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T HM 40 0

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

AUTOMATIC TRANSMISSION SERVICE GROUP 18639 SW170th AVENUE MIAMI, FLORIDA 33157 (305) 670-4161
Copyright © ATSG 1999

Updated December, 2002

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

No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without written permission of Automatic Transmission Service Group. This includes all text illustrations, tables and charts. "Portions of materials contained herein have been reprinted under license from General Motors Corp, Service & Parts Operations." The information and part numbers contained in this booklet have been carefully compiled from industry sources known for their reliability, but ATSG does not guarantee its accuracy. DALE ENGLAND
FIELD SERVICE CONSULTANT

Copyright © ATSG 1993

JIM DIAL
TECHNICAL CONSULTANT

WAYNE COLONNA
TECHNICAL SUPERVISOR

ED KRUSE
TECHNICAL CONSULTANT

PETER LUBAN
TECHNICAL CONSULTANT

GREGORY LIPNICK
TECHNICAL CONSULTANT

JON GLATSTEIN
TECHNICAL CONSULTANT

DAVID CHALKER
TECHNICAL CONSULTANT

ROLAND ALVAREZ
TECHNICAL CONSULTANT

JERRY GOTT
TECHNICAL CONSULTANT

GERALD CAMPBELL
TECHNICAL CONSULTANT

MIKE SOUZA
TECHNICAL CONSULTANT

AUTOMATIC TRANSMISSION SERVICE GROUP 18639 SW 107TH AVENUE MIAMI, FLORIDA 33157 (305) 670-4161

1

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

FORWARD CLUTCH

DIRECT CLUTCH

INTERMEDIATE CLUTCH

INTERMEDIATE ROLLER CLUTCH

FRONT BAND

REAR BAND

LOW ROLLER CLUTCH

Copyright © 1999 ATSG

Figure 1

AUTOMATIC TRANSMISSION SERVICE GROUP

3

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

4. DIRECT CLUTCH GOVERNOR 1-2 ACCUMULATOR REVERSE OR LO GOVERNOR FEED (DRIVE) GOVERNOR PRESSURE Copyright © 1999 ATSG Figure 19 AUTOMATIC TRANSMISSION SERVICE GROUP 21 . 6. 15. MANUAL LO INTERMEDIATE DRIVE LINE PRESSURE INTERMEDIATE SERVO REVERSE EXHAUST DETENT OIL MODULATOR 10. 13. 12.000 GVW AND UNDER) "COPPER" . 2. 8. 5. 11. 3.096" 8670459 "BLUE" . 7. 14.Technical Service Information 1988-1990 CASE PASSAGES 7 6 6 4 3 8 2 9 4 5 9 8 2 9 10 9 11 5 2 12 2 3 8 6 5 4 8 3 8 2 9 1 10 9 6 6 2 10 1 13 2 4 1 4 ORIFICE CUP PLUG LOCATION (10.089" 8670801 14 15 1. 9.

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

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

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

1 No. 3 No. 4 No. 5 NO. 7 NO. 6 1 ORIFICE CUP PLUG LOCATION (10.000 GVW AND UNDER) "COPPER" . 6 No.089" 8670801 NO. 2 NO. 5 No.096" 8670459 "BLUE" . 4 NO. 7 Non-Functional (Omit During Rebuild) Intermediate Servo 2-3 Drive 1-2 Shift Intermediate Lo/Reverse Reverse Copyright © 1999 ATSG Figure 23 AUTOMATIC TRANSMISSION SERVICE GROUP 25 . 2 No. 3 NO.Technical Service Information 1988-1990 CHECKBALL LOCATIONS NO. 1 No.

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

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

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

18. 44. 78. 54. 61. 42. 82.Technical Service Information LEGEND FOR FIGURE 27 1. 7. . 36. 66. 83. 17.) FRONT SERVO PISTON FRONT SERVO PISTON PIN RING FRONT SERVO PISTON PIN FRONT SERVO RETURN SPRING RETAINER FRONT SERVO PISTON RETURN SPRING REVERSE SERVO COVER RETAINING BOLTS. 56.LONG. 72. 63. 43. 35. SHALLOW PAN . 58. 5/16-18 X 1.620" REVERSE SERVO COVER REVERSE SERVO COVER GASKET REVERSE SERVO PISTON RETAINING "E" CLIP REVERSE SERVO PISTON REVERSE SERVO PISTON SEAL 1-2 ACCUMULATOR PISTON OUTER SEAL 1-2 ACCUMULATOR PISTON 1-2 ACCUMULATOR PISTON INNER SEAL REVERSE SERVO PISTON WASHER REVERSE SERVO SPRING REVERSE SERVO SPRING RETAINER REVERSE SERVO PISTON BAND APPLY PIN (SELECTIVE) 1-2 ACCUMULATOR SPRING CENTER SUPPORT TO CASE BOLT (SHORT OR LONG) OUTPUT SPEED SENSOR ASSEMBLY(SOME MODELS) OUTPUT SPEED SENSOR "ORING " SPEED SENSOR RETAINING BOLT LINE PRESSURE TEST PLUG. 67. 53. 75. 87. 12. 59. 5/16-18 X . 23. 27. 5/16-18 X . 31. 14. 6. AND SOME 7 REQ. 11. 10. 60.620" MODULATOR RETAINING BRACKET VACUUM MODULATOR ASSEMBLY MODULATOR "O" RING SEAL VACUUM MODULATOR VALVE COOLER FITTING IDENTIFICATION TAG SCREW IDENTIFICATION TAG GOVERNOR COVER RETAINING BOLTS (4 REQUIRED) GOVERNOR COVER GOVERNOR COVER GASKET GOVERNOR ASSEMBLY EXTENSION HOUSING TO CASE BOLTS. 48. 64. 57.875") MANUAL DETENT SPRING AND ROLLER ASSEMBLY VALVE BODY ASSEMBLY GOVERNOR FEED AND RETURN PIPES VALVE TO CASE BODY BOLTS. 70. 4. 1/4-20 X . 21. 71. 76.750" DETENT SOLENOID ASSEMBLY VALVE BODY TO SPACER PLA GASKET TE VALVE BODY SPACER PLATE SPACER PLATE TO CASE GASKET CHECKBALLS. 16. 79. 5. DEEP PAN ONLY MANUAL DETENT SPRING SUPPORT (SOME MODELS) 45. 86. 19. 39. 51. 77. 68.620" GOVERNOR SCREEN ASSEMBLY DETENT SOLENOID RETAINING BOLTS. 74. 49. 8.690" BOTTOM TRANSMISSION OIL PAN (SHALLOW OR DEEP) BOTTOM PAN TO CASE GASKET BOTTOM PAN MAGNET SHOULDERED FILTER BOLT. 73. 38. 81. 29. 65. TORQUE CONVERTER ASSEMBLY BOLT AND "O" RING ASSEMBLY (PUMP TO CASE) SPEEDO HOLE STEEL PLUG (4WD MODELS) OIL PUMP ASSEMBLY OIL PUMP TO CASE SEALING RING PUMP COVER TO CASE GASKET VENT PIPE TRANSMISSION CASE ASSEMBLY MODULATOR RETAINING BOLT. 5/16-18 X . 3/8-16 X 1" EXTENSION HOUSING METAL CLAD SEAL EXTENSION HOUSING ASSEMBLY BALL BEARING ASSEMBLY BALL BEARING SPACER EXTENSION HOUSING BUSHING INTERNAL SNAP RING EXTENSION HOUSING TO CASE SEAL (SOME MODELS) REAR CASE BUSHING EXTENSION HOUSING TO CASE GASKET (SOME MODELS) ELECTRICAL CONNECTOR ELECTRICAL CONNECTOR "O" RING BOTTOM PAN BOLTS. 15. 85.250" STEEL (SOME 6 REQ. 69. 50. 22. 28. 1/8" PIPE FRONT SERVO PISTON SEAL DRAIN PLUG GASKET (SOME MODELS) BOTTOM PAN DRAIN PLUG (SOME MODELS) Copyright © 1999 ATSG Figure 28 AUTOMATIC TRANSMISSION SERVICE GROUP 29 . 41. 32. 30. 20. 47. 52. 33. 1/4-20 X 1. 40. 26. 62. 9. 13. DEEPAN) P MANUAL DETENT SPRING RETAINING BOLT. 37. FILTER INTAKE PIPE (SHORT. 84. 34. (SHORT OR LONG) BOTTOM PAN FILTER ASSEMBLY FILTER SPACER.

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

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

217. 339.120" DIA X . 205.) DETENT VALVE DETENT REGULATOR VALVE DETENT REGULATOR VALVE PIN DETENT REGULATOR VALVE SPRING MANUAL VALVE 1-2 MODULATOR VALVE BUSHING (SOME MODELS) 1-2 REGULATOR VALVE (SOME MODELS) 1-2 REGULATOR VALVE SPRING (SOME MODELS) 1-2 DETENT VALVE (SOME MODELS) 324. 208.) 3-2 DOWNSHIFT VALVE SPRING 3-2 DOWNSHIFT VALVE PIN 3-2 DOWNSHIFT VALVE 1-2 MODULATOR VALVE BUSHING (SOME MODELS) 1-2 ACCUMULATOR VALVE PRIMARY SPRING (SOME MODELS) 1-2 ACCUMULATOR VALVE. U STATOR SHAFT FRONT BUSHING Copyright © 1999 ATSG Figure 31 LEGEND FOR FIGURE 33 301. 325. 212. 311.D. 206. 302.R. 330. 209. PRIMARY (SOME MODELS) 1-2 ACCUMULATOR VALVE BUSHING (SOME MODELS) 1-2 ACCUMULATOR VALVE SECONDARY (SOME MODELS) 1-2 ACCUMULATOR VALVE SECONDARY SPRING (SOME) Copyright © 1999 ATSG Figure 32 32 AUTOMATIC TRANSMISSION SERVICE GROUP .) 1-2 ACCUMULATOR VALVE (SOME MODELS) 1-2 ACCUMULATOR VALVE SPRING (SOME MODELS) 1-2 ACCUMULATOR VALVE SPRING (SOME MODELS) RETAINING ROLLED PIN DETENT REGULATOR VALVE BORE PLUG (. 331. 1-2 SHIFT VALVE 1-2 MODULATOR VALVE SPRING (SOME MODELS) 1-2 MODULATOR VALVE (SOME MODELS) STRAIGHT RETAINING PIN (. 219. 5/16-18 X 1. 328. 341. 342. 318. 309. 340.00 (2 REQ) PUMP COVER TO PUMP BODY BOLT. 321.D.560" O. 320. 313.120" DIA X 1. 304. . 317.750 (1 REQ) STATOR SHAFT REAR BUSHING PUMP COVER TO FWD DRUM THRUST WASHER (SELECTIVE) FORWARD CLUTCH SEALING RINGS (2 REQUIRED) INNER PUMP DRIVE GEAR 210.50 (1 REQ) PUMP COVER TO PUMP BODY BOLT. 303. 201.120" DIA X 1.Technical Service Information OIL PUMP ASSEMBLY EXPLODED VIEW 2. 316.D. 319. PUMP CONVERTER SEAL ASSEMBLY PUMP BODY BUSHING PUMP TO CASE "D" RING SEAL PUMP BODY PUMP COVER PUMP COVER TO PUMP BODY BOLT. 333. 335.820") 3-2 DOWNSHIFT VALVE BORE PLUG (. 343. 214. 202. 327. 337. 220. 332. 5/16-18 X 1. 305. 310. 5/16-18 X 1.500" O. 323. 204.437" O. 315. VALVE BODY CASTING 2-3 ACCUMULATOR PISTON RETAINING "E" CLIP 2-3 ACCUMULATOR PISTON 2-3 ACCUMULATOR PISTON SEAL 2-3 ACCUMULATOR PISTON SPRING GROOVED RETAINING PIN 1-2 ACCUMULATOR VALVE BORE PLUG (. OUTER PUMP DRIVEN GEAR PRESSURE REGULATOR RETAINING SNAP RING PRESSURE BOOST VALVE BUSHING PRESSURE BOOST VALVE PRESSURE REGULATOR VALVE SPRING (MODEL SENSITIVE) PRESSURE REGULATOR VALVE SPRING RETAINER PRESSURE REGULATOR VALVE SPACER PRESSURE REGULATOR VALVE PRESSURE REGULATOR VALVE BORE PLUG P VALVE BORE PL G RETAINING PIN. 326. 213. 215. 216. 203. 314. 336. 218. 7. 3.320" . 308. 207. 334. 322. 329. 344.320") 2-3 MODULATOR VALVE BUSHING 2-3 MODULATOR VALVE SPRING 2-3 MODULATOR VALVE 2-3 SHIFT VALVE SPRING 2-3 SHIFT VALVE STRAIGHT RETAINING PIN (. 211. 312.

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

703. 5/16-18 X .620" PARKING LOCK BRACKET HEX NUT. J-3289-20 J-8763-02 Copyright © 1999 ATSG 11. Remove the torque converter. HEX HEAD BOLT. 711. 15. 706. For safety considerations. 704. Remove modulator bracket retaining bolt and modulator bracket as shown in Figure 36. HEX HEAD BOLT. 707. 3/8-24 MANUAL SHAFT RETAINING PIN MANUAL SHAFT MANUAL SHAFT SEAL INSIDE DETENT LEVER PARKING LOCK ACTUATOR ASSEMBLY PARKING PAWL SHAFT CUP PLUG PARKING PAWL RETURN SPRING PARKING PAWL SHAFT RETAINING CLIP PARKING PAWL SHAFT PARKING PAWL Copyright © 1999 ATSG Figure 34 TRANSMISSION DISASSEMBLY EXTERNAL PARTS 1. as shown in Figure 36. install transmission holding fixture as shown in Figure 35.620" MODULATOR RETAINER VACUUM MODULATOR "O" RING SEAL VACUUM MODULATOR VALVE Copyright © 1999 ATSG Figure 35 Figure 36 34 AUTOMATIC TRANSMISSION SERVICE GROUP . 702. 4. 12. 705. 709. 710. 2.Technical Service Information PARK LINKAGE AND ASSOCIATED PARTS EXPLODED VIEW 701. 14. 3. 712. 13. 713. HD 5/16-18 X . Remove the vacuum modulator and modulator valve from case. 708.

26. 3/8-16 X 1" (6 REQUIRED) EXTENSION HOUSING METAL CLAD SEAL EXTENSION HOUSING ASSEMBLY (MODEL SENSITIVE) BALL BEARING ASSEMBLY (SOME MODELS) BALL BEARING SPACER (SOME MODELS) EXTENSION HOUSING BUSHING INTERNAL SNAP RING (SOME MODELS) EXTENSION HOUSING TO CASE SEAL (SOME MODELS) TRANSMISSION REAR CASE BUSHING EXTENSION HOUSING TO CASE GASKET (SOME MODELS) OUTPUT SHAFT Copyright © 1999 ATSG Figure 37 Figure 39 AUTOMATIC TRANSMISSION SERVICE GROUP 35 . 7. 20. Rear end-play should be . 5/16-18 X . 12. as shown in Figure 39. 31. EXTENSION HOUSING BOLTS. 27. 81. 83. Attach J-6125-B to one of the bolt holes at the rear of the case as shown in Figure 39. 22.019") if correct.178mm-.690" (4 REQUIRED) GOVERNOR COVER GOVERNOR COVER GASKET GOVERNOR ASSEMBLY OUTPUT SPEED SENSOR ASSEMBLY (SOME MODELS) SPEED SENSOR "O" RING (SOME MODELS) SPEED SENSOR RETAINING BOLT (SOME MODELS) Figure 38 Some Models 23. GOVERNOR COVER BOLTS. 30. 82. Remove the six extension housing bolts and remove the extension housing (See Figure 37). Move the output shaft in and out and record the amount of rear end play (See Figure 39). Install dial indicator on the shaft and index it to the end of the output shaft and zero the dial indicator. Remove and discard the extension housing seal or gasket (See Figure 37).Technical Service Information 5. Remove the four governor cover retaining bolts and remove governor assembly with a twisting motion (See Figure 38). 29. as shown in Figure 38. Continued on next Page. 9. 19. whichever it is equipped with. 28. 32. Remove the speedometer adapter or the output speed sensor. 21. 11. 33. 6. 10. 34. 8.007"-.483mm (.

Install dial indicator on bolt and index indicator to flat surface on the end of turbine shaft as shown in Figure 40. Hold output shaft forward while pushing the turbine shaft rearward to its stop. Remove the dial indicator and bolt. Rotate transmission and holding fixture so that the bottom pan is facing up (See Figure 41). Remove one oil pump retaining bolt and install J-6125-1 in bolt hole as shown in Figure 40.Technical Service Information Continued from Page 35 12.024". FILTER SPACER. 40. 17.690" BOTTOM TRANSMISSION PAN (SHALLOW OR DEEP) BOTTOM PAN GASKET BOTTOM PAN MAGNET 42. 39. BOTTOM PAN FILTER ASSEMBLY 43. Front end clearance should be . BOTTOM PAN BOLTS. FILTER INTAKE PIPE (LONG OR SHORT) Copyright © 1999 ATSG Figure 41 36 AUTOMATIC TRANSMISSION SERVICE GROUP . 15. 5/16-18 X . DEEP PAN ONL Y 45. 13. Figure 40 Deep Pan Components Shallow Pan Components 37. 14. 16. 38.007"-. 18. Zero the dial indicator. Pull the turbine shaft forward and record the indicated end-play.

30. Set the valve body aside for component rebuild. GUIDE PINS. 28.750" DETENT SOLENOID ASSEMBLY VALVE BODY TO SPACER PLATE GASKET VALVE BODY SPACER PLATE SPACER PLATE TO CASE GASKET STEEL CHECKBALLS. 50. 21.Technical Service Information 19.250" DIAMETER (6 OR 7 REQUIRED) Copyright © 1999 ATSG Figure 42 AUTOMATIC TRANSMISSION SERVICE GROUP 37 . as shown in Figure 42. Continued on next Page. and remove the filter bolt spacer if it is the deep pan model. as shown in Figure 41. Remove and discard the bottom pan gasket. 53. Governor pipes are interchangeable and need not be identified (See Figure 42). 5/16-18 X 1. 59. This affects filter components required for this unit. 49. 51. 20.875" (1 REQUIRED) MANUAL DETENT ROLLER AND SPRING ASSEMBLY VALVE BODY ASSEMBLY GOVERNOR FEED AND RETURN PIPES VALVE BODY BOLTS. . 22. 27. as shown in Figure 42. 57. 32. 58. 31. 5/16-18 X 1.620" (10 REQUIRED) GOVERNOR SCREEN ASSEMBLY. 56. as shown in Figure 41. VALVE BODY BOLTS. Remove and discard the intake pipe "O" ring. Refer to Figure 41. Remove the 10 remaining valve body bolts but leave the detent solenoid bolts in place. Remove the governor screen from the case or from the end of the governor feed pipe. shallow and deep pans. A. 29. remove and discard the filter. Remove the governor pipes from back of the valve body. 1/4-20 X . Remove the spacer plate and spacer plate to case gasket. Remove and discard the valve body to spacer plate gasket (See Figure 42). Remove the filter retaining bolt. 54. LOCATED IN CASE DETENT SOLENOID RETAINING BOLTS. 25. as shown in Figure 41. 24. Remove the intake pipe from the case as shown in Figure 41. Note: There are two different styles of the bottom pan. Remove the valve body and the governor pipes as an assembly (See Figure 42). 23. 47. Remove the bottom pan bolts and bottom pan. Remove the retaining bolt and the detent roller and spring assembly (See Figure 42). Remove the two detent solenoid retaining bolts and the detent solenoid. 52. 26. Remove the six or seven check balls from the pockets in the case depending on your model. 48.

remove and discard the reverse servo cover gasket as shown in Figure 43. FRONT SERVO PISTON FRONT SERVO RING FRONT SERVO PISTON PIN FRONT SERVO PISTON SPRING RETAINER FRONT SERVO PISTON SPRING FRONT SERVO PISTON Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 43 Figure 44 38 AUTOMATIC TRANSMISSION SERVICE GROUP . 41. 63. 77. 85. 61. Remove the reverse servo piston assembly and remove and discard servo piston seal. 72. 67. 76. 78. Remove the oil pump retaining bolts as shown in Figure 45. Install pump remover J-24773-A.620" REVERSE SERVO COVER REVERSE SERVO COVER GASKET REVERSE SERVO PISTON RETAINING "E" CLIP REVERSE SERVO PISTON REVERSE SERVO PISTON SEAL 1-2 ACCUMULATOR PISTON OUTER SEAL RING 1-2 ACCUMULATOR PISTON 1-2 ACCUMULATOR PISTON INNER SEAL RING REVERSE SERVO PISTON WASHER REVERSE SERVO PISTON SPRING REVERSE SERVO PISTON SPRING RETAINER REVERSE SERVO BAND APPLY PIN(SELECTIVE) 1-2 ACCUMULATOR SPRING 60. Remove the six retaining bolts for the reverse servo cover (See Figure 43). REAR SERVO COVER RETAINING BOLTS. Remove the 1-2 accumulator piston from the inside of the reverse servo piston. Remove the reverse servo cover. 74. 69. as shown in 46. 73. as shown in Figure 45. 39. 75. 65. 71. Rotate the transmission so that the oil pump is facing up. 38. 34. or use slide hammers to remove pump.Technical Service Information Continued from Page 37 33. 40. 37. 66. 36. 5/16-18 X . 68. Remove the 1-2 accumulator spring from the transmission case bore (See Figure 43). as shown in Figure 43. Remove the front servo components from the case as shown in Figure 44. 35. 62. 70. 64. as shown in Figure 43.

Remove the oil pump assembly from the case as shown in Figure 45. 47. 43. Remove and discard the oil pump to case "D" ring seal (See Figure 45). 48. Set the complete oil pump assembly aside for component rebuild later. 6. 7. Figure 46 FORWARD CLUTCH HOUSING 4. 45. Remove the oil pump to forward drum thrust washer which is selective (See Figure 45). OIL PUMP RETAINING BOLTS. Remove the forward clutch drum complete by lifting straight up on the turbine shaft as shown in Figure 47. Set the complete forward clutch drum aside for component rebuild later.406" COMPLETE OIL PUMP ASSEMBLY OIL PUMP TO CASE "D" RING SEAL OIL PUMP COVER TO CASE GASKET PUMP COVER TO FWD DRUM THRUST WASHER (SELECTIVE) Copyright © 1999 ATSG Figure 45 Figure 47 AUTOMATIC TRANSMISSION SERVICE GROUP 39 . as shown in Figure 45. 207. 46. 5/16-18 X 1. Continued on next Page. 8. 44. Remove and discard the oil pump cover to case gasket.Technical Service Information 42.

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

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

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

COMPONENT REBUILD

End Transmission Disassembly

Copyright © 1999 ATSG

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

Figure 53

42

AUTOMATIC TRANSMISSION SERVICE GROUP

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

Copyright © 1999 ATSG

Figure 54 PARK LINKAGE AND ASSOCIATED PARTS EXPLODED VIEW

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

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

Figure 55

AUTOMATIC TRANSMISSION SERVICE GROUP

43

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

COMPONENT REBUILD

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

GEAR TRAIN AND ASSOCIATED PARTS EXPLODED VIEW

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

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

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

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

Figure 56

44

AUTOMATIC TRANSMISSION SERVICE GROUP

10. Install the upper needle bearing race on top of the needle bearing with the inside lip facing down. as shown in Figure 59. 8623921 OUTPUT CARRIER Both Carriers Should Measure . Lubricate with small amount of transmission fluid and install the needle bearing assembly into the lower race (See Figure 59). as shown in Figure 59. and 8623922 in the gear train assembly. It is highly recommended to install new needle bearings. 11.Technical Service Information 9. MAIN SHAFT RING GEAR Continued on Page 46.024" REACTION CARRIER FEELER GUAGE Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 57 Figure 59 AUTOMATIC TRANSMISSION SERVICE GROUP 45 . SNAP RING Copyright © 1999 ATSG FEELER GUAGE Figure 58 OEM PART NO. 12. 8623921.009"-. OEM Part No's 8623920. Install the lower needle bearing race from the 8623921 package over the main shaft and onto the ring gear with the lip facing up.

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

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

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

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

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

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

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

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

Compress the spring retainer and return springs and install the snap ring. Install new direct clutch piston outer lip seal in groove of direct clutch piston. Install the 14 direct clutch piston return springs into the cavities in the piston in the positions shown in Figure 79. 8. and lubricate with a small amount of TransJelä. as shown in Figure 80. Install new direct clutch piston inner lip seal in groove of direct clutch piston. 5 or 6 lined plates depending on the specific model. Note: Direct clutch clearance should measure approximately . 10. Install new direct drum lip seal into the groove in direct drum. 16. 19. Install inner lip seal protector J-21362 on the hub of direct drum (See Figure 78). 18. 14. with the lip facing the direction shown in Figure 79. 15. leaving two blank pockets 180 degrees from one another. 636. with lip facing the direction shown in Figure 79. 629. 635.010" per lined plate. 17. 631. 13. Install the waved plate or the cushion plate.Technical Service Information Continued from Page 53 6. using the compressor as shown in Figure 75. 626. with lip facing the direction shown in Figure 79. Install the direct clutch return spring retainer on top of the springs. 621. 619. 633. 11. 632. Note: Some models use a stamped steel direct clutch piston and spacer (See Figure 79). 12. 638. 7. 634. 630. Install the direct clutches beginning with a steel plate and alternating with a friction plate. 9. Install the direct clutch piston assembly into the direct clutch housing using a twisting motion as shown in Figure 78. 625. Continued on Page 56. Install outer lip seal protector J-21409 into the direct drum as shown in Figure 78. as shown in Figure 80. 622. as shown in Figure 80. Lubricate both seals with a small amount of TransJelä. Install the direct clutch backing plate snap ring and ensure that it is seated in groove. as shown in Figure 80. and lay the snap ring on top of the retainer (See Figure 79). Note: The direct clutch may use 4. 627. Install the direct clutch backing plate with flat side down. DIRECT CLUTCH BACKING PLATE SNAP RING DIRECT CLUTCH BACKING PLATE DIRECT CLUTCH LINED PLATES (MODEL SENSITIVE) DIRECT CLUTCH STEEL PLATES (MODEL SENSITIVE) DIRECT CLUTCH RETURN SPRING RETAINER SNAP RING DIRECT CLUTCH RETURN SPRING RETAINER DIRECT CLUTCH PISTON RETURN SPRINGS DIRECT CLUTCH PISTON DIRECT CLUTCH PISTON INNER LIP SEAL DIRECT CLUTCH PISTON OUTER LIP SEAL DIRECT CLUTCH HOUSING INNER LIP SEAL DIRECT CLUTCH HOUSING INTERMEDIATE ROLLER CLUTCH ASSEMBLY (SOME MODELS) INTERMEDIATE SPRAG CLUTCH ASSEMBLY (SOME MODELS) INTERMEDIATE FREEWHEEL OUTER RACE INTERMEDIATE FREEWHEEL OUTER RACE RETAINER INTERMEDIATE FREEWHEEL RETAINER SNAP RING J-21362 DIRECT CLUTCH PISTON J-21409 DIRECT CLUTCH HOUSING Copyright © 1999 ATSG Figure 77 Figure 78 54 AUTOMATIC TRANSMISSION SERVICE GROUP . 637. 620.

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

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

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

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

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

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

depending on the model you are building. as shown in Figure 91. depending on the model as shown in Figure 90. Measure between valve and sleeve at exhaust passage with the weights full inward for .010" per lined plate. as shown in Figure 91. Install forward clutch backing plate snap ring and ensure that it is seated in groove. as shown in Figure 90. and retain with TransJelä.020" clearance. Note: The forward clutch may use 4 or 5 lined plates depending on the specific model. 403. . Install the waved plate or the cushion plate. Install the fiber thrust washer onto the top side of forward clutch hub. Install the forward clutch hub with both thrust washers into the forward clutch housing. 24. clutch clearance should measure approximately . 408. COMPONENT REBUILD (Cont'd) GOVERNOR ASSEMBLY 1.Technical Service Information Continued from Page 59 19. 25. Note: Fwd. Install the direct clutch hub/forward backing plate as shown in Figure 90. Continued on Page 62. even though no parts are available except the driven gear. 26. Set the completed forward clutch housing aside for final assembly process. Measure between valve and sleeve at the entry passage with the weights extended for . 22. and retain with small amount of TransJelä. GOVERNOR THRUST CAP GOVERNOR VALVE GOVERNOR SPRINGS GOVERNOR SECONDARY WEIGHTS GOVERNOR PRIMARY WEIGHTS GOVERNOR PINS GOVERNOR SLEEVE AND CARRIER ASSEMBLY GOVERNOR GEAR RETAINING PIN GOVERNOR DRIVEN GEAR Copyright © 1999 ATSG Figure 92 AUTOMATIC TRANSMISSION SERVICE GROUP 61 . as shown in Figure 90. We have provided you an exploded view of the governor assembly in Figure 92. Install the bronze thrust washer onto the back side of the forward clutch hub. Refer to Figure 90. 404. 2. 3. 21.020" clearance. 402.020" BETWEEN VALVE & SLEEVE . 409. 20. as shown in Figure 90. 407. 23. 405. Install the forward clutches using Figure 90 as a guide as the stack-up is different.020" BETWEEN VALVE & SLEEVE WEIGHTS EXTENDED WEIGHTS INWARD Figure 91 GOVERNOR ASSEMBLY EXPLODED VIEW 401. 406.

10. Caution: Pressure regulator spring is tightly compressed and the boost sleeve and the snap ring will be loaded with pressure.066mm (. 13. Use caution when removing the snap ring. Re-install outer and inner pump gears in proper direction with marks facing up.018mm-. Remove both pump gears and install new pump body bushing as necessary (See Figure 94). 11. Disassemble the oil pump by removing the five pump cover to pump body bolts. If it becomes necessary to replace the governor driven gear. 9. Install the roll pin into the new 1/8" hole. Install new converter helix seal using proper seal driver to prevent damage. 62 AUTOMATIC TRANSMISSION SERVICE GROUP . Caution: Clearance here is critical and should be . Install the outer and inner pump gears into the pump body with previous marks facing up. Note: Lugs on the inner gear should be flush with the pump body face. Inspect all oil pump assembly parts thoroughly for any wear and/or damage. 4.Technical Service Information Continued from Page 61 4. Remove the inner and outer oil pump gears from the pump body (See Figure 94). Inspect the weights for free movement on the pins and for free movement of the governor valve in the sleeve. as shown in Figure 95. COMPONENT REBUILD (Cont'd) OIL PUMP ASSEMBLY 1. as shown in Figure 94. mark the gear faces to ensure reassembly with same side facing up. 1/8" DRILL BIT GOVERNOR DRIVEN GEAR Copyright © 1999 ATSG Figure 93 Continued on Page 64. This clearance is shown as Dimension "A" in Figure 95. Before removing the pump inner and outer gear from the pump body. 3. 7. 8. 7. as shown in Figure 95. Remove and discard the converter helix seal using a seal remover tool (See Figure 94). Drill new 1/8 in. Note: Do Not torque at this time. Install finger tight only. Remove the pressure regulator retaining snap ring. 12. 2. and lubricate with trans fluid. Clean all oil pump parts thoroughly and dry with compressed air. remove the roll pin (408) and the governor driven gear (See Figure 92).0026"). as shown in Figure 94. 9. Set the completed governor assembly aside for the final assembly process. Install the pump cover onto the pump body and install the five retaining bolts in their proper locations as shown in Figure 96. Remove and discard the two oil seal rings. 6. Measure the clearance between the pump gears and the face of the pump body. (.0007"-. 14. as shown in Figure 94. 6. 8. Install new governor driven gear into governor sleeve and carrier assembly (See Figure 92).125") hole in the sleeve and carrier assembly and governor driven gear that is 180 degrees from the original hole as shown in Figure 93. 5. 5.

P R. CONVERTER SEAL 3. 5/16-18 X 1. OIL PUMP COVER ASSEMBLY 203. 5/16-18 X 1. OIL PUMP BODY 202. 5/16-18 X 1. PRESSURE REGULATOR VAL E SPRING V 215.0007"-. PUMP TO FORWARD DRUM THRUST WASHER (SELECTIVE) 208. OIL PUMP TO CASE "D" RING SEAL 201. PRESSURE REGULATOR BOOST VALVE SLEEVE 213. OIL PUMP DRIVEN GEAR 211. 5/16-18 X 1. STATOR SHAFT REAR BUSHING 207.32") Copyright © 1999 ATSG Figure 94 OIL PUMP DRIVE GEAR SOME GEARS ARE FACTORY MARKED OIL PUMP ASSEMBLY VENT HOLE 203 203 OIL PUMP DRIVEN GEAR 204 OIL PUMP BODY 204 DIMENSION "A" (.120" DIA.50" 205. PRESSURE REGULATOR VALVE 218.0026") 205 203.75" 206. AINER WASHER 216. 5/16-18 X 1. PUMP COVER TO PUMP BODY BOLT . PRESSURE REGULATOR VAL E BORE PLUG V 219. PUMP COVER TO PUMP BODY BOLT . PUMP COVER TO PUMP BODY BOLT . PUMP COVER TO PUMP BODY BOLT. OIL PUMP BODY BUSHING 7. PRESSURE REGULATOR SLEEVE RETAINING SNAP RING 212. A 217. PUMP COVER TO PUMP BODY BOLT. X 1. 5/16-18 X 1.00" 204.00" (2) 204.50" (2) 205. PUMP COVER TO PUMP BODY BOLT.75" (1) Figure 95 Figure 96 AUTOMATIC TRANSMISSION SERVICE GROUP 63 . VALVE SPRING SP CER .Technical Service Information OIL PUMP ASSEMBLY EXPLODED VIEW 2. PRESSURE REGULATOR BOOST VALVE 214. STRAIGHT RETAINING PIN (. OIL PUMP DRIVE GEAR 210. P R. VALVE SPRING RET . OIL SEAL RINGS 209.

OIL PUMP COVER ASSEMBLY 203. OIL PUMP BODY 202. OIL PUMP TO CASE "D" RING SEAL 201. With the pump cover to pump body bolts loose. Install the pressure regulator bore plug and the straight retaining pin into oil pump cover.120" DIA. PUMP TO FORWARD DRUM THRUST WASHER (SELECTIVE) 208. STATOR SHAFT REAR BUSHING 207.lb. 5/16-18 X 1. Install pressure regulator spring and retainer into pressure regulator bore (See Figure 97).50" 205. PUMP COVER TO PUMP BODY BOLT. 16. VALVE SPRING SP CER . PRESSURE REGULATOR BOOST VALVE SLEEVE 213.32") Copyright © 1999 ATSG Figure 97 64 AUTOMATIC TRANSMISSION SERVICE GROUP . 19. PUMP COVER TO PUMP BODY BOLT.Technical Service Information Continued from Page 62 15. of either half. STRAIGHT RETAINING PIN (. PRESSURE REGULATOR BOOST VALVE 214. Install the proper pressure regulator valve into oil pump cover. PRESSURE REGULATOR SLEEVE RETAINING SNAP RING 212. P R. AINER WASHER 216. A 217. Caution: All pressure regulator valves will not work with All oil pump covers. 20. If replacement was necessary. install the pump alignment strap J-21368 onto the pump assembly. Note: It should be mentioned here that not all pump halves will work with one another. OIL SEAL RINGS 209. push in with a pin punch to overcome spring pressure and install the retaining snap ring (See Figure 97). as shown in Figure 97. Torque pump cover to pump body bolts down to 24 Nm (18 ft. OIL PUMP DRIVEN GEAR 211. Lubricate pressure regulator boost valve and install boost valve into boost valve sleeve as shown in Figure 97. if it was removed. refer to the chart on Page 18 to ensure that you have compatable parts. 17. CONVERTER SEAL 3.00" 204. and tighten the wing nut. Care must be used to ensure proper pressure regulator valve is installed (See Figure 99). PRESSURE REGULATOR VAL E SPRING V 215.) using a crossing pattern from side to side (See Figure 98). as shown in Figure 97. 5/16-18 X 1. PRESSURE REGULATOR VAL E BORE PLUG V 219. 22. Install the boost valve and sleeve assembly in the pressure regulator bore. as shown in Figure 97. VALVE SPRING RET . 21. OIL PUMP BODY BUSHING 7. 5/16-18 X 1.75" 206. X 1. Install pressure regulator spacer or spacers. OIL PUMP DRIVE GEAR 210. PRESSURE REGULATOR VALVE 218. 18. OIL PUMP ASSEMBLY EXPLODED VIEW 2. P R. PUMP COVER TO PUMP BODY BOLT. if they were used. as shown in Figure 98.

203 204 205 203 204 J-21368 203. and retain with TransJeläRefer . 26. 5/16-18 X 1. PUMP COVER TO PUMP BODY BOLT. as determined by the front end-play check during disassembly. 5/16-18 X 1. PUMP COVER TO PUMP BODY BOLT. 24. Install the correct selective thrust washer.Technical Service Information 23. Install new pump to case "D" ring seal in the groove in the pump. 25. The 1st design pressure regulator valve with the vent holes and orifice cup plug.00" (2) 204.75" (1) Figure 98 PUMP COVER AND PRESSURE REGULATOR VALVE IDENTIFICATION 1ST DESIGN WITH ORIFICE PLUG 2ND DESIGN (SOLID) SQUARED OFF PRESSURE REGULATOR BOSS FOR IDENTIFICATION The solid pressure regulator valve (2nd Design) can be used "only" in the pump cover with the squared off pressure regulator boss as shown above. Set the completed oil pump assembly aside for the final assembly process.50" (2) 205. Copyright © 1999 ATSG Figure 99 AUTOMATIC TRANSMISSION SERVICE GROUP 65 . (See Figure 97). has been released for service and can be used to service either past model or the current pump cover. 5/16-18 X 1. Maximum line pressure will be the result if you install 2nd design valve into early cover. PUMP COVER TO PUMP BODY BOLT. ensure that it is not twisted and lubricate with small amount of TransJel ä. Install the two oil seal rings into the grooves in the pump cover and lubricate with a small amount of trans fluid (See Figure 97). to Figure 97.

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

317. 2-3 ACCUMULATOR PISTON RETAINING "E" CLIP 303.560" O.D.D.D. 343. 305. Continued on Page 68. Inspect valve body casting for porosity. Notice the position of the valve lands and bushing passages. 336. 337.500" O.) 3-2 DOWNSHIFT VALVE SPRING 3-2 DOWNSHIFT VALVE PIN 3-2 DOWNSHIFT VALVE 1-2 MODULATOR VALVE BUSHING (SOME MODELS) 1-2 ACCUMULATOR VALVE PRIMARY SPRING (SOME MODELS) 1-2 ACCUMULATOR VALVE.120" DIA X . 7. 340. 320. springs. Move the valves carefully with a pick or small screwdriver to dislodge any dirt or debris that may have accumulated. 4. 12. 326. 5. 313. Remove the 2-3 accumulator piston spring as shown in Figure 100. 311. 9. 308. Remove and discard the 2-3 accumulator piston seal ring (See Figure 100). 314. 323. 309. 339. 332. 303. damaged machined surfaces and interconnected passages. 315. 13. 1-2 SHIFT VALVE 1-2 MODULATOR VALVE SPRING (SOME MODELS) 1-2 MODULATOR VALVE (SOME MODELS) STRAIGHT RETAINING PIN (. 330. Notice also that we have provided you with all of the different valve line-ups for the various models that are out there (See Figure 100). Remove the 2-3 accumulator piston from the valve body casting using J-22269-01 press. 3. 302. Remove the valve trains one at a time and lay them out on a clean surface in the exact order that they are removed (See Figure 100). 310. 331. 312. cracks.320") 2-3 MODULATOR VALVE BUSHING 2-3 MODULATOR VALVE SPRING 2-3 MODULATOR VALVE 2-3 SHIFT VALVE SPRING 2-3 SHIFT VALVE STRAIGHT RETAINING PIN (. 8.437" O.820") 3-2 DOWNSHIFT VALVE BORE PLUG (. 304. 316.120" DIA X 1. 11. 2-3 ACCUMULATOR PISTON Figure 102 AUTOMATIC TRANSMISSION SERVICE GROUP 67 . and dry with compressed air. Position the valve body on a clean dry surface. 333.) DETENT VALVE DETENT REGULATOR VALVE DETENT REGULATOR VALVE PIN DETENT REGULATOR VALVE SPRING MANUAL VALVE 1-2 MODULATOR VALVE BUSHING (SOME MODELS) 1-2 REGULATOR VALVE (SOME MODELS) 1-2 REGULATOR VALVE SPRING (SOME MODELS) 1-2 DETENT VALVE (SOME MODELS) 324. 319. nicks and scratches. 2. VALVE BODY ASSEMBLY 302. 318. Clean the valve body assembly thoroughly in clean solvent. 334. 328. Clean all valves. 329. scoring. 6. 327. J-22269-01 301 303 302 301. 342. 10. Inspect springs for damaged or distorted coils.) 1-2 ACCUMULATOR VALVE (SOME MODELS) 1-2 ACCUMULATOR VALVE SPRING (SOME MODELS) 1-2 ACCUMULATOR VALVE SPRING (SOME MODELS) RETAINING ROLLED PIN DETENT REGULATOR VALVE BORE PLUG (. 341. VALVE BODY CASTING 2-3 ACCUMULATOR PISTON RETAINING "E" CLIP 2-3 ACCUMULATOR PISTON 2-3 ACCUMULATOR PISTON SEAL 2-3 ACCUMULATOR PISTON SPRING GROOVED RETAINING PIN 1-2 ACCUMULATOR VALVE BORE PLUG (. 335. Assemble the valve body components exactly as shown in Figure 100. bushings and valve body casting in clean solvent and dry with compressed air. 344. 321. PRIMARY (SOME MODELS) 1-2 ACCUMULATOR VALVE BUSHING (SOME MODELS) 1-2 ACCUMULATOR VALVE SECONDARY (SOME MODELS) 1-2 ACCUMULATOR VALVE SECONDARY SPRING (SOME) Copyright © 1999 ATSG Figure 101 COMPONENT REBUILD (Cont'd) VALVE BODY ASSEMBLY 1. 322. Inspect all valves and bushings for porosity.Technical Service Information LEGEND FOR FIGURE 100 301. 325. as shown in Figure 102.

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

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

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

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

Install the oil pump to case gasket onto the case as shown in Figure 112. Install the completed forward clutch housing assembly into the case by rotating back and forth until fully seated (See Figure 111). Install the completed direct clutch housing assembly into the case by rotating to engage sprag outer race into teeth of the intermediate lined plates. Lubricate the case bore for the "D" ring with a small amount of TransJelä. 18. 7. ensuring that the holes are properly aligned. Copyright © 1999 ATSG Figure 110 FORWARD CLUTCH HOUSING ASSEMBLY 4. 8. OIL PUMP RETAINING BOLTS.406" COMPLETE OIL PUMP ASSEMBLY OIL PUMP TO CASE "D" RING SEAL OIL PUMP COVER TO CASE GASKET PUMP COVER TO FWD DRUM THRUST WASHER (SELECTIVE) Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 111 Figure 112 72 AUTOMATIC TRANSMISSION SERVICE GROUP . 17.Technical Service Information DIRECT CLUTCH HOUSING MANUAL 2ND BAND CONTINUED FROM PAGE 71 14. 16. as shown in Figure 112. ensuring that it is engaged on the lug in the case (See Figure 110). Install the completed oil pump assembly into the case. Install the manual 2nd band assembly into the case. until fully seated (See Figure 110). 6. 15. 19. 5/16-18 X 1. 207.

. Move the turbine shaft in and out and observe end-play reading on dial indicator.Technical Service Information 20..) Note: If turbine shaft cannot be rotated as the pump assembly is being pulled into place.115" . Torque the oil pump retaining bolts down to 24 Nm (18 ft.126" .119" .. as shown in Figure 112.108" .lb. 22.019"). Replace the pump bolt and torque to 18 ft. This condition must be fixed before pump assembly is fully seated.071" .178mm . 27. Remove the dial indicator tools and correct as necessary..088" . one type that uses the fiber washer and one type that uses "O" ring seal as shown in Figure 113. and using the chart provided in Figure 115.. the forward and/or direct clutch housings have not been installed properly to index with all of the clutch plates.130" "O" RING SEAL TYPE PUMP BOLT COLOR I. Install dial indicator on the bolt and index it to the end of the turbine shaft (See Figure 114).. if front end-play is correct. Install J-6125 slide hammer bolt in place of the pump bolt as shown in Figure 114.lb.093" .. Proper front end play is .D. WASHER TYPE PUMP BOLT Figure 114 FRONT END PLAY WASHER CHART THICKNESS . You must use proper type of seal on the appropriate bolt. Install the oil pump assembly to case retaining bolts. 21. 24.007" .064" . 23.082" .097" .. Continued on Page 74. 25. YELLOW BLUE RED BROWN GREEN BLACK PURPLE NUMBER 0 1 2 3 4 5 6 Figure 113 Figure 115 AUTOMATIC TRANSMISSION SERVICE GROUP 73 . by changing the selective thrust on the back side of pump assembly.483mm (..104" .075" . 26. Caution: There are two different types of the pump retaining bolts.060" .

as shown in Figure 118.D..lb. Fasten with two 5/16-18 x 1" bolts and torque to 24 Nm (18 ft.098" . 35. Position J-21370-6 selector gage tool over the bore with the hex nut facing parking linkage.118" I. Install J-6125 slide hammer bolt in hole of the case.082" . Proper rear end play is .110" .. 31.102" ... as shown in Figure 116. Place J-21370-10 gage pin into the reverse servo pin bore (See Figure 118). 29.. NOTCH NUMBER None 1 On Side Of 1 Tab 2 On Side Of 2 Tabs 3 On End Of 1 Tab 4 On End Of 2 Tabs 5 On End Of 3 Tabs 6 J-21370-6 J-21370-10 REAR END PLAY SELECTIVE THRUST WASHER Copyright © 1999 ATSG Figure 117 Figure 118 74 AUTOMATIC TRANSMISSION SERVICE GROUP . OUTPUT SHAFT Copyright © 1999 ATSG Figure 116 REAR END PLAY WASHER CHART THICKNESS .094" . 34. 30.Technical Service Information CONTINUED FROM PAGE 73 28. Install dial indicator on the bolt and index it to the end of the output shaft (See Figure 114). 33.114" .090" . Remove the dial indicator tools and correct as necessary. Move the output shaft in and out and observe end-play reading on dial indicator.074" .483mm (.178mm ...086" .) (See Figure 118).078" . 32. and using the chart provided in Figure 117.007" ..106" . by changing steel selective thrust washer in the rear of transmission.019").

as shown in Figure 119.lb. 70. 74. 40. 75. REAR SERVO COVER RETAINING BOLTS. Install reverse servo piston over pin. Continued on Page 76. 37. Refer to Figure 119. 44. as necessary. Install 1-2 accumulator spring into case bore and install reverse servo assembly. 76. Install rear servo spring retainer over the servo pin selected. 38. 73. 69. as shown in Figure 119.lb.Technical Service Information 36. Install new seals onto 1-2 accumulator piston. 41. 46. as shown in Figure 119. 68.620" REVERSE SERVO COVER REVERSE SERVO COVER GASKET REVERSE SERVO PISTON RETAINING "E" CLIP REVERSE SERVO PISTON REVERSE SERVO PISTON SEAL 1-2 ACCUMULATOR PISTON OUTER SEAL RING 1-2 ACCUMULATOR PISTON 1-2 ACCUMULATOR PISTON INNER SEAL RING REVERSE SERVO PISTON WASHER REVERSE SERVO PISTON SPRING REVERSE SERVO PISTON SPRING RETAINER REVERSE SERVO BAND APPLY PIN (SELECTIVE) Copyright © 1999 ATSG 1-2 ACCUMULATOR SPRING Figure 119 Figure 120 AUTOMATIC TRANSMISSION SERVICE GROUP 75 . 42. To determine correct pin length. Install new seal onto the reverse servo piston and lube with small amount of TransJelä. as shown in Figure 119. install the reverse servo cover and torque the six bolts to 24 Nm (18 ft. compress servo spring and install "E" clip. 45. Install reverse servo spring over pin and onto servo pin. 65. 72. apply 25 ft. 67. 71. 5/16-18 X . 66. 78.) (See Figure 119. torque to the nut on gage (See Figure 118). For the various pin selections see Figure 119. Install reverse servo piston washer. and install 1-2 accumulator piston assembly iside of reverse servo piston as shown in Figure 119. 77. 43. Ensure that J-21370-10 gage pin still moves freely in the tool and case pin bore. Install servo cover gasket onto case. 39.

Caution: There are two different styles of the Manual 2 servo components.250") Dia. One with the "Castles" on top of the servo piston and one that is flat on top. Install the proper amount of 1/4" (. SERVO RETAINER SERVO RETAINER RETAINER (BACK SIDE) RETAINER (BACK SIDE) SERVO SPRING SERVO SPRING These Servo Parts "Require" The 2-3 Accumulator Piston Shown Below These Servo Parts "Require" The 2-3 Accumulator Piston Shown Below 60. 85. 63. Install the manual 2 servo components into the case bore as shown in Figure 122. checkballs into the proper pockets in the case. Install a new governor screen into the case in the position and location shown in Figure 123. FRONT SERVO PISTON FRONT SERVO RING FRONT SERVO PISTON PIN FRONT SERVO PISTON SPRING RETAINER FRONT SERVO PISTON SPRING FRONT SERVO PISTON Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 121 Figure 122 76 AUTOMATIC TRANSMISSION SERVICE GROUP . as shown in Figure 121. 64. 48. 62. as shown in Figure 124. 47.Technical Service Information FRONT SERVO AND ACCUMULATOR PARTS 1965-1970 COMPONENTS 1971-LATER COMPONENTS SERVO PISTON SERVO PISTON SERVO WASHER SERVO PIN SERVO RING SERVO PIN CONTINUED FROM PAGE 75 46. Continued on Page 78. Ensure that proper manual 2 servo components are installed into case bore (See Figure 122). 49. according to the model that you are building. The servo components must match the 2-3 accumulator piston in the valve body. 61.

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

LOCATED IN CASE DETENT SOLENOID RETAINING BOLTS. 51. Install the manual detent roller and spring onto valve body. and install the valve body bolts finger tight. Install the governor pipes into the previously completed valve body assembly (Figure 125). Install guide pins into case in the locations that are shown in Figure 125. 55. as shown in Figure 125. 56. 48.875" (1 REQUIRED) MANUAL DETENT ROLLER AND SPRING ASSEMBLY VALVE BODY ASSEMBLY GOVERNOR FEED AND RETURN PIPES VALVE BODY BOLTS. 59. . VALVE BODY BOLTS. Install the valve body and governor pipes onto the case. Connect the wire from the detent solenoid to the case connector on the inside. GUIDE PINS. 53. 59. 54. 58. 52. 53. Note: Some models also use a support spring on top of the manual detent roller and spring as shown in Figure 126. 52. 51. 54.750" DETENT SOLENOID ASSEMBLY VALVE BODY TO SPACER PLATE GASKET VALVE BODY SPACER PLATE SPACER PLATE TO CASE GASKET STEEL CHECKBALLS. Install the detent solenoid and tighten the bolts finger tight (See Figure 125). Push the valve body assembly down against the pressure of Manual 2 servo spring. 5/16-18 X 1. 1/4-20 X . 58. 56.620" (10 REQUIRED) GOVERNOR SCREEN ASSEMBLY. 57. 47. Install the proper valve body spacer plate over the guide pins and on top of the case gasket. Install a new valve body to spacer plate gasket over the guide pins on top of the spacer plate as shown in Figure 125. ensuring that the manual valve is on the pin of the inside detent lever and engaged properly and governor pipes are engaged into the transmission case (See Figure 125). and install retaining bolt. 49. as shown in Figure 125. 57. 50.Technical Service Information CONTINUED FROM PAGE 76 50. Install a new case to spacer plate gasket over the guide pins and onto case (See Figure 125). SUPPORT SPRING (SOME MODELS) A.250" DIAMETER (6 OR 7 REQUIRED) MANUAL DETENT ROLLER AND SPRING ASSEMBLY Copyright © 1999 ATSG Copyright © 1999 ATSG Figure 125 Figure 126 78 AUTOMATIC TRANSMISSION SERVICE GROUP . 5/16-18 X 1.

shallow and deep pans. 65.). Continued on Page 80. Install the bottom oil pan bolts and torque to 13 Nm (116 in. Notice in Figure 127 that the intake pipe for shallow pan is shorter than the intake pipe for the deep pan. FILTER INTAKE PIPE (LONG OR SHORT) Copyright © 1999 ATSG Figure 127 AUTOMATIC TRANSMISSION SERVICE GROUP 79 . as shown in Figure 127.lb. Torque filter retaining bolt to 10 Nm (89 in.).lb.lb. Install a new bottom pan gasket onto the case as shown in Figure 127.lb. BOTTOM PAN BOLTS. Install the proper bottom oil pan onto the case as shown in Figure 127. 63. 39. 38. FILTER SPACER. 68. Torque the detent solenoid retaining bolts down to 10 Nm (89 in. 66. 62. This affects filter components required for this unit. Install a new "O" ring onto proper filter intake pipe. BOTTOM PAN FILTER ASSEMBLY 43. 5/16-18 X . Shallow Pan Components 37.). 61. Install the magnet into the proper bottom oil pan. Note: There are two different styles of the bottom pan. Install new filter assembly on intake pipe and install filter bolt and spacer if used. as shown in Figure 127.690" BOTTOM TRANSMISSION PAN (SHALLOW OR DEEP) BOTTOM PAN GASKET BOTTOM PAN MAGNET 42. lube with small amount of TransJel and ä install intake pipe into case (See Figure 127).). DEEP PAN ONL Y 45. Refer to Figure 41. 40. Deep Pan Components 64. Torque all valve body bolts beginning in the center and working outward in a circle down to 11 Nm (98 in.Technical Service Information 60. 67. as shown in Figure 41.

71.lb). Lubricate modulator valve (15) with fluid and install modulator valve into transmission case as shown in Figure 128. and torque the 4 bolts to 14 Nm (125 in. 81.690" (4 REQUIRED) GOVERNOR COVER GOVERNOR COVER GASKET GOVERNOR ASSEMB. Rotate transmission fixture so that the bottom pan is facing down.620" MODULATOR RETAINER VACUUM MODULATOR "O" RING SEAL VACUUM MODULATOR VALVE Copyright © 1999 ATSG Figure 128 SOME MODELS SPEED SENSOR ROTOR SPEEDOMETER DRIVE GEAR (MODEL SENSITIVE) PLASTIC (REQUIRES CLIP) STEEL (PRESS ON) SOME MODELS 19. JEEP MODELS 11. Install the modulator retaining bracket. Note: Jeep models use a modulator valve that has a longer stem on the modulator side.Technical Service Information CONTINUED FROM PAGE 79 69. HEX HEAD BOLT. 5/16-18 X . 74. 5/16-18 X . 15. 70. 82. 14. torque the retaining bolt to 14 Nm (125 in.lb.LY OUTPUT SPEED SENSOR ASSEMBLY(SOME MODELS) SPEED SENSOR "O" RING(SOME MODELS) SPEED SENSOR RETAINING BOLT (SOME MODELS) SPEEDO DRIVEN GEAR (MODEL SENSITIVE) SPEEDO HOUSING (MODEL SENSITIVE) Copyright © 1999 ATSG Figure 129 80 AUTOMATIC TRANSMISSION SERVICE GROUP . 12. Install a new vacuum modulator with a new "O" ring into case. 21. 22. 13. as shown in Figure 128. 73.). GOVERNOR COVER BOLTS. 20. and requires modulator with the bellows. Install the governor assembly into case bore by rotating into position (See Figure 129). 83. as shown in Figure 128. Install the governor cover with a new gasket as shown in Figure 129. 72.

80. Remove transmission assembly from fixture. 30.035".lb. 29. 76. 79.lb. EXTENSION HOUSING BOLTS. 3/8-16 X 1" (6 REQUIRED) EXTENSION HOUSING METAL CLAD SEAL EXTENSION HOUSING ASSEMBLY (MODEL SENSITIVE) BALL BEARING ASSEMBLY (SOME MODELS) BALL BEARING SPACER (SOME MODELS) EXTENSION HOUSING BUSHING INTERNAL SNAP RING (SOME MODELS) EXTENSION HOUSING TO CASE SEAL (SOME MODELS) TRANSMISSION REAR CASE BUSHING EXTENSION HOUSING TO CASE GASKET (SOME MODELS) Copyright © 1999 ATSG Figure 130 Figure 132 AUTOMATIC TRANSMISSION SERVICE GROUP 81 . and carefully install into trans. 26. 27.) (See Figure 129). as shown in Figure 132. Install the speed sensor or the speedometer drive gear and adapter and torque the retaining bolt to 7 Nm (62 in. Torque the six extension housing bolts down to 20-25 ft.Technical Service Information 75. 78. END TRANSMISSION ASSEMBLY CHECKING CONVERTER END-PLAY Figure 131 J-3289-20 J-8763-02 Some Models 23. Install the proper speedo drive gear or speed sensor rotor onto the output shaft if it has not been previously installed (See Figure 129). Lubricate converter hub with a small amount of TransJelä. Check the torque converter end-play using the tools shown in Figure 131. 32. 34. 28. Converter end-play should be . 81.. 33. Install the proper extension housing and gasket as shown in Figure 130. 77.010" . Note: Refer to Figures 25 and 26 for various models of output shafts and extensions. 31.

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

72. 5/16-18 X . 41. 5. 61. DEEP PAN ONLY MANUAL DETENT SPRING SUPPORT (SOME MODELS) 45. DEEPAN) P MANUAL DETENT SPRING RETAINING BOLT. 5/16-18 X 1. 38. 75. 78. 73. 57. 20. 64. 11. 12. 19. (SHORT OR LONG) BOTTOM PAN FILTER ASSEMBLY FILTER SPACER. 50. 44. 10. 31. 16. 48. 18. 87. 84. 65. 74. 35. 69. 62. 5/16-18 X . TORQUE CONVERTER ASSEMBLY BOLT AND "O" RING ASSEMBLY (PUMP TO CASE) SPEEDO HOLE STEEL PLUG (4WD MODELS) OIL PUMP ASSEMBLY OIL PUMP TO CASE SEALING RING PUMP COVER TO CASE GASKET VENT PIPE TRANSMISSION CASE ASSEMBLY MODULATOR RETAINING BOLT. 23. 30. 15. 83. 17. 60. 71. 22. 4. 27. AND SOME 7 REQ.620" MODULATOR RETAINING BRACKET VACUUM MODULATOR ASSEMBLY MODULATOR "O" RING SEAL VACUUM MODULATOR VALVE COOLER FITTING IDENTIFICATION TAG SCREW IDENTIFICATION TAG GOVERNOR COVER RETAINING BOLTS (4 REQUIRED) GOVERNOR COVER GOVERNOR COVER GASKET GOVERNOR ASSEMBLY EXTENSION HOUSING TO CASE BOLTS. 33. 37. 54.690" BOTTOM TRANSMISSION OIL PAN (SHALLOW OR DEEP) BOTTOM PAN TO CASE GASKET BOTTOM PAN MAGNET SHOULDERED FILTER BOLT. 21. 3/8-16 X 1" EXTENSION HOUSING METAL CLAD SEAL EXTENSION HOUSING ASSEMBLY BALL BEARING ASSEMBLY BALL BEARING SPACER EXTENSION HOUSING BUSHING INTERNAL SNAP RING EXTENSION HOUSING TO CASE SEAL (SOME MODELS) REAR CASE BUSHING EXTENSION HOUSING TO CASE GASKET (SOME MODELS) ELECTRICAL CONNECTOR ELECTRICAL CONNECTOR "O" RING BOTTOM PAN BOLTS. 26. 7. 82. 68. 59. 1/4-20 X . 53.) FRONT SERVO PISTON FRONT SERVO PISTON PIN RING FRONT SERVO PISTON PIN FRONT SERVO RETURN SPRING RETAINER FRONT SERVO PISTON RETURN SPRING REVERSE SERVO COVER RETAINING BOLTS. 9.750" DETENT SOLENOID ASSEMBLY VALVE BODY TO SPACER PLA GASKET TE VALVE BODY SPACER PLATE SPACER PLATE TO CASE GASKET CHECKBALLS. 1/4-20 X 1. 52. 34. 14. 1/8" PIPE FRONT SERVO PISTON SEAL DRAIN PLUG GASKET (SOME MODELS) BOTTOM PAN DRAIN PLUG (SOME MODELS) Copyright © 1999 ATSG Figure 134 AUTOMATIC TRANSMISSION SERVICE GROUP 83 . 86. 79. 47. 76. 6. 58. 66.875") MANUAL DETENT SPRING AND ROLLER ASSEMBLY VALVE BODY ASSEMBLY GOVERNOR FEED AND RETURN PIPES VALVE TO CASE BODY BOLTS. 32. 42. 29. 51. 43. 39. 67. 77. 63.LONG. SHALLOW PAN .620" GOVERNOR SCREEN ASSEMBLY DETENT SOLENOID RETAINING BOLTS. 56. FILTER INTAKE PIPE (SHORT. 5/16-18 X . 70. 81. 8.Technical Service Information LEGEND FOR FIGURE 133 1. 49. . 36.250" STEEL (SOME 6 REQ.620" REVERSE SERVO COVER REVERSE SERVO COVER GASKET REVERSE SERVO PISTON RETAINING "E" CLIP REVERSE SERVO PISTON REVERSE SERVO PISTON SEAL 1-2 ACCUMULATOR PISTON OUTER SEAL 1-2 ACCUMULATOR PISTON 1-2 ACCUMULATOR PISTON INNER SEAL REVERSE SERVO PISTON WASHER REVERSE SERVO SPRING REVERSE SERVO SPRING RETAINER REVERSE SERVO PISTON BAND APPLY PIN (SELECTIVE) 1-2 ACCUMULATOR SPRING CENTER SUPPORT TO CASE BOLT (SHORT OR LONG) OUTPUT SPEED SENSOR ASSEMBLY(SOME MODELS) OUTPUT SPEED SENSOR "ORING " SPEED SENSOR RETAINING BOLT LINE PRESSURE TEST PLUG. 85. 13. 40. 28.

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

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

5/16-18 X 1. 335. 205. 334.) 3-2 DOWNSHIFT VALVE SPRING 3-2 DOWNSHIFT VALVE PIN 3-2 DOWNSHIFT VALVE 1-2 MODULATOR VALVE BUSHING (SOME MODELS) 1-2 ACCUMULATOR VALVE PRIMARY SPRING (SOME MODELS) 1-2 ACCUMULATOR VALVE.560" O. 207. 321. 202. 343.D. 209. 341.00 (2 REQ) PUMP COVER TO PUMP BODY BOLT. 315.) DETENT VALVE DETENT REGULATOR VALVE DETENT REGULATOR VALVE PIN DETENT REGULATOR VALVE SPRING MANUAL VALVE 1-2 MODULATOR VALVE BUSHING (SOME MODELS) 1-2 REGULATOR VALVE (SOME MODELS) 1-2 REGULATOR VALVE SPRING (SOME MODELS) 1-2 DETENT VALVE (SOME MODELS) LEGEND FOR FIGURE 139 324. 211. 323. 319.D. 327. 317. PRIMARY (SOME MODELS) 1-2 ACCUMULATOR VALVE BUSHING (SOME MODELS) 1-2 ACCUMULATOR VALVE SECONDARY (SOME MODELS) 1-2 ACCUMULATOR VALVE SECONDARY SPRING (SOME) Copyright © 1999 ATSG Figure 138 86 AUTOMATIC TRANSMISSION SERVICE GROUP .120" DIA X 1. AINING PIN. 220. 340. 203. 302.50 (1 REQ) PUMP COVER TO PUMP BODY BOLT. 333. 5/16-18 X 1. 320. 214. 206. 344.320") 2-3 MODULATOR VALVE BUSHING 2-3 MODULATOR VALVE SPRING 2-3 MODULATOR VALVE 2-3 SHIFT VALVE SPRING 2-3 SHIFT VALVE STRAIGHT RETAINING PIN (.320" STATOR SHAFT FRONT BUSHING Copyright © 1999 ATSG Figure 137 301. . 328. 303.D. 3. 7. 305. 312. 313. 5/16-18 X 1.500" O. 204. 336.120" DIA X . 218. 304. 215. 208. 325. 1-2 SHIFT VALVE 1-2 MODULATOR VALVE SPRING (SOME MODELS) 1-2 MODULATOR VALVE (SOME MODELS) STRAIGHT RETAINING PIN (.750 (1 REQ) STATOR SHAFT REAR BUSHING PUMP COVER TO FWD DRUM THRUST WASHER (SELECTIVE) FORWARD CLUTCH SEALING RINGS (2 REQUIRED) INNER PUMP DRIVE GEAR 210. 326.437" O. 331. 316. 213.820") 3-2 DOWNSHIFT VALVE BORE PLUG (. 329. 339. 216. 332. 311. 342. 330. VALVE BODY CASTING 2-3 ACCUMULATOR PISTON RETAINING "E" CLIP 2-3 ACCUMULATOR PISTON 2-3 ACCUMULATOR PISTON SEAL 2-3 ACCUMULATOR PISTON SPRING GROOVED RETAINING PIN 1-2 ACCUMULATOR VALVE BORE PLUG (.) 1-2 ACCUMULATOR VALVE (SOME MODELS) 1-2 ACCUMULATOR VALVE SPRING (SOME MODELS) 1-2 ACCUMULATOR VALVE SPRING (SOME MODELS) RETAINING ROLLED PIN DETENT REGULATOR VALVE BORE PLUG (. 314. 337. 219.Technical Service Information OIL PUMP ASSEMBLY EXPLODED VIEW 2. 318. 217. OUTER PUMP DRIVEN GEAR PRESSURE REGULATOR RETAINING SNAP RING PRESSURE BOOST VALVE BUSHING PRESSURE BOOST VALVE PRESSURE REGULATOR VALVE SPRING (MODEL SENSITIVE) PRESSURE REGULATOR VALVE SPRING RETAINER PRESSURE REGULATOR VALVE SPACER PRESSURE REGULATOR VALVE PRESSURE REGULATOR VALVE BORE PLUG P VALVE BORE PLUG RET . 310. PUMP CONVERTER SEAL ASSEMBLY PUMP BODY BUSHING PUMP TO CASE "D" RING SEAL PUMP BODY PUMP COVER PUMP COVER TO PUMP BODY BOLT. 309.120" DIA X 1. 201.R. 308. 322. 212.

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

Technical Service Information
PARK LINKAGE AND ASSOCIATED PARTS EXPLODED VIEW

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

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

Figure 140

88

AUTOMATIC TRANSMISSION SERVICE GROUP

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

FROM IGN SWIT BATTERY 12 VOLT

PINK/BLACK

PURPLE

B

ELECTRONIC CONTROL MODULE (ECM)

FUSE LINK

E D F A DOWNSHIFT CONTROL RELAY
TAN/BLACK

DOWNSHIFT A7

ORANGE

DETENT SOLENOID

THM 400 TRANSMISSION

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

FROM IGN SWIT

IGN/GAGE FUSE 20A

PINK/BLACK

ELECTRONIC CONTROL MODULE (ECM)

E D F A DOWNSHIFT CONTROL RELAY
TAN/BLACK

DOWNSHIFT A7

ORANGE

DETENT SOLENOID

THM 400 TRANSMISSION

Copyright © 1999 ATSG

Figure 141

AUTOMATIC TRANSMISSION SERVICE GROUP

89

Technical Service Information
BUSHING SERVICE

Figure 142

90

AUTOMATIC TRANSMISSION SERVICE GROUP

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

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

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

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

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

Technical Service Information Notes 96 AUTOMATIC TRANSMISSION SERVICE GROUP .

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