THM 400

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INDEX

COMPONENT APPLICATION CHART.......................................................................... 3 LINE PRESSURE SPECIFICATIONS AND TESTS ..................................................... 4 TROUBLE SHOOTING CHARTS ................................................................................... 5 CASE PUMP PASSAGE IDENTIFICATION ................................................................. 14 VARIABLE PITCH PASSAGE IDENTIFICATION ...................................................... 15 EARLY PUMP PASSAGE IDENTIFICATION ............................................................... 16 LATE PUMP PASSAGE IDENTIFICATION .................................................................. 17 PUMP COMPATABILITY CHART ................................................................................. 18 P.R. VALVE VERSUS PUMP COVER IDENTIFICATION .......................................... 19 CASE BOTTOM PASSAGE IDENTIFICATION ........................................................... 20 SPACER PLATE PASSAGE IDENTIFICATION ........................................................... 22 VALVE BODY PASSAGE IDENTIFICATION ............................................................... 23 6 BALL CASE CHECKBALL LOCATIONS .................................................................. 24 7 BALL CASE CHECKBALL LOCATIONS .................................................................. 25 VARIOUS EXTENSION HOUSING DIMENSIONS AND IDENTIFICATION ........ 26 VARIOUS OUTPUT SHAFT DIMENSIONS AND IDENTIFICATION ..................... 27 CASE AND EXTERNAL PARTS EXPLODED VIEW .................................................. 28 INTERNAL TRANSMISSION PARTS EXPLODED VIEW ........................................ 30 OIL PUMP ASSEMBLY EXPLODED VIEW ................................................................. 32 VALVE BODY ASSEMBLY EXPLODED VIEW ........................................................... 33 TRANSMISSION DISASSEMBLY .................................................................................. 34 COMPONENT REBUILD TRANSMISSION CASE ............................................................................................... 42 GEAR TRAIN AND RELATED PARTS ..................................................................... 44 DIRECT CLUTCH HOUSING .................................................................................... 53 FORWARD CLUTCH HOUSING ............................................................................... 57 GOVERNOR ASSEMBLY ............................................................................................ 61 OIL PUMP ASSEMBLY ............................................................................................... 62 VALVE BODY ASSEMBLY ......................................................................................... 67 FINAL TRANSMISSION ASSEMBLY PROCESS ........................................................ 68 DETENT SOLENOID ELECTRICAL SCHEMATICS, 88 AND LATER ................... 89 BUSHING REMOVAL AND REPLACEMENT ............................................................. 90 TORQUE SPECIFICATIONS ........................................................................................... 93 IDENTIFICATION TAG LOCATION AND INFORMATION ..................................... 94 SPECIAL TOOLS REQUIRED ........................................................................................ 95

AUTOMATIC TRANSMISSION SERVICE GROUP 9200 S. DADELAND BLVD. SUITE 720 MIAMI, FLORIDA 33156 (305) 670-4161
Copyright © ATSG 1999

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INTRODUCTION THM 400
This booklet contains general description and overhaul procedures necessary to repair, overhaul or service the THM 400 transmission, and is found in both passenger cars and trucks. The THM 400 transmission was first introduced in 1964 and was used through the 1990 model year with some engineering changes that occured during that time. We have included the major changes and updates in the appropriate sections of this booklet. We wish to thank General Motors Corporation for the information and illustrations that have made this booklet possible. No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without written permission of Automatic Transmission Service Group. This includes all text illustrations, tables and charts. "Portions of materials 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 their reliability, but ATSG does not guarantee its accuracy. Copyright © ATSG 1999

ROBERT D. CHERRNAY
TECHNICAL DIRECTOR

DALE ENGLAND
FIELD SERVICE CONSULTANT

WAYNE COLONNA
TECHNICAL SUPERVISOR

JIM DIAL
TECHNICAL CONSULTANT

PETER LUBAN
TECHNICAL CONSULTANT

ED KRUSE
TECHNICAL CONSULTANT

GERALD CAMPBELL
TECHNICAL CONSULTANT

GREGORY LIPNICK
TECHNICAL CONSULTANT

JERRY GOTT
TECHNICAL CONSULTANT

DAVID CHALKER
TECHNICAL CONSULTANT

AUTOMATIC TRANSMISSION SERVICE GROUP 9200 S. DADELAND BLVD. SUITE 720 MIAMI, FLORIDA 33156 (305) 670-4161 Revised December 1999

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Technical Service Information
COMPONENT APPLICATION CHART
RANGE PARK/NEUT REVERSE DRIVE 1ST DRIVE 2ND DRIVE 3RD DRIVE "2" 1ST DRIVE "2" 2ND MANUAL LOW ON ON ON ON ON ON ON ON ON HOLD HOLD ON ON ON HOLD ON ON HOLD FORWARD INTERMED CLUTCH CLUTCH DIRECT CLUTCH FRONT BAND REAR BAND INTERMED ROLLER LOW ROLLER

FORWARD CLUTCH

DIRECT CLUTCH

INTERMEDIATE CLUTCH

INTERMEDIATE ROLLER CLUTCH

FRONT BAND

REAR BAND

LOW ROLLER CLUTCH

Copyright © 1999 ATSG

Figure 1

AUTOMATIC TRANSMISSION SERVICE GROUP

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Brakes Applied. Engine At 1000 RPM DRIVE "2" . Downshift Solenoid On NORMAL P. Engine At 1000 RPM DRIVE . Engine At 1000 RPM DRIVE .Brakes Applied.Brakes Applied. Engine At 1000 RPM REVERSE .I.Engine At Curb Idle Specifications DRIVE .Brakes Applied. 55-70 60-85 60-90 135-160 95-150 90-110 Copyright © 1999 ATSG Figure 2 4 AUTOMATIC TRANSMISSION SERVICE GROUP lll lll .Brakes Applied.Technical Service Information LINE PRESSURE GUAGE INSTALLED llllllllll llll llllllllllll lll llllllllll llll LINE PRESSURE SPECIFICATIONS RANGE NEUTRAL . Engine 1000 RPM.S.

5. 4. Gasket and Seal. Damaged sealing surface on pan or case. Damaged bolt holes. 7. Missing bolts. Front Oil Seal Assembly. Porisity and/or cracks. 7. Missing bolt or gasket. Oil Pump Assembly Pump to Case Gasket. Damaged gasket or seal. Damaged cover and/or gasket. Missing bolts. 3. 2. 4. Porisity and/or cracks.Technical Service Information THM 400 DIAGNOSIS CONDITION FLUID LEAK INSPECT Oil Pan and Oil Pan Gasket. 1. Damaged hub or hub surface finish. 2. Damaged threads on fitting or case. 3. Damaged case bore. 2. Damaged case sealing surface. 6. Transmission Case. FOR CAUSE 1. 2. Cooler Line Fittings and Pressure Tap. Stripped bolt holes. 5. Low torque. Damaged bolt holes. Damaged case bore. 1. 3. Damaged or missing "O" ring seal. 6. 2. 1. 2. Electrical Connector and "O" Ring Seal. Damaged "O" ring/gasket sealing surfaces. 4. Oil Pump Seal Ring. Bolts over/under torqued. Copyright © 1999 ATSG Figure 3 AUTOMATIC TRANSMISSION SERVICE GROUP 5 . Torque Converter. 4. 1. 1. Damaged bellows or diaphragm. Damaged manual shaft. Damaged or cracked connector. Manual Shaft Seal. Missing Bolts. Loose modulator retainer. 5. Bolts over/under torqued. 4. Loose bolts or low bolt torque. 1. 1. Garter spring missing from front seal. Damaged manual shaft seal. Vacuum Modulator and "O" Ring Seal. Porus transmission case. Extension Housing. 3. Improperly seated manual shaft seal. 2. Damaged Oil Pan or Gasket. Split cooler line tubing. 2. Shallow tapped holes. Missing or damaged "O" ring seal. Governor Cover and Gasket. Damaged seams in modulator can. 4. 3. 2. 3. Damaged gasket or seal. Shallow tapped holes. Bolts over torqued. 1. 3. Damaged "O" ring/gasket sealing surfaces. 8. 3. 5. Seam weld leaks.

Intermediate clutch cup plug missing or Filler Tube and Seal. Overheating (Heavy Trailers etc. Wrong boost valve and sleeve. 6. 1. Transmission Case. adjust as necessary. Damaged intake pipe case bore. Modulator valve in case stuck. 5. Direct. Servo cover or gasket damaged. (Oil Pump and Center Support) Internal Leaks (Rear Servo and Front Accumulator). 3. 2. 2. 2. 1. 2. Damaged seal case bore. Breather hole in pump missing or blocked. Fluid level low. Damaged or porosity in valve body area. 1. 2. Intake pipe damaged or cracked. Excessive wear on pump cover (Stator). Pistons or seals damaged. 1.).. FOR CAUSE 1. or Intermediate clutches. Vacuum Modulator. 1. 6. Oil sealing ring damage or misassembly. Damaged. 7.Technical Service Information THM 400 DIAGNOSIS CONDITION FLUID LEAK (Continued) INSPECT Fluid Out Vent Pipe. LOW LINE PRESSURE Fluid Level. Transmission overfilled. Blocked or restricted filter. Oil pump to case gasket mispositioned. 1. 1. Oil Pump Assembly. Piston seal damage on Forward. Missing or damaged shaft seal.. 4. Damaged adapter or "O" ring seal. 4. Plugged vent pipe. Vacuum does not drop. 3. Pressure regulator or boost valve stuck. 3. Vacuum regulator valve (Diesel Engine Only). 3. Speedo Adapter and Seal. 4. 4. Porosity in pump body or cover. 5. bent or wrong modulator. Filter "O" ring or intake pipe damaged that will create foaming condition. Filter Assembly. Damaged speedo adapter case bore. Copyright © 1999 ATSG Internal Leaks. 1. 3. Pump body wear in gear pocket. 1. Intake Pipe and "O" Ring Seals. Pump to case gasket mispositioned. 2. 3. Damaged or missing "O" ring seal on pipe. 2. Figure 4 6 AUTOMATIC TRANSMISSION SERVICE GROUP . 1. 7. Oil pump not properly seated in case. Sealing ring groove damage or wear. Damaged seal or filler tube. 2. Excessive pump gear clearance. Internal Leaks (Clutches). Coolant in fluid. 2. inspect for carbon build up where line enters intake manifold.

Aluminum bore plug damaged. bent or wrong modulator. Modulator valve in case stuck. 1. Oil Pump Assembly. 2. Detent feed orifice in spacer plate blocked. Wrong boost valve and sleeve. 3. Improper assembly. Detent gasket missing. 1. 1. 2. 5. 3. Low vacuum from poor engine tune. Stator roller clutch damaged (Vehicle moves. 4. NO MOVEMENT ANY RANGE Fluid Level. adjust as necessary. Vacuum lines leaking. 2. 5. Refer to "LOW LINE PRESSURE". Porosity in pump body or cover. 5. Differential damaged or axle broken. Low fluid level. Incorrect pressure regulator spring. Manual valve loose from rooster cone pin. 4. Vacuum operated accessory leak. but is very sluggish). 6. 2. 3. Detent valve bore plug damaged/leaking. Valve Body Assembly. Mechanically stuck open. Rooster cone nut loose on manual shaft. 1. 4. 7. Damaged. Turbine or pump vanes damaged. 3. 4. 1. 6. Detent regulator valve or detent valve stuck. Vacuum regulator valve (Diesel Engine Only). 3. Oil Pressure. (Does speedo work in forward gear?) Detent Solenoid. 4. 2. 1.Technical Service Information THM 400 DIAGNOSIS CONDITION HIGH LINE PRESSURE INSPECT Vacuum Modulator and FOR CAUSE 1. Mounting bolts loose. Pressure regulator or boost valve stuck. Transmission Internal. Detent regulator valve pin short. Mis-stabbed (Damaged hub and gears). Linkage not properly adjusted. 2. Turbine hub splines stripped or broken. 3. Detent switch actuated or shorted. Vacuum storage tank leak. Manual Linkage Torque Converter. Spacer plate to case gasket off location or gaskets reversed. 1. Internal splines stripped or damaged. 1. Copyright © 1999 ATSG Figure 5 AUTOMATIC TRANSMISSION SERVICE GROUP 7 . 2.

1. restricted or valve body casting porosity. Center Support and Oil Sealing Rings. 2. Piston lip seals damaged or missing. Porisity in case apply pin bore. restricted or has porosity. 1. 3. Rear servo apply pin damaged or improper pin length selection. restricted or case casting porosity. 1. Spacer plate gaskets leaking. Copyright © 1999 ATSG Forward Clutch Housing. Forward clutch piston seal damage (Hard). 2. Forward clutch feed orifice in clutch housing or the pump cover restricted. 1. Direct Clutch Assembly. Cage assembly installed backwards. 3. Direct clutch housing damaged. Rear Band Assembly. 3. 3. Rear servo cover or gasket leaking. Oil seal ring grooves damaged or worn.Technical Service Information THM 400 DIAGNOSIS CONDITION NO FORWARD MOVEMENT. 6. COLD ONLY. Figure 6 8 AUTOMATIC TRANSMISSION SERVICE GROUP . Reverse oil passages blocked. 5. Valve Body Assembly. Damaged or missing components. 4. burned or broken. Reverse oil passages blocked. REVERSE OK INSPECT Oil Pump Assembly and Oil Sealing Rings. Direct piston outer seal damaged or rolled. porosity. Oil seal ring grooves damaged or worn. Oil pump seal ring damaged or worn. 3. 2. Transmission Case. NO MOVEMENT IN DRIVE OR DRIVE "2" RANGE LOW AND REVERSE OK Low Roller Clutch Assembly. Oil seal rings on stator (Fwd clutch feed) are damaged or missing. 3. Rear band damaged. restricted or has porisity. 1. Piston damaged or cracked. 4. 2. Drive feed passage in stator blocked. 2. 2. restricted or has porosity or is cracked. ALL FORWARD OK Rear Servo Assembly. 2. Oil seal rings damaged or missing. Rear servo apply pin not engaged in target area of rear band lug. Forward clutch housing damaged. Oil Pump Assembly. Oil seal rings damaged or missing. 1. Piston oil seal damaged or missing. 1. Check ball in housing damaged or missing. Reverse oil passages blocked. 1. NO REVERSE. Reverse oil passages blocked. 1. Check ball in housing or piston missing. FOR CAUSE 1. 1. Rear servo piston damaged or cracked. 2. or porosity. 2.

4. Governor feed passages restricted or leaks. 2. 5. Detent valve bore plug damaged/leaking. 2. 6. Mounting bolts loose. Copyright © 1999 ATSG Valve Body Assembly. Detent valve or detent regulator valve stuck. 6. 7. 1. Governor Assembly. Governor binding in case bore. 5. 1. 4. Installed backwards. 2. 2. Detent valve or detent regulator valve stuck. 2. 3. Valve Body Assembly. Small orifice cup plug missing from support. Governor valve stuck in governor bore. 1. 1-2 Accumulator Piston. Governor Oil Pipes and Governor Feed Screen. Governor driven gear damaged or broken. Detent switch actuated or shorted. 1. 3. Detent gasket missing. Spacer plate and gaskets damaged. 4. missing or improperly seated in valve body or case. Governor oil pipes damaged. OR FULL THROTTLE UPSHIFT ONLY Oil Pressure. 5. Governor weights binding. missing or improperly seated in valve body or case. Roller clutch not holding or damaged. 1-2 shift valve binding or stuck. Governor Assembly. 1. Figure 7 AUTOMATIC TRANSMISSION SERVICE GROUP 9 . 4. INSPECT FOR CAUSE 1. Damaged piston or seal ring groove. Detent feed orifice in spacer plate blocked. Detent Solenoid. 3. DELAYED 1-2 UPSHIFT. 1. Governor oil pipes damaged. Intermediate Roller Clutch. Damaged or missing oil sealing ring. Refer to "HIGH LINE PRESSURE". 4. Spacer plate and gaskets damaged. Governor driven gear damaged or broken. 1. Governor valve stuck in governor bore. Governor screen blocked or restricted. Damaged clutch piston or lip seals. 1. 3. Valve body casting porosity. sticking or worn.Technical Service Information THM 400 DIAGNOSIS CONDITION NO 1-2 UPSHIFT. 1-2 shift valve binding or stuck. 5. 1ST GEAR ONLY Oil Pressure. Governor feed passages restricted or leaks. Governor Oil Pipes and Governor Feed Screen. 2. 2. Center support bolt loose or broken. (Located In Rear Servo) Intermediate Clutch. 6. Mechanically stuck open. (Will have Manual "2") 2. Governor screen blocked or restricted. Detent solenoid missing or damaged. 6. Governor weights binding. Valve body casting porosity. sticking or worn. 3. Refer to "HIGH LINE PRESSURE". Governor binding in case bore. 3. 1. 5. Detent solenoid missing or damaged.

4. 1. 2. Governor Assembly. Center Support and Oil Sealing Rings. 1. Valve Body Assembly. 1. Wrong seal on 2-3 accumulator piston. Governor valve stuck in governor bore. Governor oil pipes damaged. HARSH UPSHIFTS AT MINIMUM THROTTLE Oil Pressure. 2-3 accumulator piston binding or stuck. Oil seal ring grooves damaged or worn. Copyright © 1999 ATSG Figure 8 10 AUTOMATIC TRANSMISSION SERVICE GROUP . 2-3 shift valve binding or stuck. 3. 1.Technical Service Information THM 400 DIAGNOSIS CONDITION NO 2-3 UPSHIFT. sticking or worn. 2. Governor Oil Pipes and Governor Feed Screen. 6. Governor binding in case bore. 2. 3. Intermediate accumulator piston cracked. Oil seal rings damaged or missing. 1. 4. Governor feed passages restricted or leaks. Refer to "HIGH LINE PRESSURE". 1-2 accumulator valve binding or stuck. 1-2 Accumulator Piston (Located in Rear Servo) Transmission Case. 5. Spacer plate and gaskets damaged. 2. Porosity in housing or piston. Valve Body Assembly. 3. 1ST & 2ND GEAR ONLY Oil Pressure. 2. Damaged clutch piston or lip seals. 2. Oil seal rings damaged or missing. Porosity or crack in center support. 2-3 accumulator spring broken. 2-3 accumulator piston or seal damage. 1. missing or improperly seated in valve body or case. Oil seal ring grooves damaged or worn. 1. 3. 1. Governor screen blocked or restricted. Governor driven gear damaged. 4. Refer to "HIGH LINE PRESSURE". 4. INSPECT FOR CAUSE 1. 2-3 modulator valve stuck. 3. 3. Missing check ball in piston or housing. 2. Intermediate accumulator feed passages blocked or restricted. Support bolt loose or broken. 5. Governor weights binding. Direct Clutch Housing. Valve body casting porosity.

Loose electrical connections. missing or improperly seated in valve body or case. Detent valve or detent regulator valve stuck. 3. 3. Valve Body Assembly. 7. 2. Governor driven gear damaged or broken. Detent valve bore plug damaged/leaking. Refer to "HIGH LINE PRESSURE". Mounting bolts loose. 2. 1.Technical Service Information THM 400 DIAGNOSIS CONDITION NO UPSHIFTS OR DELAYED. Mechanically or electrically defective. 6. Detent gasket missing. NO DETENT DOWNSHIFTS Detent Solenoid Circuit. 5. 4. FULL THROTTLE UPSHIFT ONLY Oil Pressure. 4. Copyright © 1999 ATSG Figure 9 AUTOMATIC TRANSMISSION SERVICE GROUP 11 . Governor feed pipes missing/misassembled. 6. INSPECT FOR CAUSE 1. 3. 4. Pinched and/or cut wiring in circuit. 1. Governor valve stuck in governor bore. Detent switch actuated or shorted. Plugged orifice. Damage to worm track passages. 6. Governor Assembly. Detent switch actuated or shorted. Mechanically stuck open. 2. 2. Detent solenoid missing or damaged. Detent Solenoid. 2. 4. Governor screen blocked or restricted. Governor Oil Pipes and Governor Feed Screen. Detent valve or detent regulator valve stuck. 3. Detent valve bore plug damaged/leaking. Damaged electrical connector. 4. and activated by PCM/TCM via TPS on 88 & later. Governor oil pipes damaged. 1-2 or 2-3 shift valves binding or stuck. Governor feed passages restricted or leaks. Detent gasket missing. 2. Mounting bolts loose. 1. Valve Body Spacer Plate. 1. 3. 2. sticking or worn. 5. 5. Governor weights binding. Valve Body Assembly. 1. Governor binding in case bore. 1. Defective electrical activation switch usually on accelerator linkage on early models. Mechanically stuck open. Detent feed orifice in spacer plate blocked. 5. 4. 1. Valve body casting porosity. Spacer plate and gaskets damaged. Transmission Case. Governor oil passages blocked or restricted.

Band apply pin not engaged properly. Sticking servo pistons. 3. Rear Band Assembly. Support bolt loose or broken. Governor Assembly. Porosity in housing or piston. 2. 2. Damaged. Leaking gaskets and/or piston seal rings. Rear servo piston case bore damage. Shift valves binding allowing partial oil feed. Governor valve stuck in governor bore. Copyright © 1999 ATSG Valve Body Assembly. sticking or worn. 4. Oil seal rings damaged or missing. creating high governor pressurre. 2. SLIPPING SHIFTS Oil Pressure. Figure 10 12 AUTOMATIC TRANSMISSION SERVICE GROUP . 2-3 accumulator spring damaged. 1. 1. Servo cover or gasket damage. 2. Front Servo Assembly. 1. Rear band anchor pin damaged. Rear band damaged or burnt. 5. 1. Oil seal ring grooves damaged or worn. bent or wrong modulator. Missing check ball in piston or housing. Case porosity or damage in worm tracks. 2. Modulator valve in case stuck. creating high governor pressure. Band apply pin too short. Porosity or crack in center support. 3. Piston or sealing ring damaged. INSPECT FOR CAUSE 1.Technical Service Information THM 400 DIAGNOSIS CONDITION EARLY SOFT OR . 1. 3. Governor weights binding. Rear Servo Assembly. Direct Clutch. 4. Valve Body Assembly. 1. 2. 2. Center Support and Oil Sealing Rings. Damaged clutch piston or lip seals. 3. NO ENGINE BRAKING LO RANGE (1ST GEAR) Transmission Case. Forward Clutch. Rear Servo Assembly. Inspect for carbon build up where line enters intake manifold. Intermediate Clutch. 1-2 or 2-3 shift valve sticking. 2-3 modulator valve binding or stuck. 3. 1. 1. 3-2 valve binding or stuck. 3. Valve body bolts with low torque. 2. Refer to "LOW LINE PRESSURE". 3. Vacuum regulator valve (Diesel Engine Only). 4. Vacuum does not drop. 1. Valve body casting porosity. Mis-assembled rear servo. 2-3 accumulator piston or seal ring damage. NO PART THROTTLE DOWNSHIFTS Vacuum Modulator Assembly. 4. 4. Damaged or broken servo springs. 3. 2. 2. Low/Rev checkball missing or off location. 1.

Front Servo Assembly.Technical Service Information THM 400 DIAGNOSIS CONDITION NO ENGINE BRAKING "D2" RANGE (2ND GEAR) INSPECT Transmission Case. Damaged. Front Band Assembly. Copyright © 1999 ATSG Figure 11 AUTOMATIC TRANSMISSION SERVICE GROUP 13 . Servo piston stuck in bore. Damaged servo piston or pin bore. 2. FOR CAUSE 1. burnt. Apply pin or anchor pin not engaged. broken or missing. 1. 2. 3. Front servo damaged or has porosity. Damaged servo piston pin. 4. Front servo mis-assembled or wrong parts. 2. 1. Damaged servo piston seal.

6. INTERMEDIATE CLUTCH CUP PLUG. 2. 6 9 1 5 4 3 10 2 Copyright © 1999 ATSG Figure 12 14 AUTOMATIC TRANSMISSION SERVICE GROUP . DRIVE OIL. 7.Technical Service Information REGULAR CASE USES STAMPED TIN OR PLASTIC CONVERTER COVER 8 7 9 1. COOLER RETURN. 4. 9. 8. 8. VENT. 9. LINE PRESSURE. 7. MODULATOR. 10. 6. 5. PUMP INTAKE REVERSE LINE PRESSURE DRIVE OIL MODUL ATOR TO COOLER COOLER RETURN VENT INTERMEDIATE CLUTCH CUP PLUG 6 1 5 4 3 2 HEAVY DUTY CASE USES CAST ALUMINUM CONVERTER COVER 8 7 1. REVERSE. MOUNTING HOLES FOR CAST ALUMINUM CONVERTER COVER. 3. TO COOLER. 2. PUMP INTAKE. 3. 4. 5.

STATOR SIGNAL 7. LUBE OIL 9. LINE PRESSURE 3. LINE PRESSURE 9. CONVERTER 3. PUMP SUCTION 11. OR INTERMEDIATE 5. CONVERTER 12. VENT 10.Technical Service Information "VARIABLE PITCH" PUMP BODY PASSAGES 1 1 8 1. DRIVE OIL 4. PUMP SUCTION 13. TO COOLER 6. COOLER RETURN 4. STATOR SIGNAL 14. REVERSE 2. MOD. DRIVE OIL 6. VENT 2. STATOR 8. STATOR 11. MOD. REVERSE 10. COOLER RETURN 7. BREATHER HOLE 8. OR INTERMEDIATE 10 SEAL DRAIN BACK HOLE 9 8 11 7 "VARIABLE PITCH" PUMP COVER PASSAGES 13 13 5 4 3 2 12 14 1 1. TO COOLER 5. EXHAUST 4 2 1 11 2 9 Figure 13 AUTOMATIC TRANSMISSION SERVICE GROUP 6 05 2 11 8 9 10 2 12 2 3 4 2 6 5 7 6 9 6 8 Copyright © 1999 ATSG 15 .

PUMP SUCTION 8 6 7 9 8 5 6 2 "EARLY" CASTING NO. REVERSE 2. OR INTERMEDIATE 7. TO COOLER 5. LUBE OIL 9. CONVERTER 12. OR INTERMEDIATE 5. EXHAUST 12 11 2 2 6 6 9 6 7 9 10 8 Copyright © 1999 ATSG Figure 14 16 AUTOMATIC TRANSMISSION SERVICE GROUP .Technical Service Information "EARLY" CASTING NO. MOD. 8626121 PUMP BODY PASSAGES 121 1 2 2 3 8 4 1 10 1. BREATHER HOLE 8. VENT 10. COOLER RETURN 4. PUMP SUCTION 13. LINE PRESSURE 9. 8626174 PUMP COVER PASSAGES 2 3 4 4 1 2 13 5 12 5 1. VENT 2. FEED HOLE 11. TO COOLER 6. COOLER RETURN 7. DRIVE OIL 6. CONVERTER 3. MOD. DRIVE OIL 4. REVERSE 10. SEAL DRAIN BACK HOLE 8. LINE PRESSURE 3. PRESSURE REG.

CONVERTER 3. TO COOLER 5. DRIVE OIL 4. LINE PRESSURE 9. PUMP SUCTION 8 6 7 9 8 5 6 2 "LATE" CASTING NO. BREATHER HOLE 8. REVERSE 2. PRESSURE REG. PUMP SUCTION 13. EXHAUST 12 11 2 2 6 6 9 6 7 9 10 8 Copyright © 1999 ATSG Figure 15 AUTOMATIC TRANSMISSION SERVICE GROUP 17 . CONVERTER RETURN 4. LUBE OIL 9. MOD. LINE PRESSURE 3. REVERSE 10. 8626895 PUMP BODY PASSAGES 895 1 2 2 3 8 4 1 10 1. VENT 2. TO COOLER 6. OR INTERMEDIATE 7. VENT 10. OR INTERMEDIATE 5. DRIVE OIL 6. SEAL DRAIN BACK HOLE 8. FEED HOLE 11. MOD. COOLER RETURN 7. 8626896 PUMP COVER PASSAGES 2 3 4 4 1 2 13 5 12 5 1.Technical Service Information "LATE" CASTING NO. CONVERTER 12.

not all of the pump covers and body assemblies produced can be used together. The reference numbers on the chart are casting numbers for identification purposes. The chart below shows which pump halves will work together with "Yes" in the box. PUMP COVERS 1964-1966 1358649 PUMP BODIES 1964-1966 1358649 1967 8624068 1968-1970 8626121 1971-1994 8626895 1968-1970 8626174 8626176 1971-1994 8626896 8627000 YES YES YES YES NO NO YES YES NO NO YES YES CASTING NUMBER LOCATIONS Copyright © 1999 ATSG Figure 16 18 AUTOMATIC TRANSMISSION SERVICE GROUP 8626896 895 8626895 .Technical Service Information PUMP AND COVER IDENTIFICATION The basic fixed stator Turbo 400 pump body and pump cover castings have been changed somewhat over the years. and are found cast into the parts in the locations shown below. Due to these casting changes.

Technical Service Information PUMP COVER AND PRESSURE REGULATOR VALVE IDENTIFICATION SQUARED OFF PRESSURE REGULATOR BOSS FOR IDENTIFICATION 1ST DESIGN WITH ORIFICE PLUG The solid pressure regulator valve (2nd Design) can be used "only" in the pump cover with the squared off pressure regulator boss as shown above. The 1st design pressure regulator valve with the vent holes and orifice cup plug. Maximum line pressure will be the result if you install 2nd design valve into early cover. has been released for service and can be used to service either past model or the current pump cover. 2ND DESIGN (SOLID) Copyright © 1999 ATSG Figure 17 AUTOMATIC TRANSMISSION SERVICE GROUP 19 .

DIRECT CLUTCH GOVERNOR 1-2 ACCUMULATOR REVERSE OR LO GOVERNOR FEED (DRIVE) GOVERNOR PRESSURE Copyright © 1999 ATSG Figure 18 20 AUTOMATIC TRANSMISSION SERVICE GROUP . 11. MANUAL LO INTERMEDIATE DRIVE LINE PRESSURE INTERMEDIATE SERVO REVERSE EXHAUST DETENT OIL MODULATOR 10. 2. 15. 6. 14.Technical Service Information 1965-1987 CASE PASSAGES 7 6 6 4 3 8 2 9 4 5 9 8 2 9 10 9 11 5 2 12 2 3 8 6 5 4 8 3 8 2 9 1 15 10 9 6 6 2 10 1 13 14 2 4 1 4 1. 3. 12. 9. 7. 8. 4. 5. 13.

7. 5. 11. 12. 6.000 GVW AND UNDER) "COPPER" . 4. 3. 2.096" 8670459 "BLUE" .089" 8670801 14 15 1. 15. 14. DIRECT CLUTCH GOVERNOR 1-2 ACCUMULATOR REVERSE OR LO GOVERNOR FEED (DRIVE) GOVERNOR PRESSURE Copyright © 1999 ATSG Figure 19 AUTOMATIC TRANSMISSION SERVICE GROUP 21 . 8. MANUAL LO INTERMEDIATE DRIVE LINE PRESSURE INTERMEDIATE SERVO REVERSE EXHAUST DETENT OIL MODULATOR 10.Technical Service Information 1988-1990 CASE PASSAGES 7 6 6 4 3 8 2 9 4 5 9 8 2 9 10 9 11 5 2 12 2 3 8 6 5 4 8 3 8 2 9 1 10 9 6 6 2 10 1 13 2 4 1 4 ORIFICE CUP PLUG LOCATION (10. 9. 13.

1-2 ACCUMULATOR 13. DIRECT CLUTCH 11. VOID 4 8 8 2 2 9 8 5 9 10 9 5 5 5 2 2 11 3 6 9 2 9 1 12 2 3 7 9 3 1 8 8 1 9 2 6 1 2 6 1 6 1 2 4 4 4 Copyright © 1999 ATSG Figure 20 22 AUTOMATIC TRANSMISSION SERVICE GROUP . LINE PRESSURE 5. DIRECT CLUTCH 11. EXHAUST 8. VOID 9 9 9 9 9 9 8 5 9 9 8 5 10 10 5 2 11 4 10 2 2 2 6 2 2 3 7 8 3 9 9 9 9 2 1 3 12 12 2 2 2 1 4 4 4 1 1 8 8 1 9 9 6 2 1 13 6 1 6 1 2 4 SPACER PLATE PASSAGES 7 6 2 5 6 6 1. INTERMEDIATE SERVO 6. GOVERNOR 12. DRIVE 4.Technical Service Information SPACER PLATE TO CASE GASKET PASSAGES 4 7 6 2 5 6 6 9 8 1. MODULATOR 10. INTERMEDIATE SERVO 6. INTERMEDIATE 3. LINE PRESSURE 5. 1-2 ACCUMULATOR 13. EXHAUST 8. REVERSE 7. MANUAL LO 2. MODULATOR 10. INTERMEDIATE 3. DRIVE 4. GOVERNOR 12. MANUAL LO 2. DETENT 9. DETENT 9. REVERSE 7.

DETENT 9. MANUAL LO 2. 1-2 ACCUMULATOR 13. INTERMEDIATE SERVO 6. MODULATOR 10. VOID 8 9 9 9 8 5 9 5 9 5 5 5 9 10 10 9 2 6 11 9 10 3 2 2 8 3 1 12 2 2 2 2 6 2 9 2 1 3 7 2 9 9 4 1 8 3 9 2 1 8 8 9 2 4 1 3 1 4 13 9 6 6 2 1 6 1 VALVE BODY PASSAGES 2 1 4 13 1 6 1. DIRECT CLUTCH 11. INTERMEDIATE 3. REVERSE 7. GOVERNOR 12. MODULATOR 10. EXHAUST 8. LINE PRESSURE 5. INTERMEDIATE SERVO 6. VOID 2 1 9 3 1 2 3 12 8 2 10 10 5 9 2 5 9 9 9 9 2 9 2 6 11 6 2 2 8 9 8 3 1 4 8 1 11 7 2 3 1 2 9 9 9 9 8 6 9 2 5 6 3 4 5 6 7 Copyright © 1999 ATSG Figure 21 AUTOMATIC TRANSMISSION SERVICE GROUP 23 . 1-2 ACCUMULATOR 13. GOVERNOR 12.Technical Service Information SPACER PLATE TO VALVE BODY GASKET PASSAGES 7 6 2 5 6 6 9 1. DETENT 9. EXHAUST 8. MANUAL LO 2. INTERMEDIATE 3. DRIVE 4. REVERSE 7. LINE PRESSURE 5. DRIVE 4. DIRECT CLUTCH 11.

2 NO. 4 No. 3 No. 1 No. 2 No. 1 No. 5 No. 4 NO. 6 NO. 5 NO. 6 Non-Functional (Omit During Rebuild) Intermediate Ser vo 2-3 Drive 1-2 Shif t Intermediate Lo/Reverse Copyright © 1999 ATSG Figure 22 24 AUTOMATIC TRANSMISSION SERVICE GROUP . 3 NO.Technical Service Information 1965-1987 CHECKBALL LOCATIONS NO.

3 NO. 3 No. 6 No.089" 8670801 NO. 1 No. 5 NO. 6 1 ORIFICE CUP PLUG LOCATION (10. 2 No. 2 NO. 1 No. 7 Non-Functional (Omit During Rebuild) Intermediate Ser vo 2-3 Drive 1-2 Shif t Intermediate Lo/Reverse Reverse Copyright © 1999 ATSG Figure 23 AUTOMATIC TRANSMISSION SERVICE GROUP 25 .Technical Service Information 1988-1990 CHECKBALL LOCATIONS NO. 4 No.096" 8670459 "BLUE" . 5 No.000 GVW AND UNDER) "COPPER" . 7 NO. 4 NO.

Technical Service Information CENTER SUPPORT OIL PASSAGE I. Direct Clutch Reverse Lubrication Direct Clutch Intermediate Clutch Reverse Bleed Orifice Cup Plug Copyright © 1999 ATSG Figure 24 VARIOUS EXTENSION HOUSINGS USED ON THM 400 AND THM 375 9-1/2" 9-1/2" 4" THM 400 2WD Short THM 400 2WD Long THM "375" 2WD Long 375 THM 13-1/2" D THM 400 Cadillac Copyright © 1999 ATSG Figure 25 26 AUTOMATIC TRANSMISSION SERVICE GROUP .D.

Ring 18-1/2" Cadillac 15" 9-1/4" THM "400" 2WD Output Shaft (32 Spline) THM "400" 2WD Output Shaft (32 Spline) THM "400" 2WD Output Shaft (32 Spline) THM "400" 2WD Output Shaft (32 Spline) THM "400" Cadillac Output Shaft (32 Spline) 15" 13" 2-1/2" 1-1/4" 9-1/4" THM "400" 4WD Output Shaft (32 Spline) THM "400" 4WD Output Shaft (32 Spline) THM "400" 4WD Output Shaft (32 Spline) THM "400" JEEP 4WD Output Shaft (10 Spline) THM "375" 2WD Output Shaft (27 Spline) Copyright © 1999 ATSG Figure 26 AUTOMATIC TRANSMISSION SERVICE GROUP 27 .Technical Service Information VARIOUS OUTPUT SHAFTS USED IN THM 400 2WD Truck Threaded For Bolt-On Yoke I.D.

Technical Service Information CASE AND EXTERNAL PARTS EXPLODED VIEW Copyright © 1999 ATSG Figure 27 28 AUTOMATIC TRANSMISSION SERVICE GROUP .

73. BOTTOM PAN FILTER ASSEMBLY 43. REAR CASE BUSHING 34. OIL PUMP ASSEMBLY 7. EXTENSION HOUSING TO CASE SEAL (SOME MODELS) 33. COOLER FITTING 17. 86. 62. 50. 1/8" PIPE FRONT SERVO PISTON SEAL DRAIN PLUG GASKET (SOME MODELS) BOTTOM PAN DRAIN PLUG (SOME MODELS) Copyright © 1999 ATSG Figure 28 AUTOMATIC TRANSMISSION SERVICE GROUP 29 . 87. 53. 76. ELECTRICAL CONNECTOR 36. 56.620" GOVERNOR SCREEN ASSEMBLY DETENT SOLENOID RETAINING BOLTS.620" REVERSE SERVO COVER REVERSE SERVO COVER GASKET REVERSE SERVO PISTON RETAINING "E" CLIP REVERSE SERVO PISTON REVERSE SERVO PISTON SEAL 1-2 ACCUMULATOR PISTON OUTER SEAL 1-2 ACCUMULATOR PISTON 1-2 ACCUMULATOR PISTON INNER SEAL REVERSE SERVO PISTON WASHER REVERSE SERVO SPRING REVERSE SERVO SPRING RETAINER REVERSE SERVO PISTON BAND APPLY PIN (SELECTIVE) 1-2 ACCUMULATOR SPRING CENTER SUPPORT TO CASE BOLT (SHORT OR LONG) OUTPUT SPEED SENSOR ASSEMBLY (SOME MODELS) OUTPUT SPEED SENSOR "O " RING SPEED SENSOR RETAINING BOLT LINE PRESSURE TEST PLUG. 85. GOVERNOR ASSEMBLY 23. 63. 61. (SHORT OR LONG) 42. BOTTOM PAN BOLTS. VENT PIPE 10. 60. 82. 5/16-18 X 1. EXTENSION HOUSING ASSEMBLY 28. 1/4-20 X 1. EXTENSION HOUSING METAL CLAD SEAL 27. FILTER INTAKE PIPE (SHORT. IDENTIFICATION TAG SCREW 18. BOTTOM PAN MAGNET 41. 79. BOTTOM PAN TO CASE GASKET 40.Technical Service Information LEGEND FOR FIGURE 27 1. 5/16-18 X . IDENTIFICATION TAG 19. 81. EXTENSION HOUSING TO CASE BOLTS. 5/16-18 X . GOVERNOR COVER RETAINING BOLTS (4 REQUIRED) 20.LONG. EXTENSION HOUSING TO CASE GASKET (SOME MODELS) 35. 48. 57. MANUAL DETENT SPRING SUPPORT (SOME MODELS) 45. BALL BEARING SPACER 30. MODUL ATOR "O" RING SEAL 15. 69. 84. 59. BOTTOM TRANSMISSION OIL PAN (SHALLOW OR DEEP) 39. 66. 1/4-20 X . PUMP COVER TO CASE GASKET 9. 58. 65. DEEP PAN) MANUAL DETENT SPRING RETAINING BOLT. 51. 78. EXTENSION HOUSING BUS HING 31.690" 38. 77. ELECTRICAL CONNECTOR "O" RING 37. 64.) FRONT SERVO PISTON FRONT SERVO PISTON PIN RING FRONT SERVO PISTON PIN FRONT SERVO RETURN SPRING RETAINER FRONT SERVO PISTON RETURN SPRING REVERSE SERVO COVER RETAINING BOLTS. BALL BEARING ASSEMBLY 29. 83. 72.250" STEEL (SOME 6 REQ. 75. . AND SOME 7 REQ. 3/8-16 X 1" 26. MODUL ATOR RETAINING BRACKET 13. FILTER SPACER. 54. TORQUE CONVERTER ASSEMBLY 4. 67. OIL PUMP TO CASE SEALING RING 8. SPEEDO HOLE STEEL PLUG (4WD MODELS) 6. GOVERNOR COVER 21. BOLT AND "O" RING ASSEMBLY (PUMP TO CASE) 5. INTERNAL SNAP RING 32. GOVERNOR COVER GASKET 22. 74.750" DETENT SOLENOID ASSEMBLY VALVE BODY TO SPACER PLATE GASKET VALVE BODY SPACER PLATE SPACER PLATE TO CASE GASKET CHECKBALLS. 71. DEEP PAN ONLY 44.620" 12. TRANSMISSION CASE ASSEMBLY 11. 70. 52. 47. VACUUM MODULATOR VALVE 16. 5/16-18 X . 68. SHOULDERED FILTER BOLT.875") MANUAL DETENT SPRING AND ROLLER ASSEMBLY VALVE BODY ASSEMBLY GOVERNOR FEED AND RETURN PIPES VALVE TO CASE BODY BOLTS. SHALLOW PAN . MODUL ATOR RETAINING BOLT. VACUUM MODULATOR ASSEMBLY 14. 49.

Technical Service Information INTERNAL TRANSMISSION PARTS EXPLODED VIEW Copyright © 1999 ATSG Figure 29 30 AUTOMATIC TRANSMISSION SERVICE GROUP .

698. 668. 625. 619. 654. 688. 644. 636. 643. 676. 642. 678. 648. 684. 662. 637. 666. 672. 618. 627. 681. 634. INTERMEDIATE CLUTCH PISTON OUTER LIP SEAL CENTER SUPPORT SEALING RINGS. 671. 651. 691. 622. 653. 670. 660. 620. 686. 617. 661. 656. 646. 633. 632. 639. 629. 613. SEE FIGURE 26) SPEEDOMETER DRIVE GEAR RETAINING CLIP SPEEDOMETER DRIVE GEAR (MODEL SENSITIVE) OUTPUT SHAFT/OUTPUT CARRIER S NAP RING OUTPUT SHAFT TO CASE BRONZE THRUST WASHER OUTPUT SHAFT TO CASE STEEL THRUST WASHER (SELECTIVE) OUTPUT SHAFT "O" RING SEAL (SOME MODELS) OUTPUT SHAFT SPEED SENSOR ROTOR (SOME MODELS) Copyright © 1999 ATSG Figure 30 AUTOMATIC TRANSMISSION SERVICE GROUP 31 . 608. 607. 665. 635. 4 REQUIRED CENTER SUPPORT ASSEMBLY CENTER SUPPORT BUSHING CENTER SUPPORT TO REAR DRUM THRUST WASHER CENTER SUPPORT TO CASE FRETTING RING (SOME MODELS) LOW ROLLER CLUTCH ASSEMBLY REAR REACTION DRUM SPACER (FOR ROLLER CLUTCH ASM) CENTER SUPPORT TO NEEDLE BEARING RACE CENTER SUPPORT NEEDLE BEARING ASSEMBLY CENTER SUPPORT NEEDLE BEARING TO SUN GEAR RACE SUN GEAR SHAFT BUSHINGS ( 2 REQUIRED) SUN GEAR SHAFT ASSEMBLY SUN GEAR REACTION DRUM AND INPUT CARRIER ASSEMBLY PINION GEAR STEEL THRUST WASHERS PINION GEAR ROLLER NEEDLE BEARINGS INPUT CARRIER PINION GEARS PINION GEAR BRONZE THRUST WASHER PINION GEAR PINS REVERSE BAND ASSEMBLY FRONT INTERNAL RING GEAR SILENCI NG RING INTERNAL RING GEAR TO RING GEAR THRUST WASHER OUTPUT CARRIER ASSEMBLY PINION GEAR BRONZE THRUST WASHER PINION GEAR STEEL THRUST WASHER PINION GEAR ROLLER NEEDLE BEARINGS OUTPUT CARRIER PINION GEARS PL ANETARY PINION GEAR PINS TRANSMISSION MAIN SHAFT TO RING GEAR SUN GEAR TO NEEDLE BEARING RACE SUN GEAR NEEDLE BEARING ASSEMBLY NEEDLE BEARING TO REAR RING GEAR RACE REAR INTERNAL RING GEAR REAR RING GEAR TO NEEDLE BEARING RACE REAR RING GEAR NEEDLE BEARING ASSEMBLY NEEDLE BEARING TO OUTPUT SHAFT RACE MAIN SHAFT/REAR RING GEAR SNAP RING OUTPUT SHAFT BUSHING OUTPUT SHAFT (MODEL SE NSITIVE. 602. 683. 679. 673. 611. 674. TURBINE SHAFT FORWARD CLUTCH HOUSING FORWARD CLUTCH HOUSING CENTER SEAL FORWARD CLUTCH PISTON OUTER LIP SEAL FORWARD CLUTCH PISTON INNER LIP SEAL FORWARD CLUTCH PISTON FORWARD CLUTCH PISTON RETURN SPRINGS FORWARD CLUTCH RETURN SPRING RETAINER FWD CLUTCH RETURN SPRING RETAINER SNAP RING FORWARD CLUTCH WAVE (CUSHION) PLATE (SOME MODELS) FORWARD CLUTCH DISHED PLATE (SOME MODELS) FORWARD CLUTCH FLAT STEEL PLATES FORWARD CLUTCH LINED PLATES FORWARD CLUTCH HUB TO HOUSING THRUST WASHER FORWARD CLUTCH HUB THRUST WASHER (FWD CLUTCH HUB TO DIR CLUT HOUSING) DIRECT CLUTCH HUB SNAP RING (FORWARD AND DIRECT CLUTCHES) DIRECT CLUTCH BACKING PLATE DIRECT CLUTCH LINED PLATES DIRECT CLUTCH STEEL PLATES DIRECT CLUTCH WAVED PLATE (SOME MODELS) DIRECT CLUTCH DISHED PLATE (SOME MODELS) DIRECT CLUTCH RETURN SPRING RETAINER SNAP RING DIRECT CLUTCH RETURN SPRING RETAINER DIRECT CLUTCH PISTON RETURN SPRINGS DIRECT CLUTCH PISTON ASSEMBLY DIRECT CLUTCH PISTON INNER LIP SEAL DIRECT CLUTCH PISTON OUTER LIP SEAL DIRECT CLUTCH HOUSING CENTER LIP SEAL DIRECT CLUTCH HOUSING ASSEMBLY INTERMEDIATE ROLLER CLUTCH ASSEMBLY (SOME MODELS) INTERMEDIATE SPRAG CLUTCH ASSEMBLY (SOME MODELS) INTERMEDIATE ROLLER OR SPRAG OUTER RACE INTERMEDIATE ROLLER OR SPRAG RETAINER INTERMEDIATE ROLLER OR SPRAG RETAINER SNAP RING FRONT BAND ASSEMBLY INTERMEDIATE CLUTCH BACKING PLATE "FLAT" SNAP RING INTERMEDIATE CLUTCH BACKING PLATE INTERMEDIATE CLUTCH LINED PLATES INTERMEDIATE CLUTCH STEEL PLATES INTERMEDIATE CLUTCH WAVED PLATE (SOME MODELS) CENTER SUPPORT TO CASE "TAPERED" SNAP RING INTERMEDIATE CLUTCH RETURN SPRING RETAINER SNAP RING INTERMEDIATE CLUTCH RETURN SPRING RETAINER INTERMEDIATE CLUTCH RETURN SPRINGS INTERMEDIATE CLUTCH PISTON INTERMEDIATE CLUTCH PISTON INNER LIP SEAL 652. 685. 682. 606. 650. 692. 655. 623. 614. 604. 657. 640. 696. 694. 690. 630. 638. 677. 641. 689. 658. 615. 645. 663. 669. 612. 626. 624. 687. 675. 647. 616. 603. 695. 667. 659. 693. 621. 680. 605. 697. 631.Technical Service Information LEGEND FOR FIGURE 29 601. 664. 609.

340. 211. VALVE BODY CASTING 2-3 ACCUMULATOR PISTON RETAINING "E" CLIP 2-3 ACCUMULATOR PISTON 2-3 ACCUMULATOR PISTON SEAL 2-3 ACCUMULATOR PISTON SPRING GROOVED RETAINING PIN 1-2 ACCUMULATOR VALVE BORE PLUG (. 317.560" O. 320. 213. 205. 313. 201. 329. 311. 319. 341. 330. 326. 1-2 SHIFT VALVE 1-2 MODUL ATOR VALVE SPRING (SOME MODELS) 1-2 MODUL ATOR VALVE (SOME MODELS) STRAIGHT RETAINING PIN (. 209. OUTER PUMP DRIVEN GEAR PRESSURE REGUL ATOR RETAINING SNAP RING PRESSURE BOOST VALVE BUSHING PRESSURE BOOS T VALVE PRESSURE REGUL ATOR VALVE SPRING (MODEL SENSITIVE) PRESSURE REGUL ATOR VALVE SPRING RETAINER PRESSURE REGUL ATOR VALVE SPACER PRESSURE REGUL ATOR VALVE PRESSURE REGUL ATOR VALVE BORE PLUG P.437" O.750 (1 REQ) STATOR SHAFT REAR BUSHING PUMP COVER TO FWD DRUM THRUST WASHER (SELECTIVE) FORWARD CLUTCH SEALING RINGS (2 REQUIRED) INNER PUMP DRIVE GEAR 210.D. 5/16-18 X 1. 215. 212. 309. 203.500" O. 333. PUMP CONVERTER SEAL ASSEMBLY PUMP BODY BUSHING PUMP TO CASE "D" RING SEAL PUMP BODY PUMP COVER PUMP COVER TO PUMP BODY BOLT.50 (1 REQ) PUMP COVER TO PUMP BODY BOLT. 312. 302. 343. 318. 218. 310. 332. 336. 342.120" DIA X 1.820") 3-2 DOWNSHIFT VALVE BORE PLUG (.) 3-2 DOWNSHIFT VALVE SPRING 3-2 DOWNSHIFT VALVE PIN 3-2 DOWNSHIFT VALVE 1-2 MODUL ATOR VALVE BUSHING (SOME MODELS) 1-2 ACCUMULATOR VALVE PRIMARY SPRING (SOME MODELS) 1-2 ACCUMULATOR VALVE. 315. 3. 314. 316. 328.120" DIA X . 334. 7. 214. 204. 207. 321. 208.320" STATOR SHAFT FRONT BUSHING Copyright © 1999 ATSG Figure 31 LEGEND FOR FIGURE 33 301. 303.Technical Service Information OIL PUMP ASSEMBLY EXPLODED VIEW 2. 327. 304. 337. 5/16-18 X 1. 5/16-18 X 1.R.) 1-2 ACCUMULATOR VALVE (SOME MODELS) 1-2 ACCUMULATOR VALVE SPRING (SOME MODELS) 1-2 ACCUMULATOR VALVE SPRING (SOME MODELS) RETAINING ROLLED PIN DETENT REGUL ATOR VALVE BORE PLUG (. 206. 217. . 216.00 (2 REQ) PUMP COVER TO PUMP BODY BOLT.D. 322.D. 219. 335. VALVE BORE PLUG RETAINING PIN.120" DIA X 1.320") 2-3 MODUL ATOR VALVE BUSHING 2-3 MODUL ATOR VALVE SPRING 2-3 MODUL ATOR VALVE 2-3 SHIFT VALVE SPRING 2-3 SHIFT VALVE STRAIGHT RETAINING PIN (. 325. 323. 339. 220. 331.) DETENT VALVE DETENT REGUL ATOR VALVE DETENT REGUL ATOR VALVE PIN DETENT REGUL ATOR VALVE SPRING MANUAL VALVE 1-2 MODUL ATOR VALVE BUSHING (SOME MODELS) 1-2 REGUL ATOR VALVE (SOME MODELS) 1-2 REGUL ATOR VALVE SPRING (SOME MODELS) 1-2 DETENT VALVE (SOME MODELS) 324. 344. PRIMARY (SOME MODELS) 1-2 ACCUMULATOR VALVE BUSHING (SOME MODELS) 1-2 ACCUMULATOR VALVE SECONDARY (SOME MODELS) 1-2 ACCUMULATOR VALVE SECONDARY SPRING (SOME) Copyright © 1999 ATSG Figure 32 32 AUTOMATIC TRANSMISSION SERVICE GROUP . 308. 202. 305.

Technical Service Information VALVE BODY ASSEMBLY EXPLODED VIEW Some Models Some Models Copyright © 1999 ATSG Figure 33 AUTOMATIC TRANSMISSION SERVICE GROUP 33 .

705.620" PARKING LOCK BRACKET HEX NUT. 708.Technical Service Information PARK LINKAGE AND ASSOCIATED PARTS EXPLODED VIEW 701. install transmission holding fixture as shown in Figure 35. HD 5/16-18 X . 703. 4. 5/16-18 X . HEX HEAD BOLT. 704. 13. 712. J-3289-20 J-8763-02 Copyright © 1999 ATSG 11. 706. 2. 12. 710. as shown in Figure 36. 709. Remove modulator bracket retaining bolt and modulator bracket as shown in Figure 36. For safety considerations. 702. 14. HEX HEAD BOLT. 713. 3/8-24 MANUAL SHAFT RETAINING PIN MANUAL SHAFT MANUAL SHAFT SEAL INSIDE DETENT LEVER PARKING LOCK ACTUATOR ASSEMBLY PARKING PAWL SHAFT CUP PLUG PARKING PAWL RETURN SPRING PARKING PAWL SHAFT RETAINING CLIP PARKING PAWL SHAFT PARKING PAWL Copyright © 1999 ATSG Figure 34 TRANSMISSION DISASSEMBLY EXTERNAL PARTS 1. 3. 711. 15.620" MODUL ATOR RETAINER VACUUM MODULATOR "O" RING SEAL VACUUM MODULATOR VALVE Copyright © 1999 ATSG Figure 35 Figure 36 34 AUTOMATIC TRANSMISSION SERVICE GROUP . Remove the torque converter. 707. Remove the vacuum modulator and modulator valve from case.

Rear end-play should be . 29. 27. 12.178mm-. 3/8-16 X 1" (6 REQUIRED) EXTENSION HOUSING METAL CLAD SEAL EXTENSION HOUSING ASSEMBLY (MODEL SENSITIVE) BALL BEARING ASSEMBLY (SOME MODELS) BALL BEARING SPACER (SOME MODELS) EXTENSION HOUSING BUS HING INTERNAL SNAP RING (SOME MODELS) EXTENSION HOUSING TO CASE SEAL (SOME MODELS) TRANSMISSION REAR CASE BU SHING EXTENSION HOUSING TO CASE GASKET (SOME MODELS) OUTPUT SHAFT Copyright © 1999 ATSG Figure 37 Figure 39 AUTOMATIC TRANSMISSION SERVICE GROUP 35 .690" (4 REQUIRED) GOVERNOR COVER GOVERNOR COVER GASKET GOVERNOR ASSEMBLY OUTPUT SPEED SENSOR ASSEMBLY (SOME MODELS) SPEED SENSOR "O" RING (SOME MODELS) SPEED SENSOR RETAINING BOLT (SOME MODELS) Figure 38 Some Models 23. 32.483mm (. 10. 82. Remove the six extension housing bolts and remove the extension housing (See Figure 37). 21. as shown in Figure 39. 9. 20. 8.007"-. 5/16-18 X . as shown in Figure 38. GOVERNOR COVER BOLTS. 30. 7. 22. 34. Install dial indicator on the shaft and index it to the end of the output shaft and zero the dial indicator. Remove the speedometer adapter or the output speed sensor. 81. 33. 19. Remove and discard the extension housing seal or gasket (See Figure 37). 83. 26.019") if correct. EXTENSION HOUSING BOLTS. Remove the four governor cover retaining bolts and remove governor assembly with a twisting motion (See Figure 38). 28. Attach J-6125-B to one of the bolt holes at the rear of the case as shown in Figure 39. 11. 31.Technical Service Information 5. 6. Move the output shaft in and out and record the amount of rear end play (See Figure 39). Continued on next Page. whichever it is equipped with.

Front end clearance should be . 16. Rotate transmission and holding fixture so that the bottom pan is facing up (See Figure 41). 17. 18. 39. BOTTOM PAN BOLTS. Pull the turbine shaft forward and record the indicated end-play. DEEP PAN ONLY 45. Remove one oil pump retaining bolt and install J-6125-1 in bolt hole as shown in Figure 40. 14.007"-. Hold output shaft forward while pushing the turbine shaft rearward to its stop. Zero the dial indicator. Figure 40 Deep Pan Components Shallow Pan Components 37. FILTER SPACER. 38. 15.690" BOTTOM TRANSMISSION PAN (SHALLOW OR DEEP) BOTTOM PAN GASKET BOTTOM PAN MAGNET 42.Technical Service Information Continued from Page 35 12. 40. Remove the dial indicator and bolt. 5/16-18 X . 13. FILTER INTAKE PIPE (LONG OR SHORT) Copyright © 1999 ATSG Figure 41 36 AUTOMATIC TRANSMISSION SERVICE GROUP . BOTTOM PAN FILTER ASSEMBLY 43.024". Install dial indicator on bolt and index indicator to flat surface on the end of turbine shaft as shown in Figure 40.

VALVE BODY TO SPACER PLATE GASKET 57. Refer to Figure 41. Remove the 10 remaining valve body bolts but leave the detent solenoid bolts in place. VALVE BODY BOLTS. Remove the two detent solenoid retaining bolts and the detent solenoid. A.620" (10 REQUIRED) 52. Remove the governor pipes from back of the valve body. Remove the retaining bolt and the detent roller and spring assembly (See Figure 42). SPACER PLATE TO CASE GASKET 59. 22. and remove the filter bolt spacer if it is the deep pan model. Remove the intake pipe from the case as shown in Figure 41. Remove the bottom pan bolts and bottom pan. DETENT SOLENOID ASSEMBLY 56. 24. 1/4-20 X . STEEL CHECKBALLS. GOVERNOR FEED AND RETURN PIPES 51. shallow and deep pans. Governor pipes are interchangeable and need not be identified (See Figure 42). DETENT SOLENOID RETAINING BOLTS. . Note: There are two different styles of the bottom pan. 29.875" (1 REQUIRED) 48. Continued on next Page. 26. Set the valve body aside for component rebuild. LOCATED IN CASE 53. Remove the spacer plate and spacer plate to case gasket. 30. remove and discard the filter. as shown in Figure 41. 23. 5/16-18 X 1.250" DIAME TER (6 OR 7 REQUIRED) Copyright © 1999 ATSG Figure 42 AUTOMATIC TRANSMISSION SERVICE GROUP 37 . Remove the governor screen from the case or from the end of the governor feed pipe. as shown in Figure 41. Remove and discard the valve body to spacer plate gasket (See Figure 42).Technical Service Information 19. Remove and discard the bottom pan gasket. 28.750" 54. This affects filter components required for this unit. GOVERNOR SCREEN ASSEMBLY. as shown in Figure 42. Remove the six or seven check balls from the pockets in the case depending on your model. as shown in Figure 42. 20. 5/16-18 X 1. Remove and discard the intake pipe "O" ring. VALVE BODY ASSEMBLY 50. Remove the filter retaining bolt. 31. as shown in Figure 41. 21. VALVE BODY SPACER PLATE 58. 47. 25. GUIDE PINS. Remove the valve body and the governor pipes as an assembly (See Figure 42). VALVE BODY BOLTS. 27. 32. MANUAL DETENT ROLLER AND SPRING ASSEMBLY 49.

73. FRONT SERVO PISTON FRONT SERVO RING FRONT SERVO PISTON PIN FRONT SERVO PISTON SPRING RETAINER FRONT SERVO PISTON SPRING FRONT SERVO PISTON Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 43 Figure 44 38 AUTOMATIC TRANSMISSION SERVICE GROUP . 70. 62. Remove the 1-2 accumulator piston from the inside of the reverse servo piston. 37. 77. Remove the reverse servo piston assembly and remove and discard servo piston seal. 72. 67. 74. 76. Remove the 1-2 accumulator spring from the transmission case bore (See Figure 43). 69. 75. as shown in 46. as shown in Figure 45. 66. Remove the oil pump retaining bolts as shown in Figure 45. 85. 38. Install pump remover J-24773-A. Remove the six retaining bolts for the reverse servo cover (See Figure 43). Remove the reverse servo cover. 41. 35. 34. 71. 40. 68. 39. 65.Technical Service Information Continued from Page 37 33. 64. 5/16-18 X . REAR SERVO COVER RETAINING BOLTS. 61. 36. Remove the front servo components from the case as shown in Figure 44. remove and discard the reverse servo cover gasket as shown in Figure 43. 63. as shown in Figure 43. or use slide hammers to remove pump. Rotate the transmission so that the oil pump is facing up. 78. as shown in Figure 43.620" REVERSE SERVO COVER REVERSE SERVO COVER GASKET REVERSE SERVO PISTON RETAINING "E" CLIP REVERSE SERVO PISTON REVERSE SERVO PISTON SEAL 1-2 ACCUMULATOR PISTON OUTER SEAL RING 1-2 ACCUMULATOR PISTON 1-2 ACCUMULATOR PISTON INNER SEAL RING REVERSE SERVO PISTON WASHER REVERSE SERVO PISTON SPRING REVERSE SERVO PISTON SPRING RETAINER REVERSE SERVO BAND APPLY PIN (SELECTIVE) 1-2 ACCUMULATOR SPRING 60.

Figure 46 FORWARD CLUTCH HOUSING 4.406" COMPLETE OIL PUMP ASSEMBLY OIL PUMP TO CASE "D" RING SEAL OIL PUMP COVER TO CASE GASKET PUMP COVER TO FWD DRUM THRUST WASHER (SELECTIVE) Copyright © 1999 ATSG Figure 45 Figure 47 AUTOMATIC TRANSMISSION SERVICE GROUP 39 . Remove the oil pump to forward drum thrust washer which is selective (See Figure 45). OIL PUMP RETAINING BOLTS. 45. 48. 47. Set the complete forward clutch drum aside for component rebuild later. 7. 46. as shown in Figure 45. 8. Remove the forward clutch drum complete by lifting straight up on the turbine shaft as shown in Figure 47. 43. Remove and discard the oil pump cover to case gasket. Remove and discard the oil pump to case "D" ring seal (See Figure 45). 5/16-18 X 1.Technical Service Information 42. Continued on next Page. 6. Set the complete oil pump assembly aside for component rebuild later. Remove the oil pump assembly from the case as shown in Figure 45. 207. 44.

50. The waved plate is used only on some models (See Figure 49). 56. 52. 641. and lift the entire gear train out of the transmission case. for disassembly of gear train. Set the entire gear train into holding fixture J-6116-01 using adapter J-21364-A. Remove the center support feed and retaining bolt using a 12 point socket (See Figure 50). Remove the intermediate clutch backing plate snap ring from the groove in case using large screwdriver (See Figure 49). Remove the intermediate clutch waved plate. 53. INTERMEDIATE CLUTCH BACKING PLATE SNAP RING INTERMEDIATE CLUTCH BACKING PLATE INTERMEDIATE CLUTCH LINED PLATES INTERMEDIATE CLUTCH STEEL PLATES (FLAT) INTERMEDIATE CLUTCH WAVED PLATE (SOME MODELS) Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 48 Figure 49 40 AUTOMATIC TRANSMISSION SERVICE GROUP . Remove the intermediate clutch backing plate from the case (See Figure 49). 643. as shown in Figure 51. Remove the intermediate clutch plates both lined and steel (See Figure 49). 644. Remove the lifting tool from gear train. 57. DIRECT CLUTCH HOUSING MANUAL 2ND BAND SOME MODELS 640. 59. 58. Remove the manual 2 band from the band lug and remove from case (See Figure 48). if it is present. 55. 642. as shown in Figure 52. Continued on Page 42. as shown in Figure 48.Technical Service Information Continued from Page 39 49. 51. Install lifting tool J-21795-02 onto the gear train. 54. Set the complete direct clutch housing aside for component rebuild later. Remove the direct clutch housing by lifting straight up.

691. 693. 698. CENTER SUPPORT ASSEMBLY REACTION CARRIER ASSEMBLY OUTPUT CARRIER ASSEMBLY OUTPUT SHAFT ASSEMBLY SPEEDOMETER DRIVE GEAR (MODEL SENSITIVE) SPEED SENSOR ROTOR (SOME MODELS) Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 51 Figure 52 AUTOMATIC TRANSMISSION SERVICE GROUP 41 . 666.Technical Service Information CENTER SUPPORT BOLT Figure 50 J-21795-02 LIFTING TOOL SOME MODELS J-21364-A ADAPTER J-6116-01 FIXTURE 654. 675.

Technical Service Information
Continued from Page 40 60. Remove the reverse band assembly from the transmission case, as shown in Figure 53. 61. Remove the bronze output shaft thrust washer from the case, if it is not stuck on the output shaft (See Figure 53). 62. Remove the steel selective thrust washer from the back of case, as shown in Figure 53. TRANSMISSION CASE 1. Clean all parts and components thoroughly and dry with compressed air. 2. The assembly of some components will require the use of an assembly lube. It is recommended that TransJelä be used during assembly. Note: "Do Not" use any type of grease to retain parts during assembly of this unit. Grease other than the recommended assembly lube may create undesirable shift concerns and/or filter clogging. 3. Inspect the transmission case for the following: Case for cracks, porosity or worm track damage. Scored bushing. All threaded holes for damage. Air check all fluid passages. Front and rear servo bores for porosity, burrs or any damage. Cooler line fittings for damage and proper torque, 38 Nm (28 ft. lb.). Intermediate clutch plate lugs for damage. Snap ring grooves for damage. Governor and modulator bores for damage. Case center support area for damage or wear.
REVERSE BAND BRONZE OUTPUT SHAFT THRUST WASHER STEEL THRUST WASHER (SELECTIVE)

COMPONENT REBUILD

End Transmission Disassembly

Copyright © 1999 ATSG

4. It is not necessary to remove the park linkage from the transmission case, but is necessary to inspect all related parts closely. However if the parts have been removed use the following procedure for installation. 5. Install the parking pawl into case, and while holding in proper position, install parking pawl pin through case bore through hole in parking pawl (See Figures 54 and 55). 6. Install parking pawl shaft cup plug into case bore using pin punch (See Figures 54 and 55). 7. Install the retaining clip into the groove in the parking pawl shaft (See Figures 54 and 55). 8. Install the parking pawl return spring. 9. Install a new manual shaft seal into the case bore using a 1/2" deep socket (See Figure 54). 10. Install the manual shaft through the seal and into the case bore (See Figure 54). 11. Install the manual shaft retaining pin (Nail) into hole in case and through groove in shaft. 12. Install the park actuator rod (708) into inside detent lever (707), and install the assembly on the manual shaft and over the parking pawl, as shown in Figure 55.

Figure 53

42

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information
13. Ensure that the flats in the inside detent lever are engaged with the flats on the manual shaft as shown in Figure 55. 14. Install the 3/8-24 nut onto the manual shaft and tighten securly (See Figures 54 and 55). 15. Install the parking lock bracket using the two bolts, as shown in Figure 55. 16. Torque the parking lock bolts to 17 ft. lb. COMPONENT REBUILD Continued on next Page.
701. 702. 703. 704. 705. 706. 707. 708. 709. 710. 711. 712. 713. HEX HEAD BOLT, HD 5/16-18 X .620" PARKING LOCK BRACKET HEX NUT, 3/8-24 MANUAL SHAFT RETAINING PIN MANUAL SHAFT MANUAL SHAFT SEAL INSIDE DETENT LEVER PARKING LOCK ACTUATOR ASSEMBLY PARKING PAWL SHAFT CUP PLUG PARKING PAWL RETURN SPRING PARKING PAWL SHAFT RETAINING CLIP PARKING PAWL SHAFT PARKING PAWL

Copyright © 1999 ATSG

Figure 54 PARK LINKAGE AND ASSOCIATED PARTS EXPLODED VIEW

701. 702. 703. 704. 705. 706. 707. 708. 709. 710. 711. 712. 713.

HEX HEAD BOLT, HD 5/16-18 X .620" PARKING LOCK BRACKET HEX NUT, 3/8-24 MANUAL SHAFT RETAINING PIN MANUAL SHAFT MANUAL SHAFT SEAL INSIDE DETENT LEVER PARKING LOCK ACTUATOR ASSEMBLY PARKING PAWL SHAFT CUP PLUG PARKING PAWL RETURN SPRING PARKING PAWL SHAFT RETAINING CLIP PARKING PAWL SHAFT PARKING PAWL Copyright © 1999 ATSG

Figure 55

AUTOMATIC TRANSMISSION SERVICE GROUP

43

Technical Service Information
Continued from Page 43 GEAR TRAIN AND RELATED PARTS 1. Disassemble the gear train parts from the bench fixture using Figure 56 as a guide. 2. Clean all parts and components thoroughly and dry with compressed air. 3. Check all parts and components thoroughly for any damage and/or wear patterns. This includes all bushings, thrust washers and needle bearings and races. (Refer to Figure 56).

COMPONENT REBUILD

4. Measure reaction carrier planetary pinion end play using a feeler guage (See Figure 57). 5. Measure output carrier planetary pinion end play using a feeler guage (See Figure 57). 6. Both planetary carriers should measure between .228mm-.610mm (.009"-.024"). 7. If removed, install the transmission main shaft into the ring gear as shown in Figure 58. 8. Install the main shaft retaining snap ring into the groove in main shaft and ensure that it is fully seated (See Figure 58).

GEAR TRAIN AND ASSOCIATED PARTS EXPLODED VIEW

657. 658. 659. 660. 661. 662. 663. 664. 665. 666. 667. 668. 669. 670. 671. 672. 673. 674. 675.

CENTER SUPPORT TO CASE FRETTING RING (SOME MODELS) LOW ROLLER CLUTCH ASSEMBLY REAR REACTION DRUM SPACER (FOR ROLLER CLUTCH ASM) CENTER SUPPORT TO NEEDLE BEARING RACE CENTER SUPPORT NEEDLE BEARING ASSEMBLY CENTER SUPPORT NEEDLE BEARING TO SUN GEAR RACE SUN GEAR SHAFT BUSHINGS ( 2 REQUIRED) SUN GEAR SHAFT ASSEMBLY SUN GEAR REACTION DRUM AND INPUT CARRIER ASSEMBLY PINION GEAR STEEL THRUST WASHERS PINION GEAR ROLLER NEEDLE BEARINGS INPUT CARRIER PINION GEARS PINION GEAR BRONZE THRUST WASHER PINION GEAR PINS REVERSE BAND ASSEMBLY FRONT INTERNAL RING GEAR SILENCI NG RING OUTPUT CARRIER TO REACTION CARRIER THRUST WASHER OUTPUT CARRIER ASSEMBLY

676. 677. 678. 679. 680. 681. 682. 683. 684. 685. 686. 687. 688. 689. 690. 691. 692. 693. 694. 695. 696. 697. 698.

PINION GEAR BRONZE THRUST WASHER PINION GEAR STEEL THRUST WASHER PINION GEAR ROLLER NEEDLE BEARINGS OUTPUT CARRIER PINION GEARS PL ANETARY PINION GEAR PINS TRANSMISSION MAIN SHAFT TO RING GEAR SUN GEAR TO NEEDLE BEARING RACE SUN GEAR NEEDLE BEARING ASSEMBLY NEEDLE BEARING TO REAR RING GEAR RACE REAR INTERNAL RING GEAR REAR RING GEAR TO NEEDLE BEARING RACE REAR RING GEAR NEEDLE BEARING ASSEMBLY NEEDLE BEARING TO OUTPUT SHAFT RACE MAIN SHAFT/REAR RING GEAR SNAP RING OUTPUT SHAFT BUSHING OUTPUT SHAFT (MODEL SE NSITIVE, SEE FIGURE 26) SPEEDOMETER DRIVE GEAR RETAINING CLIP SPEEDOMETER DRIVE GEAR (MODEL SENSITIVE) OUTPUT SHAFT/OUTPUT CARRIER S NAP RING OUTPUT SHAFT TO CASE BRONZE THRUST WASHER OUTPUT SHAFT TO CASE STEEL THRUST WASHER (SELECTIVE) OUTPUT SHAFT "O" RING SEAL (SOME MODELS) OUTPUT SHAFT SPEED SENSOR ROTOR (SOME MODELS)

Figure 56

44

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information 9. 10. Install the upper needle bearing race on top of the needle bearing with the inside lip facing down. as shown in Figure 59. Lubricate with small amount of transmission fluid and install the needle bearing assembly into the lower race (See Figure 59). OEM Part No's 8623920. and 8623922 in the gear train assembly. SNAP RING Copyright © 1999 ATSG FEELER GUAGE Figure 58 OEM PART NO. 8623921. 11.024" REACTION CARRIER FEELER GUAGE Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 57 Figure 59 AUTOMATIC TRANSMISSION SERVICE GROUP 45 .009"-. Install the lower needle bearing race from the 8623921 package over the main shaft and onto the ring gear with the lip facing up. MAIN SHAFT RING GEAR Continued on Page 46. It is highly recommended to install new needle bearings. as shown in Figure 59. 12. 8623921 OUTPUT CARRIER Both Carriers Should Measure .

20. Retain the output shaft thrust washer with a small amount of TransJelä. 16. Install the main shaft and ring gear assembly into and through the output carrier. 18. as shown in Figure 62. Install the upper needle bearing race from the 8623922 package over the ring gear snout with the inside lip facing away from the ring gear as shown in Figure 60. as shown in Figure 60. and retain with a small amount of TransJelä. and retain with a small amount of TransJelä. Install the output shaft retaining snap ring into the groove in the output carrier (See Figure 62). as shown in Figure 60. 14. and ensure that the bearing on back side of ring gear is still in the proper position. 15. OEM PART NO. 8623922 Copyright © 1999 ATSG Figure 60 OUTPUT SHAFT Continued on Page 48. Install the output shaft thrust washer onto the output shaft and ensure that the tabs engage in the holes in output shaft (See Figure 61). Set the entire assembly into the bench fixture as shown in Figure 63. to finish the assembly process for the geartrain. Install the lower needle bearing race on top of the needle bearing with the inside lip facing up. 17. 19. Install the needle bearing assembly onto the upper race and retain with a small amount of TransJelä. Install the output shaft assembly into the output carrier as shown in Figure 62.Technical Service Information Continued from Page 45 13. 21. OUTPUT SHAFT THRUST WASHER OUTPUT SHAFT "O" RING Copyright © 1999 ATSG Figure 61 46 AUTOMATIC TRANSMISSION SERVICE GROUP .

Technical Service Information OUTPUT CARRIER ASSEMBLY MAIN SHAFT AND RING GEAR ASSEMBLY OUTPUT SHAFT ASSEMBLY J-21364-A ADAPTER J-6116-01 FIXTURE OUTPUT SHAFT SNAP RING Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 62 Figure 63 AUTOMATIC TRANSMISSION SERVICE GROUP 47 .

23. Install the reaction carrier to output carrier thrust washer. 24.Technical Service Information SILENCER RING REACTION CARRIER TO OUTPUT CARRIER THRUST WASHER Continued from Page 46 22. Install the sun gear over the main shaft and into the output carrier by rotating into position. ensuring that the tabs engage in the holes in output carrier. Install the sun gear shaft into the splines of the sun gear. with inside chamfer down as shown in Figure 64. SUN GEAR FLAT SIDE FACES UP SUN GEAR SHAFT CHAMFER FACES DOWN Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 64 Figure 65 48 AUTOMATIC TRANSMISSION SERVICE GROUP . Refer to Figures 64 and 65. and retain with a small amount of TransJelä (See Figure 64). as shown in Figures 65 and 66. 25. Install the silencing ring over the top side of the output carrier.

If it was removed. 30. Install the lo-roller clutch assembly down into the reaction carrier by aligning the notches in the roller clutch cage with the notches in the reaction carrier (See Figures 67 and 68). install the lo-roller clutch spacer down into the reaction carrier assembly. 8623920 LO ROLLER CLUTCH ASSEMBLY LO ROLLER CLUTCH SPACER REACTION CARRIER ASSEMBLY Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 66 Figure 67 AUTOMATIC TRANSMISSION SERVICE GROUP 49 . ensuring that it is fully seated. 29. Continued on Page 50. as shown in Figure 67. OEM PART NO. 27. Install the lower needle bearing race from the 8623920 package over the sun gear shaft and onto the sun gear. with the inside lip facing up as shown in Figure 66. up as shown in Figure 66. Install the upper needle bearing race on top of the needle bearing with the inside lip facing. Lubricate with small amount of transmission fluid and install the needle bearing assembly into the lower race (See Figure 66). 28.Technical Service Information 26.

Inspect all center support components for any wear and/or damage. 37. in the direction shown in Figure 69. Clean all center support parts thoroughly. and dry with compressed air. 32.Technical Service Information Continued from Page 49 31. Note: Some models have a stamped steel piston which requires a return spring guide. Ensure that orificed cup plug is in place. in the direction shown in Figure 69. 33. Install a new intermediate clutch outer lip seal into the groove in the piston. 34. Install the completed reaction carrier into the sun gear and ring gear by rotating the sun gear shaft until it is fully seated (See Figure 68). Install a new intermediate clutch inner lip seal into the groove in the piston. Disassemble the center support assembly using Figure 69 as a guide. 36. INTERMEDIATE CLUTCH RETAINER SNAP RING INTERMEDIATE CLUTCH SPRING RETAINER REACTION CARRIER ASSEMBLY INTERMEDIATE CLUTCH RETURN SPRINGS SOME MODELS INTERMEDIATE CLUTCH PISTON INTERMEDIATE CLUTCH OUTER LIP SEAL INTERMEDIATE CLUTCH INNER LIP SEAL CENTER SUPPORT ORIFICED CUP PLUG Copyright © 1999 ATSG CENTER SUPPORT THRUST WASHER Copyright © 1999 ATSG Figure 68 Figure 69 50 AUTOMATIC TRANSMISSION SERVICE GROUP . as shown in Figure 69. 35.

INTERMEDIATE CLUTCH RETAINER SNAP RING INTERMEDIATE CLUTCH SPRING RETAINER INTERMEDIATE CLUTCH RETURN SPRINGS CENTER SUPPORT ASSEMBLY Copyright © 1999 ATSG Figure 71 INTERMEDIATE CLUTCH PISTON ASSEMBLY CENTER SUPPORT THRUST WASHER J-21363 LIP SEAL PROTECTOR CENTER SUPPORT ASSEMBLY ENSURE THAT ORIFICE CUP PLUG IS IN PLACE Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 70 Figure 72 AUTOMATIC TRANSMISSION SERVICE GROUP 51 . Compress the spring retainer with proper spring compressor and install the snap ring using pair of snap ring pliers (See Figure 71). and retain with TransJelä. 39. Install the return springs into the intermediate piston so that they are equally spaced around the piston (See Figure 71). as shown in Figure 70. Install J-21363 lip seal protector over the center support. 43. as shown in Figure 72. Continued on Page 53. Ensure that the orificed cup plug is in place. 44. shown in Figure 72. Install four new sealing rings into the grooves in the center support (See Figure 69). 45. 41. 42. Lubricate both lip seals and install intermediate clutch piston assembly over the seal protector and into the center support (See Figure 70).Technical Service Information 38. Turn the completed center support assembly over and install the brass thrust washer. 40. Install the intermediate clutch return spring retainer as shown in Figure 71.

Technical Service Information COMPLETED CENTER SUPPORT ASSEMBLY LIFTING TOOL Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 73 Figure 74 52 AUTOMATIC TRANSMISSION SERVICE GROUP .

DIRECT CLUTCH HOUSING 619. 629. 624. 620. 4. 630. RETURN SPRING RETAINER 633. 621. 637. 3. 625. 634. Continued on Page 54. 631. RETURN SPRING RETAINER SNAP RING 626. 632. 627. Install the completed center support assembly by rotating clockwise and turning the sun gear shaft. 626. to prepare for final assembly. 633. 636. 635. Refer to Figure 73. Clean all direct clutch parts thoroughly and dry with compressed air. Disassemble the direct clutch housing using a spring compressor. and use Figure 76 as a guide for disassembly. as shown in Figure 75.Technical Service Information Continued from Page 51 46. 47. Inspect all direct clutch parts thoroughly for any wear and/or damage. 623. 622. Install the lifting tool onto the completed gear train assembly. 638. 625. until the center support is fully seated. Also notice in Figure 76 that some models use a direct clutch waved plate and some do not. Notice in Figure 76 that some models use an intermediate roller clutch and some models use an intermediate sprag assembly. DIRECT CLUTCH HOUSING 1. 5. as shown in Figure 74. 2. DIRECT CLUTCH BACKING PLATE SNAP RING DIRECT CLUTCH BACKING PLATE DIRECT CLUTCH LINED PLATES (MODEL SENSITIVE) DIRECT CLUTCH STEEL PLATES (MODEL SENSITIVE) DIRECT CLUTCH WAVED PLATE (SOME MODELS) DIRECT CLUTCH DISHED PLATE (SOME MODELS) DIRECT CLUTCH RETURN SPRING RETAINER SNAP RING DIRECT CLUTCH RETURN SPRING RETAINER DIRECT CLUTCH PISTON RETURN SPRINGS DIRECT CLUTCH PISTON DIRECT CLUTCH PISTON INNER LIP SEAL DIRECT CLUTCH PISTON OUTER LIP SEAL DIRECT CLUTCH HOUSING INNER LIP SEAL DIRECT CLUTCH HOUSING INTERMEDIATE ROLLER CLUTCH ASSEMBLY (SOME MODELS) INTERMEDIATE SPRAG CLUTCH ASSEMBLY (SOME MODELS) INTERMEDIATE FREEWHEEL OUTER RACE INTERMEDIATE FREEWHEEL OUTER RACE RETAINER INTERMEDIATE FREEWHEEL RETAINER SNAP RING Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 75 Figure 76 AUTOMATIC TRANSMISSION SERVICE GROUP 53 .

010" per lined plate. Note: Direct clutch clearance should measure approximately . with lip facing the direction shown in Figure 79. 625. 10. Compress the spring retainer and return springs and install the snap ring. Install new direct clutch piston inner lip seal in groove of direct clutch piston. as shown in Figure 80. Install the direct clutch backing plate with flat side down. Lubricate both seals with a small amount of TransJelä. 638. 630. 11. 621. 8. Install the waved plate or the cushion plate. 634. Install new direct clutch piston outer lip seal in groove of direct clutch piston. Install outer lip seal protector J-21409 into the direct drum as shown in Figure 78. Install the direct clutch return spring retainer on top of the springs. 633. Install the direct clutch piston assembly into the direct clutch housing using a twisting motion as shown in Figure 78. DIRECT CLUTCH BACKING PLATE SNAP RING DIRECT CLUTCH BACKING PLATE DIRECT CLUTCH LINED PLATES (MODEL SENSITIVE) DIRECT CLUTCH STEEL PLATES (MODEL SENSITIVE) DIRECT CLUTCH RETURN SPRING RETAINER SNAP RING DIRECT CLUTCH RETURN SPRING RETAINER DIRECT CLUTCH PISTON RETURN SPRINGS DIRECT CLUTCH PISTON DIRECT CLUTCH PISTON INNER LIP SEAL DIRECT CLUTCH PISTON OUTER LIP SEAL DIRECT CLUTCH HOUSING INNER LIP SEAL DIRECT CLUTCH HOUSING INTERMEDIATE ROLLER CLUTCH ASSEMBLY (SOME MODELS) INTERMEDIATE SPRAG CLUTCH ASSEMBLY (SOME MODELS) INTERMEDIATE FREEWHEEL OUTER RACE INTERMEDIATE FREEWHEEL OUTER RACE RETAINER INTERMEDIATE FREEWHEEL RETAINER SNAP RING J-21362 DIRECT CLUTCH PISTON J-21409 DIRECT CLUTCH HOUSING Copyright © 1999 ATSG Figure 77 Figure 78 54 AUTOMATIC TRANSMISSION SERVICE GROUP . Install the 14 direct clutch piston return springs into the cavities in the piston in the positions shown in Figure 79. 9. 632.Technical Service Information Continued from Page 53 6. as shown in Figure 80. 631. with the lip facing the direction shown in Figure 79. Install new direct drum lip seal into the groove in direct drum. 629. Note: Some models use a stamped steel direct clutch piston and spacer (See Figure 79). 619. Install the direct clutch backing plate snap ring and ensure that it is seated in groove. using the compressor as shown in Figure 75. 15. 18. with lip facing the direction shown in Figure 79. 620. 636. 12. Continued on Page 56. 637. 635. and lubricate with a small amount of TransJelä. as shown in Figure 80. 14. Install inner lip seal protector J-21362 on the hub of direct drum (See Figure 78). 627. 622. 17. 626. 5 or 6 lined plates depending on the specific model. leaving two blank pockets 180 degrees from one another. 19. 13. Install the direct clutches beginning with a steel plate and alternating with a friction plate. Note: The direct clutch may use 4. 7. and lay the snap ring on top of the retainer (See Figure 79). 16. as shown in Figure 80.

Technical Service Information DIRECT CLUTCH SPRING RETAINER SNAP RING DIRECT CLUTCH SPRING RETAINER DIRECT CLUTCH RETURN SPRINGS DIRECT CLUTCH BACKING PLATE BACKING PLATE SNAP RING BLANK STEEL PISTON AND SPACER (SOME MODELS) BLANK DIRECT CLUTCH PISTON DIRECT CLUTCH STEEL PLATES DIRECT CLUTCH LINED PLATES DIRECT CLUTCH WAVED PLATE DIRECT PISTON INNER LIP SEAL DIRECT PISTON OUTER LIP SEAL DIRECT CLUTCH CUSHION PLATE DIRECT CLUTCH DRUM LIP SEAL DIRECT CLUTCH DRUM ASSEMBLY SOME MODELS DIRECT CLUTCH DRUM ASSEMBLY Note: The number of lined and steel plates used will vary. Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 79 Figure 80 AUTOMATIC TRANSMISSION SERVICE GROUP 55 . depending on specific model.

Set the direct clutch housing assembly aside for the final assembly process. Turn the direct clutch housing over as shown in Figures 82 and 83. 23. 634. as shown in Figure 81. 638. 637.Technical Service Information MUST FREEWHEEL CLOCKWISE Continued from Page 54 20. "SPRAG" STYLE DIRECT CLUTCH HOUSING 638 638 637 637 636 Copyright © 1999 ATSG Figure 81 "ROLLER" STYLE DIRECT CLUTCH HOUSING 636 634 INSTALL WITH OUTSIDE LIP FACING DOWN AS SHOWN 633 635 633 633. 637. There are 2 different styles of direct clutch housings. After assembly. DIRECT CLUTCH HOUSING. check the outer race for proper freewheel direction. 21. and one for the "Roller Clutch" as shown below. Use Figure 82 to assemble the "Roller Clutch" style freewheel and use Figure 83 to assemble "Sprag" style intermediate freewheel. 636. one for the "Sprag" style freewheel. 638. 635. 636. DIRECT CLUTCH HOUSING FOR INTERMEDIATE SPRAG INTERMEDIATE "SPRAG" AND END BEARING ASSEMBLY INTERMEDIATE SPRAG OUTER RACE INTERMEDIATE SPRAG OUTER RACE RETAINER INTERMEDIATE SPRAG OUTER RACE RETAINER SNAP RING Figure 82 Figure 83 56 AUTOMATIC TRANSMISSION SERVICE GROUP . 22. INTERMEDIATE ROLLER CLUTCH INTERMEDIATE "ROLLER CLUTCH" ASSEMBLY INTERMEDIATE ROLLER CLUTCH OUTER RACE INTERMEDIATE ROLLER CLUTCH OUTER RACE RETAINER INTERMEDIATE ROLLER OUTER RACE RETAINER SNAP RING Copyright © 1999 ATSG 633.

TURBINE SHAFT (MODEL SENSITIVE) FORWARD CLUTCH HOUSING FORWARD CLUTCH HOUSING CENTER LIP SEAL FORWARD CLUTCH PISTON OUTER LIP SEAL FORWARD CLUTCH PISTON INNER LIP SEAL FORWARD CLUTCH PISTON FORWARD CLUTCH PISTON RETURN SPRINGS FORWARD CLUTCH PISTON RETURN SPRING RETAINER RETURN SPRING RETAINER SNAP RING FORWARD CLUTCH WAVED PLATE (SOME MODELS) FORWARD CLUTCH DISHED CUSHION PLATE (SOME MODELS) FORWARD CLUTCH FLAT STEEL PLATES FORWARD CLUTCH FRICTION PLATES FORWARD CLUTCH HUB TO FWD. 604. Clean all forward clutch parts thoroughly and dry with compressed air. 612. 607. Disassemble the forward clutch housing using Figure 84 as a guide. 2. Set the forward clutch housing into the bench fixture J-6116-01. Inspect all forward clutch parts thoroughly for any wear and/or damage. compress the forward clutch return springs and retainer and remove the snap ring (See Figure 85). 609. 3. 7. 603. HOUSING THRUST WASHER FORWARD CLUTCH HUB FORWARD CLUTCH HUB TO DIR. Continued on Page 58. Some models also use the stamped steel piston with the selective spacer. 614. 605. Notice in Figure 84 that some models use a waved plate and some models use the dished cushion plate. 602. 616. Using a sutiable spring compressor. 615. 606. 613. 611. 4. remove and discard all lip seals. as shown in Figure 85. 618. 619. 6.Technical Service Information COMPONENT REBUILD (Cont'd) FORWARD CLUTCH HOUSING 1. HOUSING THRUST WASHER DIRECT CLUTCH HUB/FORWARD BACKING PLATE DIRECT CLUTCH HUB/FORWARD BACKING PLATE SNAP RING COMPRESSOR J-23327-1 J-25018-A SNAP RING J-6116-01 FIXTURE FORWARD CLUTCH HOUSING Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 84 Figure 85 AUTOMATIC TRANSMISSION SERVICE GROUP 57 . 608. 601. 617. 5.

13. Install forward clutch return spring retainer on top of the springs. 14. Notice that there were added oil passages in the 1967 and later model units and also notice the difference in the oil passages between "Fixed" stator turbine shafts and the "Variable" stator turbine shafts. and lubricate with a small amount of TransJelä. 16. FIXED STATOR DESIGN VARIABLE STATOR DESIGN 1966 MODEL TURBINE SHAFTS FIXED STATOR DESIGN VARIABLE STATOR DESIGN 1967 AND LATER MODEL TURBINE SHAFTS Figure 86 Copyright © 1999 ATSG 58 AUTOMATIC TRANSMISSION SERVICE GROUP . 11. Note: Some models use stamped steel forward clutch piston and spacer (See Figure 87). Install inner lip seal protector J-21362 on the hub of forward drum (See Figure 88).Technical Service Information Continued from Page 57 8. 17. Refer to Figure 86. Install outer lip seal protector J-21409 into the forward drum as shown in Figure 88. with the lip facing in the direction shown in Figure 87. with the lip facing the direction shown in Figure 87. 10. with the lip facing in the direction shown in Figure 87. Install new forward center drum lip seal into the groove in forward drum. Install forward clutch piston assembly into the forward clutch housing using a twisting motion as shown in Figure 88. 15. 9. and lay the snap ring on top of the retainer (See Figure 89). There are also several different turbine shafts for this transmission as shown in Figure 86. Continued on Page 59. Lubricate both seals with a small amount of TransJelä. Install 14 forward clutch piston return springs into the cavities in the piston in the positions shown in Figure 87. Install new forward clutch piston inner lip seal in groove of forward clutch piston. leaving two blank pockets 180 degrees from one another. 12. Install new forward clutch piston outer lip seal in groove of forward clutch piston.

Technical Service Information FORWARD CLUTCH SPRING RETAINER SNAP RING FORWARD CLUTCH SPRING RETAINER FORWARD CLUTCH RETURN SPRINGS Continued from Page 58 18. using the compressor as shown in Figure 89. Compress the spring retainer and return springs and install the snap ring. Continued on Page 61. STEEL PISTON AND SPACER (SOME MODELS) BLANK J-21362 FORWARD CLUTCH PISTON BLANK FORWARD CLUTCH PISTON J-21409 FORWARD PISTON INNER LIP SEAL FORWARD CLUTCH HOUSING FORWARD PISTON OUTER LIP SEAL Copyright © 1999 ATSG Figure 88 FORWARD DRUM CENTER LIP SEAL COMPRESSOR J-23327-1 J-25018-A SNAP RING J-6116-01 FIXTURE FORWARD CLUTCH HOUSING FORWARD CLUTCH DRUM ASSEMBLY Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 87 Figure 89 AUTOMATIC TRANSMISSION SERVICE GROUP 59 .

depending on specific model.Technical Service Information BACKING PLATE SNAP RING DIRECT CLUTCH HUB AND FORWARD CLUTCH BACKING PLATE FORWARD STEEL PLATES FORWARD LINED PLATES FORWARD STEEL PLATES FORWARD LINED PLATES FORWARD CUSHION PLATE FORWARD WAVED PLATE "FIBER" THRUST WASHER FORWARD CLUTCH HUB "BRONZE" THRUST WASHER Note: The number of lined and steel plates used will vary. FORWARD CLUTCH DRUM ASSEMBLY Copyright © 1999 ATSG Figure 90 60 AUTOMATIC TRANSMISSION SERVICE GROUP .

Technical Service Information Continued from Page 59 19.020" BETWEEN VALVE & SLEEVE WEIGHTS EXTENDED WEIGHTS INWARD Figure 91 GOVERNOR ASSEMBLY EXPLODED VIEW 401. 407. 26. Install the direct clutch hub/forward backing plate as shown in Figure 90. even though no parts are available except the driven gear. Continued on Page 62.020" clearance. 402. 404. 21. 403. 409. as shown in Figure 90. and retain with TransJelä. 23. Set the completed forward clutch housing aside for final assembly process. as shown in Figure 90.020" BETWEEN VALVE & SLEEVE . as shown in Figure 90. 3. 25. Refer to Figure 90. GOVERNOR THRUST CAP GOVERNOR VALVE GOVERNOR SPRINGS GOVERNOR SECONDARY WEIGHTS GOVERNOR PRIMARY WEIGHTS GOVERNOR PINS GOVERNOR SLEEVE AND CARRIER ASSEMBLY GOVERNOR GEAR RETAINING PIN GOVERNOR DRIVEN GEAR Copyright © 1999 ATSG Figure 92 AUTOMATIC TRANSMISSION SERVICE GROUP 61 . 406. Note: The forward clutch may use 4 or 5 lined plates depending on the specific model.010" per lined plate. Measure between valve and sleeve at exhaust passage with the weights full inward for . 24. Install the forward clutch hub with both thrust washers into the forward clutch housing. depending on the model as shown in Figure 90.020" clearance. COMPONENT REBUILD (Cont'd) GOVERNOR ASSEMBLY 1. and retain with small amount of TransJelä. 408. Measure between valve and sleeve at the entry passage with the weights extended for . Install forward clutch backing plate snap ring and ensure that it is seated in groove. clutch clearance should measure approximately . 20. 2. Note: Fwd. . 22. Install the bronze thrust washer onto the back side of the forward clutch hub. Install the fiber thrust washer onto the top side of forward clutch hub. Install the forward clutches using Figure 90 as a guide as the stack-up is different. We have provided you an exploded view of the governor assembly in Figure 92. depending on the model you are building. as shown in Figure 91. 405. Install the waved plate or the cushion plate. as shown in Figure 91.

Drill new 1/8 in. This clearance is shown as Dimension "A" in Figure 95. 5. Disassemble the oil pump by removing the five pump cover to pump body bolts. Install new converter helix seal using proper seal driver to prevent damage. 7. 13. 11. Before removing the pump inner and outer gear from the pump body. 9. Remove the inner and outer oil pump gears from the pump body (See Figure 94).Technical Service Information Continued from Page 61 4. Inspect the weights for free movement on the pins and for free movement of the governor valve in the sleeve. Remove and discard the converter helix seal using a seal remover tool (See Figure 94). Install the outer and inner pump gears into the pump body with previous marks facing up.125") hole in the sleeve and carrier assembly and governor driven gear that is 180 degrees from the original hole as shown in Figure 93. 8. 1/8" DRILL BIT GOVERNOR DRIVEN GEAR Copyright © 1999 ATSG Figure 93 Continued on Page 64. 12. remove the roll pin (408) and the governor driven gear (See Figure 92).0026"). 2.0007"-. Caution: Clearance here is critical and should be . Re-install outer and inner pump gears in proper direction with marks facing up. 10. Measure the clearance between the pump gears and the face of the pump body. 6.018mm-. Note: Do Not torque at this time. Set the completed governor assembly aside for the final assembly process. Install finger tight only.066mm (. COMPONENT REBUILD (Cont'd) OIL PUMP ASSEMBLY 1. 14. Remove both pump gears and install new pump body bushing as necessary (See Figure 94). Remove the pressure regulator retaining snap ring. Clean all oil pump parts thoroughly and dry with compressed air. Install the roll pin into the new 1/8" hole. Install new governor driven gear into governor sleeve and carrier assembly (See Figure 92). Use caution when removing the snap ring. as shown in Figure 94. as shown in Figure 94. 6. 62 AUTOMATIC TRANSMISSION SERVICE GROUP . 4. as shown in Figure 95. Install the pump cover onto the pump body and install the five retaining bolts in their proper locations as shown in Figure 96. 9. 7. mark the gear faces to ensure reassembly with same side facing up. as shown in Figure 95. Caution: Pressure regulator spring is tightly compressed and the boost sleeve and the snap ring will be loaded with pressure. 5. (. Remove and discard the two oil seal rings. 3. Inspect all oil pump assembly parts thoroughly for any wear and/or damage. If it becomes necessary to replace the governor driven gear. 8. as shown in Figure 94. Note: Lugs on the inner gear should be flush with the pump body face. and lubricate with trans fluid.

Technical Service Information OIL PUMP ASSEMBLY EXPLODED VIEW 2.0007"-.32") Copyright © 1999 ATSG Figure 94 OIL PUMP DRIVE GEAR SOME GEARS ARE FACTORY MARKED OIL PUMP ASSEMBLY VENT HOLE 203 203 OIL PUMP DRIVEN GEAR 204 OIL PUMP BODY 204 DIMENSION "A" (. OIL PUMP COVER ASSEMBLY 203.75" (1) . OIL PUMP BODY BUSHING 7.50" . STRAIGHT RETAINING PIN (. PRESSURE REGULATOR VALVE BORE PLUG 219. CONVERTER SEAL 3. PRESSURE REGULATOR VALVE 218. PUMP TO FORWARD DRUM THRUST WASHER (SELECTIVE) 208. 204. PUMP COVER TO PUMP BODY BOLT 5/16-18 X 1.00" . OIL PUMP TO CASE "D" RING SEAL 201. OIL SEAL RINGS 209. PUMP COVER TO PUMP BODY BOLT 5/16-18 X 1.120" DIA. PUMP COVER TO PUMP BODY BOLT 5/16-18 X 1.00" (2) . 216. 205. VALVE SPRING RETAINER WASHER . X 1. 204. STATOR SHAFT REAR BUSHING 207. PRESSURE REGULATOR BOOST VALVE SLEEVE 213. Figure 95 Figure 96 AUTOMATIC TRANSMISSION SERVICE GROUP 63 . P R. VALVE SPRING SPACER . PRESSURE REGULATOR BOOST VALVE 214. OIL PUMP DRIVEN GEAR 211.50" (2) . P R. PUMP COVER TO PUMP BODY BOLT 5/16-18 X 1. PRESSURE REGULATOR SLEEVE RETAINING SNAP RING 212. PRESSURE REGULATOR VALVE SPRING 215. PUMP COVER TO PUMP BODY BOLT 5/16-18 X 1.0026") 205 203. 206. PUMP COVER TO PUMP BODY BOLT 5/16-18 X 1. 217. OIL PUMP DRIVE GEAR 210. 205. OIL PUMP BODY 202.75" .

20. PUMP COVER TO PUMP BODY BOLT 5/16-18 X 1. install the pump alignment strap J-21368 onto the pump assembly. Install the boost valve and sleeve assembly in the pressure regulator bore.) using a crossing pattern from side to side (See Figure 98).Technical Service Information Continued from Page 62 15. Care must be used to ensure proper pressure regulator valve is installed (See Figure 99). VALVE SPRING RETAINER WASHER . PRESSURE REGULATOR VALVE SPRING 215. Note: It should be mentioned here that not all pump halves will work with one another. With the pump cover to pump body bolts loose. refer to the chart on Page 18 to ensure that you have compatable parts. as shown in Figure 97. 216. PUMP COVER TO PUMP BODY BOLT 5/16-18 X 1. OIL SEAL RINGS 209. CONVERTER SEAL 3. P R. as shown in Figure 97. STRAIGHT RETAINING PIN (. If replacement was necessary.75" . PRESSURE REGULATOR BOOST VALVE 214. as shown in Figure 97. VALVE SPRING SPACER . Caution: All pressure regulator valves will not work with All oil pump covers. PUMP COVER TO PUMP BODY BOLT 5/16-18 X 1. Lubricate pressure regulator boost valve and install boost valve into boost valve sleeve as shown in Figure 97. Install the proper pressure regulator valve into oil pump cover. 19. OIL PUMP DRIVE GEAR 210.50" . OIL PUMP TO CASE "D" RING SEAL 201. OIL PUMP DRIVEN GEAR 211. X 1. PRESSURE REGULATOR VALVE 218. PRESSURE REGULATOR VALVE BORE PLUG 219.lb. 18. OIL PUMP BODY 202. P R. Torque pump cover to pump body bolts down to 24 Nm (18 ft. 204.00" . Install the pressure regulator bore plug and the straight retaining pin into oil pump cover. OIL PUMP COVER ASSEMBLY 203. if they were used. 16. push in with a pin punch to overcome spring pressure and install the retaining snap ring (See Figure 97). of either half. 21. Install pressure regulator spring and retainer into pressure regulator bore (See Figure 97). OIL PUMP BODY BUSHING 7. 17. as shown in Figure 98.32") Copyright © 1999 ATSG Figure 97 64 AUTOMATIC TRANSMISSION SERVICE GROUP . PRESSURE REGULATOR SLEEVE RETAINING SNAP RING 212. OIL PUMP ASSEMBLY EXPLODED VIEW 2.120" DIA. PUMP TO FORWARD DRUM THRUST WASHER (SELECTIVE) 208. 22. if it was removed. PRESSURE REGULATOR BOOST VALVE SLEEVE 213. 205. STATOR SHAFT REAR BUSHING 207. 206. Install pressure regulator spacer or spacers. and tighten the wing nut. 217.

Install the two oil seal rings into the grooves in the pump cover and lubricate with a small amount of trans fluid (See Figure 97). (See Figure 97). Install the correct selective thrust washer. PUMP COVER TO PUMP BODY BOLT 5/16-18 X 1. and retain with TransJelä. PUMP COVER TO PUMP BODY BOLT 5/16-18 X 1. has been released for service and can be used to service either past model or the current pump cover. 26. Copyright © 1999 ATSG Figure 99 AUTOMATIC TRANSMISSION SERVICE GROUP 65 . Maximum line pressure will be the result if you install 2nd design valve into early cover. ensure that it is not twisted and lubricate with small amount of TransJelä. Install new pump to case "D" ring seal in the groove in the pump. 205. 24.75" (1) . 203 204 205 203 204 J-21368 203.50" (2) .00" (2) . Set the completed oil pump assembly aside for the final assembly process. The 1st design pressure regulator valve with the vent holes and orifice cup plug. Figure 98 PUMP COVER AND PRESSURE REGULATOR VALVE IDENTIFICATION 1ST DESIGN WITH ORIFICE PLUG 2ND DESIGN (SOLID) SQUARED OFF PRESSURE REGULATOR BOSS FOR IDENTIFICATION The solid pressure regulator valve (2nd Design) can be used "only" in the pump cover with the squared off pressure regulator boss as shown above.Technical Service Information 23. Refer to Figure 97. PUMP COVER TO PUMP BODY BOLT 5/16-18 X 1. 25. as determined by the front end-play check during disassembly. 204.

Technical Service Information VALVE BODY ASSEMBLY EXPLODED VIEW Some Models Some Models Copyright © 1999 ATSG Figure 100 66 AUTOMATIC TRANSMISSION SERVICE GROUP .

2-3 ACCUMULATOR PISTON RETAINING "E" CLIP 303. 2-3 ACCUMULATOR PISTON Figure 102 AUTOMATIC TRANSMISSION SERVICE GROUP 67 . Inspect valve body casting for porosity. 343. Clean all valves. 12. 323. 327. 312. 329. 8. and dry with compressed air. cracks. 13. 326. 330. 7. Notice also that we have provided you with all of the different valve line-ups for the various models that are out there (See Figure 100). 322. Inspect springs for damaged or distorted coils. Remove the valve trains one at a time and lay them out on a clean surface in the exact order that they are removed (See Figure 100). 10. 302. 5. 336. as shown in Figure 102. 321. Inspect all valves and bushings for porosity. 340. 337. Clean the valve body assembly thoroughly in clean solvent. 308.) 1-2 ACCUMULATOR VALVE (SOME MODELS) 1-2 ACCUMULATOR VALVE SPRING (SOME MODELS) 1-2 ACCUMULATOR VALVE SPRING (SOME MODELS) RETAINING ROLLED PIN DETENT REGUL ATOR VALVE BORE PLUG (. 304. 2. 333. VALVE BODY ASSEMBLY 302. 334. 335.) DETENT VALVE DETENT REGUL ATOR VALVE DETENT REGUL ATOR VALVE PIN DETENT REGUL ATOR VALVE SPRING MANUAL VALVE 1-2 MODUL ATOR VALVE BUSHING (SOME MODELS) 1-2 REGUL ATOR VALVE (SOME MODELS) 1-2 REGUL ATOR VALVE SPRING (SOME MODELS) 1-2 DETENT VALVE (SOME MODELS) 324.320") 2-3 MODUL ATOR VALVE BUSHING 2-3 MODUL ATOR VALVE SPRING 2-3 MODUL ATOR VALVE 2-3 SHIFT VALVE SPRING 2-3 SHIFT VALVE STRAIGHT RETAINING PIN (. Remove the 2-3 accumulator piston from the valve body casting using J-22269-01 press. 310. 11.120" DIA X . 316. Remove and discard the 2-3 accumulator piston seal ring (See Figure 100). Position the valve body on a clean dry surface.D. 315. Move the valves carefully with a pick or small screwdriver to dislodge any dirt or debris that may have accumulated. nicks and scratches. 3. 341. 319. 4. 317. VALVE BODY CASTING 2-3 ACCUMULATOR PISTON RETAINING "E" CLIP 2-3 ACCUMULATOR PISTON 2-3 ACCUMULATOR PISTON SEAL 2-3 ACCUMULATOR PISTON SPRING GROOVED RETAINING PIN 1-2 ACCUMULATOR VALVE BORE PLUG (. 339. 331. 325. 332. 318.) 3-2 DOWNSHIFT VALVE SPRING 3-2 DOWNSHIFT VALVE PIN 3-2 DOWNSHIFT VALVE 1-2 MODUL ATOR VALVE BUSHING (SOME MODELS) 1-2 ACCUMULATOR VALVE PRIMARY SPRING (SOME MODELS) 1-2 ACCUMULATOR VALVE. 9. Assemble the valve body components exactly as shown in Figure 100. 1-2 SHIFT VALVE 1-2 MODUL ATOR VALVE SPRING (SOME MODELS) 1-2 MODUL ATOR VALVE (SOME MODELS) STRAIGHT RETAINING PIN (.D.500" O. bushings and valve body casting in clean solvent and dry with compressed air.120" DIA X 1. 313. 344.560" O.820") 3-2 DOWNSHIFT VALVE BORE PLUG (. 342. 6.Technical Service Information LEGEND FOR FIGURE 100 301. 320.437" O. 311. springs. damaged machined surfaces and interconnected passages. Remove the 2-3 accumulator piston spring as shown in Figure 100. 328. 303. 314. Continued on Page 68. 309. PRIMARY (SOME MODELS) 1-2 ACCUMULATOR VALVE BUSHING (SOME MODELS) 1-2 ACCUMULATOR VALVE SECONDARY (SOME MODELS) 1-2 ACCUMULATOR VALVE SECONDARY SPRING (SOME) Copyright © 1999 ATSG Figure 101 COMPONENT REBUILD (Cont'd) VALVE BODY ASSEMBLY 1.D. Notice the position of the valve lands and bushing passages. 305. scoring. J-22269-01 301 303 302 301.

as shown in Figure 104. as shown in Figure 100. Compress the 2-3 accumulator piston against the spring pressure using J-2226-01. Install the proper 2-3 accumulator piston with a new seal on piston as shown in Figure 100. as shown in Figure 103. 16. Caution: There are two different styles of the 2-3 accumulator piston. as shown in Figure 102. Install the steel selective thrust washer with the tabs engaged into the slots in case.Technical Service Information FRONT SERVO AND ACCUMULATOR PARTS 1965-1970 COMPONENTS 1971-LATER COMPONENTS SERVO PISTON SERVO PISTON SERVO WASHER SERVO PIN SERVO RING SERVO PIN CONTINUED FROM PAGE 67 14. Install the completed case assembly into the fixture and rotate so that the bell housing is facing up. Install the 2-3 accumulator spring in the valve body bore. 15. and retain with TransJelä (See Figure 104). RETAINER (BACK SIDE) RETAINER (BACK SIDE) REVERSE BAND SERVO SPRING SERVO SPRING These Servo Parts "Require" The 2-3 Accumulator Piston Shown Below These Servo Parts "Require" The 2-3 Accumulator Piston Shown Below REAR END-PLAY SELECTIVE WASHER Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 103 Figure 104 68 AUTOMATIC TRANSMISSION SERVICE GROUP . 18. Set the completed valve body assembly aside for the final assembly process. and install retaining "E" clip. SERVO RETAINER SERVO RETAINER FINAL TRANSMISSION ASSEMBLY 1. The 2-3 accumulator piston "Must" be matched with the front servo parts. Install the manual valve into the manual valve bore in the valve body (See Figure 100). 17. 2. One with "Castles" on top and one that is flat on top.

657 Continued on Page 70. Install the "fretting" snap ring into the proper groove in the case.. and proper location in the transmission case. FRETTING RING Copyright © 1999 ATSG Figure 105 TO DETERMINE USE OF FRETTING RING "FLAT" SNAP RING (640) "TAPERED" SNAP RING (645) "A" CENTER SUPPORT FRETTING RING (657) "A" Dimension "A" . as shown in Figure 105. = "Requires" Fretting Ring (657) Dimension "A" . Note: Use of the fretting snap ring (657) is determined by the thickness of the lug area on the center support.. Refer to Figure 106 to determine whether your center support requires the fretting snap ring (657). = "No" Fretting Ring (657) Copyright © 1999 ATSG Figure 106 AUTOMATIC TRANSMISSION SERVICE GROUP 69 . if it was removed.327". The cases are the same this area.Technical Service Information 3. Install the reverse band into the case and ensure that it engages on case lugs (See Figure 104).362". 4. 657.

by carefully aligning the bolt hole in the center support with the hole in the case. Ensure that your bolt is compatable with both the transmission case and the center support for the model that you are building. Note: There are two different support bolts. Refer to Figures 107 and 108. 6. FLAT FRETTING SNAP RING (657) PREVIOUS DESIGN AFTER MARCH 1990 Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 107 Figure 108 70 AUTOMATIC TRANSMISSION SERVICE GROUP . but do not tighten.Technical Service Information TAPERED SNAP RING (645) LIFTING TOOL J-38868 CONTINUED FROM PAGE 69 5. Start a new center support bolt into the center support. Install the completed gear train assembly into the transmission case. as shown in Figure 108. and carefully lower into case. 1990 and later cases and center supports require the long bolt.

Install the "Tapered" snap ring into the groove in the case with the opening in the snap ring to the 9 O-Clock position in the case. as shown in Figure 107. 12. ensuring that it is fully seated. with the opening in snap ring facing the 3 O-Clock position in the case.) as you hold pressure on the center support. 10.lb. Install the intermediate clutches beginning with a steel plate and alternating with a lined plate. Install the intermediate clutch wave plate. SOME MODELS Copyright © 1999 ATSG Figure 109 AUTOMATIC TRANSMISSION SERVICE GROUP 71 . 13. Install the "Flat" intermediate clutch backing plate snap ring. Locate a small screwdriver into center support direct clutch passage through the case. FLAT SNAP RING INTERMEDIATE CLUTCH BACKING PLATE INTERMEDIATE CLUTCH LINED PLATES INTERMEDIATE CLUTCH STEEL PLATES INTERMEDIATE CLUTCH WAVE PLATE Continued on Page 72. 11. Now torque the new center support bolt down to 30 Nm (22 ft. 8. as shown in Figure 109. if it is used in your model (See Figure 109). until you have three of each installed. Apply pressure on the screwdriver so as to rotate the center support counterclockwise.Technical Service Information 7. Install the intermediate clutch backing plate on top of the last friction plate. Note: If the waved plate is used you begin with a lined plate on top of the waved plate and then alternate until you have three each. seating the center support lugs on the case lugs. as shown in Figure 109. 9.

18. ensuring that it is engaged on the lug in the case (See Figure 110). ensuring that the holes are properly aligned. 207. 7. 8. 17. 16. Install the completed oil pump assembly into the case. Copyright © 1999 ATSG Figure 110 FORWARD CLUTCH HOUSING ASSEMBLY 4. 19.406" COMPLETE OIL PUMP ASSEMBLY OIL PUMP TO CASE "D" RING SEAL OIL PUMP COVER TO CASE GASKET PUMP COVER TO FWD DRUM THRUST WASHER (SELECTIVE) Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 111 Figure 112 72 AUTOMATIC TRANSMISSION SERVICE GROUP . 6. Install the manual 2nd band assembly into the case. 5/16-18 X 1. Install the completed forward clutch housing assembly into the case by rotating back and forth until fully seated (See Figure 111). Lubricate the case bore for the "D" ring with a small amount of TransJelä. 15.Technical Service Information DIRECT CLUTCH HOUSING MANUAL 2ND BAND CONTINUED FROM PAGE 71 14. until fully seated (See Figure 110). OIL PUMP RETAINING BOLTS. as shown in Figure 112. Install the oil pump to case gasket onto the case as shown in Figure 112. Install the completed direct clutch housing assembly into the case by rotating to engage sprag outer race into teeth of the intermediate lined plates.

Torque the oil pump retaining bolts down to 24 Nm (18 ft.lb.071" .019").119" .075" . 21.104" . Remove the dial indicator tools and correct as necessary.108" . 22. Continued on Page 74. Install J-6125 slide hammer bolt in place of the pump bolt as shown in Figure 114. Proper front end play is .115" . You must use proper type of seal on the appropriate bolt.064" . Install dial indicator on the bolt and index it to the end of the turbine shaft (See Figure 114).007" .126" .. if front end-play is correct. 25..lb. by changing the selective thrust on the back side of pump assembly.082" . Replace the pump bolt and torque to 18 ft. WASHER TYPE PUMP BOLT Figure 114 FRONT END PLAY WASHER CHART THICKNESS . 26..093" ..178mm . and using the chart provided in Figure 115.. This condition must be fixed before pump assembly is fully seated.Technical Service Information 20. 24.D..130" "O" RING SEAL TYPE PUMP BOLT COLOR I.. one type that uses the fiber washer and one type that uses "O" ring seal as shown in Figure 113..) Note: If turbine shaft cannot be rotated as the pump assembly is being pulled into place. the forward and/or direct clutch housings have not been installed properly to index with all of the clutch plates. Caution: There are two different types of the pump retaining bolts. Move the turbine shaft in and out and observe end-play reading on dial indicator. 23. as shown in Figure 112. Install the oil pump assembly to case retaining bolts.097" . 27.483mm (.060" ..088" . YELLOW BLUE RED BROWN GREEN BLACK PURPLE NUMBER 0 1 2 3 4 5 6 Figure 113 Figure 115 AUTOMATIC TRANSMISSION SERVICE GROUP 73 .

Technical Service Information CONTINUED FROM PAGE 73 28.074" .178mm . 31.118" I.090" ... Fasten with two 5/16-18 x 1" bolts and torque to 24 Nm (18 ft. 30. and using the chart provided in Figure 117...D. 34. Remove the dial indicator tools and correct as necessary.483mm (.114" .082" .007" . Install J-6125 slide hammer bolt in hole of the case.098" . NOTCH NUMBER None 1 On Side Of 1 Tab 2 On Side Of 2 Tabs 3 On End Of 1 Tab 4 On End Of 2 Tabs 5 On End Of 3 Tabs 6 J-21370-6 J-21370-10 REAR END PLAY SELECTIVE THRUST WASHER Copyright © 1999 ATSG Figure 117 Figure 118 74 AUTOMATIC TRANSMISSION SERVICE GROUP .094" .110" .086" .. OUTPUT SHAFT Copyright © 1999 ATSG Figure 116 REAR END PLAY WASHER CHART THICKNESS . Position J-21370-6 selector gage tool over the bore with the hex nut facing parking linkage... as shown in Figure 118. Install dial indicator on the bolt and index it to the end of the output shaft (See Figure 114). by changing steel selective thrust washer in the rear of transmission.) (See Figure 118).lb. 32.078" . Proper rear end play is .102" .106" . 35. as shown in Figure 116. Move the output shaft in and out and observe end-play reading on dial indicator.019"). 33. Place J-21370-10 gage pin into the reverse servo pin bore (See Figure 118). 29..

lb. REAR SERVO COVER RETAINING BOLTS. torque to the nut on gage (See Figure 118).620" REVERSE SERVO COVER REVERSE SERVO COVER GASKET REVERSE SERVO PISTON RETAINING "E" CLIP REVERSE SERVO PISTON REVERSE SERVO PISTON SEAL 1-2 ACCUMULATOR PISTON OUTER SEAL RING 1-2 ACCUMULATOR PISTON 1-2 ACCUMULATOR PISTON INNER SEAL RING REVERSE SERVO PISTON WASHER REVERSE SERVO PISTON SPRING REVERSE SERVO PISTON SPRING RETAINER REVERSE SERVO BAND APPLY PIN (SELECTIVE) Copyright © 1999 ATSG 1-2 ACCUMULATOR SPRING Figure 119 Figure 120 AUTOMATIC TRANSMISSION SERVICE GROUP 75 . Install rear servo spring retainer over the servo pin selected. and install 1-2 accumulator piston assembly iside of reverse servo piston as shown in Figure 119. as shown in Figure 119. 39. Ensure that J-21370-10 gage pin still moves freely in the tool and case pin bore. 66. 71. as shown in Figure 119. compress servo spring and install "E" clip. Install 1-2 accumulator spring into case bore and install reverse servo assembly. as shown in Figure 119. 74. 70. 72.) (See Figure 119. 76.Technical Service Information 36.lb. apply 25 ft. 41. Continued on Page 76. 43. To determine correct pin length. Install new seals onto 1-2 accumulator piston. Install new seal onto the reverse servo piston and lube with small amount of TransJelä. 42. Install reverse servo spring over pin and onto servo pin. Install reverse servo piston over pin. install the reverse servo cover and torque the six bolts to 24 Nm (18 ft. 78. 38. 67. Refer to Figure 119. For the various pin selections see Figure 119. 73. 75. Install servo cover gasket onto case. 68. 46. 44. 37. 40. as shown in Figure 119. 65. 5/16-18 X . as necessary. 45. 69. Install reverse servo piston washer. 77.

61. The servo components must match the 2-3 accumulator piston in the valve body. Caution: There are two different styles of the Manual 2 servo components. Install the proper amount of 1/4" (. Install a new governor screen into the case in the position and location shown in Figure 123. 64. Ensure that proper manual 2 servo components are installed into case bore (See Figure 122). according to the model that you are building. Continued on Page 78. 63. 48. 85.250") Dia. Install the manual 2 servo components into the case bore as shown in Figure 122. One with the "Castles" on top of the servo piston and one that is flat on top. 47. FRONT SERVO PISTON FRONT SERVO RING FRONT SERVO PISTON PIN FRONT SERVO PISTON SPRING RETAINER FRONT SERVO PISTON SPRING FRONT SERVO PISTON Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 121 Figure 122 76 AUTOMATIC TRANSMISSION SERVICE GROUP . as shown in Figure 124.Technical Service Information FRONT SERVO AND ACCUMULATOR PARTS 1965-1970 COMPONENTS 1971-LATER COMPONENTS SERVO PISTON SERVO PISTON SERVO WASHER SERVO PIN SERVO RING SERVO PIN CONTINUED FROM PAGE 75 46. checkballs into the proper pockets in the case. 62. SERVO RETAINER SERVO RETAINER RETAINER (BACK SIDE) RETAINER (BACK SIDE) SERVO SPRING SERVO SPRING These Servo Parts "Require" The 2-3 Accumulator Piston Shown Below These Servo Parts "Require" The 2-3 Accumulator Piston Shown Below 60. as shown in Figure 121. 49.

1 Figure 124 AUTOMATIC TRANSMISSION SERVICE GROUP 77 . 5 NO. 1 NO. 6 NO. 6 1 ORIFICE CUP PLUG LOCATION (10. 7 NO. 2 Copyright © 1999 ATSG NO. 3 NO. 5 1965-1987 CHECKBALL LOCATIONS NO. 2 NO.096" 8670459 "BLUE" .000 GVW AND UNDER) "COPPER" . 3 NO.Technical Service Information GOVERNOR SCREEN Figure 123 NO.089" 8670801 1988-1990 CHECKBALL LOCATIONS NO. 4 NO. 4 NO.

57. ensuring that the manual valve is on the pin of the inside detent lever and engaged properly and governor pipes are engaged into the transmission case (See Figure 125). Install a new case to spacer plate gasket over the guide pins and onto case (See Figure 125). VALVE BODY SPACER PLATE 58. VALVE BODY ASSEMBLY 50. 5/16-18 X 1. and install retaining bolt. Note: Some models also use a support spring on top of the manual detent roller and spring as shown in Figure 126. and install the valve body bolts finger tight. VALVE BODY BOLTS. 51.Technical Service Information CONTINUED FROM PAGE 76 50. Connect the wire from the detent solenoid to the case connector on the inside.250" DIAME TER (6 OR 7 REQUIRED) MANUAL DETENT ROLLER AND SPRING ASSEMBLY Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 125 Figure 126 78 AUTOMATIC TRANSMISSION SERVICE GROUP . . 53. 52. Install the valve body and governor pipes onto the case. SPACER PLATE TO CASE GASKET 59. 1/4-20 X . VALVE BODY BOLTS. STEEL CHECKBALLS. Install a new valve body to spacer plate gasket over the guide pins on top of the spacer plate as shown in Figure 125. Install the proper valve body spacer plate over the guide pins and on top of the case gasket. GUIDE PINS. SUPPORT SPRING (SOME MODELS) A.750" 54. 47. MANUAL DETENT ROLLER AND SPRING ASSEMBLY 49.620" (10 REQUIRED) 52. Push the valve body assembly down against the pressure of Manual 2 servo spring. Install the governor pipes into the previously completed valve body assembly (Figure 125). Install guide pins into case in the locations that are shown in Figure 125. DETENT SOLENOID RETAINING BOLTS. Install the manual detent roller and spring onto valve body.875" (1 REQUIRED) 48. 59. GOVERNOR FEED AND RETURN PIPES 51. as shown in Figure 125. 54. 5/16-18 X 1. GOVERNOR SCREEN ASSEMBLY. Install the detent solenoid and tighten the bolts finger tight (See Figure 125). VALVE BODY TO SPACER PLATE GASKET 57. as shown in Figure 125. 55. 58. LOCATED IN CASE 53. 56. DETENT SOLENOID ASSEMBLY 56.

690" BOTTOM TRANSMISSION PAN (SHALLOW OR DEEP) BOTTOM PAN GASKET BOTTOM PAN MAGNET 42. FILTER SPACER. Shallow Pan Components 37.). Torque all valve body bolts beginning in the center and working outward in a circle down to 11 Nm (98 in. 39. 67. Install the magnet into the proper bottom oil pan. BOTTOM PAN FILTER ASSEMBLY 43. Torque the detent solenoid retaining bolts down to 10 Nm (89 in. 66. 40. 38. 68. 61.). as shown in Figure 127. Torque filter retaining bolt to 10 Nm (89 in. DEEP PAN ONLY 45. 63. FILTER INTAKE PIPE (LONG OR SHORT) Copyright © 1999 ATSG Figure 127 AUTOMATIC TRANSMISSION SERVICE GROUP 79 . 65. Notice in Figure 127 that the intake pipe for shallow pan is shorter than the intake pipe for the deep pan. lube with small amount of TransJelä and install intake pipe into case (See Figure 127). Install a new bottom pan gasket onto the case as shown in Figure 127. Refer to Figure 41. This affects filter components required for this unit.Technical Service Information 60. Install a new "O" ring onto proper filter intake pipe. Install new filter assembly on intake pipe and install filter bolt and spacer if used.lb. Install the proper bottom oil pan onto the case as shown in Figure 127. Deep Pan Components 64. 62.). Install the bottom oil pan bolts and torque to 13 Nm (116 in. Continued on Page 80.lb. BOTTOM PAN BOLTS.). Note: There are two different styles of the bottom pan. 5/16-18 X .lb.lb. as shown in Figure 127. as shown in Figure 41. shallow and deep pans.

22. GOVERNOR COVER BOLTS.620" MODUL ATOR RETAINER VACUUM MODULATOR "O" RING SEAL VACUUM MODULATOR VALVE Copyright © 1999 ATSG Figure 128 SOME MODELS SPEED SENSOR ROTOR SPEEDOMETER DRIVE GEAR (MODEL SENSITIVE) PLASTIC (REQUIRES CLIP) STEEL (PRESS ON) SOME MODELS 19. and torque the 4 bolts to 14 Nm (125 in.Technical Service Information CONTINUED FROM PAGE 79 69.). 81. 14. Rotate transmission fixture so that the bottom pan is facing down. 21. JEEP MODELS 11. 72. 15.690" (4 REQUIRED) GOVERNOR COVER GOVERNOR COVER GASKET GOVERNOR ASSEMB. 74. HEX HEAD BOLT. Lubricate modulator valve (15) with fluid and install modulator valve into transmission case as shown in Figure 128. 5/16-18 X . 83. 20. Install the modulator retaining bracket. and requires modulator with the bellows. 5/16-18 X . 82. 70. 71. 12. as shown in Figure 128.lb. Install the governor cover with a new gasket as shown in Figure 129. 73. torque the retaining bolt to 14 Nm (125 in.LY OUTPUT SPEED SENSOR ASSEMBLY (SOME MODELS) SPEED SENSOR "O" RING (SOME MODELS) SPEED SENSOR RETAINING BOLT (SOME MODELS) SPEEDO DRIVEN GEAR (MODEL SENSITIVE) SPEEDO HOUSING (MODEL SENSITIVE) Copyright © 1999 ATSG Figure 129 80 AUTOMATIC TRANSMISSION SERVICE GROUP . as shown in Figure 128. Note: Jeep models use a modulator valve that has a longer stem on the modulator side. Install a new vacuum modulator with a new "O" ring into case.lb). Install the governor assembly into case bore by rotating into position (See Figure 129). 13.

77. Install the speed sensor or the speedometer drive gear and adapter and torque the retaining bolt to 7 Nm (62 in. and carefully install into trans.) (See Figure 129). 81. Torque the six extension housing bolts down to 20-25 ft. Lubricate converter hub with a small amount of TransJelä. Install the proper extension housing and gasket as shown in Figure 130. 28. EXTENSION HOUSING BOLTS. 33. as shown in Figure 132. 26. Check the torque converter end-play using the tools shown in Figure 131. 79. 78.lb. 76. 27. END TRANSMISSION ASSEMBLY CHECKING CONVERTER END-PLAY Figure 131 J-3289-20 J-8763-02 Some Models 23.035".lb. 30. 80. Note: Refer to Figures 25 and 26 for various models of output shafts and extensions. 3/8-16 X 1" (6 REQUIRED) EXTENSION HOUSING METAL CLAD SEAL EXTENSION HOUSING ASSEMBLY (MODEL SENSITIVE) BALL BEARING ASSEMBLY (SOME MODELS) BALL BEARING SPACER (SOME MODELS) EXTENSION HOUSING BUS HING INTERNAL SNAP RING (SOME MODELS) EXTENSION HOUSING TO CASE SEAL (SOME MODELS) TRANSMISSION REAR CASE BU SHING EXTENSION HOUSING TO CASE GASKET (SOME MODELS) Copyright © 1999 ATSG Figure 130 Figure 132 AUTOMATIC TRANSMISSION SERVICE GROUP 81 . 29. 32. Remove transmission assembly from fixture.Technical Service Information 75. Converter end-play should be . 31. 34.010" . Install the proper speedo drive gear or speed sensor rotor onto the output shaft if it has not been previously installed (See Figure 129)..

Technical Service Information CASE AND EXTERNAL PARTS EXPLODED VIEW Copyright © 1999 ATSG Figure 133 82 AUTOMATIC TRANSMISSION SERVICE GROUP .

GOVERNOR COVER 21. OIL PUMP TO CASE SEALING RING 8. FILTER SPACER. 78. 84. 47. 66. 60. BALL BEARING ASSEMBLY 29. INTERNAL SNAP RING 32. EXTENSION HOUSING TO CASE BOLTS. OIL PUMP ASSEMBLY 7. VACUUM MODULATOR ASSEMBLY 14.690" 38. AND SOME 7 REQ.Technical Service Information LEGEND FOR FIGURE 133 1. (SHORT OR LONG) 42. 87.750" DETENT SOLENOID ASSEMBLY VALVE BODY TO SPACER PLATE GASKET VALVE BODY SPACER PLATE SPACER PLATE TO CASE GASKET CHECKBALLS. 1/4-20 X 1. BALL BEARING SPACER 30. 5/16-18 X . 70.620" 12. 49. EXTENSION HOUSING BUS HING 31. 68. SHOULDERED FILTER BOLT. 54. MODUL ATOR RETAINING BRACKET 13. BOTTOM PAN TO CASE GASKET 40. EXTENSION HOUSING TO CASE GASKET (SOME MODELS) 35. 52. EXTENSION HOUSING ASSEMBLY 28. IDENTIFICATION TAG 19. ELECTRICAL CONNECTOR 36.875") MANUAL DETENT SPRING AND ROLLER ASSEMBLY VALVE BODY ASSEMBLY GOVERNOR FEED AND RETURN PIPES VALVE TO CASE BODY BOLTS. TRANSMISSION CASE ASSEMBLY 11. SHALLOW PAN . 77. IDENTIFICATION TAG SCREW 18. 83. 57. ELECTRICAL CONNECTOR "O" RING 37. 65. 53.620" REVERSE SERVO COVER REVERSE SERVO COVER GASKET REVERSE SERVO PISTON RETAINING "E" CLIP REVERSE SERVO PISTON REVERSE SERVO PISTON SEAL 1-2 ACCUMULATOR PISTON OUTER SEAL 1-2 ACCUMULATOR PISTON 1-2 ACCUMULATOR PISTON INNER SEAL REVERSE SERVO PISTON WASHER REVERSE SERVO SPRING REVERSE SERVO SPRING RETAINER REVERSE SERVO PISTON BAND APPLY PIN (SELECTIVE) 1-2 ACCUMULATOR SPRING CENTER SUPPORT TO CASE BOLT (SHORT OR LONG) OUTPUT SPEED SENSOR ASSEMBLY (SOME MODELS) OUTPUT SPEED SENSOR "O " RING SPEED SENSOR RETAINING BOLT LINE PRESSURE TEST PLUG. 67. 75. VENT PIPE 10. GOVERNOR ASSEMBLY 23. BOTTOM PAN BOLTS. GOVERNOR COVER GASKET 22. VACUUM MODULATOR VALVE 16. 59. REAR CASE BUSHING 34. GOVERNOR COVER RETAINING BOLTS (4 REQUIRED) 20. EXTENSION HOUSING METAL CLAD SEAL 27. 72. 85. 56. 50. 51. FILTER INTAKE PIPE (SHORT. 82. 71. . 69. 73. 64. DEEP PAN) MANUAL DETENT SPRING RETAINING BOLT.620" GOVERNOR SCREEN ASSEMBLY DETENT SOLENOID RETAINING BOLTS. COOLER FITTING 17. 76. SPEEDO HOLE STEEL PLUG (4WD MODELS) 6. 48. 74. MODUL ATOR "O" RING SEAL 15. 5/16-18 X 1. BOTTOM PAN FILTER ASSEMBLY 43.250" STEEL (SOME 6 REQ. 3/8-16 X 1" 26. 61. TORQUE CONVERTER ASSEMBLY 4. MODUL ATOR RETAINING BOLT. 63. BOTTOM TRANSMISSION OIL PAN (SHALLOW OR DEEP) 39. PUMP COVER TO CASE GASKET 9. 5/16-18 X . DEEP PAN ONLY 44. MANUAL DETENT SPRING SUPPORT (SOME MODELS) 45. 86.) FRONT SERVO PISTON FRONT SERVO PISTON PIN RING FRONT SERVO PISTON PIN FRONT SERVO RETURN SPRING RETAINER FRONT SERVO PISTON RETURN SPRING REVERSE SERVO COVER RETAINING BOLTS. 1/8" PIPE FRONT SERVO PISTON SEAL DRAIN PLUG GASKET (SOME MODELS) BOTTOM PAN DRAIN PLUG (SOME MODELS) Copyright © 1999 ATSG Figure 134 AUTOMATIC TRANSMISSION SERVICE GROUP 83 . 1/4-20 X . EXTENSION HOUSING TO CASE SEAL (SOME MODELS) 33. 58. 79. 81. 5/16-18 X . 62. BOLT AND "O" RING ASSEMBLY (PUMP TO CASE) 5.LONG. BOTTOM PAN MAGNET 41.

Technical Service Information INTERNAL TRANSMISSION PARTS EXPLODED VIEW Copyright © 1999 ATSG Figure 135 84 AUTOMATIC TRANSMISSION SERVICE GROUP .

691. 608. 696. 637. 693. 607. 631. 668. 630. 656. 614. 611. 687. 639. 661. 603. SEE FIGURE 26) SPEEDOMETER DRIVE GEAR RETAINING CLIP SPEEDOMETER DRIVE GEAR (MODEL SENSITIVE) OUTPUT SHAFT/OUTPUT CARRIER S NAP RING OUTPUT SHAFT TO CASE BRONZE THRUST WASHER OUTPUT SHAFT TO CASE STEEL THRUST WASHER (SELECTIVE) OUTPUT SHAFT "O" RING SEAL (SOME MODELS) OUTPUT SHAFT SPEED SENSOR ROTOR (SOME MODELS) Copyright © 1999 ATSG Figure 136 AUTOMATIC TRANSMISSION SERVICE GROUP 85 . 666. 653. 621. 667. 632. 672. 602. 681. 624. 633. 641. 695. TURBINE SHAFT FORWARD CLUTCH HOUSING FORWARD CLUTCH HOUSING CENTER SEAL FORWARD CLUTCH PISTON OUTER LIP SEAL FORWARD CLUTCH PISTON INNER LIP SEAL FORWARD CLUTCH PISTON FORWARD CLUTCH PISTON RETURN SPRINGS FORWARD CLUTCH RETURN SPRING RETAINER FWD CLUTCH RETURN SPRING RETAINER SNAP RING FORWARD CLUTCH WAVE (CUSHION) PLATE (SOME MODELS) FORWARD CLUTCH DISHED PLATE (SOME MODELS) FORWARD CLUTCH FLAT STEEL PLATES FORWARD CLUTCH LINED PLATES FORWARD CLUTCH HUB TO HOUSING THRUST WASHER FORWARD CLUTCH HUB THRUST WASHER (FWD CLUTCH HUB TO DIR CLUT HOUSING) DIRECT CLUTCH HUB SNAP RING (FORWARD AND DIRECT CLUTCHES) DIRECT CLUTCH BACKING PLATE DIRECT CLUTCH LINED PLATES DIRECT CLUTCH STEEL PLATES DIRECT CLUTCH WAVED PLATE (SOME MODELS) DIRECT CLUTCH DISHED PLATE (SOME MODELS) DIRECT CLUTCH RETURN SPRING RETAINER SNAP RING DIRECT CLUTCH RETURN SPRING RETAINER DIRECT CLUTCH PISTON RETURN SPRINGS DIRECT CLUTCH PISTON ASSEMBLY DIRECT CLUTCH PISTON INNER LIP SEAL DIRECT CLUTCH PISTON OUTER LIP SEAL DIRECT CLUTCH HOUSING CENTER LIP SEAL DIRECT CLUTCH HOUSING ASSEMBLY INTERMEDIATE ROLLER CLUTCH ASSEMBLY (SOME MODELS) INTERMEDIATE SPRAG CLUTCH ASSEMBLY (SOME MODELS) INTERMEDIATE ROLLER OR SPRAG OUTER RACE INTERMEDIATE ROLLER OR SPRAG RETAINER INTERMEDIATE ROLLER OR SPRAG RETAINER SNAP RING FRONT BAND ASSEMBLY INTERMEDIATE CLUTCH BACKING PLATE "FLAT" SNAP RING INTERMEDIATE CLUTCH BACKING PLATE INTERMEDIATE CLUTCH LINED PLATES INTERMEDIATE CLUTCH STEEL PLATES INTERMEDIATE CLUTCH WAVED PLATE (SOME MODELS) CENTER SUPPORT TO CASE "TAPERED" SNAP RING INTERMEDIATE CLUTCH RETURN SPRING RETAINER SNAP RING INTERMEDIATE CLUTCH RETURN SPRING RETAINER INTERMEDIATE CLUTCH RETURN SPRINGS INTERMEDIATE CLUTCH PISTON INTERMEDIATE CLUTCH PISTON INNER LIP SEAL 652. 669. 683. 654. 682. 659. 604. 606. 684. 645. 677. 629. 650. 612. 665. 627. 688. 680. 675. 620. 673. 609. 670. 658. 660. 638. 657. 674. 634. INTERMEDIATE CLUTCH PISTON OUTER LIP SEAL CENTER SUPPORT SEALING RINGS. 647. 615. 605. 678. 697. 648. 698. 671. 686. 679. 689. 664. 651. 626. 635. 623. 646. 655. 622. 642.Technical Service Information LEGEND FOR FIGURE 135 601. 690. 619. 625. 694. 640. 644. 4 REQUIRED CENTER SUPPORT ASSEMBLY CENTER SUPPORT BUSHING CENTER SUPPORT TO REAR DRUM THRUST WASHER CENTER SUPPORT TO CASE FRETTING RING (SOME MODELS) LOW ROLLER CLUTCH ASSEMBLY REAR REACTION DRUM SPACER (FOR ROLLER CLUTCH ASM) CENTER SUPPORT TO NEEDLE BEARING RACE CENTER SUPPORT NEEDLE BEARING ASSEMBLY CENTER SUPPORT NEEDLE BEARING TO SUN GEAR RACE SUN GEAR SHAFT BUSHINGS ( 2 REQUIRED) SUN GEAR SHAFT ASSEMBLY SUN GEAR REACTION DRUM AND INPUT CARRIER ASSEMBLY PINION GEAR STEEL THRUST WASHERS PINION GEAR ROLLER NEEDLE BEARINGS INPUT CARRIER PINION GEARS PINION GEAR BRONZE THRUST WASHER PINION GEAR PINS REVERSE BAND ASSEMBLY FRONT INTERNAL RING GEAR SILENCI NG RING INTERNAL RING GEAR TO RING GEAR THRUST WASHER OUTPUT CARRIER ASSEMBLY PINION GEAR BRONZE THRUST WASHER PINION GEAR STEEL THRUST WASHER PINION GEAR ROLLER NEEDLE BEARINGS OUTPUT CARRIER PINION GEARS PL ANETARY PINION GEAR PINS TRANSMISSION MAIN SHAFT TO RING GEAR SUN GEAR TO NEEDLE BEARING RACE SUN GEAR NEEDLE BEARING ASSEMBLY NEEDLE BEARING TO REAR RING GEAR RACE REAR INTERNAL RING GEAR REAR RING GEAR TO NEEDLE BEARING RACE REAR RING GEAR NEEDLE BEARING ASSEMBLY NEEDLE BEARING TO OUTPUT SHAFT RACE MAIN SHAFT/REAR RING GEAR SNAP RING OUTPUT SHAFT BUSHING OUTPUT SHAFT (MODEL SE NSITIVE. 663. 692. 617. 636. 662. 616. 618. 676. 643. 613. 685.

5/16-18 X 1. 342.120" DIA X 1. 217.560" O.R. 302. 308. 344. 319.D. . 205. PRIMARY (SOME MODELS) 1-2 ACCUMULATOR VALVE BUSHING (SOME MODELS) 1-2 ACCUMULATOR VALVE SECONDARY (SOME MODELS) 1-2 ACCUMULATOR VALVE SECONDARY SPRING (SOME) Copyright © 1999 ATSG Figure 138 86 AUTOMATIC TRANSMISSION SERVICE GROUP . 201. 206. 218. 336. 318. 339.120" DIA X . 333. 325.750 (1 REQ) STATOR SHAFT REAR BUSHING PUMP COVER TO FWD DRUM THRUST WASHER (SELECTIVE) FORWARD CLUTCH SEALING RINGS (2 REQUIRED) INNER PUMP DRIVE GEAR 210. 220. 309. 313. 303. 341.320" STATOR SHAFT FRONT BUSHING Copyright © 1999 ATSG Figure 137 301.00 (2 REQ) PUMP COVER TO PUMP BODY BOLT.Technical Service Information OIL PUMP ASSEMBLY EXPLODED VIEW 2. 317.D. 5/16-18 X 1. 329. 5/16-18 X 1. 312. 311.) DETENT VALVE DETENT REGUL ATOR VALVE DETENT REGUL ATOR VALVE PIN DETENT REGUL ATOR VALVE SPRING MANUAL VALVE 1-2 MODUL ATOR VALVE BUSHING (SOME MODELS) 1-2 REGUL ATOR VALVE (SOME MODELS) 1-2 REGUL ATOR VALVE SPRING (SOME MODELS) 1-2 DETENT VALVE (SOME MODELS) LEGEND FOR FIGURE 139 324. 208. PUMP CONVERTER SEAL ASSEMBLY PUMP BODY BUSHING PUMP TO CASE "D" RING SEAL PUMP BODY PUMP COVER PUMP COVER TO PUMP BODY BOLT. 214. 321. 202. 326.437" O. 204. 328. 343. 7. VALVE BORE PLUG RETAINING PIN. 322. 331. 315. 337.320") 2-3 MODUL ATOR VALVE BUSHING 2-3 MODUL ATOR VALVE SPRING 2-3 MODUL ATOR VALVE 2-3 SHIFT VALVE SPRING 2-3 SHIFT VALVE STRAIGHT RETAINING PIN (.) 3-2 DOWNSHIFT VALVE SPRING 3-2 DOWNSHIFT VALVE PIN 3-2 DOWNSHIFT VALVE 1-2 MODUL ATOR VALVE BUSHING (SOME MODELS) 1-2 ACCUMULATOR VALVE PRIMARY SPRING (SOME MODELS) 1-2 ACCUMULATOR VALVE. 212. 213. 207. OUTER PUMP DRIVEN GEAR PRESSURE REGUL ATOR RETAINING SNAP RING PRESSURE BOOST VALVE BUSHING PRESSURE BOOS T VALVE PRESSURE REGUL ATOR VALVE SPRING (MODEL SENSITIVE) PRESSURE REGUL ATOR VALVE SPRING RETAINER PRESSURE REGUL ATOR VALVE SPACER PRESSURE REGUL ATOR VALVE PRESSURE REGUL ATOR VALVE BORE PLUG P. 209. 340.500" O. 335. 316.D. 327. 304. 320. 211. 203.120" DIA X 1.50 (1 REQ) PUMP COVER TO PUMP BODY BOLT. 330. 215. VALVE BODY CASTING 2-3 ACCUMULATOR PISTON RETAINING "E" CLIP 2-3 ACCUMULATOR PISTON 2-3 ACCUMULATOR PISTON SEAL 2-3 ACCUMULATOR PISTON SPRING GROOVED RETAINING PIN 1-2 ACCUMULATOR VALVE BORE PLUG (. 305. 334. 332. 1-2 SHIFT VALVE 1-2 MODUL ATOR VALVE SPRING (SOME MODELS) 1-2 MODUL ATOR VALVE (SOME MODELS) STRAIGHT RETAINING PIN (. 314.) 1-2 ACCUMULATOR VALVE (SOME MODELS) 1-2 ACCUMULATOR VALVE SPRING (SOME MODELS) 1-2 ACCUMULATOR VALVE SPRING (SOME MODELS) RETAINING ROLLED PIN DETENT REGUL ATOR VALVE BORE PLUG (.820") 3-2 DOWNSHIFT VALVE BORE PLUG (. 323. 3. 216. 219. 310.

Technical Service Information VALVE BODY ASSEMBLY EXPLODED VIEW Some Models Some Models Copyright © 1999 ATSG Figure 139 AUTOMATIC TRANSMISSION SERVICE GROUP 87 .

Technical Service Information
PARK LINKAGE AND ASSOCIATED PARTS EXPLODED VIEW

701. 702. 703. 704. 705. 706. 707. 708. 709. 710. 711. 712. 713.

HEX HEAD BOLT, HD 5/16-18 X .620" PARKING LOCK BRACKET HEX NUT, 3/8-24 MANUAL SHAFT RETAINING PIN MANUAL SHAFT MANUAL SHAFT SEAL INSIDE DETENT LEVER PARKING LOCK ACTUATOR ASSEMBLY PARKING PAWL SHAFT CUP PLUG PARKING PAWL RETURN SPRING PARKING PAWL SHAFT RETAINING CLIP PARKING PAWL SHAFT PARKING PAWL Copyright © 1999 ATSG

Figure 140

88

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information
DETENT SOLENOID CIRCUITS 1988 AND LATER "C" AND "K" TRUCKS
ECM/IGN FUSE 10A BRAKE SWITCH A
RED

FROM IGN SWIT BATTERY 12 VOLT

PINK/BLACK

PURPLE

B

ELECTRONIC CONTROL MODULE (ECM)

FUSE LINK

E D F A DOWNSHIFT CONTROL RELAY
TAN/BLACK

DOWNSHIFT A7

ORANGE

DETENT SOLENOID

THM 400 TRANSMISSION

DETENT SOLENOID CIRCUITS 1988 AND LATER "R", "V", AND "P" TRUCKS AND "G" VANS

FROM IGN SWIT

IGN/GAGE FUSE 20A

PINK/BLACK

ELECTRONIC CONTROL MODULE (ECM)

E D F A DOWNSHIFT CONTROL RELAY
TAN/BLACK

DOWNSHIFT A7

ORANGE

DETENT SOLENOID

THM 400 TRANSMISSION

Copyright © 1999 ATSG

Figure 141

AUTOMATIC TRANSMISSION SERVICE GROUP

89

Technical Service Information
BUSHING SERVICE

Figure 142

90

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information BUSHING SERVICE Copyright © 1999 ATSG Figure 143 AUTOMATIC TRANSMISSION SERVICE GROUP 91 .

Technical Service Information BUSHING SERVICE Figure 144 92 AUTOMATIC TRANSMISSION SERVICE GROUP .

Technical Service Information TORQUE SPECIFICATIONS Figure 145 AUTOMATIC TRANSMISSION SERVICE GROUP 93 .

Technical Service Information The Figure below shows the location of the identification tag. and how to read the information found on the tag Figure 146 94 AUTOMATIC TRANSMISSION SERVICE GROUP .

Technical Service Information SPECIAL TOOLS Figure 147 AUTOMATIC TRANSMISSION SERVICE GROUP 95 .

Technical Service Information Notes 96 AUTOMATIC TRANSMISSION SERVICE GROUP .

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