Technical Service Information ‘Transmission Service Identification TuFO. BY FORD WOTOR CO, NUSA ‘Allvehicles are equipped witha Satety Standard owe wm. Cartication Label atixed to tho et (eriver's) side row ume ua ca door lock post. Refer tothe stamped code vem ot Space marked "Trane for proper ranamission tate mer ‘Sontica ms ras 3 and tructons forthe specific transmission ar vaca ar reco identification cocing, The transmission f ls sd vines Conon 0 amcease EEN WoroR [ented by a tag on tne tranemussion body. Fea letoeeersoyrirty ‘ours TSN ‘tooe. Barna WoOELS aE BERTRED BY A SeRNCE BEMTRCATON TAG TED To HE ASEMDLY. TAGS ARE LOCATED AND CONTA EORMATION AS FOLLOWS a \ ArrAcoED To HE LOWER LEFT sap HIND ETENBON ATTACHING YEAR MONTH AY [aa on cone: AUTOMATIC TRANSMISSION SERVICE GROUP 4Technical Service Information arr ee [pan |e =p = 7 = maf = SS ‘Automatic Transmission Test Linkage Check ‘Accelerator Linkage and Operation ‘The linkage must be free and must retum toile when teloased, Manual Linkage Thoigacrtical ausinet Be sre the © (Ove tent inthe ransmission corresponds ‘xa wih tha stopin the consaieor col sent Bla Frau leakage a he mana vaive can ‘engagements and/or slipping Whe ‘peratingt the kage snot property acusted “Cante purchaaedasa separa ion,Technical Service Information ‘Automatic Transmission Fluid Checking and ‘Adding Procedure Under normal crcumstances, you do not need to ‘heck the fi lvel of he transmission, since your Wehicle does not use up transmission fui. However the transmission lg not working properly—for Instance the tranemission may shp or shit slowly, oF Yyoumay notice some eign of fui leakage tho fle ‘evel should be checked. tis preferabe to check the transmission tid level at hormal operating temperature, ater approximately 20 ines (22 Km) of erving. However, nocossary, you ‘Gan check the fd evel without having to drive 20 ‘les to obtain a normal operating temperature butside temperatures are above 10°C (60°F). NOTE: ithe vehicle has been operated for an textended period at igh speeds or nei trafic during hotweather or puling a rae, the vehicie shouldbe {ured off for about 30 minutes Yo allow the hud t0 coo! before checking. Checking The Automatic Transmission Fluid \Witn the vehicle ona level surace, star the engine landmove the transmission shat selector through a the gearranges allowing suticient time foreach position fo engage. Securely latch ine transmission Shit selectorin the park positon, tly set the parking brake and eave the engine running, NOTE: Vehicles equipped with 4x4 applications must have the 4x4 shit selector in any postion othar than peutral ‘CAUTION: YOUR VEHICLE SHOULD NOT BE DRIVEN IF THE FLUID LEVEL IS BELOW THE BOTTOM HOLE ON THE DIPSTICK AND OUTSIDE ‘TEMPERATURES ARE ABOVE 10°C (50). Wipe of the cipsick cap, pull the dipstick out and wipe theindicator end cian, Put the dipstick back into tho filer tube and make sure itis fly seated. Pull the lipstick out and read the fidlevel When checking uid at normal operating temp {he fl level should be within the crosshatched area fn the dpatick. When the vehicle has not been driven, fnd outside temperatures above 10°C (50°F). The {id tevel should be between the holes onthe dipstick Adding Fluid ‘The thi type ig stampedn the dipstick. Bafore aiding any fui, be sure that the correct type willbe tsea [Add fuidin 251 (1/2 pint) inorements through the filer {ube fa bring the level fo the corect area on the ‘stick If an overt occurs, excess fhid shouldbe removed, verti can cause the hi to foam and spilout {through the ranemission vent resulting ina tranemission maltunctin. Underfill can rcultn transmission loss of engagement of slpping. This condtion s most evident incold weather or hen the vehicle parked or being ‘riven onal ithe transmiseionfuid levelis checked when the fig Igatroom temperature tha dipstick coud indicate that {lid should be added i the dpstick is misread. fd Isadded at ths time, an overil concton coud result ‘when the ld reaches operating temperatures of (86°C-77°C (150"F-170"F) (stick hot to touch), ‘Transmission Fluid Condition Check 1. Make the normal ud check according tothe above procedure, 2, Observe color and odor ofthe fhid. should be dark reddish, not brown or black. A burnt odor ‘can sometimes incicate that theres an ‘overheating condition or cutch disc or band fale. 2, Use an absorbent white paper (facial tissue, et.) to wipe the stick. Examine he stain for evidence of solids (specks of any kind) and for faneeze signs (oum or varish on dipstick). 1 specks are present in the ollo theres evidence of ‘antireaze, the transmission ol pan must be removed for turther Inspection I anttreeze is foundin the transmission fui, the tank tranamission cooler must be repaired or replaced fad cantamnation or transmission falure i contrmed by turer evidence of ‘Coolant or excessive souds inthe pan, the transmission must be disassembled and completely ‘leaned and epaired. Ths includes clearing tho foraue converter and iranamission cooang aystem. It \Would’be a waste ot time 1 pertorm any futher hooks betore cleaning and servicing the During disassembly and assembly, all overhaul checks and adustments of clearances and end play must be made.Service Information ‘Transmission Fluid Leakage Checks Check the speedometer cable connection at the transmission. Replace the rubber O-ing necessary. Leakage atthe of pan gasket often canbe stopped by tghtenng the attaching bots to the proper torque. necessary, replace the gasket, (Check the fui filer tube conection atthe tranamission ease. Cheek filer tube O-"n9 seal for ‘damage or omesion leakages found, install anew ‘hort ol let tube and O-riag seal, or clean the area ‘and appl a eoaler around the tube. The fl tube bracket should aon properly andbe attached tothe ‘ranemsion or engine location Check the udlines and fitinga between the tranamission and the cooler nthe radiator tank for looseness, wear, oF damage. If leakage s found tighten the fiting (as shown n chart below), or place ‘the damaged parts. Trina ey ees 8a) Check the engine coolant in the radiator. transmission fad is present inthe coolant, the cooler inthe racator Is probably leaking ‘The cooler canbe further checked for leaks by iscomecting the ines from the cooler rings and ‘applying 348-517 kPa (50-TS psi ai pressure tothe fittings. Remove the radiator captorehove tho pressure buldup atthe exterior ofthe of cooler tank. {he cooler i leaking andor wil rot hold pressure, the ‘cooler must be replaced. tHleakage i found atthe downshift controliever and ‘the manvallever shaft replace the seal Inspect the pipe plug on the ltt rear side of tho transmission case. the plug shows leakage, tighten the lug to specications. leakage continue replace the plu, Fluid leakage from the converter housing may be ‘caused by engine ollleakage past the rear main, Bearing, or trom oll galley plugs, or power Steering fluid leakage trom steering system. Be Sure to determine the exact cause of the leak before starting procedures. CO-solble aniline of fuorescent dyes promixed atthe rate of 1/2 teaspoon of dye powder to 0.23 ter (1/2 ‘i of transmission fluid have proved hepfulin {ecatng the source of id leakage. Such dyes may be {Used to determine whether an engine oor transmission fi leaks pent, or the fuidin the ol ‘cooler leaks ino the angie coclant system. A black ont must be used with the fluorescent dye soluton. Fluld Leakage in Converter Area In dlagnosing and correcting fd leaks inthe tront ‘ump and converter area, uve the folowing procedures to locate the exact cause ofthe leakage. Ceakage atthe front of the transmission, evidenced by fad around the converter housing, may have several ‘sources. By carat observation, i's possbioin many iRolances, f pinpoint the soures ofthe leak before removing ihe transmiss.on from the varie. The paths ‘which the flid takes to reach the Bottom ofthe Converter nousing are shown.Technical Service Information L : housing. 1. Fhid leaking by the front pump seal fp wif tend to ‘move along the impeller hub and onto the back of the impeler housing. Excoptin the case ofa total ‘seal farur,fuid leakage bythe tp of he sea wil be deposited'on the inside ofthe converter housing only, near the outside clameter ofthe ee Cover) may alow oito flow over the ‘converter housing or seep down between the ‘converter housing and eyindar block, {causing ol tobe present in or atthe Bottom of the converter housing, (Oi galley pla leaks wil tow ol to flow down 2. Fic leakage by the outsige camer othe seal andirent pp boaywlfollow the sare path ‘hich the leaky the font pu Sea fohow 3. Fluid hat oaks by a front pump-to-case bol wal be deposited on he nade othe converter, Rousing ony. Puls wil not be deposed othe the rea face of te Bock othe Bottom Oe aot of te converte. 4. Leakage by the ont pump-o-case gasket may cause ai to seep down between Ne ron! othe ase and converter hous 5. Fhid leakage tom the converter-ofywheel sid weld wil appear at the outside damoter ofthe Converter onthe back lace ofthe fywheel ard in {he converter housing ony nar the ywnet Engine ol leaks are sometimes inproperty lagnosed as transmission rant pump seal leaks. ‘The following araasof posible leakage should also be checked to determine engine olleakage 's causing the probiem: converter housing. © Leakageby the crankshaft seal wil work back fo the flyhea, ane! then int the cenverter hosing. 6. Fidleakage from other areas, such as the power stosting system forward ofthe transmission, could cause Tid tbe present ‘around the converter housing Gue to blow back or ‘oad drat, The folowing procedures should be {Used to determine the cause of the leakage, before any repairs are made.|. Technical Service Information 1. Remove the transmission dipstick and note the color ofthe us, Original factory Tid 's dyed reo, toad n determing leakage ls from the ongine or Wansrsion. Unless 2 Considerable amount of makeup fuid has ‘been added, or the fad has been change the color should assist in pinponting the led ‘Since road draft may cause leaking power slaering fuid tobe present onthe ‘ranamission, fis eakage, f prasont, should be eiminated belore checking the ‘wansmission for fue leakage. . Rlomove the converter housing cover. Clean ff any lid rom the top and bottom ofthe Sonverter Rousing, front ofthe transmission ‘case, and rear face ofthe engine and engine Sllpan. Clean the converter area by washing ‘with a suitable nonfammable elven, and ‘low cry with compressed ai, ‘c. Wash out the converter housing andthe front ‘ofthe flywheel. The converter housing may ‘Be washed ot using leaning solvent and a ‘quit type ol can. Blow al washed areas dry ‘with compressed ai Start andrun the engine uni the transmission ‘eachesits normal operating temperature. ‘Gaserve the back ofthe block and top ofthe ‘convertor housing for evidence offs leakage. aise the vehicle ona hoist and run the engine a fast ide, then at engine ide, ‘oceasionally shifting to the crive and reverse ‘anges to nevoase pressure within the {tanamission. Observe the front ofthe Aywhel, back of the block (mas far 85 possi}, and inside the converter housing End trontof the tranemission case. Run the ‘engine uti fid leakage is evident and the probable source of leakage can be BSetermined. Converter Leakage Check lt wolds onthe torque converter indicate leakage, temave the convertor and make the following check, | —Aile Poor ‘Assemble Rotunda 02 00047 or 021-0084 Torque Converier Leak Tester or equvaient tothe converter fas shown. Test the converter for laaks flowing the rections supped withthe detector kil Control Pressure Test Thore are two methods of performing the contro! pressure test. One so perform he test using tho {Engine vacuum, The second mathod isto use aremote Vacuum source such as the one provided by @ ‘etbutor tester or a hand Operated vacuum pump. Engine Vacuum Pressure \When the vacuum diaphragm units operating property ‘andthe manual and downehttrkage s adjusted broperiy al he transmission shifts (automatic and Kickdown) shoul occur within the road speed mits Istedin he Technical Service Bulsin— Spec! Specieations issue. the shifts do not occur within finite, or the transmission sipe dung the ahi point tet, use tho following procedure to determsne whether the engine, transmission inkage, vacuum diaphragm unt, or valve bag is causing the condition.Technical Service Information ‘Attach tachometer to the engine anda Vacuum Gauge, Rotunda Number 089-00008, or ‘equvalont tothe transmission vacuum ine atthe ‘manifold vacuum port = Ei arian conecnon 2. Attach a pressure gauge tothe contol pressure ‘utiet atthe tranamision 3. Firmly apply the parking brake and stat the engine. 4. Check the throttle and downshift linkage for 2 ‘binding condition. Winkage is satistactory, check {or vacuum leaks in the ansmission aptyagm Uunitandits comecting tubes and hoses. Check all ‘other vacuuraperated units (auch as the power brake} for vacum leaks. Refer tothe two control pressure diagnostic guides to ‘show what components are noperative when the ‘contol pressure tests not within specications. Do ‘ot proceed withthe main hagnosis guide untl you hhave made any repairs, as required, and the control pressurois withn specications aslistedin the Performance Specifications Book or Special Spectications issue ofthe Technical Service Buletn, Vacuum Pump Method {nstallan adjustable vacuum source. Disconnect and ‘temporary plug the vacuum neat the vacuum slaphragm unt Apply both the parking and service brakes. Start the engine and vacuum pup. Set the vacuum at 18 inches, road and record the control pressure in al selector positions. Run the engine up to $1000 rpm, and reduce the vacuum to 1Oinches, Read and record the contro pressurein @),D-2 and 1. Keep the engine at 1000 rpm and reduce the vacuum fo 1 Inch. load and record the contre pressure in @, D1, 2andR, Refer tothe two control pressure diagnosis charts to ‘show what components are lnoperatve when the ‘control pressure test snot witha specication Do nat proceed withthe maln diagnosis char unt serviced Ee requed, and the control pressures within Spectication aslistedin he Performance: ‘Specifications Book or Special Spectictions Issue of the Technical Service Bult, 10Technical Service Information ‘Attach tachometer to the engine anda Vacuum Gauge, Rotunda Number 089-00008, or ‘equvalont tothe transmission vacuum ine atthe ‘manifold vacuum port = Ei arian conecnon 2. Attach a pressure gauge tothe contol pressure ‘utiet atthe tranamision 3. Firmly apply the parking brake and stat the engine. 4. Check the throttle and downshift linkage for 2 ‘binding condition. Winkage is satistactory, check {or vacuum leaks in the ansmission aptyagm Uunitandits comecting tubes and hoses. Check all ‘other vacuuraperated units (auch as the power brake} for vacum leaks. Refer tothe two control pressure diagnostic guides to ‘show what components are noperative when the ‘contol pressure tests not within specications. Do ‘ot proceed withthe main hagnosis guide untl you hhave made any repairs, as required, and the control pressurois withn specications aslistedin the Performance Specifications Book or Special Spectications issue ofthe Technical Service Buletn, Vacuum Pump Method {nstallan adjustable vacuum source. Disconnect and ‘temporary plug the vacuum neat the vacuum slaphragm unt Apply both the parking and service brakes. Start the engine and vacuum pup. Set the vacuum at 18 inches, road and record the control pressure in al selector positions. Run the engine up to $1000 rpm, and reduce the vacuum to 1Oinches, Read and record the contro pressurein @),D-2 and 1. Keep the engine at 1000 rpm and reduce the vacuum fo 1 Inch. load and record the contre pressure in @, D1, 2andR, Refer tothe two control pressure diagnosis charts to ‘show what components are lnoperatve when the ‘control pressure test snot witha specication Do nat proceed withthe maln diagnosis char unt serviced Ee requed, and the control pressures within Spectication aslistedin he Performance: ‘Specifications Book or Special Spectictions Issue of the Technical Service Bult, 10Technical Service Information Cmca wartog oe cto HIE oR, nthe | I eens ee | cxaton esoaren eeeronaes olde ee mau oer donee ccae| line Berectinte ase i SFexing ReaucaTon i boost valves Sune REDUATOR VALVE vacuum oupwmaan unr] | excessive Lemans. 0M | —— SRSMERRG Tanaris] | Revie eoracre == es i tf Pe= Technical Service Information i Vacuum Supply Test The vacuum supply to the vacuum diaphragm unit and the diaphragm tel! must be checked, To check the ‘supply. disconect the vacuur ine at ihe Saphragm Unt an connect to a vacuum gauge. With he engine iding, he gauge must have a steady aceeprable, ‘vacuim reading forthe attude at which the testis ‘being performed. If the vacuum reading is lw, check fora vacuum leak of poor engine vacuum. the vacuum reading is OK. rapidly accelerate the engine momentariy. The vacuum reading must drop rapa at Acceleration andreturn immediately upon release of the accelerator Il the vacuum reading does not ‘change or changes stowly, the transmission vacuum line is pugged, restricted or connected toa reservoir ‘supply Correct as requved Vacuum Diaphragm Test—On Vehicle ‘To check the vacuum diapheagm unt, start the vacuum Bump and set the regulator knob so thatthe vacuum (gauge reads 18 inches withthe end ofthe vacuum hose blocked of Then connect the vacuum hose fo the clapiragm unit. the gauge stil reads 13 inches, the vacuum claphragm uns not leaking, the reading {does not remain at Ta inches, but drop, the vacuum ‘iaphragm untigleaking. Replace the vacuum ‘diaphragm unt. Als, automate tranemiesionfuidis Bresentin the vacuum sie ofthe daphragm orin the ‘vacuum hose, the diepivagm leaking and must be replaced, ‘Vacuum Diaphragm Test—Oft Vehicle Tocheck the vacuum unt for diaphragm leakage, ‘remove the unit rom the trancmission, Use a Vacuum Tester, Rotunda Number 021-000 1, or equivalent ‘Aust the tester unt the vacuum gauge reads 18 inches with the end ofthe vacuum hove blocked of. ‘Connect the vacuum hose to the manifold vacuum port {as shown. I the gauge stil reade 1B inches, he ‘vacuum unit diaphragm isnot leaking. A second leakage check can bo made a the hace fs removed {rom the transmission vacuum unt, Hold a finger over the end ofthe control rod. When the hoses removed the internal spring ofthe vacuum unt shoud push te Control rod outward. the vacuum claphragm needs Feplacing, install anew unt that has been released for ‘service. Vacuum daphragm assembly entiation is ‘Given at endof tis section, 2ATSG], Technical Service Information Converter Clutch Test NOTE: Engine coolant temperature must be above 53°C (128°F) and below 116°C (240"F). This temperature cane obtained ater approximately 15 ‘minutes of highway driving Since mast converlor Cluch shits are dificult 10 fel (much ess noticeable than a 120r 2:3 upshit) a tachometer and/or vacuum ‘auge must be connected tothe engine. To chack the converter clutch or engagement’ disengagement, drive ths vehicle at approximatoly 80 km/h (60 mph) and while maintaining his speed tap the brake pedal wth theleft {oot The engine rom ang vacuum should increase ‘when he cute dlsengages, wih ight brake ped ‘Applcation, and decrease wien the pedals released ‘and the duich engages. he converter clutch does ot engage, see Diagnosis portion af ths section Stall Test ‘The stall test checks converter one way clutch operation and installation, the holding alt of the orward dutch, reverse clutch, the lowreverse bands, ‘the planetary one-way clutch and engine performance 13Technical Service Information oo [IST BANOS) (ASA MATTER OF NORA. MARTENOEE AEGISTNG THE BANDS 6 NOT NECESSARY) ‘ree Paton Sa Spee oh Ta Sp or Toes Das en Oy CP = ore ‘Gna Cu Fad OE ‘Dower Foner Ou Gowen 0.2.1 ask ‘Gerard ProtiersPressue Test ow ‘Gane Cy Owe Croan Ca, = ‘vse igh Coon a Ree Breve = Tow ‘wee On Way Cc wae S To Tw ae ae Baan — "Sn Tans Fd Gnon in Be Dara Tsing pio hs ‘The test shoul be done only with the engine coolant {nd transmission fd at proper levels and at operating temperature. ‘Apply the service and parking brakes fly for each sta test. 4. Find the specified stall rpm forthe vehicle by felerring to the Performance Specification Book ‘0r Specal Specifications Issue of the Technical Service Bulletin, Use a grease penal to mark the ‘pm on tho chal ofa tachometer 2. Connect the tachometer tothe engin. 3, Ineachot the following ranges, 0.2, 1, R, press the aceslerator tothe floo and std jut long tenough tole the engine get ofl pm, While ‘making this tet, do not hold the throttle open for mora than fve seconds at atime Note the reautsin each range. After each range, move the selector lover oN ‘Neutra andrun the engine at 1000 rpm for bout 19 seconds to coo) the converter before ‘making the next test. CAUTION: Ifthe engine speed recorded by the tachometer exceeds the maximum limits siven in Specifications, release the Rccelerator immediately, because clutch or Band slippage fs nlc Governor Check “The governor can be checked at the same ime as the Contrl Prassure Tests performed andinthe sameTechnical Service Information Rais the vehicle with an axle or frameboist so that the reat wheels are clea of the floor Disconnect and ‘pg the vacium ine tothe vacuum diaphragm unt. {Connect thaline from the adjustable vacuum source to the vacuum dlapivagm unt. ‘CAUTION: pxceed 96 km/h (60 mph) ‘speedometer speed. Place the transmission in" o¢ "0" range noload nthe engine, and apply 1Oinches of vacuum tthe Vacuum iaphvagm unt. Increase the speed slow and Watch the speedometer, Check the km/h (mph) at which the contol pressure cutback occurs. shoul cour between 12-19 km/h (5-15 mph). Decrease the \acuum atthe vacuum daphragm 100-2 inches Contr pressure cutback should oocur between 18-28 enim (r20men) NOTE: Alter each test, move the selector toN (Neutra and run the engine at 1000 pet cool the ‘wansmission. “The governor is goad ifthe cutback occurs within these specficatons I the culback does not occur \witun spectications, chock shit speed to verily that Js the governor ang nota stuck cutback valve, then service or replace the governor. overarve range ©. (Approx ‘Yacuum) The tranemiaion shous startin fst gear, thitto second gear, shit fo turd goa, shift to fourth {ear (overcrve] and then tock tne converter cutch, ‘Fhe converter lockup is often aificut to fee, theretore a Vacuum gauge and tachometer snould be used to Setermine lockup sit points, Refer tothe Ford Performance Speoifcations Book or the Special ‘Specticationstssue of tho Technical Service Bullet al St point vehiie speed. When the selector lever i nD position, the {ranamission wilake al automatic upahits except the 34 ‘When the selectors at 2 (Second, the transmission ‘can operate only n second gear. ‘Wits the trangmissionn thd goar and road speed ‘over 72 km/h (45 mph) the transmission shoul shit to second gear when the selector lover is moved from 1 (Drive) or2 (Second) to 1 (Fist). Ths check will determine ifthe governor pressure and shift, ‘control valves are functioning propery. the vehicles traveling t approximately 72 km/h (G5 mph) and the ealoctor lever ls moved trom ©) (Overdrive) to 1or to 1 (closed trot), the trangmission wil immediately downshift io second ‘Transmission Fluid Cooler Flow Check The inkage,fhidlevel and control pressure must be thin specications betore performing this ow check Remove the transmission cipstick from the filer tube. Place a uanalin he transmission filer ube. Raise the Wohicle; remove the cooler return ine from its iting in the case. Attach ahove tothe coor return ine and {asten the free ond ol the hose nthe funnel stalled in the file Tobe, Start the engine and set ile the tranemsion nN (Neutral (Observe the fue flow atthe funnel. When the flow is Sold” (ar boeding has been completed), the flow shouldbe liberal tf fare ie nota tberal ow at 1000 pm in (Neutral) low pump capaciy, main circu System leakage, stuck converter charge rete valve or Bolar systemrestictions nacated ‘To separate transmission rouble rom cooler system troubie, observe the low atthe transmission case onverierout iting at 1000 rpm with ‘gear Aa oad speed drope below 48 km/h (30 mph) the tianomission wal downshift 0 first pe Fora coastdown from approximately 72 km/ (45 raph) with he transmission n @ postion and at closed thrott, the downshift sequence sas flows: Converter eutch uniocks eloctronicaly when the fccelerator padali¢ released, as veicie speed crops. 43.9.2 andfnally 2 downshifts happen. Inshop ‘Ashi test can be performed in the shop to check shift Valve operation, governor ecu, shit delay pressutes, throtie boost and downshift valve action. Rioe the vehicle with an axle o rare hoist so that the rear wheel are clear of the Noor Disconnect anc ‘lug the vacuum lng irom tha engine tothe laphragm Connect theline rom the adjustable vacuum soures the vacuum diaptagm uni CAUTION: Never exceed 96 km/h (60 mph) ‘speedometer speed. 1. Tocheck the shift valves ard governr circuits, ply 18 inches of vacuum tothe transmission Nacuum daphragm unt Pace the transmission in {© (Overerive) and make @ minimum throttle 1-2, Shift Point Checks Road Test “Tis check wil determine the electronics, governor {and shift control valves are functioning property a.344 andlockup shit. the shit points are ‘within specication, the 1-2, 2 converter clutch {nd 84 shit valves and governor are OK the shit points are not within specication, perform a ‘governor cheek fo isoate the problem NOTE: After each test, move the selector ever to Neutral, run the engine at 1000 rpm to coo! the transmission. 15Technical Service Information 2. Tocheck the shift delay pressures and tht ‘boost, decrease the vacuum at the vacuurn diaphiagm 100-2 inches. Makea 1-2 shift est. {he shit pont raises to specication, the thot boost and shift delay systems are functioning NOTE: Alter each test, move the selector laver to "Neutra, run the engine at 1000 rpm to coal the, transmission, 3, To.check downshit valve action, leave the vacuum tothe vacuum diapiagm at 02 Inches, Postion the cownahiltinkage nthe wide open throttle postion (through ine detent) and repeat the 1-2 shift test. The speed atthe shit point ‘shouldbe higher ‘Shit speed specications can be found inthe Performance Spectteations ook or the Special ‘Specifications lesue ofthe Technical Service Buln, ‘Air Prossure Checks ‘ANODRIVE condtion can exist, even with cortect transmission fla pressure, because of inoperative ‘tenes or bands, On automatic transmissions, an ‘erratic shift can be caused by a stuck governor valve. ‘The inoperative units can be cated thyough a series cof checks by substituting a pressure fr fd pressure to determine the locations ofthe malfunction When the selector leveris at 2 (Second) a NO DRIVE condition may be caused by an inoperative forward sysom, 6. Damages or wom governor. Senco 0 replace governor — Sean screon Sones or opace as require, 7. Vacuum diaphragm bent, ticking or lass €@. Bity oF sckng vave boo 8 an, se pace ve 7 aga raranconyes erro | ioe Ri Perini Raid lvel chek toon 2, Manual tokago —misadustod | 2. Check and aust or service 28 samaged roauied 13. Govemor skin 8, Porlorm governor test Serco 25 required 4. Main contol pressure too high. | 4. Contes pressure lst Sorce a5 reauied 5, Valve body bois —Ieooatoo sight. | 5. Ten to specieaton. 5 6. Vato body ceysteking valves. | 6. Detemine soutce of 7. Vscuum lak to daphragm unt. | 7. Perfor vacuum supply and 8. Vacuum diaphragm ben, scing, | 8. Chock diaphragm unt. Service as leaks. ‘Automatic Transmission Service Group 25Ele Technical Service Information DIAGNOSIS — AUTOMATIC TRANSMISSION (CONDITION (POSSIBLE CAUSE RESOLUTION Mashyeary a upstits pile op! T Low main conv pressure Catal esses. Hee penis 2. Vato body bolts oosatoo tht. ‘Foren to spucaton 5 VaWe booy or tote conta! vate steer. contamination. Service as ‘eaures 4. Governor valve sticking 4. Berorm gover tet Ropar as requires 5. Kickdown linkage misadusted, | 5, Adjust inkage, service as Seung or caragod required. No 1 wpanih Improper tid eve 1 Peron ta vel check 2. Klxsown system damaged, 2. Replace damaged pars. ‘3 Manual nkaga — misadusted | 3. Check and adjust oF sorice as emaged. reauies 44 Govemor valve sticking 4, Perform governor test. Sendcw a recued 5. Intermaciata band out of ‘gust ereciate bard, 5 aajusirent 6, Vacuum lek to daphrapm unt, | 6. Check vacuum ines to Sdaprragm. Service 3s required. 7. Vacuum diaphragm bert, sicking, | 7. Check diaphragm unt. Service leave is necessary 1, Vawe body bots —loosateo | & Titan fo specication 8, Determine source of ont 8, Valve body cinyisicing valves. ‘contamination. Service as reauied 10, intermediate band andior servo | 10. Peiorm ar pressure tas assombly burt. Feughtnrahiolayed 12 upani improper ful oval 1 Retann a el So 2. Boor engine parformanes. 2 Tune engine. 3. Kekcown inkage misadustes. | 3. Adustfrkage, 4 Intermediate band out of '¢ Agustintomecate band ‘gustan 5. Main contol pressure too high. | 5. Conta prssuce tat. Note ‘eau, 6, Goverer vive sticking, 6. ero sovemor et Sarin 5 requred 7. Damaged inamedaw sexo. | 7. Ar pean checkinomedate €. Engine vacuum leak 8, Grok engine vacuum snes ‘Check vacuum diaphragm nit Perform vacuum soppy and daphrag test Serve as ecosery. ®. Vaio body bots —toosaroo | 9, Tighten 10 specications, ght, 10. Vatve body dnystckng vaves. | 10. Determine source of ‘1, Vacuum ak to claptvagm unt. | 11. Check vacuum Snes to laphragm 12, Vacuum diaphragm bent, sticking, | 12. Check laphragm unt, Service as reas. Automatic Transmission Service Group 26|. Technical Service Information DIAGNOSIS — AUTOMATIC TRANSMISSION COROTION POSSWLE CAUSE ‘RESOLUTION Taieanysepping 2 up 7 proper ha TT Poa vel hack 2. Mat egutr oven vane stu | 2 Senice a requ 2. erect enghe poromance. 3. Tune eng as roquites. 4 nemesit bad ctf assent. | 4. Aqustnemedite bend 5. Low man conto pressure. 5. Conta! resets, Note resus. 6, Vab bay bts ose Sh 6. Then to speccaton 7 Va by ny sing vas. 7. Daterine suc o naminaton. Sov as roqured 8, Govemorvaho sick. 18. Porm govemer tet Sani as emu. 8, Damaged manmade sano orbans. | 9. Peterm ar presi tst Save as eeu. 10 Poehed, zed ineecine banc or | 10 Sercn or opie as raqued. Wes oan T Low td va 1 Povo Pi ve rack 2. Kekdounsystom cages. 2, Replace camage pans. 2 Low man con proseue to rese- | 3. Conto pressure et Noe rests, high out 4 Va boy tote —Sooetaa taht | 4 Tito spectaton. 5. Vv body dystkirg vabes, 5. Dette source of coraiaton, them sore 0 equa 6. Reveratigh eich assonby sum’ | 6. Obimine cause of contin. Sais vom, as requrec Taravceayed 23 wea 7 hanrea enghe parommance 1 Check engin heap 2, Eng vacua 2, Check engin veouum Ines, Check vacasn dephvagn ut. Prem, ‘assum sup) nd apvag es ‘Sores ab neceaaey 3. Kekdoun sso crag, oplce damaged pars, 4, Damaged o worn tamed stro | 4. Ar rosaue ts th into sano ‘elem androvarsetigh cach ion |” appy and recase he reversenih Guck al. fhoeh ton eho bal Svcs a5 requrea 5, Vave bay bots —Ieosato tight. | 6. Thien to specticaton 6. Va by lysing vas. 6 Detrina sour of codon. Seve 3 rogues, 7. Vacuum dageagm bet, sing, ks. | 7. Chock dapragm. pice as necessary, 8, Tote va sick 8. Savion os rue, ‘Automatic Transmission Service Group 27Technical Service DIAGNOSIS — AUTOMATIC TRANSMISSION Information 9. Vate body aityisicking valves. 4 Vacuum diaphvagm of TV cont ‘od bontseking oak, 5. Tote vave stuck POSSIBLE CAUSE. RESOLUTION 1 Kicksown system damaged. Replace damaged pars 2. Vale body bots loosatoo tht. | 2. Tighten to epeceation Determine source of contamination, Service required (Check daptragm and rd. piace as necossary Senco a8 raquted 1. Pear engine pariomance, 2. Vacuum tine damaged. 3. Valve body bots — losetoo tight 4. Valve body dtysticking valves. 5. Governer valve stuck 6. Output shat calectorbooy soa) Pe No ‘Gheak engine bnew. Service as required. ‘Tighon to spectcaton ‘inge damaged, Sata Ooo 1 ntarmadiate bard out of T Aaja bana adj 2. Damages intamediate sen ana! | 2. Perorm a pressure test, Service rine Ine, front seve andor intake 3. Improper band or etch pplication, o pressure contol system, Plshed lazed band ot crum, Dinysicy vane body, or ‘govemor 6. Governor valve suck. 7. Kickdown system out of agjusomont Perform contol pressure test. ‘Sorice or replace band oe cru. Clean, sanice or replace vahe ogy oF governor Perio goveror test. Service as required, ‘Adjust Kekdown system. ‘igine overepeeds on 8 an 7, Kickown system damaged 2. Improper band or chach appteaton oF ol pressure contol yee. 3. Damaged or wer reverae high clutch andr lvormediat sero piston, 4, lnteriedato servo piston seal ct, tealong 5. Diny or sckng va body 6. Tote vale stick 7. Damaged vacuum diaphragm. Replace damaged pars Pertorm contol pressure tet. Prior ai pressure tet. Sarin as required Replace seals. Check for leaks. Clean, sorice or replace valve booy. Service as require, Replace vacuum caphragm. Automatic Transmission Service Group 28Technical Service Information DIAGNOSIS - AUTOMATIC TRANSMISSION COROTION. POSSIBLE CAUSE ‘RESOLUTION Rougyengoor 52 ent af ceed Boden 8. Trapret engine te or portance: 2. inrope cow itape 3. Improper cLtch or band appcaton ‘ral pressure corsa sytem 4 Improper goveror operation 5: Dity oF sching vaive body. Tune, and acu engine i 2. Sere o adit kckdown incape. 8. Pero coneo prossue test 4. Parton governor test. Sevice as required 5. Clean, sonics or rplace valve Sooy Te aa an Sa mn cloaid a not bang od ‘secrcaly.Wres" ‘SRored rn open ticue eu contin: Ssetnod sie pn 52 should ‘ead approx. 20 of fsitance. 2. Trans case connector and harness connect ot seas 2. Matuneton of EEC procossor 2 Vasiamfine daconnecte rom ‘tap sensor ap senso ‘Tie postion sensor. Veracie Spd sensor 4. Check O., Band autmet. 5. Ovarcve servo damaged oF ‘ean. 6. Poighed or glazd overive band oun, 2. Satanic or king 4 st © Getanrted and steirg 24 T Perorn EEC IV aghast check eMfoy on engine of Check circu continty wth break ‘5 box toto, TSL"S0, and vot Crock power nn, 57 sea Pomsf ackieesy 2 oot sme, check fr ‘etlnraen, Som end Perform EEC IV alagreste chock PPfey on ~ engine 9, Porm BEC IV aageasse chock Pho on angie 0 4. Reset bang to 20 uns for 2.3, BG'era 9a oF 3 tone or Spoleations hack over saa ane piston Soom = replace frequlred 6. Sorvice or repace. S805. SE ale for obo ot movement. 1. Gran oF replace 3:4 solenoid and {her eloove aseamy. Sipping Gear T Check OD band adsiant. 2. Overrve serv damaged ot feats 8, Polished or glazed overcve band eeu T Reset band to 2.9 wana fr 23 20 ane SOL, oF 3 tus fr 4.0L Sephetone. 2. Check cover ss! and piston ‘Ssemy race Toque. 8, Service or repace Engine Hal peed ecaeaea OY cae . T Vacuum sem 2. Low main contol pressure 7 Check and eonica vaso Spear 2. Gontol pressure tas Chock and ean valve body Replace valve args ‘Automatic Transmission Service Group 29ATSG], Technical Service nn Information DIAGNOSIS — AUTOMATIC TRANSMISSION — (Cont'd) 2. verse and high clutch damaged. ‘CONDMON POSSIGLE CAUSE RESOLUTION Engine Sal epeed exceededin RL | 1. Lowheverse servtband damaged. | 1. Check engine braking 1. Wat ‘ocin@,D. 2 and t ‘OK, check service oF replace required the lowreversa sero and anc 2. Wowreverse servo OK. check Laem ge xa Tapp ma ead emeIn S| ODER AT Or oe | Ges a TURRET DOK in R. © way Clutch damaged. and 1. 104 rpalr O° or rar ono way thiches, Clan tranamdssion. "2 ups eabove 64 fea T Vacuum ayatom, 2. Main contr! pressure. ‘3. Governor damaged or wom. 4 iy or stekng vane body. 7. Check and sence hoses and ‘vacuum dapiragm Mt requod. 2. Control pressure test. '8, Perr governor check. Replace cor service governcr. 4. Clea, sores or rapace vive body. ‘Automatic Transmission Service Group 30Technical Service Information ‘IAGHOSIS — AUTOMATIC TRANSMISSION POSSIBLE CAUSE 1. Kockown system demeged. 2. Main conto! prose. 3. Govern damaged or wom. 7, Replace damaged pars. 2. Peron conte pressure fst |. Pertorm govemor check. Repice or sorice gover. Tears Leas 3 1, Kiciown eysiom damaged. 2. Maln contol preseure. ‘8. Diy or scking vate body 4. Keown cabo over aust 1. Replace damaged parts. 2. Peron conte pressure test |. Chack kckdowun valve. Clean of teplace vate body. 4. Act Kckown cabo. 1. Main contro pressure. 2. Goveror damaged oF wor. 3 Diy or sticking valve body. 1, Contr pressure tat 2. Check governor. ‘8. Clean or replace vahe body. 1. Main contol pressure. 2. ttarmediata band out of astment 2. Overdve chich damaged. "1, Pert conto! pressure tet. 2. Adjust band. Check intermediate ‘3. Repair or replace overtve catch, 1. Main conl pressure, 2. Dirty or scking valve Body. 8. Governor damaged or wer. 4. Kecioun tnkage misacusted oF sce 1: Parlor main contol pressure 2. Gloan or replace vae body. 3, Peron gover check. Replace ‘or sence goverer. 4, Aust or rpair ickown nage. ‘When moving selacior rom to manual, 86 Kt (8 mph) ‘wth scolerairrlonsed. Fst oar ‘it occur under 24 kmh 15 mp) i BEEs 1. Main contol pressure 2. Diy or etching vane body. 3. Lowieverse servo damaged. 3. Check and sonic as ruled. 4. Governor damaged oF wom. “4 Peron governor check. Replace ‘rence goverce. 5. Overdeve ch damaged. ‘5. Ropal or roplce as rogue. 1: Perform contol pressure test. 2. Clean or replace vahe body. Automatic Transmission Service Group 31t ATSG), Technical Service Information ‘DIAGNOSES — AUTOMATIC TRANSLESSION Sean TossmLE CADRE ESGLITON Tee rant en eae cameo Raa dacs pars 2 rato cao aca 2 next tom oe, 5 uneged nema Kk age, | 3. Senn tara How kag 4 appre cc and apts or | 4 Pt carl peso a Space coon oak Dir esing gorena 8: Since gover, ean 04 srg vat ty 6. Gna, evn, an vat ay Tighe onan a8 Soma geet ot ache 1 Saves orate 2 imamesat tans outot aime. | 2. At ome bnd 2 moe ere at pon an | Pwo unr en nom ae +eetccmmmnnmnes | ee RS ue 4 Pott, nd tao nn. Sereno op Oey rsa a ty an, en na 7 Neal a age aga Gasca ai sone wo aaa Saree eam 2 or mar le rte. 2. Tepe nt punto. ‘Manure pn caragst. | 3. Ad ag nd ea i ry 1 pope Rl 1 Pare od ceo 2 core ene a, ptomaren. | 2 Te ratte te. 2 appa cc car psn or | 3 Param col pac to Suan cons pose 4 Rete cle 4. Sete mavin 4 Sozadconnt cneey ch | gc ery sch, vy sng vat Ca, a eva ay. oa + oe Si vr Fe ry ‘se Baer * Seats eae 2 eae a esa, Bainter oe Sitvrawee Ta Ras ware po Teck one wo 2 Torqn conn onewny dich | 2 Race rq comet soos Ter roay — wae woman Pesce 1 Poa aos 2 Uinags 0 aire 2 Sven erat age 5 per tae of uch apeatn ar | 3 ete core rece a Tomas coe gee Nove cugee may egrets ary | 4 Caner mes gerag. 4 rep carte, page cance. amor oben | 5. oxy cr sch we toh 5. Cun soe an va by 6 moral osage osu cnn, | 6 Sane w gure Tiga sal waar ORG RG Tae | Law eg Yet gg a pa oot 2 rhan conver cich ste vate | 2. Raglce comer chith Sut ae =e ee ‘Automatic Transmission Service Group 32ATSG], Technical Service Information TRANSMISSION NOISY — OTHER THAN VALVE RESONANCE Test ster RESULT De] ACTION TO TAKE [VERY ROE 18 Check for goar noise 1 very within normal range, | Noi witin —@R) Pp] Normal condton. tome! roe reruns (BP co. rena By 3 [awace GSE Gtk nae or oer asta oar @poows Seon Br service nertace Seas, let 7 [OER © ceckn a oper nr ricinat inn @ | 00 4 Santas Seas See spoea Spence a vents BP] 100 pct io _. Se eeance. = cans Sei se, it bisasseneue,cLean macs BP) vossoee ‘feramison. FLUSH {orque converter and cool [sa Test * Pert ho Stal Test ns described under Sat Test | Noite stops ©) | GOW 5. Fipe Bagnous wr Tansy prtn of ssc Nose coosnt GB] EXAMINE tcne ten converter en pany Seige or nero ‘rates Aso AEE or coe ere Sorverorton ‘vag owe (Or etiion of cartaminalion, refer 16 Transmssion Fld Condon athe Diagnosis and Testing porton ofthis socion. ‘Automatic Transmission Service Group 33Technical Service Information TRANSMISSION NOISY — OTHER THAN VALVE RESONANCE (Cont'd) TEST STEP, RESULT] _ AGHONTO TARE 5 NOSE CHECK ‘© Fun waramiosio in al goare and check or noise. | Note cooent stop np GO 06. cy oer Note stops in Low and Bol SERVICE trad Rony etm ercor neoay deh oie stops 2, HIGH Po] SERVICE reso so Rony, poeta. HGH only Dy SERVICE bon araaree [SPEEDOMETER GER + Remove the speedometer gear an check for noe. | Nake sts Dy REPLICE sposcometer oor Noise dosent stop bl CHECK extension feusing Ssting_ sal or Sivestak SERGE or REPLACE en rogues CLEANING AND INSPECTION ‘Transmission Fluid Drain and Refill ‘Normal maintenance and bricston requirements do ‘not necessitate periodic automatic transmission Nid Changes. I major service, such asa eutch band, bearing, ot, is requedin the transmission, It wil have tobe romoved for service, At this time the converter, transmission cooler and cooler lines ‘must be thoroughly flushed to remove any drt. When used under continous or severe conditions, the tranemission shouldbe drained and refileg with tid ‘as specified, Before acing Mud, be sure that the Correct type wil be used. Irn doubt, check the Safety Standard Gertiication Label fixed tothe at front ‘door face panel or door ilar forthe Transmission Goce. For AALD Automatic Transmission (Code 1) use fid that moets Ford Specification, Motorcrat Mercon® ‘Mult;Purpose Automatic Transmission lus XT-2-QDX OrDOX (ESP-M120 166-4 or equivalent CAUTION: Use ofa fluid other then specitied ‘above could result in transmission malfunction ‘and/or allure. When fing a dry transmission and converter, refer to ‘Specifications far capacity. Check the fs level following the room tomperature checking procedures. Procedures for partial drain and refi, 6ve to inveicle service operation areas folows. 1. Loosen the pan attaching bots to drain the fig fromthe transmission, 2, When al uid nas drained trom the transmission, remove and thoroughly clean the pan. Discard angacket 8. Place a new gasket onthe pan, andinstalipan on transmission. 4. Add 2.8 ters (3 quarts of hid to transmission {trough the filer ibe. 5. Check the us lev! following the room temperature checking procedures, itis necessary to perform a compete drain and refi, twill be necessary to remove the Fesicua td from the cooler ines and Mush cooler nes complotlyJ; Technical Service Information ‘Transmission Fluid Lines |When one or more ofthe fui cooler stee tubes must ‘bereplaces, each replacement tube must be fabriated tram the same ize steel ubing a8 the original ine. Using the old tube 28a guide, bend the new tube as roqutfed. Add the necessary ftings, and instal the ‘bo, Make sue that the replacement tube has. arance to other components, especial ‘ystom and parts having sharp edges, adoaut fheext ‘ter thefitings have been tightened, add hid as tneeded: and check for ud leaks, Vacuum Tubes Rete to the folowing istration for vacuum tube instalation gino rom ron - = Ne oR Poet PRESSURE 35Technical Service Information ‘servicing of the transmission. ‘Clean the parts with suitable solvent and use ‘mostureroo airtocry off alle parts and cleanout fid passages. ‘The compostion clutch plates, bands and synthetic seals should not be cleaned|n a vapor dogreaser ot With any type of detergent solution, To clean these parts, wipe them off witha int free cloth. New chtch ates or bands shouldbe soakedin transmission tid ‘spectid for that transmission type fo tean minutes before being assembled. Control Valve Body 1. Clean al parts thoroughly in clean solvent, and Blow dry with moisture-tree compressed ai, 2. Inspect all valve and plug bores for scores, Check allfud passages for obstructions Inspect the ‘check valve or free movement. Inspect all mating ‘Surfaces for burs or datortion. Inspect a plugs {and valves for burrs or scares, Use crocus oth topalsh valves and ploge. Avoid rounding the ‘sharp edges of tne valves and plugs withthe both 8. Inspect al springs for distortion. Check al valves ‘and pligs for ree movement in hel respective bores. Valves and lugs, when cry, must falfrom ‘their own weight n they respective bores, 4. lll the manual valve ona lat surtace to check. for bent conition. Overdrive and Intermediate Servos 1. Inspect the serve bore for racks, the sarvo Piston for damage, andthe piston bore and eervo piston stem for scores. Chack fuid passages for ‘obstructions. Replace damaged seals, 2. Check the serve spring and servo band strat(s) for distortion 8. Inspect the cover seal and gasket cover sealing surface for damage, 4. Inspect the band ning for excessive wear and for proper bonding tothe metal band. NOTE: Kentty servo covers, pistons, and ‘springs witha tag for proper identiieaton, Servo 41. Inspect the bore for scores, 2. Check the uid passages for obstructions. ‘3. Inspect the band fr cistorton. Inspect the band ends for cracks. 4. Inspect the serve spring for estortion. Inspect the band ining for excessive wear and for proper bonding tothe metal band, Roplace damaged cover ee 7. Replace piston seals damaged. Extension Housing 1. Inspect housing for cracks, pect gask surface for burs or warpage, 36Technical Service Information 2. Inspect bushing for scores or wear. Replace t required 3, Inspect the rear seal for hardness, cracks, oF ‘wear! the seal shows wear or deterioration, replace the sea. 4. Inspect the seal counterbore and remove all burrs ‘and scores with crocus cloth, 5. Check vent for obstructions. Governor 1. Inspect the governor valves and bore for scores. Minor scores may be removed from the valves ‘with crocus cloth. Replace the governor the ‘Valves or body is Goeply scored. 2. Check for free movement ofthe valve in the bore. “The valve should slide freely of own weight in the bore when dy. Inspect hid passages in the ‘valve body and collector body for obstructions. [Allfluid passages must be clean. 3. Inspect the mating surfaces of the governor body ‘and collector body for burrs and distortion. ‘Mating sutaces must be smooth and at O—~xz, ome Reverse-High and Overdrive Clutches 1 Inspect the drum band surface, bushing, nd trust surfaces for scores. Minor scores may be removed with crocus cloth. Badly scored parts ‘ust be replaced. the clutch piston bore and the piston inner ‘and outer bearing Sutaces for scores. ‘3, Check the fid passages for obstructions, All flu pascages must be clean and ree of obetructons. 4. Ingpeet the clutch plates for wear, scoring ana ft onthe clutch hub serrations. Replace al plates that are badly scored, worn, or do not fit reelyin the hub serrations. 5. Inspect the clutch pressure pate for scores on the dutch plato bearing surface. Check the clutch ‘release spring for distortion 6. The clutch cylinders have chock balls. Inspect the ‘chock bals fr freedom of movernent and propor ‘seating, Pump 1. nspectmatngsurtacee of pump body andcate 2. Ingpeet the dive ang driven gear bearing surtace for scares and check gear teeth fr but. 3. Inspect the front pump seal for cuts or nicks. and pump bushing for eooting, 4. Chock hid paseages for obstructions. 1 any parts are found damages or worn, replace the purp as a unl. Minar burrs and scores may De removed with crocus cioth veo aL ASSEMALY aap everest CT 451 OH covteve cLuven nan fears Est) pect the clutch cylinder thrust surfaces, piston bore and lute plate serallone for scores or burrs. Minor scores or burrs may be removed with crocus cloth Replace cutch cylinder tis Daly scored or damaged. 37Technical Service Information ‘Check uid pressure inthe clutch cyinder or ‘bstrutions. Clean out al fu passages. Inspect Clutch pston for scores and replace necessary, Inspect the piston check ball or reedom ot ‘movement and proper seating CCheck clutch retease springs for distortion and cracks. Replace springs I they are distorted or cracked Inspect composition clutch piates, stool clutch plates, and Gutch pressure pate ior worn or ‘scored bearing surface. Replace allparts that are ‘seeply scores. {Check clutch plates fr flatness andi onthe dutch hub serrations. Discard any plate that oes not side freely onthe serations or that is not fat. 16. Check clutch hub thrust surfaces for scores and clutch hub spines for wear ‘Check input shaft for damaged or worn spines. Raoplace shaft the splinas are excessively worn. Inspect bushing in stator support for scores, Overdrive One-Way Clutch and Planetary Rear fay Clutch 1. lsspeet outer and inner races for scores or damaged surface areas where llers contact 2, Inspect roles and springs for excessive wear or damage. 3. Inspect spring an roller cage for bent or damaged spring retainers 1. Thoroughly deain remaining solvent tnrough he ‘converter hub, 2. Add 1.9. (2.0US. quarts) of clean transmission {id tthe converter. Agitate by hand. a solution through the converter ‘Thoroughly hub. Converter End Play and One-Way Clutch Check ‘The Converter One-Way Ciutch Torauing Toot ‘T77L-7902-8 and D84L-7902-A One-Way Cutch Holding Tool or an equivalent fabricated holding tool ‘are used to check the converter one-way clutch Fondong ToS End Play Check 1. Insert Toque Converter End Pay Checking Tool, ‘TBOL-7802-A or equivaler into the converter Impeller hub, untait botoms. Converter and Fluid Cooler Wen internal wear or damage has occurred inthe tranemission, metal particles, clutch plate material, or ‘band material may have been carried into the Converter andollcoole. These contaminants are a ‘major cause of recurring transmission troubles and MUST be removed from the syatem betore the ‘ransmission's put back nto service. Whenever a transmission has been cieassembled to replace worn or damaged parts or because the valve body sticks trom foreign material the converter, ol cooler and oll cooler ines MUST be cleaned and {ished by using the Rotunda Torque Converter ‘Caeaner (rode! 014-0028) or equivalent Under NO ‘Sreumstances should an attorptbe mae to clean ‘converters by hand agitation wth solvent ‘The lack ofa drain plugin the A4LD converter increases the amount of resiavalushing solvent Fetained nthe converter after clearing, This retained Solvent isnot acceptable and a method of diutog tis Fequred. The folowing procedures tobe used after Femoval of the ALD torque converter trom the Cleaning equipment ones SD” Merges ro 2. Expand sleeve inthe turbine spine by tightening the threaded ier post unt the folie securely locked m the spine. 38Technical Service Information ‘Attach Dia Indicator with Bracketry TOOL 4201-C or equivalent tothe Torque Converter End Play Checking Too! TGOL-7902-A Srequivslent Poston the incicator button on tho Converter impeller Rousig, and sat the alfa at0 Gero). Lift tool upward as far ast wil go and note indicator reading, The indicator reading is the {otal end play which the turbine and stator share. FRoplace the converter uit the total end play exceeds the mits, Refer to Spectications, Loosen threaded inner post to foe tool, and remove the ool rom the converter, Converter One-Way Clutch Check 1. Use One-Way Ciuton Holing T ‘Sr equivalent or fabricate a oneway clutch Folding tol ae shown below” 2. Insert one-way clutch holding toolin one ofthe {roovee in he stator trust washer. 8. Insert the Converter One Way Clutch Torguing ‘Tool, 177-Te02 in the converter impair hub so asto engage the one-way clutch inner race, 4. Attach torque wrench tothe one-way clutch forguing tot With the one-way clutch holding toot held stationary, turn torque wrench Counterclockurse, The converter one-way cluch Should lockup and hols 14 Nem (10 tb) torque. {The converter one way eutch should rotate freely ina clockwise drection Ty the one-way ich for lockup and hold sat least ve diferent locations around the converter 5. the one-way clutch falls to lockup and hold at 14 Nam(io tb) torque, replace the torque converter 39ATSG], Technical Service Information ‘Stator To Impolier interference Check 11. Postion ront pump assembly on a bonch with spline end ofthe stator shaft pointing up. 2. Mount a convertr on the pump with spines on the one-way clutch inner race ‘mating splines of the stator suppor. The paler ‘hub wil then engage the pump drive gear. 3. Hold pump stationary and try to rotate the torque Converter both clockwise and counterclockwise ‘The converter should rotate freely without any signs of interference or seraping within the Convertor assembiy, 4. here's aningication of scraping, the traiing ‘20996 ofthe stator blades may be interfering with the leading edges ofthe impeller blades. In sich ‘cases, replace the converter. Pinion Carriers Individual parts ofthe planet carriers are not ‘serviceable.Technical Service Information Check pins and shatsin planet assemblies for loose t and/or complota disengagement. Use a ‘ew planet assembly elther condition exist. Boloreinstalinga planet assomty, the shalt Fetaning pins should be checked for adequate Staking nacessary, restake the pins botore instalation. When restakng, the retaining ins ‘must ot be even no the eager any further than ‘Lom (0.040 inch) below the surface ofthe 2. Inspect pion gears for damaged or excessively ‘wor fest, 2. Check for ree rotation of pinion oars. Stator Support 1. Inspect stator support spines for burrs and wear 2. Check oiling grooves in stator support for nicks, burrs or damaged oxges. 3. Check ront and rear bushings of stator support for wear or searing Sheek ront pump suppor sea. (Check seal ings for damage. Case Inspect the case for cracks and stripped threads. Inspect the gasket surfaces and mating ertaces for burrs. Gheck the vent for obstructions, and check all fluid passages lor obstructions ard leakage Inspect the case bushing for scores. Check al parking linkage pars for wear or damage. lta transmission case threadis damaged, service kits ‘may be purchased trom localjoboers, To service a ‘damaged thread, the folowing procedures should be caret folowe: 1 Drllout the damaged threads, using the same Gril eize asthe thread outside dlameter. For example, sea! Tench drilfora 8/1618, theead. ‘Select the proper special tap and tap the oiled fale. The taps marked forthe size o the thread being paired: Thus, the epecialtap marked 57 16-16 wll ot cut the same treed es 8 Standard 516-18 tap, taoes cut a tread large enough to accommodate the insert, and ater the insert is nstalog, the orga thread size (i 16-10) isrestored ‘Select the proper col inserting too, These tools fare marked wih the thread size being repaired Pace the insert onthe tool and adust the sleeve to thelengtrof the ert being used. Press the Insert agamst he face ofthe tapped hole. Tun {he tool clockwise and the sort nt tho hole untl the insert 81/2 1b below the face. Working trough the inset, bend the insert tang Siraight up and Gown uni breaks of at the notch Improperly installed inserts canbe removed with the extractor tool Place the extractor toolin the Insert with the biade esting against the top col ‘rato 1/2 turn away from the end of he co. ‘Tap the too! sharply witha hammer ut the bi cutainto the inser. Exert downward pressure on the tool and tun t counterclockwige uns the inser ie removed REMOVAL AND INSTALLATION 1 3 ‘Transmission Removal Disconnect the battery negative cable, Raise the vehicle ona hoist. Place. drain pan under the transmission tic pan. On Explorar vehicos, pry tha lower cps of transmission eat shield back slightly to alow focess to pan bots Starting atthe rear of the anand working toward the rot, loosen the Bttaching bots and alow the fuidto drain, Then Femove allo! the pan attaching bots except wo the font to alow the fi to further drain. After athe tuidhas drained, instal wo bots on the ea sic of he pan to temporary hola im place, Remove the converter access cover rom the converter housing. Remove ona (1) bolton the ‘access cover of 8 cylinder applications (3.0L) vot swing cover open Femove the starter to-converter housing {hing bolts and postion the starter out of the way. NOTE: On2.9t and 4.0L engines, the convertor fattaching nuts are accesaed rough the starter ‘motor mounting hole On 2 SL engines, the Converter attaching nuts are accessed through the cover on the engine ol pan Femove the fou fywhee!to converter attaching ‘ulsby placinga 22mm sockel and breaker bar bn the crankshalt pulley attaching batt. Rotate the pulley clockwise (as viewed from the front to ‘amaccese to each ot the outa CAUTION: On 2.3L bell driven overhead cam engines, never rotate the pulley ina ‘counterclockwise direction (as viewed from the front). aLTSG]. Technical Service Information 7. Scribe a mark indexing the driveshaft to the rear aslo flange, Remove the crivashatt instal he extension housing seal replacertoolin. the extension housing, 8. Remove the speedometer cable rom the ‘extension housing, 9. Disconnect the shit rod atthe transmission ‘manual ever: Remove the kckdown cable fom the ball stud lever. Depress the tab onthe cable downshift retainer and remove the cable rom the bracket 10. Disconnect the neutral start switch wires and the converter cuten solenoid connector. 11. Remove the vacuum line from the transmission ‘vacuum modulator. 12. Position a transmission ack under the transmission and aise slighty, 18, Remove the engine rear support tocrosemember bots 14, Remove the crossmember-to frame side support altaching bolts and remove the crossmember insulator and support and damper. 16. 16. ¥, 18, 19. a Lower the jack under the transmission and alow ‘he transmiesion fo nang. Position a jack tothe trot ofthe encine and raise {the engine fo gain access tothe two upper ‘converter housing-o-engine attaching bel on Rangor and Explorer vehicles, Disconnect the oll cooler ines atthe transmission. Plug all openings to Keep out dt. Remove the lower converter hovsing-o-engine attaching bolts. Remove the transmission filer tube. ‘Secure the transmission tothe jack with a safety chain, Remove the two upper convertor housing to-engine attaching bolts. Move the transmission tothe rear sot engages from the ‘dowel pins andthe converter is isengaged rom the fywneel. Lower the vanemiesion rom the vehicle 42Technical Service Information NOTE: tthe transmissions to be removed for a Period of time, support the engine with safely Stand and wood block stallation Postion the converter tothe transmission making sure the converter nub fly engaged the pump gear. To accomplish ths, push and rotate the converter unt two (2) "bumps" are elt. Keep pushing ard rotating unt dimension "A" shown Below, is reaches, NOTE: Make sure the torque converter rotates freely andis not bound up Dimension “A” should be: Minimum: 10.23rm 7/16) Maximum: 14,43m (816 in) \Witn the converter propery instaie. pace the transmission onthe jack and secure witha satety chan Rotate the converter so the criva studs arein alignment wit ther holes m the flywheel With the transmission mounted ona transmission Jack, move ihe converter and transmission assembiy forward into postion beng careful not te damage the lipwheel and the converter plot. During this move, to avoid damage, donot allow the transmission to get nto anose down position 238 this will cause the converter to move forward land disengage from the pump gear. The Converter housing is piloted into position by dowels in the rear of the engine biock. The ‘convorter must rest squarely against ihe fiywheel. This indicates that the converter pilotis. ‘ot binding in the engine crankshett. 5. Insta two (2) converter housing to-engine attaching bolts atthe engine dowel locations, Tighten to 6851 Nem (26-38 1). 6. _nstallthe remaining converter housing to-engine attaching bolts and tighten to 36-51 N(28-38. feo) 7. Remove the safety chain rom the transmission 8. lnsortthe filer tube inthe stub tube and secure it fo the cyindorbiocx with the attaching bot. Tighten the bol to 38-51 Nem (28-98 Hb). the sub tube loocaned or ailnaged, should be replaced 9. nstallhe oil cooler ines inthe retaining clip at he {ylnder block: Connect the ines tothe tranemission case Remove the jack supporting the trnt ofthe engine. 11. Raise the transmission. Position the Crossmember,insulatx and support and damper To the frame side suppocte and metal the attaching bolts. Tighten the bolts to 27-41 Nm (oo tie, 10. Lower the transmission andinsta the rear engine ‘Supportto-crosemember nit Tighten the bolt to 82-108 Nir (60-00 ft), 13. Remove the transmission jack 14. Install the vacuum hose on the trenemssion vacuum unt Insta the vacuum hoa into the retaining cp ‘Connect the neutral start ewiteh plug tothe ‘Switch. Insta the converter cuteh/2'4 sh, solenoid connector. the four ywheeto-converter attaching When assembling the fywhee! 0 the converter, fistineak the attacring nus and ighten fo 27-46 Ne (20-34 1). Install the converter access cover and adapter plate bots. Tighten te bos to 16-22 Nem (12.16 fab) On2 at engines, ohten the ol pan access cover balist6 2.536 Nim (22-32 mio) 18. Insta the starter and tigen he attaching bots to 20-27 Nen(15-201b) Connect the muti niet pipe to the exhaust manifold isconnected fr ema 43, Technical Service Information 20, a 22, 2 24, 25 26, ‘Connect the transmission shit rod to the manual lever CConnaet te downshitt cable tothe downshift lever Install he speedometer cable as describedin Section 13:02, Speedometer Odometer. Install the driveshaft so the marks scribed on the ‘riveshalt and roar axie flange are in aigrmnent. Tighten the companion lange U-bot attaching rte to 95-130 Nem (70-95 fh). ‘Adjust the manual and downshift linkage as requeee. Lower the vehicle. Connect the battery negative Cable Filthe tranamasion tothe proper level with the specie fd PPourinfve quarts offi; then run the engine and ‘6d hid es fequired Check the transmission. converter assembly and bilegoler ins for oaks, Vacuum Removal and inst 1 2 iaphragm lation Disconnect hose trom vacuum diaphragm. Flemove vacuum diaphragm retaining bolt and clamp. Do not pry or bend clamp. Pull vacuum ‘Saprragm trom Wansmission case. Remove the vacuum eiaphragm control od ftom transmission case Install vacuum eiaphragm controlrod in 5. Push vacuum diaphragm into case and secute with retaning clamp ana bot. Tighten bol 10 912 Nim (@0- 108 ir). 3 vacuum dlaphragm hose to vacuum ciaphragm Control Valve Body Removal 1. Raise vehicle ona hoist so transmission and pan Saccessbie 2. Loosen pan attaching bolts and drain tid fom ‘ranemisson If the same fluid ie to be used again, iter through a 100 mesh ser Reuse fluid only tit ig in good conaltion. 3. Remove ransmissionfuid pan attaching bot, anand gasket emove titer screen and O-ings, Remove low everse servo cover, platen, sering and gasket 6. Disconnect two wires atthe converter elach solenoid and ne two wires athe St Shit solenodTechnical Service Information 7 Remove bots from the contro valve body. Note {hat the bolts are of eifferent lengths and their locations are different from the bolt lgeations on other automatic transmissions. Carefully ease the body from the case while Lunlocking and detaching the selector lever connecting rod. Lownevense Sno coven ma aa Clean and inspect ne vaive body prior to instalation, as detalled inthis section. 10 [Attach and lock the selector lever connecting roa (Lino to the manual valve and ease control Body int the case, CAUTION: Use care not to bend selector lever connecting rod (Z-Link). Insert correct length bots, fingersight,inholes A and to position control Body to case, Insert all remaining bolts (corect length except {iter screen bol and tighten to spectication. Remove the bot from hole A and install detent ‘spring fo Bolt, than reassemble and ighten and Biocations to specication. Inetal ow reverse servo cover, piston, spring and asker Connect the converter clutch solenoid wires. Clean iter screen with solvent. Then instal iter screen Oving and iter screen. Using a new gasket, install fd pan. Tighten retaining bots to 1 1-13.51 (6-10 F). Lower vehicle and ft transmission with proper rade and quantity of id Pour in 2.8L (3 quarts) of fd. Run engine and ‘dd Wie 8 rogues. (Operate vehicle and check for leaks. 45Technical Service Information + vauve s00¥ 20. ‘CENTER OF VALVE come SRS aTechnical Service Information Low-Reverse Servo Removal 1 2. Raise vehicle on a hoist lace a dain pan under transmission fuid pan. ‘Starting at rear of pan and working toward front, loosen attaching bots and alow fii to drain. FRomove all of th pan attaching bots excopt two alte front fo allow uid to urine drain. Finaly Femove allot bolte and remove the pa. 3, Remove ol iter soreen and gasket. Remove retaining screws, low-reverse servo cover, piston, spring and gasket, Installation 1 2 Installowreverse serve piston and sping in the ‘servo housing, Install servo cover and gasket. ‘Gean and replace itr screen and gasket. Position ransmission tid pan anda new gasket. Install retaining screws in two steps. Refi ransmission with the proper orade and quantity of fad Pour in 2.8 (3 quarts) of uid. Run engine and ‘ad8 Mid ag required ‘Operate vehicle and check for leaks. Extension Housing Oil Seal Removal and installation 1. alge vehicle on a holt 2. Remove driveshatt. Driveline General Service. Make scribe marks on ‘driveshaft end yoke and rear axle companion flange to assure proper postoning of driveshaft ‘uring assembly 3. Romove ol seal using Extension Housing Seal Remover 17 1P-T657-A or equivalent, 4. Ramove extension housing bushing using Extension Housing Bushing Remover T77L-7697-£ or oquivalont. 5. Instat new extension housing bushing using Extension Housing Busting Replacor ‘TYTL-7697-F or equivalent. 6. Before instaling a new seal, inspect the seating ‘surface of te universal oit yoke for scores. ‘scoring found, replace yoke. 7 Inspect counterbore of housing for burs. Remove ‘any buts wth crocus cloth. 8. _nstallnow ol soa using Extension Housing Seal Roplacer 174P-77052"A or equvalent. Coat Inside ameter atthe end of the rubber Boot Portion of seal with Long-Life Lubricant 1Az-10500-BA (ESA MIC7S.8) or equivalent Coat the front universal joint spine wth Long-Life Lubricant G1Az-19680-BA (ESA MIC7E-B) or ‘equivalent 8. stall driveshaft using scribe mark as a guide to ‘assure correct balance 47(aarse], Technical Service Information 10. Lower vehicle and check oillevelin transmission, ‘Addl necessary. =F Installation 1. Clean and inspect extension housing as outined, 2. Install a now extension housing gasket on case. Extension Housing ‘3. Verity that park pawl and park paw cetur spring Removal are instaled property in extension housing and 1. Rais vehicle on a host are preloaded, 2. Remove drveshat Make scribe markson ‘rivoshaft end yoke and rear axle companion flange to assure proper positioning of driveshatt during assembly ‘Suppor transmission with a transmission jack. 4. Remove speedometer cable romextension housing. 8. Remove rear support to-crossmember attaching batts ont 6. Reise transmission sghty and emoverear Suppor rom extension naxsing. 7. Loosen extension housing bolts and alow the 4. Position extension housing onthe case, making twansmission fd to drain Betcarec so permease a 8. Remove bolts and extension hous inthe gue cup borein extension instal the heeded “7 {elaining bots: Tighten bolts to 3752 Neen 27-99 ‘). Insta reer support and lower transmission, Insta attaching bots. Remove the transmission ack, 7. nstallthe speedometer cable as described In ‘Section 13:02, Speedometer Osometer 8. stall rveshat using srbe mark as acide to ascure correct balance, 8. Lower vehicle and fi transmission with uid, _adaing as requred while running engine,Technical s ervice Information 10. Check extension housing area for Tid leaks. 2. Postion governor body over the ol feed holes of the oll colector Body. 3. Install governor body to il collector body atlacring batts and tighten to specrtication 4. Install extension housing as outined, Governor Removal 1. Remove extension housing as desorbed. 2. Remove governor body to oll colector body attaching bls 3. Remove governor body, vale, spring and weight from collector body. NOTE: Components are not retained once the ‘governor body tool collector body attaching Batts nave Been removed. itis therefore necessary to hold the governor body and Components whe remewg or astaling. Installation 1. Assemble governor body and components DISASSEMBLY AND ASSEMBLY NOTE: Betore beginning the transmission overhaul, review the folowing guidelines. These general ves {re provided to emphasize the ned for attention 3 ‘tall and care when servicing an automale ‘wanamssion. «© Ifthe transmission is being removed fr major ‘overhaul its important to completely clean a transmission components incuding converter, ‘cooler, cooler lng, an contol valve body, ‘govertor, al cutchos, and all chock bals after ‘any anemission servicing that generates ‘contamination, Theea contaminants are a ‘major cause of recurring transmission troubles ‘and must be removed from the system before the transmission is put back into service, ‘© Taocough leaning ofthe transmission exterlor wilreduce the possibilty that damaging Contaminants might enter the subassemblies (uring disassembly and assembly ‘© Alltastoners must be tightened 10 Spectication ‘© When bulding up sub assemblies, each ‘component part should be lubricated with clean ‘ranasmission fi. tis also good practice So lubricate the sub-assembies as thoy are” installed n the case, 1 Needle bearings, thrust washers and seals shouldbe lightly coatod with petrooum ely uring subassernaly bullup or transmission ascombly ‘¢ Many components and surfaces inthe transmission are precision machined. Careful handing during disassembly, clearing, Inspection ang assembly can prevent ‘Unnecessary damage fo machined surfaces, * When buiding up sub-assembies or bling the ansmission, aways use new (skets and seas ‘¢ Tho transmission service area should be kept clean, well organized and suppied wih clean lnetrée shop cloths. © Whenever a sealis removed trom a piston, shaft or servo, note the type of seal and when applicable, the rection o the sealing li. ‘© Always use the spected transmission uid ‘wen ibrcating seals or other components rior to assembly, Refer to Spectications, 49ATSG), Technical Service Information 4.0LEnginesec ° o € . ° - < o ° > o ao o ° c £ ° o F 2.3L, 2.91 and 3.0L EnginesATSG] Technical Service Informationc ° © € . ° - c o ° > o a o ° c ad ° o BF eee BeReES al sfele| lela] e| =| alels| ef el=ire| Toate Pan=O0Gun | "Ra sa ORT ew TOT ‘Automatic Transmission Service Group 33c ° = © — . ° c o ° > L o ao o ° c £ ° o BK = Sal fw Be Soro Oe ‘Galt — a Se Sep Fa Gr ip ‘Automatic Transmission Service GrouTechnical Service Information ‘Transmission 3. Remove eighteen 13mm botts, then ol pan. NOTE: Bolt identitication sizes for the folowing procedures ndicate he head &2@, not the thread sz Disassembly 1. Remove torque converter 4. Remove 1Ommbolt (MB x 48mmlong) then remove titer screen 5. Remove detent ring 2. Remove input shat. NOTE: The two splined ends are citferent 35Technical Service Information 6. Disconnect 2 wires at converter cuich solenoid Disconnect the 2 wives athe 3-4 shit solenoid, 7. Remove twenty fve- 10mm bolt retaining valve body to case. While easing valve body out o the Itanarsssion, unlock and remove selector lever Connecting ink. Remove valve body and gasket, NOTE: There ara four diferent lengths of bolts —aomm, 36mm, 40mm and 45mm 8 Remove Sm alen‘ead retaining bolt holaing center support. 36Technical Service Information 11, Remove two 10mm bots, hen remove governor. +2. Mount tranemigsion in Bench Mounted Holding Fixture 7571-5008 (or equivalent) as shown, 19, Two 10mm bolt, 5Omm ing wil be required. 14, Remove eight 17mm bolt, then comove ‘converter housing and purnp as an assembly 15, Rotate andi sothatcutches wal stay in place. Remove the No, rvust wasner an the gasket. SS =F)Technical Service Information 16. Remove nycrauic pun oll seal using Seal Remover 174P-77248¢A, oF equivalent, wth a 17, Remove the hyseaulc pump trom the converter housing and remove the steel pate (berind ol Beal) wth tne O-ring 16, Loosen overdrive band lock nut ane back of gusting serew. 19. Locknut wile discarded and a new nut wil be ‘sed, a lock nut and seal aa one pies 20. Remove anchor and apply strut, 21, Lit out overcrive clutch assembly and band NOTE: Idontily band as “overdrive” and identity either “apply or anchor” endfor eeinstalation inorder to dtingush i rom the mormedate band. 4.01 appications use a double wrap desion band 3 23 22. Li out overcrve one-way clutch andplenetary by 0 ee c> y/ S SB Wes F 24. Remove overdrive apply lever and shat. 28. Remove overdrive contro bracket from valve body sige at case.Technical Service Information fe apply lover does not have a co rea to ply sever The overcrive apply 82, Remove anchor and apply struts.88. Forall applications except 4.0L. ‘shaping rom reverse plane! gearATSG] Technical Service Information e146, Remove thrust washer. Technical Service Information oTechnical Service Information 47. Remove intermediate apply lever and shat 448, This apply lever nas a boss onthe shatt hole and tha shat fe shorter than the overdrive shat. NOTE: A contra brackets not used 49, Tur transmission so that output shal points Upwara 50, Remove output shat by puling upward NOTE: f output shattis tobe replaced, 4.0L ‘applicatons use an output shaft that does not havea hbrcant hole, 51. Remove park gearcolector body assebly ron tear of 52. Remove thrust washer '53, Remove one 10mm (M8 x 12mm long) bolt and ‘54, Remove vacuum diaphragm and throttle valve ‘ctuatorrodTechnical Service Information ‘55. Verity that th throttle valve moves freely using fat needle nose pies, 58. Remove trate valve, using neectenose piers, ST. Remove interme servo cover snap ring 58. Transmission caseis notched out to permit easy snap ring removal 59, Romove intermediate servo cover, piston and spring, 60. Remove overdve servo cover snap ring 61. Remove overdrive servo cover, pston and spring. WARNING: COVERS CAN POP OFF DUE TO ‘SPRING PRESSURE BEHIND PISTON, 62. Covers usually can beremavedty tapping lightly oncover or sige of case, 63. Occasionaly, covers mustbe removed using ait CAUTION: Identity the overdrive cover and piston from the intermediate cove in the incorrect bore and concerns due to pressure (ey (ee De 64. Air pressuremay be used on release sides of pistons, CAUTION: Air prossure should not be greater than 197 kPa (20 psi. 65. Remove neutral start switch using Neutral Start Switch Socket T74P-77247-4 or equivalentTechnical Service Information 70. Remove case solenoid comector. 71, Atab onthe outsie ofthe case on backside of ‘connector must be depressed whi paling with pers. The ab s depressed with a smal par of focking piers. NOTE: The comector neednot beremoved Unless itis to be replaces, and/or tthe caseis to De immersed ina degreaser. Assembly NOTE: Before beginning assembly ofthe transmisson, the folowing high clutch seal sizing procedure must be perormed 41. Installnew high clutch seals onthe support hub. Isnecessary 10 size these sea NOTE: The seal grooves have a “dovetail” Contour with straight sidewalls onthe pressure ‘sealing sies| NOTE’ thi isnot done, the seals can be cutor ‘olleg aver when entering the intermediate brake ‘rum cavity. ‘Apply aiberal amount of petroleumjely tothe center ‘support nub and seals 2. Use overdrive brake drum as siing too. Caretuly rotate te contor support who inserting. 3. Observe the soals as they enter the cavity to soe that they donot rl over or get cut 4. Besure the contr supports seated fly nto the ‘overdrive drum. Allow to stand for several ‘rinutes so thal the saale seat inthe grooves. Set ‘ide unt required for reassembly later insTechnical Service Information 5. Piage thrust washer No. 11 (78388) into back of {8 Install governor on cotacter body with wo Frenne Tinto & ant 20 to) 7. Instat output shat NOTE: a new output shatis being installeg ‘4.0L applcations use an output shaft that dows ot have a ubrcant noe 67ATSG] Technical Service InformationSG], Technical Service Information 11. Install output shat cing gear and snap ring onto 13, Use petroleum oly tohots twust washers in tena positon on planet assembly |e 14. Instat nap regincromtonod lane aso in shalt Steove (ubrecant guide). E NOTE: 4.0L applications do not havea snap ring atts location 12, Install thrust washer No, 9(70429), reverse planet assembly and trust washer No.8. Go423) 6Technical Service Information 16, Install low-reverse band, 19, Installintrmediate servo spring, piston, cover ‘and snapring. eter to the Speciications portion ‘Ol this secton for proper means of identiieg ‘Overdrive fromintermediate ervo covers ans ‘components, = EL * 1 (WN 16. Replace servo piston or Oring itnecossary. 17. instal low-reverse servo piston to hold bangin sion 20, Replace piston or Oring it necessary, 21. Install overdrive servo spring, piston, cover and ‘snap ring. Enaure correct cover einstalied, 2 identified by a tag during cisassemcly 18. Replace piston or Oxingit necessary. 22. Locate and identity intermediate servo apply lever and shaft 70MAATSG] Technical Service Information 23, Theintermediate servo apply lever isthe lever 26, Instllthe complete forward cutoh an that has a boss onthe shaft hole and the shat is and high clutch assembles shorter than the overdrive shat. aTechnical EE Service Information 28, Inca he intermediate band anchor strut and input shat (emporary) as an aignment gud, then go to he Wansmiasion fear ena play check. 20. The transmission ear endplay check eters: ‘2, the amount of space existing between the thrust washer surtacaa of tne overdve ‘center suppert and theintermodiate brake Seam 1. the thickness ofthe No. 4 thrust washer that 's required to obtain an end play of 0.200.S4mm(0.012-0.022 wch). To pertorm the ond play check, fabricate a depth gauge fiture froma spare overdrive center support. A Simm (1/8 inch) hole must be eiled through the trust ‘washer surface othe canter support. This allows, Depth Micrometer D80P.420%-k or equivalent access fo the area between the thst sufeces ofthe support {andthe termediate brake drum. Remove the rubber ‘seals rom the spare centr support fo alow easy ineertion nto the intermediate brake crum. 7Technical Service Information 90, Place Depth Micrometer D8OP-4201-A or lequvalent over drifted hole inthe fabricated depth ‘gauge fixture. Extend micrometer probe unl tis flush wih the trust washer surface ofthe fixture. Record the merometer raacing, Ths is Reading, & nee | perm menoweren Bere 81, Installthe depth gauge and input shat fixture into the intermediate brake drum and make sureitle {uly eaten he tranamation nse, Gay "wiggle" input shat fo allow confer support fixture to side into intermediate brake arm using its own weight. The fixture axially locates the ‘drum nits proper positon. ‘92. Place depth micrometer over the driled hoe in the fixture, 33. Continue extending the micrometer probe unt it contacts the thrust washer surtace 0! the intermediate brake drum. This 's Reading 4. Subtract Reading A from Reading B, The dlference between these readings ie Dimension ‘A. Thisis the space between he thrust surfaces, 35, Remove and rotate the fixture 180 degrees, Repeat steps 30 through 34 38. Average the two Dimension Are the fina Dimension & reading 37. Locate the nal Dimension & reading inthe following chart and selec the proper trust washer roguiredto obtain the spectied en play (0f0.90-0.54mm (6.012.0.022 neh. Dimension As outside the specified its, thisincicates. Improper assemtly, missing parts or parts out of ‘specication. This roqures a rebuild othe unt ngs o obtainTechnical Service Information ‘Muvewsio 0 Pu SLECTVE UST WASHER CHART — ze = = Tae Soea z oo sarees oeats Sanaa seco 2aer SOT TOREGR Fc aeaas t o ETOH prs oasace i ons OTHE ey Soe a aan Saat oer ‘eas [oor ¢ a] ‘ern 26306 eso ° ra ae BOT ia ‘sosans | orz0ane £ oe one ‘BODT-700TA 38, Remove depth gauge andinput shat fixture from ‘overarve orum, Th provedute (sizing of seals) was bogunin steps 1 through 4 of thie section (Granamission Aseembiy), Pasion the correct No. 4 (700 18) selective washer on rea af cantar ‘suppor using petroleum ty. Insert the input shaft short splines down) through the center support and nto the spiage inthe forware etch cylin. 40. Caretuly place the coner suppor into the case, butdo not start int the ntermerhate brake rum. Be sure tis square wth the case ang the SSmm aller-hoad bolt retainer nuts oriented with teal oom the casa, support. Gently "wiaale” the input shat allowing the center suppor fo aide mo the termediate ‘rake rum yoing is own weight Perform ts ‘operation uti the support is aly seates, Remove the input shat 41, DONOT apply any pressure tothe canter | | 4=. Technical Service Information 42. Position No. 3(7L826) thus! washer ontop of NOTE: Two types of center support retaining center support. Snap rings are used, One's ientiied by holes icceted.n theinner and cuter diameter the other typeof snap raghas no holes. They shouldbe positioned as shown, SS 43. Insta large snap cing to retain center suport in ‘Boston with taper srap ring toward the ront of {he transmasion NOTE: The ends ofthe snap ring should be ppositonadin the wide shallow cavity located in the tive o'ctock positon. 144, Install Sum allen-hoad bolt that retain conter ‘supporto case 45. Install aun gear and overdrive clutch adapter into ‘overdrive planet assembly and one-way clutch, ‘The part number onthe adapter should face the sun gear.