RENR6507-02

October 2004

Specifications
773E Off-Highway Truck and 775E
Off-Highway Truck Power Train
BDA1-Up (Machine)
BEC1-Up (Machine)
 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
RENR6507-02 3
Table of Contents

Table of Contents
Specifications Section
Gear Pump (Power Train) ....................................... 4
Pressure Switch (Power Train Oil Filter) ................. 6
Torque Converter ................................................... 7
Relief Valve (Torque Converter Outlet) ................... 8
Lockup Clutch and Solenoid Valve (Torque
Converter) ............................................................. 9
Lockup Clutch and Solenoid Valve (Torque
Converter) ............................................................ 11
Solenoid Valve (Torque Converter Lockup
Clutch) ................................................................. 14
Temperature Sensor (Torque Converter Oil and
Brake Oil) ............................................................ 14
Transmission Control ........................................... 14
Accelerator Control ............................................... 15
Transmission Hydraulic Control ........................... 16
Selector and Pressure Control Valve
(Transmission) .................................................... 19
Pressure Control Valve (Transmission) ................ 22
Solenoid Valve (Transmission Upshift/
Downshift) ........................................................... 24
Rotary Actuator (Transmission) ............................ 25
Transmission Planetary ....................................... 26
Speed Sensor (Transmission) .............................. 28
Transfer Gears ..................................................... 28
Drive Shaft (Main) ................................................. 29
Differential and Bevel Gear .................................. 30
Differential and Bevel Gear .................................. 32
Differential ............................................................ 33
Rear Axle Housing ............................................... 34
Rear Wheel .......................................................... 35
Magnetic Sensor (Wheel Speed) .......................... 36
Final Drive ............................................................ 37
Tire Valve ............................................................. 38
Window Wiper and Wiper Motor ........................... 38

Index Section
Index ..................................................................... 40
4 RENR6507-02
Specifications Section

Specifications Section
i01865701

Gear Pump (Power Train)

SMCS Code: 5073-PWT
Part No.: 111-6841

g00951251
Illustration 1

Rotation of the pump is counterclockwise when the (1) Clearance between a new gear and a new
pump is viewed from the drive end. body ... 0.112 ± 0.026 mm (0.0044 ± 0.0010 inch)

Lubricate the pump with oil before you operate the
pump.
Bench test requirements: SAE 10W oil must be
stabilized at 52° ± 3°C (125° ± 5°F) before the test is
performed.
(2) Clearance between a new gear and a new
manifold ................................. 0.089 ± 0.028 mm
(0.0035 ± 0.0011 inch)
(3) Dimensions of new shafts and of new pump
bodies

(A) Scavenge Section
Minimum output ............. 200 L/min (53 US gpm)
Test pressure .............................. 70 kPa (10 psi)
Test speed of pump ............................. 1800 rpm
(B) Charging Section
Minimum output ............. 160 L/min (42 US gpm)
Test pressure ........................ 2760 kPa (400 psi)
Test speed of pump ............................. 1800 rpm
Diameter of the drive shafts and diameter of the
driven shafts ........................ 31.742 ± 0.005 mm
(1.2497 ± 0.0002 inch)
Diameter of the bores in the pump
body ..................................... 31.786 ± 0.008 mm
(1.2514 ± 0.0003 inch)
RENR6507-02 5
Specifications Section

g00951246 g00951245
Illustration 2 Illustration 4
Section C-C Section E-E

(G) Location of the bearing joint from the vertical (K) Depth of bearings into body ........ 1.5 ± 0.25 mm
centerline .................... 30 degrees ± 15 degrees (0.06 ± 0.010 inch)

(H) Depth of bearings into manifold .... 1.5 ± 0.5 mm (L) Measurement from end of dowel to face of
(0.06 ± 0.02 inch) body .................. 5.0 ± 0.5 mm (0.20 ± 0.02 inch)

(G) Location of the bearing joint from the vertical

centerline .................... 30 degrees ± 15 degrees

g00951248
Illustration 3
Section D-D

g00951254
(J) Measurement from end of dowel to face of Illustration 5
body ...................................... 7.9 mm (0.31 inch) Section F-F

(G) Location of the bearing joint from the vertical

centerline .................... 30 degrees ± 15 degrees

(M) Depth of bearings into body ................... 1.5 mm

(0.020 inch)
6 RENR6507-02
Specifications Section

i01613764

Pressure Switch (Power Train

Oil Filter)
SMCS Code: 5068-QW
Part No.: 116-9846

g00531833
Illustration 6

(1) Torque for final installation of the

switch ............................. 30 ± 3 N·m (22 ± 2 lb ft)

The contacts are normally closed.

Actuation pressure ......... 276 ± 28 kPa (40 ± 4.0 psi)

Minimum deactuation pressure ....... 179 kPa (25 psi)

RENR6507-02 7
Specifications Section

i01615465

Torque Converter
SMCS Code: 3101
Part No.: 1T-1213
S/N: BDA1-Up
Part No.: 200-3117
S/N: BEC1-Up

g00836328
Illustration 7

(1) Lockup clutch
Thickness of three new discs and of two new
plates ...... 21.35 ± 0.50 mm (0.840 ± 0.020 inch)
Thickness of one new 1T-0887 Friction
Disc ................... 4.83 ± 0.08 mm (0.19 ± 0.003 inch)
Thickness of one new 1T-1315
Plate ................ 3.43 ± 0.13 mm (0.135 ± 0.005 inch)
(2) Torque for eight bolts ..... 50 ± 7 N·m (37 ± 5 lb ft)
(3) Put a small amount of lubricant on the lip of the
seal before installation.
(4) Torque for 18 bolts ... 120 ± 15 N·m (89 ± 11 lb ft)
(5) Torque for bolt ........ 240 ± 25 N·m (177 ± 18 lb ft)
(6) Torque for two bolts ..... 80 ± 10 N·m (59 ± 7 lb ft)
8 RENR6507-02
Specifications Section

(7) Add shims in order to achieve a shim pack

thickness of 0.13 ± 0.25 mm (0.005 ± 0.010 inch)
less than the measured gap.

Thickness of one 1T-1011 Shim ............... 0.25 mm

(0.010 inch)

Thickness of one 1T-1012 Shim ............... 0.08 mm

(0.003 inch)

(8) Torque for six bolts ........ 50 ± 7 N·m (37 ± 5 lb ft)

(9) Torque for eight bolts ..................... 120 ± 15 N·m

(89 ± 11 lb ft)
g00507584
(10) Torque for 36 bolts ....... 50 ± 7 N·m (37 ± 5 lb ft) Illustration 8

Table 1 Always install new springs (12) and rollers (11) in

the one-way clutch. Install springs (12) with the
maximum loops to the outside of the cam for the
one-way clutch. The stator should only turn in the
Clearance clockwise direction, as the torque converter is viewed
Components Across The Running(1) from the engine side.
Diameter

i00994608

Relief Valve (Torque Converter

0.72 to 0.92 mm 0.36 to 0.46 mm
(A) Stator new (0.028 to 0.036 (0.014 to 0.018 Outlet)
and inch) inch)
Turbine
SMCS Code: 3133-OL
max 1.37 mm 0.68 mm
worn (0.054 inch) (0.027 inch)
Part No.: 8P-1471

0.72 to 0.92 mm 0.36 to 0.46 mm

(B) Stator new (0.028 to 0.036 (0.014 to 0.018
and inch) inch)
Impeller max 1.37 mm 0.68 mm
worn (0.054 inch) (0.027 inch)
0.56 to 0.71 mm 0.28 to 0.36 mm
new (0.022 to 0.028 (0.011 to 0.014
(C) Stator inch) inch)
and Ring
max 1.07 mm 0.53 mm
worn (0.042 inch) (0.021 inch)
(1) One half of the clearance across the diameter

g00507614
Illustration 9
RENR6507-02 9
Specifications Section

i01906767

Lockup Clutch and Solenoid

Valve (Torque Converter)
SMCS Code: 3124-VC; 5479-VC
Part No.: 128-2352
S/N: BDA1-74
Part No.: 128-2352
S/N: BEC1-75

NOTICE
g00507615
Do not use caustic (corrosive) materials to clean any
Illustration 10 parts in this valve group. Caustic material will cause
Section A-A corrosion and damage to parts.

Pressure setting ................ 414 ± 34 kPa (60 ± 5 psi)

Settings for a test stand:
Flow rate ...... 132.5 ± 0.8 L/min (35.0 ± 0.2 US gpm)
Flow rate ...................... 19 ± 4 L/min (5 ± 1 US gpm)
(1) Torque for the plug ......... 35 ± 4 N·m (26 ± 3 lb ft)
Pressure from the pump .................... 3450 ± 70 kPa
(2) Torque for the plug ......... 45 ± 4 N·m (33 ± 3 lb ft) (500 ± 10 psi)

(3) 5M-9548 Spring Pressures on a test stand:

Length under test force ....... 21.3 mm (0.84 inch) Pilot pressure for the lockup clutch .... 1725 ± 70 kPa
Test force .................. 4.4 ± 0.4 N (1.00 ± 0.08 lb) (250 ± 10 psi)
Free length after test .......... 34.0 mm (1.34 inch)
Outside diameter ................ 12.2 mm (0.48 inch) Lockup clutch primary pressure ........... 960 ± 35 kPa
(139 ± 5 psi)
(4) 5M-9624 Spacer
Pressures at low idle speed on a machine:
Thickness ......................... 0.25 mm (0.010 inch)
Pressure change with one spacer ............. 5 kPa Pilot pressure for the lockup clutch .... 1725 ± 70 kPa
(0.7 psi) (250 ± 10 psi)
5M-9623 Spacer Maximum pressure for the lockup
clutch .......................... 1720 ± 70 kPa (249 ± 10 psi)
Thickness ......................... 0.90 mm (0.035 inch)
Pressure change with one spacer ........... 18 kPa
Lockup clutch primary pressure ........... 960 ± 35 kPa
(2.6 psi)
(139 ± 5 psi)
5M-9622 Spacer
Thickness ......................... 1.60 mm (0.063 inch)
Pressure change with one spacer ........... 32 kPa
(4.6 psi)

(5) 8M-8627 Spring

Length under test force ........ 53.6 mm (2.11 inch)
Test force .............. 395.2 ± 31.6 N (88.8 ± 7.1 lb)
Free length after test .......... 78.7 mm (3.10 inch)
Outside diameter ................ 19.8 mm (0.78 inch)

(6) Torque for four bolts ....... 48 ± 7 N·m (35 ± 5 lb ft)

10 RENR6507-02
Specifications Section

(5) Torque for two plugs ...... 70 ± 7 N·m (52 ± 5 lb ft)

g00993163
Illustration 11
g00993165
Illustration 13
(1) Torque for plug ............... 25 ± 5 N·m (18 ± 4 lb ft) Section A-A

(2) Torque for four bolts ....... 30 ± 7 N·m (22 ± 5 lb ft)
(A) Position of the
adapter ....................... 30 degrees ± 10 degrees
(6) Torque for plug ............... 30 ± 3 N·m (22 ± 2 lb ft)
(7) 6Y-7267 Spring (inner)
Color code ........................................... red stripe
Length under test force ....... 65.0 mm (2.56 inch)
Test force .............. 55.3 ± 2.8 N (12.43 ± 0.63 lb)
Free length after test .......... 96.1 mm (3.78 inch)
Outside diameter .................. 8.1 mm (0.32 inch)

(8) 8E-6144 Spring (outer)

Color code ........................... red and white stripe
Length under test force ........ 79.0 mm (3.11 inch)
Test force ............ 141.4 ± 9.0 N (31.79 ± 2.02 lb)
Free length after test .......... 95.8 mm (3.77 inch)
Outside diameter ................ 14.8 mm (0.58 inch)

(9) 8J-4452 Shim

Thickness of shim ............. 0.12 mm (0.005 inch)
Pressure change with one shim .............. 10 kPa
(1.5 psi)

2S-0675 Spacer

Illustration 12
g00993164 Thickness of spacer .......... 0.40 mm (0.016 inch)
Pressure change with one shim .............. 32 kPa
(3) Refer to Specifications, “Solenoid Valve (Torque (4.7 psi)
Converter Lockup Clutch)”.
9J-1330 Shim
Installation torque .......... 50 ± 5 N·m (37 ± 4 lb ft)
Thickness of shim ............. 0.79 mm (0.031 inch)
(4) Torque for six plugs ....................... 5.5 ± 1.5 N·m Pressure change with one shim .............. 62 kPa
(49 ± 13 lb in) (9.0 psi)

(10) Torque for two bolts ..... 30 ± 4 N·m (22 ± 3 lb ft)

RENR6507-02 11
Specifications Section

(11) 9P-0683 Spring (17) 5J-2721 Shim

Length under test force ....... 25.4 mm (1.00 inch) Thickness of shim ............. 0.13 mm (0.005 inch)
Test force ................ 35.6 ± 2.8 N (8.00 ± 0.63 lb) Pressure change with one shim .............. 10 kPa
Free length after test .......... 66.0 mm (2.60 inch) (1.4 psi)
Outside diameter ................ 21.4 mm (0.84 inch)
6J-3993 Shim
(12) 4M-2381 Spring
Thickness of shim ............. 0.25 mm (0.010 inch)
Length under test force ....... 12.2 mm (0.48 inch) Pressure change with one shim .............. 19 kPa
Test force .......... 2.31 ± 0.18 N (0.519 ± 0.041 lb) (2.8 psi)
Free length after test .......... 22.6 mm (0.89 inch)
Outside diameter .................. 7.6 mm (0.30 inch) 5J-1036 Shim

(13) 9D-7884 Spring Thickness of shim ............... 0.8 mm (0.031 inch)

Length under test force ....... 18.5 mm (0.73 inch)
Test force ............................... 161.5 N (36.31 lb)
Free length after test .......... 23.9 mm (0.94 inch)
Outside diameter ................ 15.7 mm (0.62 inch)
(14) 8P-9739 Cascade Orifice
Thickness of orifice ........... 6.50 mm (0.256 inch)
Pressure change with one shim .............. 60 kPa
(8.7 psi)
(18) 4M-2381 Spring
Length under test force ....... 12.2 mm (0.48 inch)
Test force .................. 2.3 ± 0.2 N (0.52 ± 0.05 lb)
Free length after test .......... 22.6 mm (0.89 inch)
Outside diameter .................. 7.6 mm (0.30 inch)

i01864283

Lockup Clutch and Solenoid

Valve (Torque Converter)
SMCS Code: 3124-VC; 5479-VC
Part No.: 212-0394
S/N: BDA75-Up
Part No.: 212-0394
S/N: BEC76-Up

g00993166
Illustration 14
Section B-B

(15) Torque for two bolts ..... 30 ± 7 N·m (22 ± 5 lb ft)

(16) 9W-7410 Spring

Color code ....................... three light blue stripes
First test
Length under test force ....... 79.5 mm (3.13 inch)
Test force .............. 78.3 ± 3.9 N (17.60 ± 0.88 lb)
Second test g00950556
Illustration 15
Length under test force ....... 63.0 mm (2.48 inch)
Test force ............ 237.3 ± 8.7 N (53.35 ± 1.96 lb)
Free length after test ...... 87.63 mm (3.450 inch)
Outside diameter ............ 14.73 mm (0.580 inch)
12 RENR6507-02
Specifications Section

NOTICE
Do not use caustic (corrosive) materials to clean any
parts in this valve group. Caustic material will cause
corrosion and damage to parts.

Settings for a test stand:

Flow rate ...................... 19 ± 4 L/min (5 ± 1 US gpm)

Pressure from the pump .................... 3450 ± 70 kPa

(500 ± 10 psi)

Pressures on a test stand:

Pilot pressure for the lockup clutch .... 1725 ± 70 kPa

(250 ± 10 psi)

Lockup clutch primary pressure ........... 960 ± 35 kPa

(139 ± 5 psi)
g00950562
Illustration 16
Pressures at low idle speed on a machine:
(7) Torque for three plugs .... 25 ± 5 N·m (18 ± 4 lb ft)
Pilot pressure for the lockup clutch .... 1725 ± 70 kPa
(250 ± 10 psi)
(8) Torque for three bolts ..... 48 ± 7 N·m (35 ± 5 lb ft)
Maximum pressure for the lockup
(9) Torque for four bolts ....... 30 ± 7 N·m (22 ± 5 lb ft)
clutch .......................... 2135 ± 70 kPa (310 ± 10 psi)
(C) Position for the adapter ....................... 30° ± 10°
Lockup clutch primary pressure ........... 960 ± 35 kPa
(139 ± 5 psi)

(1) Torque for nut ..... 9.0 ± 0.5 N·m (79.7 ± 4.4 lb in)

(2) Refer to Specifications, “Solenoid Valve

(Torque Converter Lockup Clutch)”. Installation
torque ............................ 50 ± 5 N·m (37 ± 4 lb ft)

(3) Torque for plug .. 5.5 ± 1.5 N·m (48.7 ± 13.3 lb in)

(4) Torque for plug .. 5.5 ± 1.5 N·m (48.7 ± 13.3 lb in)

(5) Torque for two plugs ...................... 5.5 ± 1.5 N·m

(48.7 ± 13.3 lb in)

(6) Torque for plug ............... 70 ± 7 N·m (52 ± 5 lb ft)

g00950558
Illustration 17

(10) Torque for plug ............. 30 ± 3 N·m (22 ± 2 lb ft)

(11) Torque for two plugs .................... 5.5 ± 1.5 N·m

(49 ± 13 lb in)

(12) 6Y-7267 Spring

RENR6507-02 13
Specifications Section

Color code .......................................... Red stripe

Length under test force ......... 65.0 mm (2.6 inch)
Test force .......... 55.28 ± 2.76 N (12.43 ± 0.62 lb)
Free length after test ........ 96.13 mm (3.79 inch)
Outside diameter ................ 8.12 mm (0.32 inch)

(13) 8E-6144 Spring

Color code ......................... Red and white stripe
Length under test force ......... 79.0 mm (3.1 inch)
Test force ................ 141.4 ± 9.0 N (31.8 ± 2.0 lb)
Free length after test ........ 95.77 mm (3.77 inch)
Outside diameter .................. 14.8 mm (0.6 inch)

(14) Shim Pack

9J-1330 Shim
Thickness of shim ............. 0.79 mm (0.031 inch)
Pressure change with one shim .............. 62 kPa
(9.0 psi)
2S-0675 Spacer g00950564
Illustration 18
Thickness of spacer .......... 0.40 mm (0.016 inch)
Pressure change with one shim .............. 32 kPa (21) Torque for two bolts ..... 30 ± 7 N·m (22 ± 5 lb ft)
(4.7 psi)
8J-4452 Shim (22) Shim Pack
Thickness of shim ............. 0.12 mm (0.005 inch) 5J-2721 Shim
Pressure change with one shim .............. 10 kPa Thickness of shim ............. 0.13 mm (0.005 inch)
(1.5 psi) Pressure change with one shim .............. 10 kPa
(1.5 psi)
(15) 9P-0683 Spring
6J-3993 Shim
Length under test force ......... 25.4 mm (1.0 inch)
Test force .................... 35.6 ± 2.8 N (8.0 ± 0.6 lb) Thickness of shim ............. 0.25 mm (0.001 inch)
Free length after test ........ 66.04 mm (2.60 inch) Pressure change with one shim .............. 19 kPa
Outside diameter .............. 21.44 mm (0.84 inch) (2.8 psi)
5J-1036 Shim
(16) 4M-2381 Spring
Thickness of shim ................. 0.8 mm (0.03 inch)
Length under test force ..... 12.19 mm (0.48 inch) Pressure change with one shim .............. 60 kPa
Test force .......... 2.30 ± 0.18 N (0.517 ± 0.041 lb) (8.7 psi)
Free length after test ........ 22.61 mm (0.89 inch)
Outside diameter ................ 7.62 mm (0.30 inch) (23) 9W-7410 Spring

(17) 9D-7884 Spring Color Code ..................... Three light blue stripes

Length under test force ... 18.62 mm (0.733 inch) First Test
Test force ................................. 161.5 N (36.3 lb) Length under test force ....... 79.5 mm (3.13 inch)
Free length after test .......... 23.9 mm (0.94 inch) Test force ................ 78.3 ± 3.9 N (17.6 ± 0.88 lb)
Outside diameter ............ 0.846 N·m (0.622 lb ft)
Second Test
(18) 8P-9739 Cascade Orifice Length under test force ......... 63.0 mm (2.5 inch)
Test force ................ 237.3 ± 8.7 N (53.3 ± 2.0 lb)
Thickness of orifice ........... 6.50 mm (0.256 inch)
Free length after test ........ 87.63 mm (3.45 inch)
Outside diameter .......... 14.732 mm (0.580 inch)
(19) Torque for plug ...... 5.5 ± 1.5 N·m (49 ± 13 lb in)
(24) Torque for plug ............. 70 ± 7 N·m (52 ± 5 lb ft)
(20) Torque for two bolts ..... 30 ± 4 N·m (22 ± 3 lb ft)
(25) 4M-2381 Spring
Length under test force ..... 12.19 mm (0.48 inch)
Test force .......... 2.30 ± 0.18 N (0.517 ± 0.041 lb)
Free length after test ........ 22.61 mm (0.89 inch)
14 RENR6507-02
Specifications Section

Outside diameter ................ 7.62 mm (0.30 inch) i01509211

(26) Torque for plug ............. 70 ± 7 N·m (52 ± 5 lb ft) Temperature Sensor (Torque
Converter Oil and Brake Oil)
i01764782
SMCS Code: 509T-PWT
Solenoid Valve (Torque Part No.: 118-7226
Converter Lockup Clutch)
SMCS Code: 5479-L7
Part No.: 144-6292

g00104202
Illustration 20

(1) Final installation torque .. 20 ± 3 N·m (15 ± 2 lb ft)

g00293315
Illustration 19 i01904760

Coil Transmission Control

Nominal voltage ...................................... 24 VDC SMCS Code: 3065
Current at 25° ± 5°C (77° ± 9°F) ..... 0.75 Ampere
Resistance at 25° ± 5°C Part No.: 210-9515
(77° ± 9°F) ................................. 32.6 ± 1.6 ohms

(1) Torque for nut ........... 9.0 ± 0.5 N·m (80 ± 4 lb in)

(2) Final installation torque ..................... 50 ± 5 N·m

(37 ± 4 lb ft)

g00783280
Illustration 21
RENR6507-02 15
Specifications Section

i01930706

Accelerator Control
SMCS Code: 1276
Part No.: 137-0013

g00783284
Illustration 22
Section A-A

(1) Transmission shift lever

(2) Sleeve bearing

(3) Timing marks

(4) Bolts

(5) Shift lever switch

g01004523
(6) 6G-4093 Spring Illustration 23

Quantity ........................................................ four (1) Apply 9S-3263 Thread Lock to the threads of
Length under test force ....... 19.2 mm (0.76 inch) the two screws.
Test force ...... 45.20 ± 2.26 N (10.161 ± 0.508 lb)
Free length after test ................... 26.6 ± 0.6 mm (2) Position Sensor
(1.05 ± 0.02 inch)
Outside diameter .............. 4.25 mm (0.167 inch) (3) Insert the threaded pin in the bracket from the
left side only.
Note: Fill the cavity with lubricant from the 1P-0808
Grease Cartridge before you install springs (6).
16 RENR6507-02
Specifications Section

i01907379

Transmission Hydraulic
Control
SMCS Code: 3167
Part No.: 3T-1510

g00993534
Illustration 24
Top view

(1) Refer to Specifications, “Solenoid Valve Installation torque .......... 80 ± 5 N·m (59 ± 4 lb ft)
(Transmission Upshift/Downshift)”.
RENR6507-02 17
Specifications Section

(2) Torque for the four bolts that are marked with an
“X” .................................. 48 ± 4 N·m (35 ± 3 lb ft)

(3) For more information on the torque converter

inlet relief valve, refer to Specifications, “Selector
and Pressure Control Valve (Transmission)”.

(4) 3T-1511 Transmission Hydraulic Control Valve

All of the valves in this group must be tested as a unit.

All of the valves in this group must be assembled into
the transmission as a unit. Individual parts of this unit
may not be interchanged at any time after the unit
has been tested. During repair service, individual
parts of this group will be furnished.

g00993541
Illustration 25
View A-A

(6) Torque for two bolts ....... 48 ± 4 N·m (35 ± 3 lb ft)

NOTICE
Do not use any caustic (corrosive) materials in order
to clean any parts of this group. Caustic materials will
cause corrosion and damage to the parts.
(A) Position of adapter ......... 30 degrees ± 1 degree
(5) Torque for two bolts ....... 48 ± 4 N·m (35 ± 3 lb ft)
(7) Position Sensor
(8) The notch on the connector for the wiring harness
should face upward. The centerline of the notch
on the connector should be parallel with the
mounting face of the switch.
18 RENR6507-02
Specifications Section

(9) Lubricate the sealing lip with a small amount of

the lubricant that is being sealed.

Before you install the lip seal, put a coat of 7M-7260

Liquid Gasket on the sealing bore. Allow the liquid
gasket to dry before you install the seal. Do not put
any liquid gasket on the lip seal. Install the seal so
that the seal lip faces the inside of the component.

g00993553
Illustration 26
3T-1511 Transmission Hydraulic Control Valve

(10) Refer to Specifications, “Pressure Control Valve (17) Torque for bolt .............. 30 ± 4 N·m (22 ± 3 lb ft)
(Transmission)”.
(18) Refer to Specifications, “Rotary Actuator
(11) Torque for bolt .............. 48 ± 4 N·m (35 ± 3 lb ft) (Transmission)”.

(12) Torque for five bolts ..... 30 ± 4 N·m (22 ± 3 lb ft)

(13) Torque for bolt .............. 30 ± 4 N·m (22 ± 3 lb ft)

(14) Torque for 12 bolts ....... 30 ± 4 N·m (22 ± 3 lb ft)

(15) Refer to Specifications, “Selector and Pressure

Control Valve (Transmission)”.

(16) Torque for two bolts ..... 30 ± 4 N·m (22 ± 3 lb ft)

RENR6507-02 19
Specifications Section

i01864914

Selector and Pressure Control

Valve (Transmission)
SMCS Code: 3083
Part No.: 3T-1512

g00950661
Illustration 27

(1) Torque converter inlet relief valve
Installation torque ........ 85 ± 10 N·m (63 ± 7 lb ft)
Pressure setting ...... 955 ± 95 kPa (139 ± 14 psi)
(2) Torque for cap .............. 85 ± 10 N·m (63 ± 7 lb ft)
(3) 3T-9920 Spring
Length under test force ....... 38.6 mm (1.52 inch)
Test force .......................... 307 ± 25 N (69 ± 6 lb)
Free length after test ...... 52.32 mm (2.060 inch)
Outside diameter ............ 20.95 mm (0.825 inch)
(4) 145-0107 Spacer
Thickness of spacer .............. 1.6 mm (0.06 inch)
Pressure change with one spacer ........ 94.3 kPa
(13.68 psi)
(5) 145-0105 Spacer
Thickness of spacer .......... 0.25 mm (0.010 inch)
20 RENR6507-02
Specifications Section

Pressure change with one spacer ........... 41 kPa Free length after test .......... 22.6 mm (0.89 inch)
(6.0 psi) Outside diameter .................. 7.6 mm (0.30 inch)
145-0106 Spacer (14) Torque for two bolts ..... 30 ± 7 N·m (22 ± 5 lb ft)
Thickness of spacer .......... 0.90 mm (0.035 inch)
Pressure change with one spacer ......... 145 kPa (15) Torque for two bolts ..... 30 ± 7 N·m (22 ± 5 lb ft)
(21.0 psi)
(16) Torque for bolt .............. 30 ± 7 N·m (22 ± 5 lb ft)
145-0107 Spacer
Thickness of spacer .......... 1.60 mm (0.063 inch) (17) Torque for screen filter ................. 6.1 ± 0.7 N·m
Pressure change with one spacer ......... 261 kPa (55 ± 6 lb in)
(37.9 psi)
(D) Installation depth for the dowel .. 0.80 ± 0.25 mm
(6) 6T-5409 Spring (0.032 ± 0.010 inch)

Color code ........................................ white stripe (E) Installation depth for the pins ........ 1.5 ± 0.5 mm
Length under test force ..... 72.19 mm (2.84 inch) (0.06 ± 0.02 inch)
Test force ................................... 1034 N (232 lb)
Free length after test .......... 86.8 mm (3.42 inch) Note: Use 5P-3931 Anti-Seize Compound to coat
Outside diameter ............ 21.34 mm (0.840 inch) the outside surfaces of the pins, prior to assembly.
Install the outer pin prior to installing the inner pin.
(7) 8M-6402 Spring Orientation of the slot in the inner pin must be 180° ±
20° from the slot in the outer pin.
Color code ........................................... red stripe
Length under test force ....... 85.9 mm (3.38 inch)
Test force .......... 841.0 ± 66.7 N (189.0 ± 15.0 lb)
Free length after test ......... 110.5 mm (4.35 inch)
Outside diameter ................ 19.8 mm (0.78 inch)

(8) 5M-3492 Spacer

Thickness of spacer .......... 0.25 mm (0.010 inch)
Pressure change with one spacer ........... 17 kPa
(2.5 psi)
7M-1397 Spacer
Thickness of spacer .......... 0.91 mm (0.036 inch)
Pressure change with one spacer ........... 60 kPa
(8.7 psi)

(9) 6T-3177 Spring

Length under test force ....... 32.3 mm (1.27 inch)
Test force .................. 89.0 ± 4.0 N (20.0 ± 0.9 lb)
Free length after test .......... 44.5 mm (1.75 inch)
Outside diameter ................ 21.0 mm (0.83 inch)

(10) Do not put sealant on the threads of the plugs.

(11) 5M-9548 Spring

Length under test force ....... 21.3 mm (0.84 inch)
Test force .................. 4.4 ± 0.4 N (1.00 ± 0.08 lb) Illustration 28
g00950796
Free length after test .......... 34.0 mm (1.34 inch) View A-A
Outside diameter ................ 12.2 mm (0.48 inch)
(18) Retainer
(12) Torque for two bolts ..... 30 ± 7 N·m (22 ± 5 lb ft)
(19) Torque for two bolts ..... 30 ± 7 N·m (22 ± 5 lb ft)
(13) 4M-2381 Spring
Length under test force ....... 12.2 mm (0.48 inch) (20) Bolt and washer
Test force .............. 2.31 ± 0.18 N (0.52 ± 0.04 lb)
(21) Spring assembly
RENR6507-02 21
Specifications Section

Note: See the Power Train Testing and Adjusting,

“Selector and Pressure Control Valve (Transmission)
- Adjust” for the proper adjustment procedure.

g00950797
Illustration 29
Section B-B

(F) Installation depth for the dowel ...... 4.0 ± 0.5 mm

(0.16 ± 0.02 inch)

g00950799
Illustration 30
Section C-C

(10) Do not put sealant on the threads of the plugs.

22 RENR6507-02
Specifications Section

i01907496

Pressure Control Valve

(Transmission)
SMCS Code: 3074
Part No.: 3T-1513

g00950905
Illustration 31
RENR6507-02 23
Specifications Section

Table 2
Shims For The Pressure Control Valve
Pressure Change Per Shim
Station(1) A B C E F G H
Engaged
2 1 7 5 4 6 3
Clutch
Thickness of Pressure Pressure Pressure Pressure Pressure Pressure Pressure
Shim Change Change Change Change Change Change Change
5J-2721 Shim
0.13 mm 14 kPa 20 kPa 20 kPa 15 kPa 15 kPa 20 kPa 17 kPa
(0.005 inch) (2.0 psi) (2.9 psi) (2.9 psi) (2.2 psi) (2.2 psi) (2.9 psi) (2.5 psi)
6J-3993 Shim
0.25 mm 28 kPa 41 kPa 41 kPa 30 kPa 30 kPa 41 kPa 33 kPa
(0.010 inch) (4.1 psi) (5.9 psi) (5.9 psi) (4.4 psi) (4.4 psi) (5.9 psi) (4.8 psi)
4M-1751 Spacer
0.41 mm 45 kPa 65 kPa 65 kPa 48 kPa 48 kPa 65 kPa 53 kPa
(0.016 inch) (6.5 psi) (9.4 psi) (9.4 psi) (7.0 psi) (7.0 psi) (9.4 psi) (7.7 psi)
5J-1036 Shim
0.80 mm 87 kPa 125 kPa 125 kPa 92 kPa 92 kPa 125 kPa 103 kPa
(0.031 inch) (12.6 psi) (18.2 psi) (18.2 psi) (13.3 psi) (13.3 psi) (18.2 psi) (14.9 psi)
(1) Station “D” is not used.

(1) Torque for 14 plugs .. 5.5 ± 1.5 N·m (49 ± 13 lb in)
(2) 9G-7132 Orifice Plug
Quantity .......................................................... six
Color code ................................................. green
Orifice size ........................ 1.57 mm (0.062 inch)
Torque for plug ........ 5.5 ± 1.5 N·m (49 ± 13 lb in)
Test force .................... 35.6 ± 2.8 N (8.0 ± 0.6 lb)
Free length after test .......... 66.0 mm (2.60 inch)
Outside diameter ................ 21.4 mm (0.84 inch)
(8) 9W-7410 Spring (outer)
Quantity ...................................................... three
Color code ....................... three light blue stripes

(3) 8P-9738 Cascade Orifice First Test

Quantity ........................................................ four
Orifice thickness ............... 4.58 mm (0.180 inch)
(4) 9D-7884 Spring
Quantity ..................................................... seven
Color code ........................................ white stripe
Length under test force ....... 18.5 mm (0.73 inch)
Test force ................................. 161.5 N (36.3 lb)
Free length after test .......... 23.9 mm (0.94 inch)
Outside diameter ................ 15.7 mm (0.62 inch)
(5) Torque for two plugs ...... 50 ± 7 N·m (37 ± 5 lb ft)
(6) 4M-2381 Spring
Quantity ..................................................... seven
Length under test force ....... 12.2 mm (0.48 inch)
Test force .............. 2.31 ± 0.18 N (0.52 ± 0.04 lb)
Free length after test .......... 22.6 mm (0.89 inch)
Outside diameter .................. 7.6 mm (0.30 inch)
(7) 9P-0683 Spring
Quantity ..................................................... seven
Length under test force ....... 25.4 mm (1.00 inch)
Length under test force ....... 79.5 mm (3.13 inch)
Test force .............. 78.3 ± 3.9 N (17.60 ± 0.88 lb)
Second Test
Length under test force ....... 63.0 mm (2.48 inch)
Test force ............ 237.3 ± 8.7 N (53.35 ± 1.96 lb)
Free length after test ...... 87.63 mm (3.450 inch)
Outside diameter ................ 14.7 mm (0.58 inch)
(9) 7T-0569 Spring (inner)
Quantity .......................................................... six
Color code .......................... two light blue stripes
Length under test force ....... 63.9 mm (2.52 inch)
Test force .................. 86.7 ± 4.3 N (19.5 ± 1.0 lb)
Free length after test .......... 80.4 mm (3.17 inch)
Outside diameter .................. 8.6 mm (0.34 inch)
(10) Shims
Note: Refer to Table 2 for the pressure change due
to adding a shim at each station.
(11) 7T-0571 Spring (inner)
Quantity ........................................................ one
24 RENR6507-02
Specifications Section

Color code ....................... two light green stripes i01798810

Length under test force ....... 63.9 mm (2.52 inch)
Test force .................. 72.3 ± 3.6 N (16.3 ± 0.8 lb) Solenoid Valve (Transmission
Free length after test .......... 80.4 mm (3.17 inch) Upshift/Downshift)
Outside diameter .................. 8.6 mm (0.34 inch)
SMCS Code: 5479-T3
(12) 8P-9737 Cascade Orifice
Part No.: 144-6292
Quantity ........................................................ one
Orifice thickness ............... 2.54 mm (0.100 inch)

(13) 9W-7412 Spring (outer)

Quantity ...................................................... three
Color code ..................... three light green stripes
First Test
Length under test force ....... 79.5 mm (3.13 inch)
Test force .................. 68.0 ± 3.4 N (15.3 ± 0.8 lb)
Second Test
Length under test force ....... 63.0 mm (2.48 inch)
Test force .............. 313.8 ± 10.8 N (70.6 ± 2.4 lb)
Free length after test .......... 84.1 mm (3.31 inch) Illustration 32
g00921131

Outside diameter ................ 14.7 mm (0.58 inch)

(1) Torque for nut ........... 9.0 ± 0.5 N·m (80 ± 4 lb in)
(14) 201-6618 Plug (screened orifice)
(2) Coil
Quantity ........................................................ one
Color code ................................................ yellow Duty .................................................. Continuous
Orifice size ........................ 1.40 mm (0.055 inch) Nominal voltage ...................................... 24 VDC
Torque for plug ........... 1.0 + 0.2 N·m (9 + 2 lb in) Resistance at 25° ± 5°C
(77° ± 9°F) ................................. 32.6 ± 1.6 ohms
(15) 8P-9739 Cascade Orifice
Note: Position the lead wire of the solenoid valve at
Quantity ......................................................... two a minimum of 15 degrees lower than horizontal. This
Orifice thickness ............... 6.60 mm (0.260 inch) will reduce the entry of moisture into the solenoid
valve.
(16) 9W-7411 Spring (outer)
Quantity ........................................................ one
Color code ........................... three yellow stripes
First Test
Length under test force ....... 79.5 mm (3.13 inch)
Test force .............. 93.9 ± 4.7 N (21.11 ± 1.06 lb)
Second Test
Length under test force ....... 63.0 mm (2.48 inch)
Test force .......... 282.1 ± 10.3 N (63.42 ± 2.36 lb)
Free length after test ...... 87.76 mm (3.455 inch)
Outside diameter ................ 14.7 mm (0.58 inch)
RENR6507-02 25
Specifications Section

i01465296

Rotary Actuator
(Transmission)
SMCS Code: 3166-T3
Part No.: 9W-4119

g00765354
Illustration 33

g00765355
Illustration 34
Section A-A

(1) Torque for two bolts ....... 30 ± 4 N·m (22 ± 3 lb ft)

(2) Cover

(3) Torque for two bolts ....... 13 ± 3 N·m (10 ± 2 lb ft)

(4) Rotor

Note: Do not tighten bolts (3) until cover (2) is

installed and until bolts (1) are tightened.

Put SAE 30 oil on rotor (4) before assembly. After

the bolts are tightened, rotor (4) must turn freely for
270 degrees of rotation.
26 RENR6507-02
Specifications Section

i01924151

Transmission Planetary
SMCS Code: 3160
Part No.: 9G-9628

g00509538
Illustration 35

Table 3 Thickness of one new 1P-4110 Friction

Table For Speed Selector
Disc ........... 5.56 ± 0.08 mm (0.219 ± 0.003 inch)
Thickness of one new 2P-4472
Speed Engaged Clutches Plate ......... 6.35 ± 0.08 mm (0.250 ± 0.003 inch)
Neutral 4
(2) No. 2 clutch
Reverse 1 and 7
Thickness of four new friction discs and of five
First Gear 1 and 6 new plates ............................... 42.50 ± 0.72 mm
Second Gear 3 and 6 (1.673 ± 0.028 inch)
Thickness of one new 3S-7981 Friction
Third Gear 2 and 6 Disc ........... 4.65 ± 0.08 mm (0.183 ± 0.003 inch)
Fourth Gear 3 and 5 Thickness of one new 3P-8160
Plate ......... 4.78 ± 0.08 mm (0.188 ± 0.003 inch)
Fifth Gear 2 and 5
Sixth Gear 3 and 4 (3) No. 3 clutch

Seventh Gear 2 and 4 Thickness of three new friction discs and of two
new plates ............................... 27.55 ± 0.40 mm
(1.085 ± 0.016 inch)
(1) No. 1 clutch Thickness of one new 9W-4662 Friction
Thickness of three new friction discs and of two Disc ........... 4.95 ± 0.08 mm (0.195 ± 0.003 inch)
new plates ............................... 29.38 ± 0.40 mm Thickness of one new 3S-0044
(1.157 ± 0.016 inch) Plate ......... 6.35 ± 0.08 mm (0.250 ± 0.003 inch)
RENR6507-02 27
Specifications Section

(4) No. 4 clutch
Thickness of three new friction discs and of two
new plates ............................... 27.55 ± 0.40 mm
(1.085 ± 0.016 inch)
Thickness of one new 9W-4662 Friction
Disc ........... 4.95 ± 0.08 mm (0.195 ± 0.003 inch)
Thickness of one new 3S-0044
Plate ......... 6.35 ± 0.08 mm (0.250 ± 0.003 inch)
(5) No. 5 clutch
Thickness of three new friction discs and of two
new plates ............................... 29.38 ± 0.40 mm
(1.1567 ± 0.0157 inch)
Thickness of one new 1P-4110 Friction
Disc ........... 5.56 ± 0.08 mm (0.219 ± 0.003 inch)
Thickness of one new 2P-4472
Plate ............ 6.35 ± 0.08 mm (0.250 ± 003 inch)
(6) No. 6 clutch
Thickness of five new friction discs and of four
new plates ............................... 53.20 ± 0.72 mm
(2.095 ± 0.028 inch)
Thickness of one new 1P-4110 Friction
Disc ........... 5.56 ± 0.08 mm (0.219 ± 0.003 inch)
Thickness of one new 2P-4472
Plate ......... 6.35 ± 0.08 mm (0.250 ± 0.003 inch)
(7) No. 7 clutch
Thickness of three new friction discs and of three
new plates ............................... 36.87 ± 0.48 mm
(1.452 ± 0.019 inch)
Thickness of one new 1S-3736 Friction
Disc ........... 5.56 ± 0.08 mm (0.219 ± 0.003 inch)
Thickness of one new 3P-4057
Plate ......... 6.73 ± 0.08 mm (0.265 ± 0.003 inch)
Test force .................... 110 ± 11 N (24.6 ± 2.5 lb)
Second Test
Length under test force .............. 9.42 ± 0.13 mm
(0.371 ± 0.005 inch)
Test force .................... 206 ± 19 N (46.2 ± 4.2 lb)
Free length after test ................. 8.26 ± 0.39 mm
(0.325 ± 0.015 inch)
Outside diameter ..................... 14.96 ± 0.13 mm
(0.589 ± 0.005 inch)
(12) 5B-1952 Springs
Quantity for No. 4 clutch ................................... 5
Length under test force ... 47.62 mm (1.875 inch)
Test force ................... 107 to 138 N (24 to 31 lb)
Free length after test .... 95.504 mm (3.760 inch)
Outside diameter ............ 12.70 mm (0.500 inch)
(14) 4M-5016 Springs
Quantity for No. 6 clutch ................................. 10
Length under test force ....... 68.1 mm (2.68 inch)
Test force .......... 124.6 ± 10.0 N (28.00 ± 2.24 lb)
Free length after test .......... 83.3 mm (3.28 inch)
Outside diameter ............ 14.30 mm (0.563 inch)
(15) 7M-5813 Springs
Quantity for No. 7 clutch ................................. 12
Length under test force ..... 46.23 mm (1.82 inch)
Test force .............. 133.4 ± 10.7 N (30.0 ± 2.4 lb)
Free length after test ........ 58.93 mm (2.32 inch)
Outside diameter ............ 14.27 mm (0.562 inch)
Procedure to Install the Manifold
1. Torque six bolts (16) to 7 N·m (5 lb ft).

(8), (13) 4M-9592 Springs 2. Torque bolt (17) to 47 ± 9 N·m (35 ± 7 lb ft).

Quantity for No. 1 clutch (8) ............................ 10 3. Torque six bolts (16) to 47 ± 9 N·m (35 ± 7 lb ft).
Quantity for No. 5 clutch (13) .......................... 10
Length under test force ... 34.92 mm (1.375 inch)
Test force ................ 116.5 ± 5.8 N (26.2 ± 1.3 lb)
Free length after test ........ 44.70 mm (1.76 inch)
Outside diameter ............ 14.27 mm (0.562 inch)

(9) 8P-5058 Springs

Quantity for No. 2 clutch ................................. 20
Length under test force ....... 25.4 mm (1.00 inch)
Test force ................................. 54.4 N (12.24 lb)
Free length after test ...... 32.51 mm (1.280 inch)
Outside diameter ............ 15.24 mm (0.600 inch)

(10), (11) 9M-6193 Spring

Quantity for No. 3 clutch (10) .......................... 15
Quantity for No. 4 clutch (11) .......................... 30
First Test
Length under test force .............. 6.58 ± 0.13 mm
(0.259 ± 0.005 inch)
28 RENR6507-02
Specifications Section

Table 4 i00997355

Planetary Dimensions Transfer Gears

Location Shaft Gear Bore Carrier
Diameter Bore SMCS Code: 3159
A 26.436 ± 34.399 ± 26.462 ± Part No.: 9G-9625
0.008 mm 0.008 mm 0.010 mm
(1.0408 ± (1.3543 ± (1.0418 ±
0.0003 inch) 0.0003 inch) 0.0004 inch)
B 35.255 ± 43.221 ± 35.278 ±
0.008 mm 0.008 mm 0.010 mm
(1.3880 ± (1.7016 ± (1.3889 ±
0.0003 inch) 0.0003 inch) 0.0004 inch)
C 35.255 ± 43.221 ± 35.278 ±
0.008 mm 0.008 mm 0.010 mm
(1.3880 ± (1.7016 ± (1.3889 ±
0.0003 inch) 0.0003 inch) 0.0004 inch)
D 42.395 ± 51.948 ± 42.418 ±
0.008 mm 0.010 mm 0.010 mm
(1.6691 ± (2.0452 ± (1.6700 ±
0.0003 inch) 0.0004 inch) 0.0004 inch)
E 42.395 ± 51.948 ± 42.418 ±
0.008 mm 0.010 mm 0.010 mm
(1.6691 ± (2.0452 ± (1.6700 ±
0.0003 inch) 0.0004 inch) 0.0004 inch)
F 44.397 ± 57.127 ± 44.420 ±
0.008 mm 0.010 mm 0.010 mm
(1.7479 ± (2.2491 ± (1.7488 ±
0.0003 inch) 0.0004 inch) 0.0004 inch)

i01923866

Speed Sensor (Transmission)

SMCS Code: 3175
Part No.: 144-0178

g00509799
Illustration 37

(1) Torque for 10 bolts ....... 50 ± 10 N·m (37 ± 7 lb ft)

(2) Add shims in order to achieve a bearing end play

of 0.15 ± 0.05 mm (0.006 ± 0.002 inch).
g01001238
Illustration 36
Thickness of one 3P-8147 Shim Pack ...... 2.40 mm
(1) Final installation torque for the speed (0.094 inch)
sensor ............................ 25 ± 5 N·m (18 ± 4 lb ft)
(3) Lubricate the bore with a small amount of the
lubricant that is being sealed.
RENR6507-02 29
Specifications Section

(4) Lubricate the sealing lip with a small amount of

the lubricant that is being sealed. Coat the seal
bore of the cage with 7M-7260 Liquid Gasket.

Note: Allow the 7M-7260 Liquid Gasket to dry before

installing the lip seal. Do not apply 7M-7260 Liquid
Gasket to the lip seal case.

(5) Torque for bolt ........ 270 ± 25 N·m (200 ± 18 lb ft)

(6) Add shims in order to achieve a bearing end play

of 0.15 ± 0.05 mm (0.006 ± 0.002 inch).

Thickness of one 7G-1157 Shim Pack ...... 2.30 mm

(0.091 inch)

(7) Torque for 13 bolts ....... 50 ± 10 N·m (37 ± 7 lb ft)

i00997442

Drive Shaft (Main)

SMCS Code: 3253
Part No.: 9D-3520

g00509998
Illustration 38

(1) Torque for eight bolts ..................... 160 ± 15 N·m

(118 ± 11 lb ft)

(2) Torque for eight bolts ..................... 160 ± 15 N·m

(118 ± 11 lb ft)
30 RENR6507-02
Specifications Section

i01924174

Differential and Bevel Gear

SMCS Code: 3256; 3258
Part No.: 9D-6130
S/N: BDA1-284
Part No.: 9D-6130
S/N: BEC1-211

g00511380
Illustration 39

(1) Torque for the 14 bolts ................... 440 ± 40 N·m Note: Apply 7M-7456 Compound to the threads of
(325 ± 30 lb ft) bolts (4).

(2) Height of installation of the two pins above the (4) Torque for the ten bolts .................. 135 ± 20 N·m
bore ...................................... 7.6 mm (0.30 inch) (100 ± 15 lb ft)

(3) 9M-5874 Shim Pack thickness ............ 3.30 mm (5) Lubricate the bore with a small amount of the
(0.130 inch) lubricant that is being sealed.
RENR6507-02 31
Specifications Section

(6) The mating surfaces between the gear and the

differential must be free of paint.

(7) Lubricate the bore with a small amount of the

lubricant that is being sealed.

(8) 6G-1881 Shim

Quantity ............................................................ 8
Thickness ..................... 0.178 mm (0.0070 inch)

6G-1893 Shim
Quantity ............................................................ 6
Thickness ..................... 0.127 mm (0.0050 inch)

(9) Torque for four bolts ................... 1100 ± 150 N·m

(811 ± 111 lb ft)
32 RENR6507-02
Specifications Section

i01907876

Differential and Bevel Gear

SMCS Code: 3256; 3258
Part No.: 9D-6130
S/N: BDA285-Up
Part No.: 9D-6130
S/N: BEC212-Up

g00950958
Illustration 40
RENR6507-02 33
Specifications Section

Note: Prior to assembling the differential, i00999444

assemble the bevel gear to the housing. Ream
one hole to a diameter of 19.050 ± 0.013 mm Differential
(0.7500 ± 0.0005 inch). Install one bolt into the
reamed hole. Use the bevel gear as a guide in order SMCS Code: 3258
to ream the remaining thirteen holes. Install bolts (1).
Part No.: 6G-7560
(1) Torque for the 14 bolts ................... 440 ± 40 N·m
(325 ± 30 lb ft)

(2) Refer to Systems Operation/Testing and

Adjusting, “Differential and Bevel Gear - Adjust”
for the proper adjustment procedure.

(3) Lubricate the bore with a small amount of the

lubricant that is being sealed.

(4) 9M-5874 Shim Pack thickness ............ 3.30 mm

(0.130 inch)

Note: Refer to Systems Operation/Testing and

Adjusting, “Differential and Bevel Gear - Adjust” for
the proper adjustment procedure.

(5) Torque for the ten bolts .................. 135 ± 20 N·m

(100 ± 15 lb ft)

Note: Apply 7M-7456 Compound to the threads of g00511499

bolts (5). Illustration 41

(6) Refer to Systems Operation/Testing and
Adjusting, “Differential and Bevel Gear - Adjust”
for the proper adjustment procedure .
(7) The mating surfaces between the gear and the
differential must be free of paint.
(8) Lubricate the bore with a small amount of the
lubricant that is being sealed.
(9) 6G-1881 Shim
Quantity ............................................................ 8
Thickness ..................... 0.178 mm (0.0070 inch)
6G-1893 Shim
(1) Torque for eight bolts that fasten the housings
together ................. 395 ± 20 N·m (291 ± 15 lb ft)
(2) Bearing assembly
Note: Rotate bearing assembly (2) while you are
tightening nut (3). This will ensure the proper seating
of the rollers.
(3) Nut
Installation torque ...... 70 ± 15 N·m (52 ± 11 lb ft)
Note: Refer to the Power Train Testing and Adjusting,
“Differential Pinion Bearing - Adjust” for the correct
adjustment procedure.

Quantity ............................................................ 6
Thickness ..................... 0.127 mm (0.0050 inch)
Note: Refer to Systems Operation/Testing and
Adjusting, “Differential and Bevel Gear - Adjust” for
the proper adjustment procedure.
(10) Refer to Systems Operation/Testing and
Adjusting, “Differential and Bevel Gear - Adjust”
for the proper adjustment procedure.
(11) Torque for four bolts ................. 1100 ± 150 N·m
(811 ± 111 lb ft)
(4) Height of the two locating dowels above the
housing assembly ...................... 3.60 ± 0.10 mm
(0.142 ± 0.004 inch)
(5) Height of the two locating dowels above the
housing assembly ...................... 3.60 ± 0.05 mm
(0.142 ± 0.002 inch)
(6) Height of the four locating dowels above the
housing assembly ...................... 3.96 ± 0.05 mm
(0.156 ± 0.002 inch)
34 RENR6507-02
Specifications Section

i01614220 5D-1500 Shim

Rear Axle Housing Thickness ......................... 0.25 mm (0.010 inch)

SMCS Code: 3260-RE 5D-4363 Shim

Part No.: 9D-6140 Thickness ......................... 0.13 mm (0.005 inch)

Note: See the Power Train Testing and Adjusting,

“Rear Axle Housing End Play - Adjust” in order to
determine the shim pack thickness that should be
installed.

(2) Torque for eight bolts ..................... 550 ± 20 N·m

(405 ± 15 lb ft)

Note: Perform the Power Train Testing and Adjusting,

“Rear Axle Housing End Play - Adjust” before you
install these bolts.

(3) Torque for 24 studs .. 100 ± 14 N·m (75 ± 10 lb ft)

g00835684
Illustration 42 (4) Orient the fitting upward.
Left side view
(5) Lubricate the end of the king bolt with 6V-4876
Lubricant before assembly.

(6) Torque for nut ............................ 2600 ± 260 N·m

(1920 ± 190 lb ft)

Note: Apply 4C-5592 Anti-Seize Compound to the

threads, to the nut face, and to the tapers of the
kingbolt housing prior to assembly.

g00835685
Illustration 43
Section A-A

g00835686
Illustration 44
View B-B

(1) 5D-1499 Shim

Thickness ......................... 1.07 mm (0.042 inch)
RENR6507-02 35
Specifications Section

i02209308

Rear Wheel
SMCS Code: 4201-RE
Part No.: 8X-9972

g00950845
Illustration 45

(1) Torque for 33 bolts .. 750 ± 70 N·m (553 ± 52 lb ft) Table 5

Torque
Note: Apply 4C-5592 Anti-Seize Compound on the
faces of the washers and the threads of bolts (1). Procedure with Anti-Seize Procedure without
Compound Anti-Seize Compound
(2) Lubricate the seal with a small amount of the 1200 ± 50 N·m 2100 ± 200 N·m
lubricant that is being sealed. (885 ± 37 lb ft) (1550 ± 150 lb ft)

(3) Nuts
Note: The use of 4C-5592 Anti-Seize Compound
on the faces of the washers and the threads for 14
nuts (3) alters the required torque for nut (3). Use the
appropriate torque value from the chart below.
(4) 4D-5738 Shim Pack
Full Shim Pack Thickness ......... 2.90 ± 0.08 mm
(0.114 ± 0.003 inch)
Note: See the Power Train Testing and Adjusting,
“Rear Wheel Bearing - Adjust” in order to determine
the amount of shims to use.

(5) Torque for eight bolts ..................... 250 ± 15 N·m

(184 ± 11 lb ft)
36 RENR6507-02
Specifications Section

Note: Apply 9S-3263 Thread Lock Compound on

the threads of bolts (5).

Note: Perform the procedure in the Power Train

Testing and Adjusting, “Rear Wheel Bearing - Adjust”
before these bolts are installed.

(6) Apply 155-0695 Thread Lock Compound to the

threads of the bolts.

(7) Rim mounting surfaces must be clean and free

of oil and grease before the wheel assembly is
installed.

(8) Torque for 14 nuts ........................ 1210 ± 55 N·m

(892 ± 41 lb ft)

Note: Apply 4C-5592 Anti-Seize Compound on the

faces of the washers and the threads of nuts (8).

i01865543

Magnetic Sensor (Wheel

Speed)
SMCS Code: 4803-MPU
Part No.: 205-9873, 3T-2469 Illustration 47
g00512842

(1) Torque for four bolts ....................... 740 ± 65 N·m

(546 ± 48 lb ft)

Note: Apply 4C-5592 Anti-Seize Compound to the

face of the washer and the threads of the bolts (1).

(2) Installation torque of the speed

sensor ............................ 30 ± 5 N·m (22 ± 4 lb ft)

Note: Apply 5P-3413 Pipe Sealant to the threads

of the speed sensor.

(3) 5T-8042 Shim

g00512840
Illustration 46 Thickness ......................... 0.16 mm (0.006 inch)

5T-8168 Shim
Thickness ......................... 0.05 mm (0.002 inch)

5T-8169 Shim
Thickness ............................. 0.8 mm (0.03 inch)

Note: As required, use shims in order to adjust

dimension (X).

(X) Required dimension .............. 167.36 ± 0.08 mm

(6.589 ± 0.003 inch)

(4) Torque for the adapter ... 55 ± 7 N·m (41 ± 5 lb ft)

RENR6507-02 37
Specifications Section

Note: Apply 154-9731 Thread Lock Compound to (1) Apply 9S-3263 Thread Lock Compound on the
the threads of the adapter. threads of the bolts.

(5) Torque for two bolts on the clamps .... 30 ± 5 N·m (2) Torque for 35 bolts .. 430 ± 60 N·m (317 ± 44 lb ft)
(22 ± 4 lb ft)
(3) Torque for six studs ..... 65 ± 10 N·m (48 ± 7 lb ft)
Note: Apply 154-9731 Thread Lock Compound to
the threads of the bolts. Stake the bolts in order to (4) 8X-5699 Shaft
prevent the bolts from loosening.
Outside diameter of a new
shaft ..................................... 89.225 ± 0.010 mm
Adjustment Procedure For The (3.5128 ± 0.0004 inch)
Adapter
Note: Measure the diameter at the contact point of
Note: Only the adapter requires adjustment. The the roller bearings.
speed sensor is installed into the adapter.
(5) 148-4468 Gear
1. Measure distance (A) from the machined
Inside diameter of a new
counterbore surface to the gear tooth.
gear ................................... 129.334 ± 0.020 mm
(5.0919 ± 0.0008 inch)
2. Add the thickness of the adapter hex flange to
distance (A).
Note: Measure the diameter at the contact point of
the roller bearings.
3. Subtract the distance that was found in Step 2
from required dimension (X). This is the shim pack
thickness. Type 2
4. Use shims (3) in order to create the shim pack.
Install the shim pack between the machined
counterbore surface and the adapter hex flange.

i01653726

Final Drive
SMCS Code: 4050
Part No.: 8X-9981

Type 1

g00853856
Illustration 49

(1) Apply 9S-3263 Thread Lock Compound on the

threads of the bolts.

(2) Torque for 35 bolts .. 430 ± 60 N·m (317 ± 44 lb ft)

(3) Torque for six studs ..... 65 ± 10 N·m (48 ± 7 lb ft)

g00512081
Illustration 48
38 RENR6507-02
Specifications Section

(4) 212-3477 Shaft i02039255

Outside diameter of a new Window Wiper and Wiper

shaft ..................................... 89.225 ± 0.010 mm
(3.5128 ± 0.0004 inch)
Motor
SMCS Code: 7305-MQ; 7305
Note: Measure the diameter at the contact point of
the roller bearings.

(5) 148-4468 Gear

Inside diameter of a new
gear ................................... 129.334 ± 0.020 mm
(5.0919 ± 0.0008 inch)

Note: Measure the diameter at the contact point of

the roller bearings.

i01914726

Tire Valve
SMCS Code: 4202-VL
Part No.: 7D-5007

g01048770
Illustration 51
Windshield wiper blade

g00512671
Illustration 50

(1) Torque for small nut .. 8.5 ± 1.0 N·m (75 ± 9 lb in)

(2) Torque for large nut ..................... 21.5 ± 1.0 N·m

(190 ± 9 lb in)

Note: Tighten the large nut before the small nut is

tightened.

g01042890
Illustration 52
Wiper motor

(1) Torque for three bolts ... 6 ± 1 N·m (4.4 ± 0.7 lb ft)

(2) Wiper arm assembly

Torque for nut .......... 23 ± 1 N·m (17.0 ± 0.7 lb ft)
RENR6507-02 39
Specifications Section

After waiting 0.5 hours to 4 hours, tighten the nut

again to the following torque. ............. 23 ± 1 N·m
(17.0 ± 0.7 lb ft)

(3) Torque for nut .......... 19 ± 1 N·m (14.0 ± 0.7 lb ft)

With the arm in the park position, set the wiper blade
parallel with the windshield (base). Adjust the wiper
blade so that clearance (X) and clearance (Y) for
the wiper blade is approximately equal. Refer to
Illustration 51.
Index
A S

Accelerator Control................................................ 15 Selector and Pressure Control Valve

(Transmission) ..................................................... 19
Solenoid Valve (Torque Converter Lockup
D Clutch) ................................................................. 14
Solenoid Valve (Transmission Upshift/Downshift).. 24
Differential ............................................................. 33 Specifications Section ............................................. 4
Differential and Bevel Gear ............................. 30, 32 Speed Sensor (Transmission) ............................... 28
Drive Shaft (Main).................................................. 29

F
Final Drive ............................................................. 37
Type 1 ................................................................ 37
Type 2 ................................................................ 37
G Transmission Control............................................. 14
Gear Pump (Power Train) ....................................... 4
T
Table of Contents..................................................... 3
Temperature Sensor (Torque Converter Oil and
Brake Oil)............................................................. 14
Tire Valve............................................................... 38
Torque Converter..................................................... 7
Transfer Gears ...................................................... 28
Transmission Hydraulic Control............................. 16
Transmission Planetary ......................................... 26
Procedure to Install the Manifold ....................... 27

I
W
Important Safety Information ................................... 2
Window Wiper and Wiper Motor............................ 38

Lockup Clutch and Solenoid Valve (Torque

Converter)......................................................... 9, 11

Magnetic Sensor (Wheel Speed)........................... 36

Adjustment Procedure For The Adapter ............ 37

Pressure Control Valve (Transmission) ................. 22

Pressure Switch (Power Train Oil Filter) ................. 6

Rear Axle Housing................................................. 34

Rear Wheel............................................................ 35
Relief Valve (Torque Converter Outlet).................... 8
Rotary Actuator (Transmission) ............................. 25

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