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th400 FSM PDF
th400 FSM PDF
qnj> ayeIpauLarU! puE PIEALO] ax, AavMNnS Paads apriyan Jo ssoypresar 208 pong ov yrysdn youue> ‘suey | — 33H pudsos ut st uopsmusuen ap 2oug ‘pug 10H 3th Ade pue uorsid ~rayur SOE STH, “28uEy ,] WY DAfeA [eRUCUE ay Sunsmeyxa Aq pordde st pueq 1wo0sy 241 Burye=q our “pods eo Jo spurs ‘ante ys £7 a top AEA MIS EZ Z DATA 1800 ouMssazg £91 omg 29 -29]96 2x9 Bu!sout Aq paysyiduosoe oq wes yIysUMop 7- V sanzayeu[ — YONI JOY 2 — WIND srpooAYT PeBinosog — _ prousjog 121d BO purg seoy BO Yai wend aanoayg — feuds aimypousnuy ug— purg wos YO— — yang premsod onitod 1909 uoses uy soe, — Bucy 27 ‘sienueg jo uoqeedy76-48 TURBO HYDRA-MATIC 400" AUTOMATIC TRANSMISSION—$5-46-48-49000 SERIES ‘onisod seo WH} w SOAIEA - poods IsHLA - UPL 11 -9F-9; 1 amaTea TURBO HYDRA-MATIC "400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES sr-90 coSuvy y] ~ 2893 say UI st vorssIUSUEN ou “par de 91e purg 494 pue yoIn|> premsoy ay], “paods suSu9 30 1 40 ssofpanias 338 puooas 01 ysdn jouuRD uowsstu 2p ‘98uey J — peads 1814 “sea asny 01 anys yum wos sue aw pue HaW or-oe Seweuoxdde mois poods pipe A 1 ple 0 10U19408 804 Z- 240 Uo BUN in a 0 a 1 sansoyat— Yanni JPHOR YO— 1pIN|D awipouzaryy praifious-oq — __ prousjog w919q o— " pueg way HO “yoni ang ‘aansayaut — Beads arerpausouy HO puog 1u0s-4 ¥O— — yom presog LVapjsed 2009 48114 W S9NreA, —ae0p yong — Bury 11 ‘syanuog jo vonesedg “&76-51 TURBO HYDRA-MATIC ““400" AUTOMATIC TRANSMISSION—45-46.48-49000 SERIES ves “asroaay UF S| uoysstua sun aq. paydde ase pung 3294 pue yoomy9 Iooup au, AMVINNOS: -aunssaud aun] 009 01 2 Wo asioray ‘purg svas ue oas98.mmay 24) 07 SOY 3009 2anssoud ayp Uo si9e Ost ‘OMS 241 UO SI "YPa4P P SIPDS }H0 980A Aqddv 0} uorsid youny St pue atiessed yr wos 2A) “aaea ys €-T js €-2 94 01 puz Worstd YIN weLIp a 2an2oyauy — yom uQ— pug may wo— HO purq wos HO — WoInyD PsEATOS prousjos suoiN youl — Beads ayeiponso1yy Jo vare sv] 249 01 Smoy a4pea fenuRUL ayp Oss [0 3SI9KIy Toso 86 aga OOg amssoug “yp oAng sy “g wosi “| (2¢-92 aunty 9G) ‘341 0) SMol] HOY) [Yo 98IDADY “yMOUID 9SIOA91 4p fo ainssoud auyy Moye 0 pouorsodas sf aajea jenueut ayy ‘wontsed asioa3y at 01 panow How wo wink ein} Pa as19n0y sjanueg 40 vopesedg -yTURBO HYDRA-MATIC "400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES 76-52 onsjursmeay Jo woncag S804) - gf aunaiy £58-9L HOUNID 4aTION YOLWIS AIVHS TVANWW ATaWASSY AGOS JATWA Avawassy 4aLI4 JAVHSNIVW. AVHS YVIO NNS ava N3AING aalawoaaads: awao aAlad YaLIWOGIIS HOLM SULWIG3WaaLNI HOLM1D 193u1a HOLMD ATION aNva ayaa OvudS JLWIGIWYIINI JAVHS LNdLNO HOUND GavAMOSTURBO HYDRA-MATIC "400" AUTOMATIC TRANSMISSION—45. 48-49000 SERIES 76. DIVISION III JADJUSTMENTS AND MINOR SERVICE 76-12 DETENT SWITCH ADJUSTMENT 362018 RETAINER MUST KOT _ OVERLAP cRIMPeD ‘At DumnueD LOCATION ‘AFTER REMOVING PERFORATEL SECTION OF INGULATION curs. || cagte AsseweLy DETENT CARLE ASSEMBLY (irre CODE wntTEl -TWROTTLE CABLE [PERFORATED SECTION J Srineucarion aos Lemme screw Houe DmiLLeD PIERCE 165/160 HOLE _/ [ST DIMBLE LOCATION 1. INSTALL CABLE THRU THROTTLE LEVER ROLE. INSTALL RETAINER [iivLon Reig SURE TT Is SEATED, 2, POSITION RETAINER ON UPPER. Exbor Gaace PER VIEWS": 2, WITH THROTTLE CABLE. GonneecTeo To canBURETOR SNDTHROTTLE LEVER, FULLY DEPRESS ACCELERATOR PEDAL TO ADJUST RETAINER. dam oi aerone asseMoLy. m2 Figure 76-39 - Detent Switch Adjustment 76-13 REMOVAL OF CONVERTER AND VACUUM MODULATOR 1, With transmission in portable jack, remove J-21366, Remove converter assembly, by pulling straight out, NOTE: The converter contains a large amount of oil. 2. Install Holding Fixture 8763-01 on the transmission so that the modulator assembly willbe located on the side of the holding fixture that is nearest the bench. 3. Install fixture and transmission into Holding Tool Base, 45-3289-20, with bottom pan facing up. See Figure 76-40. 4. Remove modulator assembly attaching bolt and re- tainer. See Figure 76.41 3. Remove modulator assembly and "0" ring seal from cease. See Figure 76-42. 6, Remove modulator valve from transmission case. 76-14 REMOVAL OF GOVERNOR, SPEEDOMETER DRIVEN GEAR, OIL PAN, AND FILTER NOTE: The following operations can be performed with transmission in vehicle76-84 TURBO HYDRA-MATIC 400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES Figure 76-40 Figure 76-41 1. Remove attaching belts, governor cover and gasket. See Figure 76-43, 2. Withdraw governor assembly from case. Sc Figure 76-44. 3. Remove speedometer driven gear attaching bolt and retainer. See Figure 76-45. MODULATOR VALVE r= — RING SEAL, VACUUM MODULATOR 74-5054, Figure 76-42 Figure 76.43 4. Witdruw speedometer driven gear assembly from case. See Figure 76-46, 5. Remove cil pan attaching bolts. 6. Remove oil pan and gasket. Discard gasket 7. Remove the filter assembly retainer bolt. See Figure 70.47.GOVERNOR“ ASSEMBLY 74507, Figure 7-44 ‘SPEEDOMETER DRIVEN GEAR ASSEMBLY igure 75-46 Figure 76-45 8. Remove filter and intake pipe assembly. Discard filter. See Figure 76-48 9, Remove intake pipe ta case "0" ring seal and discard. See Figure 76.48 7-15 INSTALLATION OF OIL FILTER 1. Install new case to intake pipe "O" ring on intake pipe and new filter assembly. See Figure 76. 48, 2. Install filter and intake pipe assembly attaching filter to valve body assembly with retainer bolt. Torque to 10 Ib. fl. See Figure 76-47. Figure 16-47 43. Insiall a new pan gasket on cil pan. Install attaching bolts and torque 10-13 1b. ft 78-16 INSTALLATION OF MODULATOR VALVE AND. VACUUM MODULATOR 1. Install modulator valve into the case, stem end out. See Figure 76-42 2, Install the "0" ring eal on the vacuum modulator, 3. Install the vacuum modulator into the case7656 TURBO HYDRA-MATIC "400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES LOCATING. TABS Figuee 76.48 4 Install the mogulator retainer and attaching bolt. ‘Torgue bolt to 13-20 Ib.ft. See Figure 76-41 76-17 INSTALLATION OF GOVERNOR ASSEMBLY 41, Install governor assembly into case, See Figure 76-44, 2. Attach the governor cover and new gasket with four (4) attaching bolls. Torque bolts to 15-20 Ibft. See Figure 76-34. Figure 76-34 DIVISION IV REMOVAL AND INSTALLATION 76-18 TRANSMISSION ASSEMBLY - REMOVAL AND INSTALLATION A. Removal 1. Raise vehicle and provide support for front and rear of 2. Disconnect front exhaust crossover pipe if necessary. 3. Disconnect propeller shaft 4, Place suitable jack under transmission and fasten trans- mission securely to jack. 5, Remove vacuum line from vacuum modulator. See Fig- lure 76-45. 6. Loosen cooler fine muts and separate cooler lines from transmission. See Figure 76-56. 7, Remove transimission mounting pad 10 cross member bolts. 8. Remove transmission cross member support to frame rail bolts. Remove cross member. 9. Disconnect electiical wire harness from transmission electrical connector. 10. Disconnect speedometer cable. 11. Disconnect shift linkage from transmission. 12. Disconnect transmission filler pipe at engine. Remove filler pipe from transmission. 13, Support engine at oil pau. 14. Remove transmission flywheel cover pan to case Lap- ping screws. REMOVE FLYWHEEL COVER PAN. 15, Mark flywheel and converter pump for reassembly in same pesition, and remove three converter pump 10 fly- ‘wheel ols. 16, Remove transmission case to engine black bolls 17. Move transmission rearward to provide clearance be- ‘ween converter pump and crankshaft, Install Converter Holding Tool J-21366 to retain converter. Lower trans- mission and move to bench. 1, Assemble transmission to suitable transmission jackTURBO HYDRA-MATIC "400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES 76-57 and raise transmission into position, Rotate converter 10 permit coupling of flywheel and converter with original relationship. Remove J-21366, 2. Install transmission case to engine block bolts. Torque to 30-40 Ib. ft. Dot not overtighten, CAUTION: Converter assembly must rotate freely by hand after converter pilot has been pushed forward into the engine crankshaft pilot hole. 3. Install flywheel to converter pump bolts. Torque to 25-35 Ib. ft. 4, Install transmission cross member support. Install ‘mounting pad to cross member. 5. Remove transmission jack and engine support. 6. Install transmission flywheel cover pan with tapping 7. Install transmission oil filler pipe using a new "O” ring. 8, Reconnect speedometer cable. 9. Connect electrical wire harness to transmission electri- cal connector. 10, Install propeller shaft 11, Reinstall front exhaust crossover pipe, if removed. 12, Install oil cooler lines to transmission. See Figure 76- 56, 13, Install vacuum line to vacuum modulator. 14. Fill transmission with fluid as described in Paragraph 76-41, subparagraph C.TURBO HYDRA-MATIC "400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES 76-58 spusdigy pus 2ury sermjapoy UMNORA - 55-94 27TH Aawassy 3u0438 Wo Aréav <> taaules —__aavewassy nai apoa smn ‘S aie Tena 3ONvTa SIL ‘ ASVHSANVHD 40 3 OL TaTwavd ANI 3a aSOH \ ~ 4 oan Sa NaHM soaps (87 10F-0E) (aaoway) 108 ond ‘ONiadiHs— 480 3ONVTS SIL ony "SNOLLIGNOD ONILVHad0 HIGNN Sova 40 33¥4 34 1snW SNOILOANNOD ® SANIT T1¥ tanoway) anid ‘ONIddIHS ® was- vis adia~TURBO HYDRA-MATIC ““400” AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES 76-59 "ART OF TRANSMISSION ASM PLUG (2) SHIPPING Oo” PLUG (2) - PART OF RADIATOR ASSEMBLY. REMOVE PRIOR TO INSTALLATION senewl awe MEW A PAINT COLOR (PINK) | PIPE ASM - INLET 1 ' . - NUT (2) 15:25 LB-FT | . PIPE ASM - OUTLET 1 | | 1525 BT 7 _NUT (2) ALL LINES & CONNECTINGS MUST BE FREE OF LEAKS UNDER OPERATING CONDITIONS. LINES MUST NOT CONTACT CHASSIS COMPONENTS. PAINT COLOR (PINK) q CLEARANCE BETWEEN iPES & RADIATOR HOSE TO BE .50 MIN, Figure 76-56 - Oil Cooler Lines7% }0__TURBO HYDRA-MATIC 400" AUTOMATIC TRANSMISSION: 1000 SERIES 6-4 DIVISION V 3. Remove valve body attaching bolts and detent roller and spring assembly, See Figure 76-59. OVERHAUL AND MAJOR SERVICE 76-19 REMOVAL OF PRESSURE SWITCH ASSEMBLY, DETENT ROLLER AND VALVE BODY ASSEMBLY, GOVERNOR PIPES, AND SPRING ASSEMBLY DETENT SPRING ASSEMBLY NOTE: The following operations can be performed with transmission in vebiele 1. Disconnect the lead wire assembly from the pressure switch assembly. See Figure 76-57 Figure 76.5? NOTE Do not remove solenoid attaching bolts NOTE Iftransmission isin vehicle. front servo group may drop out 28 control valve assembly is removed. 4, Remove valve body assembly and governor pipes. See Figure 76-60, covernor PIPES CONTROL VALVE Figure 16:57 ASSEMBLY, 2. Inecessary, remove the pressu: Figare 76-58, Figure 76-60 NOTE Do not allow manual valve to fall out of valve body assembly. = 76.903. 1. Remove governor screen assembly from governor feed pipe in case or from end of governor feed pipe. See Figure Figure 76-58 Y6-61, Clean screen in clean solvent and air dry.TURBO HYDRA-MATIC 400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES 76-61 GOVERNOR SCREEN ASSEMBLY GOVERNOR FEED PIPE HOLE Figure 75-61 DETENT SOLENOID WIRE ELECTRIC WIRE CLIP Figure 16-83 1, Remove rear servo cover attaching bolts, servo cover, 6. Remove governor pipes from valve body assembly, and gasket. (Discard gasket), See Figure 76- 64. See Figure 76-62. REAR SERVO COVER 74-815 Figure 76-62 7. Disconnect detent solenoid wire from case connector. 2. Remove rear servo assembly from case. See Figure: See Figure 76-63 7665 78-20 REMOVAL OF SERVO, CASE CONNECTOR. VALVE BODY SPACER, GASKET FRONT SERVO, MANUAL DETENT, AND PARK LINKAGE 3, Remove serve accumulator spring. Sex Figure 16-66 NOTE: The following operations cen be performed with the transmission in the vebicle 4. Check band apply Pin,76-62 TURBO HYDRA-MATIC "400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES REAR SERVO ASSEMBLY Figure 76-66 44. Attach band apply pin Selection Gage J-21370-6 with 32137055, to teancmission ease with altaching bolts Torque 6-10 Ib. b. Apply 25 Ibift. torque and seiecr proper pin to be used daring assembly of transmission, See Figure 76-61, TORQUE Figure 76-67 ‘These are three selective pins identified as follows: Pin Identification Pin Size 3 Rings. Long 2 Rings Medium I Ring Short 76-47 IF hoth steps of J-21370-5 are below the gage surface, the long pi should be used. If the gage surface is between the steps, the medium length pin should be used. The short pin should be used if both steps of the gage pin are above the gaze surface. The identification ring is located on the band lug end of the pin. Selecting the proper pin is theequivalent of adjust ing the bang. NOTE: Ifa new pin is required, make note of pin size required, and remove gage from transmission case. ‘Compress fingers on electrical connector sleeve and \draw. See Figure 76-63, CAUTION: 1f the transmission isin the vehicle, be careful When the detent solenoid is removed, as it prevents the spacer plate and gasket and check balls from dropping down.Figure 76.68, Figuce 76-70 & Remove six (6) check balls trom cored passages in ‘transmission case. See Figure 76-71. 6. Remove detent solenoid attaching bolts, solenoid as- sembly, and gasket. Soe Figure 76.69. 7. Remove valve body assembly spacer plate and gasket. See Figure 76-70, Figure 7671 9, Remove front servo piston, retainer ring, servo pin, soring fetainer, and spring from transmission. See Figure 76-71. 10. Tit becomes necessary to remove the internal manual linkage proceed as follows:76-64 TURBO HYDRA-MATIC “400” AUTOMATIC TRANSMISSIOI 15-46-48-45000 SERIES MANUAL SHAFT SERVO PISTON RETAINER RING SERVO PIN oa SERVO SPRING Pee SERVO PISTON RETAINER =~ SPRING setae, LG Figure 75-72 Figure 76-74 Soe putrescl jam nut holding detent lever to manval shaft, NOTE: Ze may be necessary to bend pin to remove See Figure 76-73 ¢. Remove deteat lever from the manual shah . Remove manual shaft and jam nut from case. See Fig- ure 76-75, RETAINING PIN. raxninG LOCK NUT sy, LOCK” DETENT LEVER, BRACKET DeTENT ROLLER D swanvar AND MINE ASSEMBLY: SHAFT PARKING PAWL papa, ACTUATOR ACsemexy Anne nespaine —uPseat—7 PAWL SHAFT V" RETAINER: FO ae AINE Pa ‘ RETURN SPRING “cur plus ) 145318 Figure 76-75 Figure 76-73 NOTE: IFrecessary remove manual shaft 49 cas: lip sat CAUTION: Bo not lose jam nut as it becous free trom ¢. Remove parking pawl actuator red and detent lever shan. assembly, b, Remove manuel shaft retaining pin rom case, See Fig- _f, Remove attaching bolts and parking lock braket. See ure 76-74. Figure 76-76.TURBO HYDRA-MATIC ““400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES 76-65 74-532 Figure 76-76 Figure 76-78 i. Remove parking pawl shaft cup plug by inserting a seewdriver between the parking pawl shaft and the case 1, and prying outward. Sec Figure 76-79. g. Remove parking pawl return spring, See Figure 76-77 CUP PLUG Figure 76.77 Figure 76-79 NOTE: The following steps are to be compleied only ifone or more of the parts invalved require replacement. j. Remove parking pavl shaft, and parking pawl. See Fig- hh, Remove parking pawl shaft retainer. See Figure 76-78. ure 76-80.TURBO HYDRA-MATIC ‘400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES 2. Remove extension housing to case attaching bolts, See Figure 76-42. PARKING PAWL Figure 76-80 Figure 76-82 76-21 REMOVAL OF REAR OIL SEAL AND EXTENSION HOUSING 3, Remove extension housing and extension housing to case gasket. See Figure 76-83, NOTE: The allowing operation can be perorned with the wansmission in the vehicle. 1, I necessary to replace, pry the rear oil seal from the Figure 76.83 76.214 FRONT UNIT END PLAY CHECKING PROCEDURE 1. Check front unit end play as follows; Figure 7681 . Remove one front pump attaching boltTURBO HYDRA-MATIC "400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES b. Install a 5/16-18 threaded slide hammer bolt or J-7004, into bolt hole in pump. See Figure 76-84. Figure 76-84 Mount dial indicator on the rod and index indicator to register with end of turbine shaft. See Figure 76-84. 4, Push turbine shaft rearward. Posh output shaft forward £ Set dial indicator to Zero. g Pull turbine shaft forward. Read the resulting travel or end play which should be 1003” - 024". The selective waster controlling this end play is the washer located between the pump cover and the forward clutch housing. If more or less washer thickness is re- quired to bring end play within specifications, select the proper washer from the chart below. Thickness, Color 060-.064 Yellow 071-075 Blue 082-.086 Red 093-.097 Brown 104-.108 Green Black 2126-.130 Purple 76-48 76-67 NOTE: An oil soaked washer may tend to discolor so that it will be necessary (0 measure the washer for its actual thickness. 7622 REMOVAL OF OIL PUMP, FORWARD CLUTCH. INTERMEDIATE CLUTCH AND GEAR UNIT ASSEMBLY 1, If'seal replacement is necessary, pry seal from pump. See Figure 76-85, Figare 76.85 2. Remove pump aitaching bolts. 3. Install threaded stide Hazamers, 3.7004, into holt holes in the pump body, tighten jam nuts and remove pump assembly from cust, See Figure 76-86. TIGHTEN JAM NUTS BEFORE REMOVING PUMP. Figure 76-8676:68 TURBO HYDRA-MATIC “400” AUTOMATIC TRANSMISSION—45.46-48-49000 SERIES 4, Remove and discard pump to case oil sal ring end 8. Remove front band assembly. gasket 9. Remove sun gear shat. See Figure 76-9, 4, Remove forward clutch and turbine shaft assembly from transmission. See Figure 76-87. Figure 75-89 Figure 76-87 10. Check rear end play as follows: 6. Remove forward clutch hub to direct clutch housing. Install J-7004 into an extension housing attaching bolt thrust washer, if it did not come out with forward clutch ole, housing assembly, . Mount dial inéicator, on Slide Hammer Bolt J-7004 and 7. Remove direct clutch assembly. Sco igure 76-88, index with end of the output shaft. Sex Figure 76.90. DIAL INDICATOR 47004 74-548 Figure 76-98 Figure 76.90TURBO HYDRA-MATIC "400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES 76-69 c. Move output shaft in and out to determine end play. End play should be from .007° - 019". The selective ‘washer controlling this ead play is the steel washer having. 3 lugs that is located between the thrust washer and the rear face of the transmission case Af different washer thickness is required to bring the end play within specification, it can be selecied from the fol- Towing chart. Notches and/or Thickness Numeral 074-078 None 1 082-.086 1TabSide 2 .090-.094 2Tabs Side 3 098-102 1TabO.D. 4 106-110 2TabsOD. 5 14118, 3TabsOD. 6 76-49 1, Remove center support to case bolt using 2 3/8" 12 point thin wall deep socket, See Figure 76.91 a, 6-758 Figure 7691 12, Remove intermediate clutch backing plate to ease snap ring. See Figure 76-92. 13, Remove intermediate clutch backing plate, 3 composi tion ond 3 steel clutch plates. See Figure 76-93. 14, Inspect condition of composition and sted plates. Do not diagnose 4 composition drive plate by color. = Figure 76-93 ‘A. Dry composition plates with compressed wir and in- spect the composition surface for: 1 2 3 iting and faking Wear Glazing Cracking Charing Chips or metal particles imbedded in Tining7&7 TURBO HYDRA-MATIC '*400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES If @ composition drive plate exhibits any of the above conditions. replacement is required, B. Wipe steel plates dry and check for heat discoloration. If the surface is smooth and an even color smear is in dicated, the plates should be reused, If severe heat spot discoloration or surface scuffing is indicated, the plates must be replaced, 15. Remove center support to case retaining snap ting. See Figure 76-94. igure 76.94 16, Remove entire gear unit assembly by lifting with J- 21795 and J-7004 Slide Hammer. See Figure 76. 95 Figure 7695 17. Remove output shaft to case thrust washer from rear ‘of the output shaft or inside case. See Figure 76-96. THRUST WASHER 74-554 Figure 76.96 18. Remove output shaft 10 yoke “O" ring if required. 19. Place gear unit assembly with output shaft facing own in hole in work bench, See Figure 76.97 Figure 76.97 20. Remove rear unit selective washer from the transmis. sion case. See Figure 76-98,\ATIC "400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES 76-71 REAR BAND “® Figure 76.98 ‘Figure 7-100 21. Remove support to ease spacer. See Figure 76.99 ee = 76-23 GEAR UNIT ASSEMBLY (S09 Figure 76-288) amabiy 1. Remove center support assembly. See Figure 76-101 CENTER SUPPORT TO CASE SPACER LOCATE SPACER GAP ‘ADJACENT TO CASE CENTER BAND ANCHOR PIN SUPPORT ROLLER CLUTCH Figure 76-99 e808 Figure 76-101 22, Remove rear band assembly. See Figure 76- 100, 2, Remove center support 10 reaction carrier thrust washer, See Figure 76-102.STHRUST WASHER, Install J-7004, Slide Hammer into bolt hole Figure 76260 ¢, Mount the dial indicetor om the rod and index indicator to register with end of turbine shatt 4. Push turbine shaft rearward ¢. Push ourput shaft forwaed {Sel dish indicator to zee «Pall turbine shaft forward Read the resulting travel or end play which should be 003" - 024”. The selective washer controlling this end play is the washer located between the pump cover and the forward clutch housing. If more or less washer thickness is te- quired to bring end play within specifications, select the proper washer from the chart below. Thickness Golor .060-.064 Yellow 071-075 Bluc 082.086 Red 093.097 Brown 104-,108 Green «115-119 Black -126-.130 Purple 78-48 NOTE: An oil soaked washer niay tend to discolor so that ‘twill be necessary 10 measure the washer far its actual thickness 24, Install the remaining front pump attaching bolt and ‘new seal. Torque bolts to 15-20 lb. f. 76-34 REAR EXTENSION HOUSING 1, Thsiall the extension housing to case gasket on the extension housing, 2, Attacls the catursion huusiag tw tht case using attaching, bolts. Torgue belts to 20-25 Tb. A. 3. If necessary, install a new rear Seal, coat the outside diameter with a good sealer and using Tool J-21464 on. "BI" and Tool J-21359 on other models, drive the seal in place. See Figure 76-261,76-116 TURBO HYDRA-MATIC "400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES 5. Install retaining hex-lock nut on manual shafi. See ‘igure 76-263. #21404 (Br) 1.21359 (Bs Ow", “BC 8 "BB REAR SEAL 76-766 MANUAL | SHAFT | DETENT Figure 76-261 | IVER per 78-36 INSTALLATION MANUAL LINKAGE Finure 76-2 1. If necessary, install a new manual shaft to case lip seal lig 5/4" Glnmietse-r00 60 era sh case 6, Install manual shaft retaining pin indexing with groove 64 jin manual shaft, See Figure 7 2. If removed, insert the actuator rod into manval detent lever from side opposite pin. 3, Install the actuator rod plunger under the parking bracket and over the parking paw 4, Install the manval shaft through the case and detent lever. See Figure 76-262 RETAINING PIN Figure 76-264 NOTE it may be necessary to bend pin to install Straighten pin as it is installed. Figure 76-262 7. Tighten lock nut on manual shatt.TURBO HYDRA-MATIC "400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES 76-117 7636 INSTALLATION OF CHECK BALLS, CONTROL VALVE SPACER PLATE AND GASKET, DETENT SOLENOID, FRONT SERVO ASSEMBLY, AND ELECTRICAL CONNECTOR 1. Tnsiall two control valve assembly a heads cut off as guide pins, as shown in (GUIDE PINS Figure 76.255 2. Install sla check bally into ball seat pockets i tania sion case. See Figure 75-266, Figuce 76-266 NOTE 17 rransmission is in car, install check balls into ball seat pockeis on spacer plate. See Figure 76-266A, SPACER PLATE TO CASE GASKET SPACER PLATE 76-2660, Figure 76-2664, 3. Install conirol valve spacer plate-to-case gasket (gasket with extension for detent solenoid). 4, Install control valve spacer plate. 5. Install detent solenoid gasket. See Figure 76+ 267, SOLENOID ASSEMBLY Figure 76-267 6, Install detent solenoid assembly with connector facing outer edge of case. Do not tighten bolts al. +this time.76-118 TURBO HYDRA-MATIC ‘-400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES SERVO SPRING we €) SPRING RETAINER TEFLON OIL SEAL RING SERVO PISTON 76-268 Figure 76-268 7, Install front servo spring and spring retainer Into transmission case, See Figure 76-268, 8. Install retainer ring in front servo pin groove und install pin into case so thal tapered end contacts band. Make certain retainer ring is installed in servo pin groove, 9. Install seal ring on servo piston, iF vemoved, snd install ‘on scrvo pin with flat side of piston positioned toward bottom pan. See Figure 76-268, LOCATE FEELER MULATOR PISTON CAN} ENTER BORE aaa 76-2684 Figure 76-2684, NOTE: The teflon ring allows the front servo piston to side very freely in the case. The free fit of the ting in the bare isa normal characteristic and does not indicate leak age during operation. The teflon ring should enly be re placed if't shows damage or if evidence of leakage during operation exists, NOTE. 4 crausunssion is tn car, assemote tront serv group, as shown in Figure 76-208, and install ibis group Of purts into front servo bore in case and hold Slip a X ELECTRICAL CONNECTOR Figure 76.269TURBO HYDRA-MATIC 400" AUTOMATIC TRANSMISSION—45-46- length of straight, clean feeler gauge or shim stock (atout 020") between spacer plate and front servo piston to tem- orarily retain front servo group. See Figure 76-2684. 10. Install “O* ring seal on the solenoid connector. 11. Install connector with lock tabs facing into cass, posi- tioning locator tab in notch on side of case. See Figure 76-26. 12 Tnslall detent wire and lead wire to case connecter. See Figure 76-270, = ae ELECTRIC WIRE CLIP, igure 75-270 REAR SERVO ASSEMBLY Figure 76-271 49000 SERIES 76-119 NOTE: Check by pulling on detent connector wire. If de- feat couaevtor wire cast be removed, turn wire connector over and reistall into connector. See Figure 76-270 76.37 INSTALLATION OF REAR SERVO ASSEMBLY | Install rear servo accumulator spring into case. 2, Install rear servo assembly into case. See Figure 76-271 3. Install rear servo gasket and cover. See Figure 76-272 REAR SERVO COVER. Figure 76-272 4, Tastall attaching bolts ‘Torque bolts to 15-20 Ib. ft. See Figure 76-273, servo cover {7 Figure 75.27376-120 TURBO HYDRA-MATIC “400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES 76.38 INSTALLATION OF CONTROL VALVE ASSEMBLY, GOVERNOR PIPES, AND GOVERNOR SCREEN ASSEMBLY |. Install governor pipes on control valve assembly. Gov- ernor pipes are interchangeable. See Figure 76-274 74.782 Figure 76-274 2. Install governor sereen assembly, open end first, into governor feed pipe hole in case Chole nearest the center of transmission). See Figure 76- 275. GOVERNOR SCREEN ASSEMBLY GOVERNOR FEED PIPE HOLE Figure 16-275 NOTE: If wransmission is in vehicle, before installing the control valve assembly and governor pipes, as outlined in Step 3 below, insert governor screea, closed end first, into governor feed pipe. (This pipe locates in the govemor feed Pipe hole in the case nearest the center of the transmis sion). See Figure 76.265 3. Install control valve aembly and governor pipes on transmission, while carefully aligning the governor feed pipe over the governor screen. See Figure 76- 265, Make Certain gasket and spacer do not become mispoxitioned, NOTE: Check manual valve to make sure it is indexed! ‘properly with pin on detent lever and goveraoe pipes to make certain they are properly seated in case holes. 4, Start control valve assembly altuching bolis and make certain lead wire assembly clin is installed NOTE: if transmission is in vehicle, remove Peeler stock before tightening any contral valve bolts 5. Remove guide pins and install detent roller and spring. assembly and remaining bolis. See Figure 76- 276. DETENT ROLLER AND SPRING ASSEMBLY Figure 76.275 6. Tighten solenoid and valve body attaching bolls, Torque bolts to 6-10 Ib. 7. If removed, install the pressure switch assembly, 8, Connect lead wire assembly to pressure switch assem- bly, 76-39 INSTALLATION OF SPEEDOMETER DRIVEN GEAR ASSEMBLY AND CONVERTER ASSEMBLY 1. Insta the speedometer driven gear assembly. See Fig- ure 76-277.TUREO HYDRA-MATIC “400 AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES 76-121 2. Remove the output shaft, valve body, support plate, and = governor from the cate. 3, Assemble transmission case in fixture J-8763 and mount in a vise. See Figure 76-279. — Sy SPEEDOMETER DRIVEN: RY GEAR ASSEMBLY yh ‘O° RING SEAL 2. Install the speedometer driven gear retainer and attach- ing bolt. See Figure 76278 4, Clean off excess stock from the governor o- ring seal to case mating surface. Sev Figure 76-260. Figuie 76.278 3, Install converter assembly into oll pump. Extreme care ‘must be taken not to damage sea. NOTE: Make certain converter hub drive tangs are fully ‘engaged with pump drive your tang, eae 4. Install Converter Holding Too! J-21366 to retain con- cvantegtunll ready fo-inetall'in'c4r: 5. Loosely bolt the drill bushing fixture J-22976-1 to the 78-40 INSTALLATION OF GOVERNOR BUSHING eS 1, Remove transmission from car. 6. Place the alignment arbor J-22976-3 into the drill bush-76-122 TURBO HYDRA-MATIC "400" AUTOMATIC TRANSMISSION. ing fiature and down into the governor bore until it bot- toms on the dowel pin. See Figure 76-281, Figure 76-281 7. Torque the bolts on the drill bushing fixture 8-12 Ib f Do not over torque and strip the threads. NOTE: The alignment arbor should be sble to rotate freely. after the bolts are properly torqued. Ifthe aligament arbor cannot be rotated by hand, rechack the work performed in step 4, 8, Remove the alignment arbor, 9. Using reamer J-22976.9 and drive rachet, and ream the governor bore using the following procedure: CAUTION: Hand Ream Only 4. Oil the reamer, drill bushing, and governor bore. b, Use 5-10 Ibs. of feeding force on the reamer. See Figure 76.282 © Affer each 10 revolutions remove the reamet and dip it into a cup full of transmission cil. This will clean the chips from the reamer and lubricate it. See Figure 76-283. 4, When the reamer reaches the end of the bare, continue reaming the bore until the reamer bottoms out on the dowel pin in the case. Ar this point, rotate the reamer 10 complete revolutions. ¢, Remove the reamer using a clockwise rotation and 5-10, Ibs. force upward. IMPORTANT: Pulling the reamer ont without rotating it may score the borecausing a leak between the case and the bushing. }6-48-49000 SERIES RATCHET 8 SOCKET 5-22976-9. TRANSMISSION on 75208 Figure 76-283 10. Remove the drill bushing fixture from the cast 11. Thoroughly clean the chips from the case, visually check the governor iced holes to insure that they are free from chips, 12. Install the bushing using the following procedure: a. Note the two (2) notches at one end of the bushing. b. Position the notches so that one notch is toward the front of the case and the other is toward the bottom of the case. See Figure 76-284.TURBO HYDRA-MATIC "400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES NOTCHES BUSHING Figure 76-284 . Use J-22976-3 alignment arbor and bushing installer to rive the bushing into the case. See Figure 76-285 CAUTION: 4 drasy Aaunmer should be used 10 strike the hardened steel bushing installer (ool BRASS HAMMER Figure 76-284 4. Drive the bushing until it is flush with the top of the bore. See Figure 76-286. 12, Oil a new governor and insert it into the installed bushing, The governor should spin freely. If slight Koning on the busing is necessary, use crocus or fine emery cloth and move in the angular direction nly. 76-123 Figure 76-286 8. Transmission Identification Number A production identification number is stamped on a metal tag, located in the lower right side of the trancmission ‘The production code number is located along the top of the tag. Since the production code number furnishes the key lo.construction and interchangeability of parts in each transmission, the number should be used when selecting replacement parts as listed in the master parts list. The umber should always be furnished on product reports, AFA forms, aud all correspondence with the factory concerning a particular transmission, (On all 1971 Turbo Hydra-Matic 400 transmissions, the car serial number is stamped on a pad located just abore the bottom pan face on the left hand side of the transanise C. Turbo Hydre-Matic 400 Fluid Recommendations Use DEXRON Automatic Transmission Fluid only in all 1971 model Turbo Hydra-Matic 400 automatic trans- missions (GM Part No. 1050568-69-10 or other fluid hav= ing DEXRON identifications) DEXRON js an especially formulated automatic trans- mission fluid cesigned to improve transmission operation. NOTE: Die DEXRON or tyne ‘A" automatic transmis Sion fluid identified by the mark "AQ-ATF" followed by at mumber and the suffix letter "A" (AQ- ATF-XXXX-A) in all automatic transmissions prior t0 the 1968 models. The oil pan should be érained and the filter replaced every 24,000 miles and fresh fluid added to obtain the proper level on the dipstick. See sub-paragraph 2 for proper refill76-124 TURBO HYDRA-MATIC "400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES procedures. For cars subjected to heavy city traffic during hot weather, or in commercial use, when the engine is regularly idled for prolonged periods, the oil pan should be drained and the filter replaced every 12,000 miles 1. Checking and Adding Fivid Fluid level should be checked at every engine oil change, The "FULL" and "ADD" marks on the transmission dipstick indicate one pint difference, To determine proper fluid level, proceed as follows: CAUTION: The full mark on the dipstick is an indication of transmission fluid at normal operating temperature of 180 degrees F. This temperature is only obtained efter at least 15 miles of expressway driving or equivalent of city driving. 1. With manual control lever in Park position start engine. DO NOT RACE ENGINE. Move manual control lever through each range. 2. Iinmediately check fluid level with selector lever in Park, engine running, and vehicle on LEVEL surface. At this point, when a reading is made, fluid level on the dipstick should be at the “FULL’ mak. 3, Ifadditional fluid is required, add fluid to the "FULL" mark on the dipstick. If vehicle can not be driven 15 expressway miles oF equiva- Tent, and it becomes necessary to check fluid level, the transmission fluid must be at room temperature (70 de- grees F), With fluid at room temperature (70 degrees F) follow steps 1, 2, and 3 below. 1. With manual control ieverin Park position start engine DO NOT RACE ENGINE, Move manual control lever ‘through esch range. 2. Immediately check Muid level with selector lever in Park, engine running, and vehicle on LEVEL surface, At this point, when a reading is made, fluid level on the dipstick should be 1/4” below the “ADD* mark. 3. additional fluid is required add Muid to bring level to, 1/4” below the “ADD” mark on the dipstick, CAUTION: Do nor Overfill, as foaming and loss of Nuid through the vent pipe might occur as fluid heats up. If Mluid 18 too low, especially when cold, complete loss of drive may result which can cause transmission failure. NOTE: 1f transmission fluid level is correctly established at 70 degrees F it will appear at the “FULL” mark on the dipstick when the transmissions reaches normal operating temperature (180 degrees F). The fuid level is set 1/4" below the “ADD” mark on the dipstick to allow for ex- pansion of the fluid which occurs as transmission temper atures rise to normal operating temperature of 180 degrees F 2. Draining Oi! Pan and Replacing Filter (a) Raise ear on hoist or place on jack stands, and provide container to collect draining fluid. (b) Remove oil pan and gasket. Discard gasket (©) Drain fluid from oil pan. Clean pan with solvent and dry thoroughly with clean compressed air. (@) Remove oil filter retainer bolt, oil filter, intake pipe assembly and intake pipe to case “O" ring. Discard the filter and intake pipe to ease “O" ring. (6) Install new “0” ring seal on intake pipe and place pipe assembly into grommet on new filter assembly. With new “O" ring on intake pipe, install pipe and filter assembly into case, attaching filter to valve body assembly with retainer bolt, Torque to 10 ib (© Install new gasket on oil pan and install pan, Tighten attaching bolts to 12 Ib. (g) Lower car and add 5 pints of transmission fluid through filler tube (h) With manual control lever in Park position, start en- gine. DO NO RACE ENGINE. Move manual control lever through each range. (i) Immediately check fluid level with selector lever in Park, engine running, and vehicle on LEVEL surface. () Add additional fluid to bring level to 1/4" below the FADD" mark on the dipstick. NOTE: The fluid level is set 1/4” below the “ADD” mark on the dipstick to allow for expansion of the uid which occurs as transmission temperatures rise to normal oper- ating temperature. CAUTION: Do aot overfill. 3. Adding Fluid to Fill Dry Transmission and Converter Assembly The fluid capacity of the Turbo Hydra-matic 400 trans- mission and converter assembly is approximately 23 pints, bbut correct level is determined by the mark on the dipstick rather than by amount added. In cases of transmission overhaul, when a complete fill is required, including a new converter proceed as follows: NOTE: The converter should be replaced only if the con- verter itself fails. On any major failure, such as a clutch or gearset, the filter must be replaced.76-125 TURBO HYDRA-MATIC “400” AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES 282-92 Nid ONINIVI3Y ond 208 ONIUdS IATA ZS Nid ya>vdS BAIWA TE Nid ONINIVLAY ONIHSNG YOLVINGOW EZ DNIUdS ATVA E% BAIWA HOLY INGOW €-% ONIMdS ALVIGAWAALNI Z-E favon omnia AAIWA 14IHS 6% “Le AATWA YOLWINWNDOW ANVWIad Z- “Of ONIHSNE YOLVINWNDDY ZL “6% BATWA HOLY INWNDOV Z-L * “82 (12GOW 8a. NI. G3SN LON) ONINdS: “kt AAVANOIAS HOLY INWNDOV Z-L “"% 9M 3408 “St Nid ONINIW138 G7AOCYD ve Nid ONINIVLY * 4 ‘ONIHSNA HOLY INGOW Z-L “ FATWA HOLW IND GL We ONIUdS AYWWId HOLY INWNDDY ZL" OL 1 iL tL “ut ONIUdS IATVA YOLVINGOW Z-1 “VOL NINES HOLVINDIY 2 JAVA YOLVINGOW @ JATVA LNSLIG 7-1 JATWA LAIHS 2-1 ONS YOLVINT 1NILIG Nid Y3DveS JAIWA YOLWINOT NIG SATA LNa1a0 nid 2408 Nid ONINIV94 3ATWA TWANYW Haddon aod & ‘Ol5 3 3 7 Z 3 a 3 3 2 g 5 = 8 2 HYDRA-MATIC = 76-126 URKEY IIH 4890) JO IA popoTde guz-gg omni, 88C-9L zova 30NVU ‘al Livus av20. NaS \ arawassv avao Nas Onn avao 4,28HN2 ay a} ania Now NOUV! aaHSVM ISNYHL Onwvaa arassy “By yaRV> ‘oNnvas And 10 Me = LVS Nivy ONtd avNS ~ 9 JQ . JOVA JONVU “al ava 30NV TO OND ..0, ava9 { WNIBINI m \ ONBVaE \ away Ss yova avy BONY "CO ONVU aT d aaHsv Im v ‘SMH GONVI avao aang 4a 3WOUAMS ONa ayNsTURBO HYDRA-MATIC “400” AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES 76-127, DIVISION VI SPECIFICATIONS 76-41 GENERAL SPECIFICATIONS [A MODEL DESIGNATIONS esses) SR ote nl oR | "MARS PES ct onl FART [BNC| colon eee |Raieeoutton 76-42 BOLT TORQUE SPECIFICATIONS thread Torque Location Sie tie. Selenord Assembly fo Cose nee a0 a Valve Body to cere. 1420 a Pump Body to Cover. 5/1618 18 Pump Assembly To Case Bret 18 Rect servo Cover fo Cote Shere 18 Governor Covor fo Cose. =. sets te Porkina Brake Bracket fo Cos bree 18 Vacuum Meduleor Retoner to Case... siete 18 Valve Body to Cone. siete ° Oil Pen to Case. : seis 2 Gove Extension 0 Cose me ae 16 23 Oil Fier to Volve Body : : 420 io Pressure Sich Assembly Vez s10 Core to Center Support. Be16 2025 Manuel Shalt fo Iraide Detent Lever gen 1520 Line Pressure Toke Of 827 ots Cooler Connector sors vais 2320 nas76-128 TURBO HYDRA-MATIC ‘"400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES (a) Add 10 pints of transmission fluid through filler tube, NOTE: {7 installation of a new converter is not required add only 6 pints of transmission fluid. (b) Wich manual control lever in Park position start en- zine and place fast idle screw on middle of fast idle cam. DO NOT RACE ENGINE. Move manual control lever through each range. (c) Immediately check Muid level with selector lever in Park, engine running, and vehicle on LEVEL surface. (@) Add additional fluid to bring level to 1/4” below the “ADD” mark on the dipstick NOTE: Fluid level is set at 1/4° below the “ADD* mark ‘on the dipstick to allow for expansion as Muid heats up. CAUTION: Do not overfill, D. Turbo Hydra-matic 400 Tawing Instructions Tia Buick equipped with Turbo Hyéra-matie 400 trans- ‘mission must be towed, the following precuutions must be observed: The car may be towed safely on its rear wheels with the shift lever in neutral position at speeds of 35 miles per hour or less under most conditions. However, the drive shaft must be disconnected or the car towed on its front Wheel if Tow speeds in excess of 35 mph are necessary, ‘Car must be towed for extended distances (over 50 miles) or, Transmission is not operating properly. Af car is towed on its from wheels, the stecring whes! should be secured to keep the front wheels in straight- ahead position E Rocking Car Irit becomes necessary to rock the car to free it from sand, mud or snow, move the selector lever from “D’ to "R" in a repeat pattern while simultaneously applying moder- ate pressure to the accelerator. Do not race engine. Avoid spinning wheels when trying to free the car.ra 76-130 TURBO HYDRA-MATIC “400" AUTOMATIC TRANSMISSION—45-46-48-49000 SERIES J-3289-20 J-8763 J-21363 J-21362 3-21409 J-21368 J-21366 J-2619 \J-7004 J-4880 J-5586 J-9578 J-21795 J-21370 J-8001 J-21464 J-21359 -21369 J-21465 J-8092 J-BB \J-21885 HOLDING FIXTURE BASE HOLDING FIXTURE SEAL INSTALLER SEAL INSTALLER SEAL INSTALLER PUMP BODY TO COVER ALIGNMENT BAND CONVERTER HOLDING STRAP SLIDE HAMMER SLIDE HAMMERS SNAP RING PLIERS SNAP RING PLIERS SPEEDO GEAR REMOVER GEAR ASSEMBLY REMOVER AND INSTALLER APPLY PIN SELECTION GAUGE DIAL INDICATOR SET REAR SEAL INSTALLER OIL PUMP SEAL INSTALLER CONVERTER PRESSURE CHECK FIXTURE BUSHING SET DRIVE HANDLE FT. LB. TORQUE WRENCH 1-2 ACCUMULATOR "'C'' CLAMP T&795 Figure 76-201 - Tool Picture Identification