parts are properly seated to this point, the overrun clutch hub will be approximately 3/16" below the snap ring groove in the input housing hub.

15. Install the overrun clutch return spring assembly onto the overrun clutch piston, locating the springs on the piston tabs. 16. Lay the overrun clutch snap ring on top of the overrun clutch return spring assembly. 17. Install the proper spring compressor as shown in Figure lIS, and compress the return spring assembly carefully. 18. Install the snap ring with a pair of snap ring pliers. 19. Remove the spring compressor.

AUTOMATIC

TRANSMISSION
71

SERVICE GROUP

(~~T5[iJ
A

Technical
,-644

Service

Information

ff'I~-.
637 638 639 643 THE NOTCHES ABOVE EACH@ SPRAG MUST POINT UP AS SHOWN WHEN ASSEMBLED INTO THE OUTER RACE 637 638 639 641 642 643 644 BEARING ASSEMBLY, INPUT SUN GEAR· SNAP RING. OVERRUN CLUTCH HUB RET. HUB, OVERRUN CLUTCH RETAINER &. RACE ASSEMBLY,SPRAG FORWARD SPRAG ASSEMBLY RETA)NER RINGS. SPRAG ASSEMBLY RACE. FORWARD CLUTCH OUTER

644

641

CJ

A B C 642 644

RECESSED FACE NOTCHES POINT UPWARD AS SHOWN LIPPED EDGE FORWARD SPRAG ASSEMBLY RACE. FORWARD CLUTCH (OUTER)

Figure

119

Figure 122 FORWARD CLUTCH SPRAG ASSEMBLY 1. Disassemble and inspect the forward clutch sprag assembly (Figure 122). 2. Install the forward sprag assembly in the outer race from the side opposite the recess (See Figure 119). 3. The notches in the sprag assembly cage MUST face upward as shown in Figure 119. 4. Install wear plate onto the inner race and install the inner race into the sprag assembly by pushing in and turning to the left (See Figure 120). 5. Install the remaining wear plate. 6. Install the overrun clutch hub and the overrun hub snap ring (Figure 122). 7. Test the complete assembly,as·shown in Figure 121. If the assembly operates backwards, you have installed the sprag backwards. Reassemble correctly. INSTALL OVERRUN CLUTCH PLATES 1. Install the overrun clutch plates into the input housing (See Figure 124). 2. The overrun clutch plates are smallest of the three sets of plates in the input housing. 3. Start the pack with a steel plate and alternate with a friction untill you have installed two of each. 4. The overrun clutch steel plates must be indexed into the input housing, and requires ONLY two lined and two steels (See Figure 123). 5. Install input housing lube oil seal in the input housing as shown in Figure 125. There are two different seals depending on output shaft design, but the hard plastic will work either way. See Figure 100.

641----~~~~~\ 642--~~1\\ 643 644 A PUSH IN AND TURN COUNTERCLOCKWISE TO INSTALL 641 RETAINER &. RACE ASSEMBLY. SPRAG 642 FORWARD SPRAG ASSEMBLY 643 RETAINER RINGS, SPRAG ASSEMBLY 644 RACE, FORWARD CLUTCH (OUTER)

Figure

120

THE OVERRUN CLUTCH HUB MUST TURN CLOCKWISE, BUT NOT COUNTERCLOCKWISE 639 644 HUB, OVERRUN CLUTCH RACE, FORWARD CLUTCH (OUTER)

Figure

121

AUTOMATIC

TRANSMISSION
72

SERVICE GROUP

ALL MODELS 2 2 Figure 123 6. It should be down against the thrust bearing when installed properly. 7.. Figure 125 Figure 126 AUTOMATIC TRANSMISSION 73 SERVICE GROUP . 8.248mm • 2.400mm (. shown in Figure 126. as shown in Figure 125. Install the thrust bearing into the input housing. Retain the bearing with Trans-Jel. by turning. 094·) COMP. and indexing the overrun clutch hub into overrun clutch friction plates.079·) NO.03mm (. Install the pre-assembled forward sprag assembly into the input housing. as shown in Figure 126.Technical Service Information OVERRUN • ALIGN WIDE NOTCHES TO CASE LUGS Figure 124 OVERRUN CLUTCH MODEL FLAT STEEL THICK· NESS 2.089· . NO. 9. FACED THICK· NESS 2.

070·) 2.169" Thick) as shown Figure 127 and 128. 4. Install the proper forward clutch backing plate as shown in Figure 131. with the teeth aligned to the apply plate. Install the forward clutch wave plate on top of the apply plate as shown in Figure 130. Install the remainder of the forward clutch plates beginning with a steel plate on top of the waved plate.79mm (. with stepped side facing up. Install the forward clutch apply plate on top of the overrun clutch plates with the teeth aligned with the overrun plates (See Figure 129).78mm CHART REQUIRED QUANTITY ALL MODELS 1 1 5 APPLY PLATE WAVED STEEL CLUTCH PLATE FLAT STEEL CLUTCH PLATE COMPOSITION FACED CLUTCH PLATE BACKING PLATE (. 5. 3. 2.1~~T5G) Technical OVERRUN AND Service Information CLUTCH PACKS FORWARD OVERRUN AND FORWARD CLUTCH PACK STACK-UPS ARE THE SAME ON ALL 1987-1993 MODELS AND IS SHOWN ABOVE.040"-.169W) 1. Install the backing plate snap ring using a screwdriver as shown in Figure 133.30mm (. which is . and alternating with friction plate until you have installed five steel plates and five friction plates. Figure 127 FORWARD CLUTCH INFORMATION PLATE TYPE THICK· NESS 4.070W) SELEC· TIVE 5 1 Figure 128 INSTALL FORWARD CLUTCH PLATES 1. Refer to Figures 127 and 128. Check the forward clutch backing plate travel with a feeler gage as shown in Figure 132.063".29mm (. The forward clutch apply plate is the thickest (. Change the selective backing plate as necessary to obtain the desired travel. AUTOMATIC TRANSMISSION 74 SERVICE GROUP . 6. 7.090·) 1. 8.

232") . 6.15mm (.272" . 063..56mm ·4.89mm .71mm (.07mm (. 5.30mm •. 1.75mm .225" 5.92mm·7.I~RTSGI Technical Service Information Figure 129 Figure 130 Figure 131 FORWARD CLUTCH BACKING PLATE SELECTION ALL MODELS BACKING PLATE TRAVEL PLATE THICKNESS 6.) IDENTIFICATION A . 5.48mm 255") •• B 5.74mm (. 278·) 6.203" ..030" •.33mm (.60mm (.249 H - .180··185·) Figure 133 Figure 132 AUTOMATIC TRANSMISSION 75 SERVICE GROUP . 208") C o E 4.

. Install the 3-4 clutch retainer as shown in Figure 135. FORWARD CLUTCH BACKING PLATE RETAINER 652 PLATE. 3RD & 4TH CLUTCH BACKING PLATE RETAINER Figure 134 AUTOMATIC TRANSMISSION 76 SERVICE GROUP . THERE ARE THREE DIFFERENT 3-4 CLUTCH STACK-UPS DEPENDING THE MODEL THAT YOU ARE WORKING ON (SEE FIGURE 141).(~RT5G) Technical Service Information 656 655 654C 621 653 Le. 2. with the step facing up. Install the 3-4 clutch STEPPED apply plate as shown in Figure 136. This plate has wide tabs as shown in Figure 137. FORWARD CLUTCH (WAVED) 649A PLATE ASSEMBLY. INPUT 646 PLATE. SOME MODELS DO NOT USE FLAT APPLY PLATE (SEE FIGURE 141). FORWARD CLUTCH APPLY 648 PLATE. 4. FORWARD CLUTCH (FIBER) 649B PLATE. 652 660 Figure 135 INSTALL 3-4 CLUTCH PLATES 1. 3RD & 4TH CLUTCH APPLY (STEPPED) 654A PLATE ASSEMBLY. SOME MODELS USE A DIFFERENT TYPE OF RETAINER THAT ALSO SERVES AS APPLY PLATE (SEE FIGURE 141). DESCRIPTION 600 SPRING ASSEMBLY. ILL. Install the 3-4 clutch FLAT apply plate as shown in Figure 137. Install the 3-4 clutch plates into the input housing using Figure 141 as your guide. 3RD & 4TH CLUTCH (STEEL) 664C PLATE. Be sure that each tab on the retainer is on the outside of the legs of the 3-4 apply ring. 3RD & 4TH CLUTCH (FIBER) 664B PLATE. NO. FORWARD CLUTCH BACKING (SELECTIVE) 651 RING. SOME MODELS DO NOT USE THE STEPPED APPLY PLATE (SEE FIGURE 141). 3. 3RD & 4TH CLUTCH RING RETAINER 663 PLATE. 3-4 CLUTCH BOOST (5) 621 HOUSING & SHAFT ASSEMBLY. 3RD & 4TH CLUTCH BACKING (SELECTIVE) 656 RING. FORWARD CLUTCH (STEEL) 650 PLATE. 3RD & 4TH CLUTCH (STEEL) 665 PLATE.

Install the proper 3-4 clutch backing plate as shown in Figure 137. NEW APPLY PLATE THAT REPLACES THE THREE PREVIOUS APPLY PLATES. INSTRUCTION SHEET. 7. AN UPDATED 3-4 CLUTCH SERVICE PACKAGE WITH THICKER 3-4 STEEL PLATES (SHOWN IN FIGURE 141). "145" FRICTION PLATES. THIS BACKING PLATE IS DIFFERENT ON THE DIFFERENT MODELS. Figure 139 ATSG RECOMMENDS THAT YOU REMOVE AND DISCARD THE 3-4 LOAD RELEASE SPRING ASSEMBLIES SHOWN ABOVE. BACKING PLATE WAS MADE THINNER. MAKE SURE OF THE MODEL YOU ARE WORKING ON TO INSURE PROPER BUILD CONTENT (SEE FIGURE 141). FOR A MUCH IMPROVED 2-3 SHIFT AND BETTER 3-4 CLUTCH DURABILITY. THERE IS NOW AVAILABLE UNDER OEM PART NUMBER 8690923. 6. 6. WHEN THE THICKER 3-4 STEEL PLATES WERE INTRODUCED. NEW THICKER STEEL PLATES. "2050" FRICTION PLATES. 7. THE NUMBER 44 HOLE IN THE SPACER PLATE SHOWN IN FIGURE 26 MUST BE DRILLED OUT TO . 8. EVEN IF THE HOLE IS NOT THERE! AUTOMATIC TRANSMISSION 77 SERVICE GROUP .093" AT THE SAME TIME. NEW APPLY RING WITH SHORTER LEGS.Technical Service Information Figure 136 Figure 137 5. NEW SELECTIVE BACKING PLATE. 3-4 backing plate travel should be . 2.080" (See Figure 142). 4. SEE PAGE 78 FOR THE MODELS THAT USE THIS PLATE. 5. INCLUDES THE FOLLOWING: 1. Install the 3-4 clutch backing plate snap ring as shown in Figure 138 using a screwdriver. 3.060"-. ALL MODELS. SOME MODELS ALSO USE A "2050" FRICTION PLATE IN THE 3-4 CLUTCH PACK.

THE TWO DIFFERENT FRICTION PLATES ARE CALIBRATION SENSITIVE AND INTERCHANGING THE WRONG PLATES MAY CAUSE PREMATURE FAILURE. 1991 1AAM 1APM 1CNM 1CYM 1FYM 1KWM 1LHM lRCM 1RDM 1YHM 1992 2ADM 2AKM 2BFM 2CHM 2CJM 2FUM 2KJM 2LHM 2WCM 2YCM 2YDM 1993 3AAM 3AFM 3BAM 3BCM 3BHM 3BWM 3FAM 3FFM 3LHM 3YAM 3YDM 3ADM 3ASM 3BBM 3BFM 3BRM 3CPM 3FDM 3FMM 3SFM 3YCM AUTOMATIC TRANSMISSION 78 SERVICE GROUP . THE FOLLOWING CHART SHOWS WHICH MODELS SHOULD USE THE PLATES LABELED "2050" AS SHOWN IN FIGURE 140 ABOVE.(~~TSG) Technical Service Information Figure 140 IN SOME OVERHAUL AND REPAIR KITS THERE ARE TWO DIFFERENT SETS OF 3-4 CLUTCH FRICTION PLATES.

1991 1AAM 1APM 1CNM 1CYM 1FYM 1KWM 1LHM 1RCM 1RDM 1YHM 1992 2ADM 2AKM 2BFM 2CHM 2CJM 2FUM 2KJM 2LHM 2WCM 2YCM 2YDM 1993 3AAM 3AFM 3BAM 3BCM 3BHM 3BWM 3FAM 3FFM 3LHM 3YAM 3YDM 3ADM 3ASM 3BBM 3BFM 3BRM 3CPM 3FDM 3FMM 3SFM 3YCM AUTOMATIC TRANSMISSION 78 SERVICE GROUP . THE FOLLOWING CHART SHOWS WHICH MODELS SHOULD USE THE PLATES LABELED "2050" AS SHOWN IN FIGURE 140 ABOVE. THE TWO DIFFERENT FRICTION PLATES ARE CALIBRATION SENSITIVE AND INTERCHANGING THE WRONG PLATES MAY CAUSE PREMATURE FAILURE.(~~T5G) Technical Service Information Figure 140 IN SOME OVERHAUL AND REPAIR KITS THERE ARE TWO DIFFERENT SETS OF 3-4 CLUTCH FRICTION PLATES.

l~nT5GI Technical DIFFERENT Service Information STACK-UPS 3-4 CLUTCH FIVE FRICTION STACK-UP SIX FRICTION STACK-UP SIX FRICTION STACK-UP WITH THICK STEELS Figure 141 AUTOMATIC TRANSMISSION 79 SERVICE GROUP .

060/l-.161/1 THICKNESS IDENTIFICATION STAMPED /IA/I STAMPED /IB/I STAMPED "C/I 3-4 CLUTCH BACKING PLATE TRAVEL SHOULD BE .(~nT5G) 3-4 Technical Service Information BACKING PLATE SELECTION 1987-1993 MODELS PART NUMBER 8685046 8685047 8685048 .196/1 .224/1-.231/1 .080"} AND MEASURED AS SHOWN BELOW.154/1-.187/1-. 655 Figure 142 AUTOMATIC TRANSMISSION 80 SERVICE GROUP .

682// IDENTIFICATION STAMPED //4// STAMPED //7// IDENTIFICATION 3-4 CLUTCH APPLY RING (THIN STEEL) 3-4 CLUTCH APPLY RING (THICK STEEL) Figure 143 8642374 8685043 AUTOMATIC TRANSMISSION SERVICE GROUP 81 .076//) THICK (.~-------A------~~ STEEL PLATES THIN (.711// 3.(~~T5GI 3-4 Technical Service Information CHART CLUTCH APPLY RING 1987-1993 MODELS I~.106//) DIMENSION //A// 3.671//-3.700//-3.

6. and re-sizing tool. Solid rings will require installation tool. Set the input housing on the bench with turbine shaft up (See Figure 144). in addition to the Trans-Tool numbers in Figure 144 can be used for this operation. air will exit the forward clutch feed hole in the turbine shaft. 4. forward. Set the completed input housing aside untill final assembly. 10. This will ensure no damage when we install the oil pump into transmission. 2. close the hole with your finger when making this test.1~~T5G) Technical Service Information T-1574 RESIZING TOOL TURBINE SHAFT Figure 145 SOLID TEFLON SEALING RINGS Figure 144 SEALING RING INSTALLATION 1. 8. as shown in Figure 144. Figure 146 9. Adjust the screw to obtain the proper height for each seal ring. When the overrun clutch is checked. 5. AUTOMATIC TRANSMISSION 82 SERVICE GROUP . Air check the 3-4. and the overrun clutches by applying air to the feed holes in the turbine shaft (See Figure 144). Install the four turbine shaft sealing rings onto the turbine beginning with the bottom ring (See Figure 144). The Kent-Moore tool numbers J-36418-1 and J-36418-2A. 7. 3. Solid Teflon sealing rings should ALWAYS be used in these positions. NOTE: It would be best to leave the re-sizing tool installed on the input housing sealing rings untill you are ready for final assembly.

REVERSE INPUT CL. Remove the spring compressor and the return spring assembly from housing. 605 DESCRIPTION HOUSING. Remove the backing plate snap ring from the reverse input housing. 6.• REVERSE INPUT CLUTCH 610 RING. RETAINING Figure 148 AUTOMATIC TRANSMISSION 83 SERVICE GROUP . Turn the housing over to remove the entire reverse input clutch pack. REVERSE INPUT CLUTCH BACKING 614 RING. NO. as shown in Figure 145. compress the reverse input return spring assembly. Remove the reverse input piston from the housing.Technical Service Information J 25018·A UNDER J 23327·1 605 Figure 147 REVERSE INPUT HOUSING DISASSEMBLY 1. remove and discard the piston lip seals (See Figure 148).• REVERSE INPUT CLUTCH 608 SEALS. 4. DRUM ASSEMBLY. 3. Remove the return spring snap ring with snap ring pliers. (BELLEVILLE) 612A PLATE ASM . 5. Install spring compressor J-23327-1 as shown in Figure 147.• REVERSE INPUT CLUTCH (FIBER) 612B PLATE. REVERSE INPUT CLUTCH !INNER. as shown in Figure 146. with a screwdriver. REVERSE INPUT CL. REVERSE INPUT CLUTCH SPRING RETAINER 611 PLATE. REVERSE INPUT CLUTCH 607 PISTON ASM . as shown in Figure 147. OUTER) 609 SPRING ASM . 2. REVERSE INPUT CLUTCH (STEEL) 613 PLATE. ILL.

REQUIRES PUMP COVER WITH . HAS LARGE SQUARE HOLE BETWEEN THE SEALING RINGS IN HOUSING. REQUIRES 1993 CHECKBALL LOCATIONS IN VALVE BODY. LATE 1987-1992 ONLY! 1. HAS ROUND . 4. 4. Figure 149 AUTOMATIC TRANSMISSION 84 SERVICE GROUP .095" ORIFICE HOLE BETWEEN THE SEALING RINGS IN HOUSING. 3.215" HOLE BETWEEN THE SEALING RINGS. 6. USES STEEL PISTON.-3. 2. USES CAST ALUMINUM PISTON.(~RTSG) REVERSE EARLY Technical INPUT Service HOUSING Information IDENTIFICATION 1987 ONLY! 1. 2. REQUIRES PUMP COVER WITH . 2. 5. USES CAST ALUMINUM PISTON.215" HOLE BETWEEN THE SEALING RINGS. HAS LARGE SQUARE HOLE BETWEEN THE SEALING RINGS IN THE HOUSING. 1993 MODEL ONLY! 1. USES A BELLVILLE PLATE IN' THE CLUTCH PACK. USES A BELLVILLE PLATE IN THE CLUTCH PACK. HAS BALL CAPSULE IN HOUSING. REQUlREsPUMP COVER WITH . 5. 3. DOES NOT USE BELLVILLE PLATE IN THE CLUTCH PACK. AND USES THREE.095" HOLE BETWEEN THE SEALING RINGS. 5. BALL CAPSULE ELIMINATED IN HOUSING. SEE CHECKBALL LOCATIONS SECTION OF THIS MANUAL. 4. BALL CAPSULE ELIMINATED IN HOUSING.

Check the reverse input housing using a straight edge. The "TECKPAK" orifice cup plug goes into the back side of the reverse input piston. 3. 3. REVERSE INPUT CLUTCH Figure 150 REVERSE INPUT PISTON MODIFICATION Figure 151 AUTOMATIC TRANSMISSION 85 SERVICE GROUP . There are 3 different reverse input housings. We recommend that you reduce the size of the bleed orifice in the ALUMINUM reverse input piston. THAT WILL NOT INTERCHANGE. 2. as shown in Figure 150. REVERSE INPUT PISTON MODIFICATION 1. We recommend that this modification be done on ALL MODELS WITH ALUMINUM PISTON. A CHECK FOR DISHING AT THIS POINT 605 HOUSING 11& DRUM ASSEMBLY. as shown in Figure 151. Use Figure 149 to identify which of the reverse input housings you have.(~~TSG) Technical Service Information REVERSE INPUT HOUSING IDENTIFICATION 1. to ensure proper build content. using an orifice cup plug that is available at "TECKPAK" under part number 77761C. to ensure that you have a flat band surface. 2.

068") SELECTIVE Figure 154 AUTOMATIC TRANSMISSION 86 SERVICE GROUP .Technical Service Information Figure 152 Figure 155 Figure 153 REVERSE INPUT CLUTCH 10.091") 2.074") 1. BELLEVILLE PLATE FLAT STEEL CLUTCH PLATE COMPOSITION FACED CLUTCH PLATE BACKING PLATE THICKIESS Figure 156 2.210mm (.892mm (.730mm (.087") 4 4 2.081") 1.311mm (.075") 1.880mm (.045mm (.

compress the reverse input return spring assembly. Install the inner and outer lip seal onto the reverse input piston. as shown in Figure 153. Install the reverse input "Bellville" plate (IF SO EQUIPPED). as shown in Figure 151.40 076W) W •• IDENTIFICATION 5 6 7 8 Figure 157 REVERSE INPUT HOUSING ASSEMBLY 1. Clearance should be . Figure 158 11.45mm I. Lips on seals must face the direction shown in Figure 151.(~nT5GI Technical Service Information CHECK FOR (. 267W) 6.299w •. Remove the spring compressor. 19.075". Install the reverse input clutch backing plate.82mm-5. Inspect all components of the reverse input clutch assembly for damage or wear. 4.075 BACKING PLATE TRAVEL W ) REVERSE INPUT CLUTC·H BACKING PLATE SELECTION ALL MODELS BACKING PLATE TRAVEL PLATE THICKNESS 7. as shown in Figure 152.94mm-6. Install the return spring assembly on top of the reverse input piston. chamfered side up. and lubricate with Trans-Jel.13mm I. 14. 18. 9. Install spring compressor J-23327-1 as shown in Figure 147. into reverse input housing. Install the return spring snap ring with snap ring pliers. 16. 7. 3. 10.47mm 1. If the tangs of the reverse input housing and the tangs of the sun gear shell have "Flared" out. Alternate friction and steel plates untill you have installed 4 friction and 4 steel plates.221 215W) W •• 1. ALWAYS USE LONG LIP SEALS IN THE OUTER LIP SEAL LOCATIONS. Install the backing plate snap ring as shown in Figure 156. Lubricate reverse input housing seal surfaces with Trans-Jel. CONCAVE SIDE GOES DOWN.02mm· 1. 8. Check the reverse input clearance with a feeler gage between the backing plate and snap ring. as shown in Figure 155.79mm I.60mm . Install the reverse input clutch plates beginning with a flat steel plate. by installing the orifice cup plug.040w·. Change backing plate as necessary.28mm . using screwdriver. 2. 15. 6. Install the reverse input piston into the housing.94mm lO.247w -". replace the forward sprag regardless of how good it happens to look and/or check. 12. as shown in Figure 148. as shown in Figure 147. as shown in Figure 150. 13. 293W) 6. Air check the reverse input housing to ensure no damage to lip seals during the assembly process. 17. Inspect the reverse input ciutch housing with a straight edge. AUTOMATIC TRANSMISSION 87 SERVICE GROUP . 7. using care not to damage the lip seals.040"-.. 6. Refer to Figure 149 for clutch stack-ups to ensure proper build content.241W) 5. for flatness.273w . Modify the reverse input ALUMINUM piston. 5. using the chart in Figure 157.

Technical

Service

Information
CORRECTLY INSTALLED

Figure 159 ASSEMBLE REVERSE INPUT CLUTCH AND INPUT CLUTCH HOUSINGS 1. Install the selective thrust washer and thrust bearing assembly onto the input housing, as shown in Figure 160. 2. The thrust bearing should be on top of the selective washer, with the BLACK side facing up. 3. Install the reverse input housing by rotating and index the reverse input clutch plates onto the hub of the input clutch housing (See Figure 159. 4. When installed properly, the thrust bearing will turn with the reverse input clutch housing. 5. Install the reverse input and the input clutch housing assembly into the transmission case as shown in Figure 161. 6. There will be three items to index properly during installation. • 3-4 clutch plates must be indexed onto the input ring gear. • Input sun gear must be indexed into the forward sprag inner race. • Reverse input housing tangs must be indexed into the sun gear shell. 7. Great care must be exercised to ensure that all clutch plates are fully seated. 8. When properly assembled, the reverse input housing will be located just below the case oil pump surface.

ILL. NO. 615 616 621

DESCRIPTION BEARING ASSEMBLY, STATOR SHAFTI SELECTIVE WASHER WASHER, THRUST (SELECTIVE) HOUSING & SHAFT ASSEMBLY, INPUT

Figure 160

A 10 48 605 621

BAND ANCHOR PIN LOCATION CASE. TRANSMISSION PIN. BAND ANCHOR HOUSING 4& DRUM ASSEMBLY. REVERSE INPUT CLUTCH HOUSING & SHAFT ASSEMBLY, INPUT

Figure 161

AUTOMATIC

TRANSMISSION
88

SERVICE GROUP

(~J:lT5G)

Technical

Service

Information

Figure

163

Figure

162

2-4 BAND ANCHOR PIN

INSTALL 2-4 BAND ASSEMBLY 1. Install the 2-4 band assembly beginning as shown in Figure 162. 2. Line up the anchor pin hole in the band with the hole in the case, and the clip end of the band as shown in Figure 163. 3. Install the band anchor pin into the case hole as shown in Figure 164. 4. Index the 2-4 band onto the band anchor pin. 5. Anchor pin will be just below valve body surface when properly installed.

Figure

164

AUTOMATIC

TRANSMISSION
89

SERVICE GROUP

1~~T5[i1

Technical
PUMP COVER

Service

Information

IDENTIFICATION

EARLY

1987

ONLY!

1. HOLE BETWEEN SEALING RINGS IS .095" DIAMETER. 2. REQUIRES REVERSE INPUT HOUSING WITH BALL CAPSULE AND STEEL PISTON. REFER TO FIGURE 149. 3. CAN USE SCARF CUT SEALING RINGS BUT SOLID SEALS ARE RECOMMENDED. 4. MODELS WITHOUT AUXILIARY VALVE BODY MUST HAVE CUP PLUG IN THIS HOLE.

LATE .215" HOLE

1987-1992

ONLY!

1. HOLE BETWEEN SEALING RINGS IS .215" DIAMETER . 2. REQUIRES REVERSE INPUT HOUSING WITH ALUMINUM PISTON AND .095" DIAMETER HOLE BETWEEN SEAL RINGS. REFER TO FIGURE 149. 3. CAN USE SCARF CUT SEALING RINGS BUT SOLID SEALS ARE RECOMMENDED.

REQUIRES SOLID SEALS

1993

MODEL

ONLY!

1. HOLE BETWEEN SEALING RINGS IS .215" DIAMETER. 2. REQUIRES REVERSE INPUT HOUSING WITH ALUMINUM PISTON AND LARGE SQUARE HOLE BETWEEN SEALING RINGS. REFER TO FIGURE 149. 3. REQUIRES SOLID SEALING RINGS. 4. REQUIRES 1993 CHECKBALL LOCATIONS, AND USES THREE. REFER TO CHECKBALL LOCATIONS SECTION OF THIS MANUAL;

Figure 165

AUTOMATIC

TRANSMISSION
90

SERVICE GROUP

7086 .7076 . Select exact size replacements.0.974 17. Refer to the chart in Figure 168 for proper rotor and slide selection.7066 0.948 17.987 18.7071 . Figure 168 ROTOR AND/OR SLIDE REPLACEMENT 1.0.7071 0.987·18.000 .948 . to ensure proper build content.974 17.7081 0. 3.) 230 RING. capable of measuring in tenths.0.000 18.961 17. There are two different oil pump covers THAT WILL NOT INTERCHANGE! 2. Measurement of rotor and slide must be made on undamaged surfaces.0. OIL RING. PROPER selection of rotor and slide sizes are very important on this transmission.974 17.0.000 18.7086 .7071 • 0. AUTOMATIC TRANSMISSION 91 SERVICE GROUP . OIL SEAL (STATOR SHAFT) Figure 166 17.7086 . PUMP 214 ROTOR.(~~T5G) Technical Service Information OIL PUMP ROTOR SELECTION CHART THICKNESS (mm) THICKNESS (In.18.7081 0.7071 0.7086 .7066 0.961 17. as shown in Figure 168.0. as shown in Figure 165. will be required to accurately measure the pump slide and the rotor.17.17.7081 .0. 3.0. 4. 2.7081 . 4. Use Figure 165 to identify which one of the oil pump covers that you have.013 0.7076 0.961 . Some models use scarf cut seal rings on the stator shaft.7091 OIL PUMP SLIDE SELECTION CHART THICKNESS (mm) THICKNESS (In.) 17.987 17.17.7076 .7091 J 39855-2 4 230 PUMP ASSEMBLY.0. OIL SEAL (STATOR SHAFT) Figure 167 206 SLIDE. OIL PUMP PUMP COVER IDENTIFICATION 1. The solid seal rings are REQUIRED on 1993 models.961 17. Lightly hone both sides of replacement rotor/slide to remove any nicks. as shown in Figure 165.000 - 17. A one inch micrometer.013 0.7076 0.974 .987 18. but the solid seal rings will fit ALL previous models and are recommended.

NEVER USE A SEVEN VANE ROTOR IN THE 1987-1993 MODEL YEAR PUMPS. Install five pump cover to pump body bolts. Install ten vanes into the pump rotor. 2. WHEN REPLACING THE FRONT PUMP BUSHING ORIENT THE SEAM OF THE NEW BUSHING SO IT IS POINTED AT THE BOLT HOLE NEXT TO THE PIVOT PIN AS SHOWN IN FIGURE 169. 12. Pull the pump slide straight towards the slide seal with one hand. and seal retainer (See Figure 170). Install "0" ring back-up and oil seal ring into the groove on the back side of the pump slide (See Figure 169). as shown in Figure 171. Install new front pump seal. 7. 13. if necessary. Install both of the pump slide springs (See Figure 170). Align and install oil pump cover onto the oil pump body. Install a new pump body bushing into the pump body. Install rotor guide onto pump rotor and retain with Trans-Jel. 3. Proper selection of rotor and slide sizes are very important. 9. 4. 6. Install one vane ring into pump pocket. Install pump slide assembly into pump pocket being carefull not to disturb slide seals. Refer to the chart in Figure 168 for proper rotor and slide selection. but DO NOT tighten them yet.Technical Service Information WHEN REPLACING THE FRONT PUMP BUSHING. and with the other hand install the pivot pin and spring (See Figure 169). Install slide seal support and the Teflon slide seal onto pump slide and retain with Trans-Jel (See Figure 169). Bushing be driven out from the seal side of body and reinstalled from the pump pocket side of the pump body. ORIENT THE SEAM OF THE NEW BUSHING SO IT IS POINTED AT THE BOLT HOLE NEXT TO THE PIVOT PIN AS SHOWN BELOW. 11. Install pump rotor and guide assembly into pump pocket with guide towards the pump pocket (See Figure 170). 10. 16. 15. Install alignment tool J-21368 onto the oil pump assembly. Install remaining vane ring into the pump rotor (See Figure 170). (Continued on Page 94) Figure 169 AUTOMATIC TRANSMISSION 92 SERVICE GROUP . Ensure that pump slide moves back and forth freely in the pump pocket. 204 205 207 SLIDE BACK UP SEAL AND RING SPRING 208 210 211 PIVOT PIN SUPPORT SLIDE SEAL ASSEMBLE PUMP BODY AND PUMP COVER 1. 14. 17. 8. 5.

PUMP SPRING. OIL SEAL (STATOR SHAFT) SEAL. (REVERSE CLUTCH) RETAINER & BALL ASSEMBLY. PUMP RING. OIL PUMP CONVERTER CLUTCH VALVE RETAINING VALVE. OIL PUMP COOLER FEED PLUG. OIL PUMP AIR BLEED PLUG. PUMP SLIDE SEAL SEAL. PUMP SLIDE RING. CONVERTER CLUTCH SPRING. BOOST RING. ROTOR ROTOR. T. FRONT HELIX SEAL TUBE. T. OIL PUMP VANE. (OVERRUN CLUTCH) 217 229 218 228 219 227 220 221 222 210 223 211 226 225 -~224 243 203 MAIN ~OO3 OIL PUMP ASSEMBLY EXPLODED VIEW Figure 170 AUTOMATIC TRANSMISSION 93 SERVICE GROUP . PRESSURE RELIEF SPRING. OIL BUSHING. PUMP VANE GUIDE. PUMP SLIDE (INNER) RETAINER & BALL ASSEMBLY. REVERSE BOOST VALVE VALVE. NO. PUMP SLIDE (OUTER) SUPPORT.V. OIL SEAL (SLIDE TO WEAR PLATE) SEAL. PUMP VALVE. OIL PUMP COVER PLUG. PIVOT PIN PIN. STOP VALVE. REVERSE BOOST SLEEVE. "0" RING (SLIDE SEAL BACK-UP) SLIDE. CONVERTER CLUTCH VALVE (INNER) RIVET. STATOR COVER. PRESSURE REGULATOR SPRING.V. AUXILIARY ACCUMULATOR VALVE BODY. PRESSURE RELIEF RING.(~~T5[i) Technical Service Information ILL. OIL PUMP CONVERTER CLUTCH SIGNAL SCREW. STATOR SHAFT (M6 x 1 x 16. CONVERTER CLUTCH VALVE (OUTER) SPRING. PRESSURE REGULATOR VALVE VALVE. PIVOT SLIDE SPRING. OIL PUMP REVERSE BOOST VALVE RETAINING RING. M8 x 1.26 x 40 (COVER TO BODY) PLUG. 002 003 094 096 203 204 206 206 207 208 209 210 211 212 213 214 215 21 6 21 7 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 242 243 244 245 DESCRIPTION SEAL ASSEMBLY. PUMP SHAFT.0) SPRING. PRESSURE RELIEF BOLT BALL. PUMP BODY RETAINER. BOOST BUSHING. OIL PUMP COVER SCREEN SCREEN. OIL PUMP COVER BOLT.

OIL 601 WASHER. AUTOMATIC TRANSMISSION 94 SERVICE GROUP . Push the entire assembly down with a small screwdriver. as shown in Figure 166. 18. while the alignment strap is tight. Ensure t~at the valve moves freely in the bore. push down with screwdriver. or purchase the updated pressure regulator valve that is available under part NO. Install the converter clutch apply valve into the same bore. 34.lbs. boost valve into the T. as shown in Figure 175. Install inner and outer converter clutch apply valve springs into the pump cover (See Figures 170 and 175).R. Install the T. ensuring that washer tabs are engaged in slots. 27. as shown in Figure 165.V. 31. 23. Install the reverse boost valve into the reverse boost valve bushing. Install the two sealing rings on the pump cover (See Figure 170). THRUST (PUMP TO DRUM) 4 Figure 173 Continued from Page 92. 20. boost valve bushing "Exactly" as shown in Figure 175. Grind two "Flats" on the second land of the pressure regulator valve. Install the reverse boost assembly in the P. 29.Technical Service Information Figure 171 J 39855-2 4 PUMP ASSEMBLY. Torque the five pump cover to pump body bolts to 18 ft.V. 30. Install the thrust washer on back of the pump cover. Install converter clutch valve stop. but the solid seal rings will fit ALL previous models and are recommended. OIL 230 RING. 21. and retain with Trans-Jel (See Figure 173). boost assembly into the P. with the valve installed exactly as shown in Figure 175. Refer to Figure 170. 19.R. Install T. 28. 26. as shown in Figure 174.V.V. 24. 33. Some models use scarf cut seal rings on the stator shaft. bore on top of reverse boost assembly as shown in Figure 175. Install modified pressure regulator valve into pressure regulator valve bore in the pump cover (Figure 170). Remove the alignment strap from pump. OIL SEAL (STATOR SHAFT) Figure 172 4 PUMP ASSEMBLY. 25. as shown in Figure 175. 32. 8684048. Install pressure regulator valve spring into the same bore. The solid seal rings are REQUIRED on 1993 models. 22. 35. and install snap ring with the flat side facing out (See Figure 170). and install snap ring with the flat side facing out.V. bore on top of spring.

PRESSURE REGULATOR SPRING. 42. 38. OIL PUMP CONVERTER CLUTCH VALVE RETAINING VALVE. T. OIL PUMP REVERSE BOOST VALVE RETAINING RING. REVERSE BOOST SLEEVE. Lubricate the "0" ring with Trans-JeI. 41. If installing the solid sealing rings use J-39855-1 and J-38735-3 to install the seal rings on the stator as shown in Figure 172. CONVERTER CLUTCH SPRING. 22'''iJ 222~ 223~g 224~ ~226 -=- --DESCRIPTION ILL. Use J-39855-2 to resize the solid seals after installation. as shown in Figure 172.V. REVERSE BOOST VALVE VALVE.(~RTSGI Technical Service Information 219~ 1-~22' 229 220~ PRESSURE REGULATOR VALVE Figure 174 36. V. CONVERTER CLUTCH VALVE (OUTER) SPRING. NO. 43. T. Adjust the screw on the tool to obtain the proper height. Oil pump assembly is now ready for assembly into the transmission. PRESSURE REGULATOR VALVE VALVE. CONVERTER CLUTCH VALVE (INNER) Figure 175 AUTOMATIC TRANSMISSION 95 SERVICE GROUP . 40. The chamfered edge of the "0" ring should be facing out. BOOST BUSHING. BOOST RING. and make sure that it is not twisted in the groove. It is recommended to leave the resizing tool in place over the solid sealing rings untill you are ready to install the oil pump into case. STOP VALVE. 37. Install the oil pump to case "0" ring into the groove in the oil pump body. 218 219 220 221 222 223 224 225 226 227 228 229 VALVE. 39.

Install oil pump retaining bolts and remove the alignment dowels. 4. If you are using scarf cut seal rings ensure that they are installed proper as shown in Figure 176. Remove the resizing tool from sealing rings. Install new "0" rings onto the pump retaining bolts. 5.150". . 2. 7.(~RT56) Technical Service Information 233 RING. CAUTION: There should be clearance between the reverse input housing and the sun gear shell. Figure 177 Figure 178 AUTOMATIC TRANSMISSION 96 SERVICE GROUP . Torque all oil pump retaining bolts to 18 ft. 8. 6. 9. Install the complete oil pump assembly into the transmission case using the alignment dowels as shown in Figure 177. Lubricate the sealing rings with a small amount of Trans-Jel. install the remaining bolts (See Figure 178). 10. for easy installation. Lubricate the case pump bore where the "0" ring rides. DO NOT try to shim the internal parts because of this clearance. Install the proper "0" ring on turbine shaft AFTER end clearance is checked and properly set. if you are using solid seals. When installed these two parts have a normal clearance of Approx .lbs. Install oil pump to case gasket into case and retain with Trans-Jel. OIL SEAL (STATOR SHAFT) Figure A ALIGNMENT PINS 4 PUMP ASSEMBLY. OIL 176 INSTALL OIL PUMP ASSEMBLY 1. 3.

087" (.D. If dial indicator shows no end play. 3. as shown in Figure 180.015"-.04 .080" (.015".036" CAUTION: NEVER SET END PLAY ANY CLOSER THAN . Refer to Figure 160.3.97 2.107" (.120" .(~RT5GI Technical Service Information TRANSMISSION END PLAY WASHER SELECTION CHART WASHER THICKNESS I. 4.65 2.2. (. select the proper washer from chart in Figure 179.094" (.124") - 67 68 69 70 71 72 73 74 Figure 179 CHECKING TRANSMISSION END PLAY 1.074" (. 5. as shown in Figure 181. or J-34725 adapter on turbine shaft. Pull up on lifting tool J-24773-A and observe the reading. Proper end play is . If more or less end play is required. Install J~25022 adapter.06 .14 2.111·) . Refer to Figure 160 for proper assembly.104") .82 2. Install lifting tool J-24773-A and a dial indicator as shown in Figure 181.2.100" (.48 2.99 3.21 .2.091") ..87·1.113". 6.118") . 1. the selective washer and thrust bearing may have been mis-assembled.38 .72 .084") .16 mm mm mm mm mm mm mm mm (.2. 2.31 2.89 .2.2. BECAUSE ALUMINUM PUMP WILL EXPAND OR "GROW" AND YOU COULD END UP WITH A NEGATIVE END CLEARANCE. Set the dial indicator to zero.55 . A 298mm TURBINESHAFT B 245mm TURBINESHAFT Figure 180 A DIAL INDICATOR B 278mm (11") BOLT C LOCK NUT Figure 181 AUTOMATIC TRANSMISSION SERVICE GROUP 97 .078") . Remove a front pump bolt and install an 11" bolt and lock nut.098") . NOTE: The selective washer which contraIls the end play is located between the input housing and thrust bearing that rides on oil pump cover hub.

(~RT5GI Technical Service Information 1982 THRU EARLY 1987 ONLY! VALVE BODY CHECKBALL LOCATIONS (WITHOUT AUXILIARY VALVE BODY) LATE 1987 THRU 1992 ONLY! VALVE BODY CHECKBALL LOCATIONS (WITH AUXILIARY VALVE BODY) 1993 MODELS ONLY! VALVE BODY CHECKBALL LOCATIONS (WITH AUXILIARY VALVE BODY) Figure 182 AUTOMATIC TRANSMISSION 98 SERVICE GROUP .

(~nTSG) Technical Service Information 1982 THRU 1987 ONLY! CASE CHECKBALL LOCATIONS 1988 THRU 1993 ONLY! CASE CHECKBALL LOCATIONS Figure 183 AUTOMATIC TRANSMISSION 99 SERVICE GROUP .