You are on page 1of 110
ATSG] Technical Service Information ‘Transmission Service identification Allvehicles are equipped with a Safety Standard ow on, Certication Label affixed to the left (criver’s) side ron oun aan can door lock post. Rete: tothe stamped code in the we wo ‘Space marked "Trans." for proper transmission res es isentication as ras Plates and instructions for the specific transmission ar acon a reicoun identification coding, The transmission is also ee identified by a tag on the transmission body. nL Sono Ts ARCA FEDS OT Sie NE GWT BOOT TREE TORE T Soa "AUTOMATIC TRANSMISSION ‘Nobel DeNnecaTiOn 'WODELS ARE DENTIED BY A SERVICE DENTPCATION TAG AFFUED TO THE ASSEMBLY. TAGS ARE LOCATED AND CONTAN FORMATION AS FOLLOWS: T TRANSMISSION MODE. Lye SHIFT CODE ATTACHED TO THE Lowen LeF| eer mip HAND EXTENSION ATTAGHING oO AUTOMATIC TRANSMISSION SERVICE GROUP , Technical Service Information om Oa | area [Somme [ee Jom gam Se] Se ‘ine "| "trae" |ugvenne|cuant|\" iow [ean | a vse | — nes | vas [e oe | ae ra om 1 aes Tay |e co ‘es | Ts [ee ey | ie “es | i gat _| se ers i fe I 7 ic Transmission Test Linkage Check f Linkage and Operation ‘The linkage must be free and must return to idle when released, ijustment. Be sure the @ inthe transmission corresponds ‘exactly with the stop in the console or column insert plate. Hycrauiic leakage at the manual valve can Cause delay in engagements and/or sipping while ‘operating the kage Ie not properly adjusted. *Ganbe purchased Technical Service Information ‘Automatic Transmission Fluid Checking and ‘Adding Procedure Under normal cieumstances, you do not need to check the fhid level of the transmission, since your ‘vehicle does not use up transmission fuid. However, if the transmission is not working properly —for instance, he transmission may sip or shift slowly, or ‘you may notice some sign of fhid leakage—the uid level should be checked itis preferable to check the transmission fd level at normal operating temperature, after approximately 20 miles (32 km) of driving. However, necessary, you ‘can check the fuid level without having to drive 20 mies fo obtain a normal operating temperature if Outside tomporatures are above 10°C (50° NOTE: Ifthe vehicle has been operated for an ‘extended period at high speeds or in city tratfic during hot weather, or puling a trailer, the vehicle should be turned off for about 30 minutes to allow the hid o coo! before checking Checking The Automatic Transmission Fluid With the vehicle on a level surface, start the engine land move the transmission shift selector through allof the gear ranges allowing sufficient time for each. postion to engage. Securely latch the transmission hit selector n the park position, fuly st the parking brake and leave the engine running NOTE: Vehicles equipped with 4x4 applications must have the 4x4 shift selector inany position other than. neutral. CAUTION: YOUR VEHICLE SHOULD NOT BE DRIVEN IF THE FLUID LEVEL IS BELOW THE BOTTOM HOLE ON THE DIPSTICK AND OUTSIDE ‘TEMPERATURES ARE ABOVE 10°C (50). Wipe off the dipstick cap, pull the dipstick out and wipe the indicator end clean. Put the dipstick back into the filer tube and make sure is fully seated. Pull the sipstick out and read the fluid level ‘When chacking fluid at normal operating temperature, the fluid level should be within the crosshatched area fn the dipstick. When the vehicle has nol been driven, nd outside temperature is above 10°C (60°F). The {uid evel should be between the holes on the dipstick. ‘Adding Fluid ‘The tid type ig stamped on the dipstick. Before ‘adding an fluid, be sure thal the correct type wil be used ‘Ad fluid in.26L (1/2 pint) increments through the filer {ube to bring the level tothe correct area on the dipstick. tt an overt occurs, excess flid should be removed. ‘Overfill can cause the fluid to foam and spillout through the tranamission vent resulting in a transmission malfunction Underfill can result in transmission loss of ‘engagement or sipping. This condition is most evident ‘ncold weather or when the vehicle is parked or being driven on a hil It the transmission fuid level is checked when the fuid {eat room temperature the dipstick could indicate that fluid should be added ifthe dipstick is misread. I fd is added at this ime, an overil condition could result ‘when the fluid reaches operating temperatures of (66°C-77°C (150°F-170°F) (dipstick hot to touch). ‘Transmission Fluid Condition Check 4. Make the normal uid check according to the above procedure. 2. Observe color and oso ofthe fli. t should bo dark reddish, not brown or black. A burnt odor Can sometimes indicate that there is an ‘Overheating condition or clutch disc or band tailure. 3, Use an absorbent white paper (facial tissue, ete.) to wipe the dipstick. Examine the stain for ‘evidence of solids (packs of any kind) and for ‘antifreeze signs (gum or varnish on dipstick), It specks are present inthe oil or there is evidence of antfreeze, the transmission ol pan must be removed for further inspection. I antlreeze is found in the transmission fui, the in-lank transmission cooler must be repaired or replaced. If uid contamination or transmission falure is confirmed by further evidence of Coolant or excessive sols in the ollpan, the transmission must be disassembled and completely cleaned and repaired. Ths includes cleaning the torque converter and transmission cooling system. It ‘would be a waste of tme to perform any further ‘checks before cleaning and servicing the transmission. During disassembly and assembly, all overhaul checks aed adustments of clearances and end pay must be Technical Service Information Transmission Fluid Leakage Checks Check the speedometer cable connection at the transmission. Replace the rubber Oving i necessary. Leakage at the ol pan gasket often can be stopped by tightening the attaching bolts tothe proper torque. necessary, replace the gasket. Check the fi filer tube connection at the transmission case. Check filer tube O-ring seal for damage or omission. leakage is found, install anew shor oll inet tube and O-ring Seal, or clean the area and apply @ sealer around the tube. The filer tube bracket should align properly and be attached to the transmission or engine locations. Check the fluid ines and fittings between the transmission and the cooler inthe radiator tank for looseness, wear, or damage. Ifleakage is found, ‘tighten the iting (as shown in chart below), or replace the damaged parts. Fi ne a Bar ce 203 rc 1526 ‘Check the engine coolant inthe radiator. If {transmission fluid is present in the coolant, the cooler inthe radiator is probably leaking, ‘The cooler can be furthar chacked for leaks by disconnecting the Ines from the cooler fittings and ‘pplying 348-6 17 kPa (50-75 ps) ar pressure fo the Iitings. Remove the radiator cap to relieve the pressure buldup a the exterior ofthe oil cooler tank. the cooler is leaking and/or wil not hold pressure, the ‘cooler must be replaced. ifleakage ig found at the downshift controllever and the manual lever shaft, replace the seal Inspect the pipe plug onthe left rear side of the transmission ease. I the plug shows leakage, tighten the plug to specifications. leakage continues, replace the plug. Fluid leakage from the converter housing may be ‘caused by engine oll leakage past the rear main ring, 9 trom ol galley plugs, of Pow before starting service procedures. Cit-soluble ariline o fluorescent dyes premixed at the rate of 1/2 teaspoon of dye powder to 0.23 iter (1/2 pial) of tranemission fluid have proved helpful in locating the source of fuid leakage. Such dyes may be used to determine whether an engine ollor ‘ansmission fluid leak is present, of the fluid inthe oi ‘cooler leaks into the engine cootant system. A black. light must be used with the uorescent dye solution. Fluid Leakage in Converter Ai In diagnosing and correcting uid leaks inthe front pump and converter area, use the following Procedures to locate the exact cause ofthe leakage. Ceakage at the ront ofthe transmission, evidenced by ‘uid around the converter housing, may have several sources, By caret observation, iis possible inmany inetances, to pinpoin the source of the leak before removing the transmission from the vehicle. The paths ‘which the fuid fakes to reach the bottom ofthe. Converter housing are shown, Technical Service Information coandnarr CONVERTER 10 rune. — ose tee 1. Fluid leaking by the front pump seal lip wil tend to ‘move along the impeller hub and onto the back of the impeller housing. Except in the case of a total seal failure, thd leakage by the fp of the seal wil 'be deposited on the inside ofthe converter hhousing only, near the outside diameter ofthe housing. 2. Fluid leakage by the outside diameter of the seal ‘and front pump body will follow the same path which the leaks by the front pump seal follow. 3, Fluid that leaks by a front pump-to-case bot wll 'be deposited on the inside of the converter housing only. Fiid will not be deposited on the back of the converter, 4. Leakage by the front pump-to-case gasket may Cause ido seep down between the front of the cease and converter housing 5. Fluid leakage from the converter-to-fywhee! stud Weld will appear atthe outside diameter ofthe ‘converter on the back face of the flywheel, and in the converter housing only near the flywheel Engine oleaks are sometimes improperly Siagnosed as transmission front pump seal leaks, ‘The following areas of possibie leakage should also be checked to determine f engine ol leakage 's causing the problem: 2, Leakage at the rocker arm cover (valley ‘cover) may allow oilto flow over the converter housing or seep down between the ‘converter housing and cylinder block. ‘causing oi to be present in or at the Bottom of the converter housing. b. Oil galley plug leaks wil allow oto flow down the rear face ofthe block to the bottom ofthe Converter housing, Leakage by the crankshatt seal will work back to the flywheel, and then into the ‘converter housing. Fluid leakage from other areas, such as the ower steering system forward of the transmission, could cause flid to be present ‘around the converter housing due to low-back or ‘oad dratt. The folowing procedures should be Used to determine the cause of the leakage before any repairs are made. o = [Saarse), Technical Service Information ‘2, Remove the transmission dipstick and note the color of the ui. Original factorycfil hid is dyed red, to ad in determining leakage is, from the engine or trangmission. Unless a considerable amount of makeup fid has been added, or the fhid has been changed, the color should assist in pinpointing the leak. ‘Since road draft may cause leaking power leering fluid to be present on the trangmission, this leakage, present, should be eliminated before checking the transmission for fhid leakage. 'b, Remove the converter housing cover. Clean off any fluid from the top and bottom of the ‘converter housing, front of the transmission ‘case, and rear face ofthe engine and ongine pan. Clean the converter area by washing ‘wih @ autablenontiammable solvent, and low dry with compressed ar. ©. Wash out the converter housing and the front ofthe fywheel. The converter housing may be washed out using cleaning solvent and a squit-type oll can. Blow all washed areas cry with compressed air. 4, Start and run the engine unti the transmission Feaches its normal operating temperature. (Observe the back ofthe block and top of the ‘converter housing for evidence of fluid leakage. Raise the vehicle on a hoist and run the engine at fast ide, then at engine ich occasionally shifting tothe drive and reverse ranges to Increase pressure within the transmission, Observe the front of the ‘lywhool, back of the block (inas far as possible}, and inside the converter housing fd front of the transmission case. Run the ‘engine unt fd leakage is evident and the probable source of leakage can be Setermined. Converter Leakage Check welds on the torque converter incicate leakage, remove the converter and make the following check ressunzanon aguer Eehfnesne |_ nite soov Tew oerecron ‘Assemble Rotunda 021-00047 or 021-0054 Torque ‘Converter Leak Tester or equivalent tothe converter ‘as shown, Test the converter for leaks following the irections supplied wit the detector kit. ne “rgpace Control Pressure Test There are two methods of performing the control pressute test. One is to perform the test using the fngine vacuum. The second method is to use a remote vacuum source such as the one provided by a istributor tester oF a hand operated vacuum pump. Engine Vacuum Pressure \When the vacuum diaphragm unit's operating property and the manual and downshift inkage is adjusted properly, all the transmission shifts (automatic and Fickdown) should occur within the road speed limits Istedin the Technical Service Bulletin—Special Spectications Issue. Ifthe shits do not occur within imi, or the {ransmission sips during the shit point test, use the {ollowing procedure to determine whether the enaine, transmission linkage, vacuum diaphragm unit or valve body is causing the condition Technical Service Information Engine Vacuum Procedure 1. Attach a tachometer to the engine and a Vacuum Gauge, Rotunda Number 058-0008, or equivalent to the transmission vacuum ine at the manifold vacuum port. vast Por ‘uAPHAAoM conNecTION 2. Attach a pressure gauge to the control pressure utiet at the transmission, RE OFF HAE 3. Firmly apply the parking brake and start the engine. ‘4. Check the throttle and downshift linkage for 2 binging condition. linkage s satisfactory, check for vacuum leaks in the transmission claphragm unit and its connecting tubes and hoses. Check all other vacuurm-operated units (such as the power ‘show what components are inoperative when the Control pressure testis not within specifications. Do not proceed with the main agnosis guide untl you have made any repairs, as required, and the control pressure is within specifications as listed in the Performance Specifications Book or Special ‘Specifications Issue of the Technical Service Bulletin Vacuum Pump Method Install an adjustable vacuum source. Disconnect and ‘temporarily plug the vacuum line atthe vacuum dlaphragm unit, Apoy both the parking and service pressure inal selector positions. Run the engine up to "1000 rpm, and reduce the vacuum to 10 inches. Read and record the control pressure in @), 0:2 and 1. Keep the engine at 1000 rpm and reduce the vacuum fo 1 inch. Head and record the control pressure in, D-1, Band A. Reter to the two control pressure diagnosis charts to ‘show what components are inoperative when the control pressure testis not within spectfcation. Do not ‘proceed with the main diagnosis chart unt serviced {88 required, and the control pressure is within ‘specification as listed in the Performance: ‘Specifications Book or Special Specifications Issue of the Technical Service Bulletin 10 Technical Service Information Engine Vacuum Procedure 1. Attach a tachometer to the engine and a Vacuum Gauge, Rotunda Number 058-0008, or equivalent to the transmission vacuum ine at the manifold vacuum port. vast Por ‘uAPHAAoM conNecTION 2. Attach a pressure gauge to the control pressure utiet at the transmission, RE OFF HAE 3. Firmly apply the parking brake and start the engine. ‘4. Check the throttle and downshift linkage for 2 binging condition. linkage s satisfactory, check for vacuum leaks in the transmission claphragm unit and its connecting tubes and hoses. Check all other vacuurm-operated units (such as the power ‘show what components are inoperative when the Control pressure testis not within specifications. Do not proceed with the main agnosis guide untl you have made any repairs, as required, and the control pressure is within specifications as listed in the Performance Specifications Book or Special ‘Specifications Issue of the Technical Service Bulletin Vacuum Pump Method Install an adjustable vacuum source. Disconnect and ‘temporarily plug the vacuum line atthe vacuum dlaphragm unit, Apoy both the parking and service pressure inal selector positions. Run the engine up to "1000 rpm, and reduce the vacuum to 10 inches. Read and record the control pressure in @), 0:2 and 1. Keep the engine at 1000 rpm and reduce the vacuum fo 1 inch. Head and record the control pressure in, D-1, Band A. Reter to the two control pressure diagnosis charts to ‘show what components are inoperative when the control pressure testis not within spectfcation. Do not ‘proceed with the main diagnosis chart unt serviced {88 required, and the control pressure is within ‘specification as listed in the Performance: ‘Specifications Book or Special Specifications Issue of the Technical Service Bulletin 10 ATSG] Technical Service Information A ; CONTROL PREBSURE TEST Low sro vic a ue oars Ras ASU with | | eoxiowrwo ise re | oxaton Sreoetae Sadan oat Sette Enrcten woseon ses | |ovecx vicum ourewcn eit ett Coban eeccerocase| [ow wanars vacton helen un SOO eter wcace| tive, Se*cowrnge noe, 1 Hus Petes caer Gor | |eMicxma ResueaToR i Bec tatieeser ona] |soosr ate EAE RcaGaton cate vacuum papas yur] [excessive venwage. Low weramaguereace wr] | Recs cannon asinine SE SaMe oe | | he Sonex | | Foawaee Fopwago ovenoave | | overonve ‘vaave soor | | vawvesoov SOR au aren “cauren oGRo* ‘cute Low ao Lon 0 Pevense Reverse pat ‘SERVO. n Technical Service Information Vacuum Supply Test ‘The vacuum supply to the vacuum diaphragm unit and the diaphragm itself ust be checked. To check the supply, disconnect the vacuum line at the diaphragm Unit and connect it toa vacuum gauge. With the engine iding, the gauge must have a steady acceptable. ‘vacuum reading for the alttude at which the test is being performed. If the vacuum reading is low, check. for a vacuum leak o° poor engine vacuum. I the vacuum reading is OK. rapidly accelerate the engine momentarly. The vacuum reading must drop rapidly at ‘acceleration and return immediately upon release of the accelerator. I the vacuum reading does not ‘change or changes slowly, the transmission vacuum line's plugged, restricted or connected toa reservoir supply. Correct as required. Vacuum Diaphragm Test—On Vehicle To check the vacuum diaphragm unt, start the vacuum pump and set the regulator knob so that the vacuum ‘gauge reads 18 inches with the end of the vacuum hose blocked off. Then connect the vacuum hooe to the ciaphragm unit. the gauge stil reads 18 inches, the vacuum diaphragm untis not leaking. Ifthe reading does not remain at 18 inches, but drops, the vacuum | SERVICE bom planets. 6 SPEEDOWETER GEAR. «Remove the speedometer gear and check for noise. | Noise stops D>) REPLACE speecometar goer CLEANING AND INSPECTION ‘Transmission Fluid Drain and Refill Normal maintenance and lubrication requirements do not necessitate periodic automatic tranemission fd ‘changes. I major service, such as a clutch band, bearing, ac., is required in the transmission, it wil have to be removed for service. At this time the converter, transmission cooler and cooler lines ‘must be thoroughly flushed to remove any dirt. ‘When used under continuous or severe conditions, the transmission should be drained and reflied with fic a specified. Before adding flid, be sure that the ‘correct type willbe used. iin doubt, check the Safety Standard Certification Label affixed othe left front ‘door face panel or door pilar forthe Transmission Code. For A4LD Automatic Transmission (Code 7), use fluid that meets Ford Specification, Motorcraft Mercon® Multi-Purpose Automatic Transmission Fluid XT-2-QDX oF DDX (ESP-M2C 166-H) or equivalent. for partial drain and rfil, due to in-vehicle service operation, are as follows, 4. Loosen the pan attaching bolts to drain the fuis from the transmission 2. When all ud has drained trom the transmission, remove and thoroughly clean the pan. Discard pan gasket 3. Place anew gasket on the pan, and install pan on tranamission 4. Add 2.8 titers (3 quarts) of fu to transmission ‘through the file tube ‘5. Check the uid level folowing the room temperature checking procedures. Hitis necessary to perform a complete drain and rel, itwil be necessary to remove the residual fud from ‘the cooler ines and flush cooler ines completely. CAUTION: Use of a tluld other than specitieg ‘above could result in transmission malfunction ‘and/or fallur When filing a dry transmission and converter, reer to ‘Specifications for capacity. Check the fuid level following the room temperature checking procedures, 34 Technical Service Information ‘Transmission Fluid Lines When one or more ofthe fd cooler steel tubes must bbe replaced, each replacement tube must be fabricated trom the same size steel tubing as the original ine, Using the old tube as @ guide, bend the new tube 2s i une requited. Add the necessary fitings, and install the PS Soe tube. Make sure thatthe replacement tube has Z uate clearance to other components. especially < = the exhaust system and parts having sharp edes. ‘tr the fitings have been tightened, add fluid as ‘needed, and check for fuid leaks. Vacuum Tubes Refer tothe following ilustration for vacuum tube installation een rom eStore ron Poth ake einen sont Fen eee iver ron fon ‘eansunsson BSR tSon ro eto Technical Service Information Transmission important to completely clean all transmission components, including converter cooler, cooler lin ajor ‘cause for recurring transmission troubles and ‘must be removed from the system before the ‘Giean the parts with suitable solvent and use. moisture-free air to dry off allthe parts and clean out fluid passages. ‘The composition clutch plates, bands and synthetic seals should not be cleaned in'a vapor degreaser oF with any type of detergent solution. To clean these Parts, wipe them off wih a lint-free cloth, New clutch plates or bands should be soaked in transiniasion fluid ‘Specified for that transmission type for ffteen minutes before being assembled Control Valve Body 1. Clean ali parts thoroughly in clean solvent, Dlow dry with moisture tree compressed a 2. Inspect all vaive and plug bores for scores. Check all fuid passages for obstructions. Inspect the ‘check valve for free movernent. Inspect all mating surfaces for burrs or distortion. Inspect all pugs ‘and valves for burs or scores, Use crocus cioth {0 polish valves and plugs. Avoid rounding the sharp edges of the valves and plugs with the lath. 3, Inspect al springs for distortion. Check all valves: ‘and plugs for free movement in thei respective ‘bores. Valves and plugs, when dry, must fall from their own weight in their respective bores. 4, Rll the manual valve on a flat surface to check for bent condition. Overdrive and intermediate Servos 1. Inspect the servo bore for cracks, the servo Piston for damage, and the piston bore and servo Piston stem for scores. Check fluid passages for obstructions. Repiace damaged seals, 2. Check the servo spring and servo band strut(e) for distortion 3, Inspect the cover seal and gasket cover sealing ‘surface for damage. 4. Inspect the band ining for excessive wear and for proper bonding tothe metal band, NOTE: Identity servo covers, pistons, and ‘springs with a tag for proper identification Low-Reverse Servo 1. Inspect the bore for scores. ‘Check the fluid passages for obstructions, Inspect the band for distortion. Inspect the band lends for cracks, 4. Inspect the servo spring or distortion, ‘5. Inspect the band ining for excessive wear and for proper bonding to the metal band. 6. Replace damaged cover seal 7. Replace piston sealsit damaged Extension Housing 4. Inspect housing for cracks. Inspect gasket surface for burs or warpage. 36 Technical Service Information 2. Inspect bushing for scores or wear. Replace it required. 3, Inspect the rear seal for hardness, cracks, or ‘wear. If the seal shows wear or deterioration, replace the seal. 14, Inspect the seal counterbore and remove all burrs and scores with crocus cloth. 5. Check vent for obstructions. Governor 1. Inspect the governor valves and bore for scores. ‘Minor scores may be removed from the valves with crocus cloth. Replace the governor if the. Valves or body is deoply scored. 2. Check for free movement ofthe valve inthe bore. ‘The valve should slide trealy ofits own weight in the bore when dry. Inspect flid passages in he valve body and collector body for obstructions. Allfluid passages must be clean. 3. Inepect the mating surfaces of the governor body ‘and collector body for burrs and distortion Mating surfaces must be smooth and fla. O—~zz, Reverse-High and Overdrive Clutche 1. Inspect the drum band surface, bushing, and thrust surfaces for scores. Minor scores may be removed with crocus cloth. Badly scored parts ‘must be replaced. 2. Inspect the clutch piston bore and the piston inner ‘and outer bearing surfaces for scores. 3. Check the id passages for obstructions. All fluid passages must be clean and tree of obstructions 4, Inspect the clutch plates for wear, scoring. and fit ‘on the clutch hub serrations. Repiace all plates. that are badly scored, worn, or do not fit freely in ‘the hub serrations. Inspect the clutch pressure plate for scores on the clutch plate bearing surface. Check the clutch release spring for distortion. 6. The clutch cylinders have check balls. Inspect the check ball for freedom of movement and proper seating. Forward Clutch STON SEAL ow it Pump + ager aig src ot rom at ancase oa 2. Inspect the drive and driven gear bearing surface for scores and check gear teeth for buts. ‘3. Inspect the front pump seal for cuts or nicks, and pump bushing for scoring, 4, Check thid passages for obstructions. 6. any parts are found damaged or worn, replace the pump as a unil. Minor burrs and scores may bbe removed with crocus cloth. aap neve 0 CLUTCH (CAST BOWL OvERORTE GLUTEN Gv TAME STEEL) 1. Inspect the clutch cyiinder thrust surfaces, piston bore, and clutch plate serrations for scores or burrs, Minor scores or burrs may be removed with crocus cloth, Replace clutch cylinder if itis badly scored or damaged. 37 Service Information 2. Check fluid pressure in the clutch cylinder for ‘obstructions, Clean out all uid passages. Inspect ‘lutch piston for scores and replace if necessary, Inspect the piston check ball for freedom of movement and proper seating 3. Check clutch release springs for distortion and cracks. Replace springsit they are distorted or cracked, 4, Inspect composition clutch plates, steel clutch plates, and clutch pressure plate for worn or ‘Scored bearing surface. Replace all parts that are ‘deeply scores. 5. Check clutch plates fr lainess and it on the Clutch hub serrations. Discard any plate that {does not side freely onthe serrations or that is pot fat 6. Check clutch hub thrust surfaces for scores and clutch hub spines for wear. 7. Check input shalt for damaged or worn splines. Replace shaft if the splines are excessively worn Inspect bushing in stator support for scores. 1. Thoroughly drain remaining solvent through the converter hub, 2. Add 1.9L (2.0U.S. quarts) of clean transmission {uid to the converter. Agitate by hand, 3. Thoroughly drain solution through the converter hub, Overdrive One-Way Clutch and Planetary Rear One-Way Clutch 1. Inspect cuter and inner races for scores or damaged surtace areas where rollers contact, 2. Inspect rollers and springs for excessive wear or damage, 8. Inspect spring and roller cage for bent or damaged spring retainers, Converter and Fluid Cooler Wien internal wear or damage has occurred inthe transmission, metal particles, clutch plate material, or ‘band material may have been carried into the converter and oil Cooler. These contaminants are a ‘major cause of recurring transmission troubles and MUST be removed from the system before the ‘transmission i put back ito service, \Whonever a transmission has boon disassembled 10 replace worn or damaged parts or because the valve body sticks trom foreign material, the converter, of ‘cooler and all cooler lines MUST be cleaned and fished by using the Rotunda Torque Converter ‘Cieaner (mode! 014-0028) or equivalent. Under NO ‘iecumstances should an attemp! be made to clean Converters by hand agitation with solvent. The lack of a drain plugin the AALD converter increases the amount of residual fushing solvent retained inthe converter after cleaning. This etsined Solvent is nol acceptable and a method of diluting itis required, The folowing procedures to be used atter removal of the A&LD torque converter from the cleaning equipment. Converter End Play and One-Way Clutch Check The Converter One-Way Clutch Torquing Too! ‘T77L-79028 and DB4L-7902-A One-Way Clutch Holding Tool or an equivalent fabricated holding toot are used to check the converter one-way clutch, Tonauing Toot oubmve TOOL End Play Check 1. Insert Torque Converter End Play Checking Too), ‘TBOL-7802-A or equivalent into the converter, impelir hub, unt it bottoms. d= Tee aeese 9 Siro 2. Expand sleeve inthe turbine spline by tightening the threaded inner post unti the toolis securely locked m the spine. 38 Technical Service Information ‘Attach Dial indicator with Bracketry TOOL -4201-C or equivalent tothe Torque Converter End Play Checking Tool TBOL-7902-A ‘or equivalent. Position the inicator button on the ‘converter impeller housing, and set the dial face ‘at 0(zer0) Lift tool upward as far as it wil go and note Indicator reading. The indicator reading is the ‘otal end play which the turbine and stator share. Roplace the converter unit if the total end play ‘exceeds the limits. Refer to Specifications. Loosen threaded inner post 10 fre tool, and remove the tool from the converter. ow mocaToR Converter One-Way Clutch Check Use One-Way Clutch Holding Tool, DB4L-7902-A ‘or equivalent or fabricate a one-way clutch holding tool as shown below. (oMe.way CLUTEH WOLDING TOOL er Insert one-way clutch holding toolin one ofthe ‘arooves in the stator thrust washer. Insert the Converter One-Way Clutch Torquing ‘Tool, 1771-79028 in the converter impeller hub 80.8 to engage the one-way clutch inner race. [Attach a torque wrench to the one-way clutch torquing tool. With the one-way clutch holding toot hold stationary, turn torque wrench Counterciockwise. The converter one-way clutch Should lockup and hold @ 14 Nem (10 fb) torque. ‘The converter one-way clutch should rotate freely in a clockwise direction. Try the one-way clutch for lockup and hold in atleast five diferent locations around the converter. the one-way clutch tals to lockup and hold at 14 Nam 10 ftib) torque, replace the torque converter. 39 ATSG], Technical Service Information Stator To Impeller intorterence Check 11. Position front pump assembly on a bench with ‘spline end of the stator shaft pointing Up. 2. Mount a converter on the pump with spinas on the one-way clutch imer race engaging the ‘mating splines of the stator support. The impeber hub wil then engage the pump drive gear. 3. Hold pump stationary and try to rotate the torque ‘converter both clockwise and counterclockwise. ‘The converter should rotate ireely without any signs of interference or scraping within the Converter assembly ‘4, Mtthere is an indication of scraping, the trailing ‘edges of the stator biades may be intertering with the leading edges of the impeller blades. In such cases, replace the converter. Individual parts ofthe planet carriers are not serviceable, Technical Service Information ‘Check pins and shatts in planet assemblies for loose fit and /or complete disengagement. Uso a ew planet assembly if either condition exists. Belore instaling a panet assembly, the shaft retaining pins should be checked for adequate: ‘staking. necessary, restake the pins before installation. When restaking, the retaining pins ‘must not be driven into the Garter any further than 4.0mm (0.040 inch) below the Surface of the 2. Inspect pinion gears for damaged or excessively worn teeth 3. Check for tree rotation of pinion gears. Stator Support 1. Inspect stator support splines for burs and wear. 2. Check oll ring grooves in stator support for nicks, burrs or damaged edges. 3. Gheck front and rear bushings of stator support for wear or scoring 4. Check front pump support seal 8. Check seal ings for damage. Case Inspect the case for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for burrs. Check the vent for obstructions, and check al fluid passages for obstructions and leckage. Inspect the case bushing for scores. Check al parking linkage parts for wear or damage. Wa transmission case thread is damaged, service kits ‘may be purchased trom local jobbers, To service a damaged thread, the following procedures should be carefuly folowed: Dil out the damaged threads, using the same drill Size as the thread outside diameter. For ‘example, use a §/ 18 inch drilfor a 5/ 16-18 thread, Select the proper special tap and tap the driled hole. The tap is marked for the size ofthe thread being repaired. Thus, the special tap marked '5/ 16-18 wil nt cut the same thread as a Standard 5/ 16-18 tap. tdoes cut a thread large enough fo accommodate the insert, and after the inserts instafed, the orignal thread size (6716-18) is restored. ‘Select the proper coil inserting tool. These tools are marked with the thread size being repaired. Place the insert on the tool and adjust the sleeve tothe length of the insert being used. Press the insert against the face of the tapped hole. Tura the fool clockwise and wind the insert into the hole unti the insert is 1/2 turn below the face Working through the insert, bend the insert tang straight up and down until it breaks off atthe noteh, Improperly installed inserts can be removed with the extractor too), Place the extractor toolin the ingert with the blade resting against the top coll 4/4 to 1/2 turn away from the end of the col. ‘Tap the tool sharply with a hammer until the blade cits into the inser. Exert downward pressure on the tool and turn it counterclockwise until the insert is removed. REMOVAL AND INSTALLATION 1 2. 3, Transmission Removal Disconnect the battery negative cable. Raise the vehicle on a hoist Place a drain pan under the transmission fuid ppan. On Explorer vehicles, pry the lower clips of {transmission heat shiels back sligntly to allow ‘access to pan bolts. Stating at the rear of the ‘pan and working toward the front. loosen the Attaching bolts and allow the fui to drain. Then remove allo the pan attaching bolts except two atthe front, to allow the fluid to further drain. After all the urd has drained, install two botts onthe Tear side ofthe pan to temporary hold tin place. Remove the converter access cover from the ‘converter housing. Remove one (1) bolton the ‘access cover of 6 cylinder applications (3.0L) pivot/ swing cover open. lemove the starter-to-converter housing attaching bolls and position the starter out of the way. NOTE: On 2.01. and 4.0L engines, the converter attaching nuts are accessed through the starter ‘motor mounting hole. On 2.SL engines, the Converter attaching nuts are accessed through the cover on the engine oil pan. Remove the four flywheel-to-converter attaching ruts by placing a 22mm socket and breaker bar on the crankshall pulley attaching bolt Rotate ‘the pulley clockwise (as viewed from the front) to ‘gain access to each ofthe nut, CAUTION: On 2.3L belt driven overhead cam ‘engines, never rotate the pulley in a counterclockwise direction (as viewed from the front). 4 Technical Service Information 7. Seribe a mark indexing the driveshaft tothe rear axle flange. Remove the drivashatt install the extension housing seal replacer tool in the extension housing. 8. Remove the speedometer cable from the extension housing 8. Disconnect the shittrod atthe transmission ‘manual lever, Remove the kiekdown cable from the ball stud lever. Depress the tab on the cable downshift retainer and remove the cable from the bracket. 10. Disconnect the neutral start switch wires and the ‘converter clutch solenoid connector 14. Remove the vacuum line from the transmission vacuum modulator. 13. Remove the engine rear support-to-crosamember bolts. 14, Remove the crossmember-toframe side support altaching bolts and remove the crossmember insulator and support and damper. 15. 1, 18 19, 21 Transussion Lower the jack under the transmission and allow the transmission to hang, Position a jack tothe front of the engine and raise the engine to gain access to tho two upper ‘converter housing-to-engine attaching Bolts on Ranger and Expiorer vahicles. Disconnect the ol cooler lines at the: transmission. Piug all openings to Keep out dit Remove the lower converter housing:to-engine attaching bots, Remove the transmission filer tube, ‘Secure the transmission tothe jack with a safety chain Remove the two upper converter housing-to-engine attaching bolts. Move the ‘transmission fo the rear 601 disengages from the ‘dowel pins and the converter is disengaged trom the flywheel. Lower the transmission from the vehicle = iF Technical Service Information NOTE: I the transmissionis to be removed for a period of ime, support the engine with a safety. ‘Stand and wood Block, rns Installation 1. Position the converter fo the transmission making sure the converter hub is fully engaged in the ump gear. To accomplish his, push and rotate the converter unt two (2) “bumps” are felt. Keep ‘bushing and rotating until dimension "A" shown below, is reached, NOTE: Make sure the torque converter rotates freely andis not bound up. Dimension "A" should be: Minimum: 10, 23mm (7 16 in) Maximum: 14.43mm (8/ 16 in) 2, With the converter property installed. place the transmission on the jack and secure witha safety chain 3. Rotate the converter so the crive studs are in alignment with their holes inthe yuh 4. With the transmission mounted on a transmission Jack, move the converter and transmission assembly forward into position being careful not to damage the llywhee! and the converter plot During this move, to avoid damage, do not allow the transmission to get into a nose down position a this will cause the converter to move forward and disengage from the pump gear. The converter housing is piloted into position by dowels in the rear of the engine block. The converter must rest squarely against the ‘flywheel. This indicates that t converter pilot Is rot binding in the engine crankshatt. 5 10. 1. 1 13 4 15, w 18 Install two (2) converter housing-to-engine attaching bolts al the engine dowel locations. Tighten to 38-51 Nem (26-38 Ib) Install the remaining converter housing to-engine aftaching bolts and tighten to 38-51 Nem (28-38, feo). Remove the safety chain from the transmission. Insert the filer tube inthe stub tube and secure it {0 the cyinder block with the attaching bot. Tighten the bolt to 38-5 1 Nem (28:38 fb). ifthe stub tube is loosoned or disiodged, it should be ‘replaced Install the oil cooler lines in the retaining clip a the cylinder block. Connect the lines tothe transmission case. Femove the jack supporting the front of the engin. Raise the transmission. Position the ‘rossmember, insulator and support and damper fo the frame side supports and install the attaching bolts. Tighten the bots to 27-43 Nam (20-30 #6). Lower the transmission and install he rear engine Supportto-crossmember nut. Tighton the Bolt 10 182-108 Nem (60-601), Remove the transmission jack Install the vacuum hose on the transmission ‘vacuum unit Install the vacuum line into the retaining clip. Connect the neutral start switch piug tothe Switch, instal the converter cluten /d-4 att solenoid connector. Instal the four flywheetto-converter attaching ruts When assembiing the flywheel to the converter, first install the attaching nuts and tighten to 27-46 Nam (20-34 ft). Install the converter access cover and adapter plate bots, Tighten the bolts to 16-22 Nam (12-16 fteb). On 2.3L engines, tighten the ol pan access ‘cover bolts to 2.6:3 6 Num (22-32 wld) Install the starter ans tighten the attaching bolts 10 20-27 Nem (15-20 1-10) Connect the muir inlet pipe to the exhaust manioldit disconnected for removal 43 (area) Technical Service Information 20. 21 22. 23. 24 25. 26. ‘Connect the transmission shift rod to the manual lever. Connect the downshitt cable to the downshift lever. Install the speedometer cable as describedin Section 13-02, Speedometer ‘Odometer. Install the driveshaft so the marks scribed on the driveshaft and rear axie lange are i alignment. Tighten the companion flange U-bot attaching ruts to 95; 120 Nem (70-95 feb) {Adjust the manual and downshift linkage as required, Lower the vehicle, Connect the battery negative Cable. Fil the iransmission to the proper level with the specified fli Pour in five quarts of fu; then run the engine and ‘add fuid 2s required, ‘Check the transmission, converter assembly and ilcooler lines for leaks. 5. Push vacuum diaphragm into case and secure with retaining clamp and bolt, Tighten Bol to 9-12 Nem (80-108 ib). 6. Insta vacuum diaphragm hose to vacuum diaphragm. 1 2 Vacuum Diaphragm Removal and Installation Disconnect hose fram vacuum diaphragm, Remove vacuum diaphragm retaining bolt and clamp. Do not pry or bend clamp. Pull vacuum siaphragm trom transmission case. Remove the vacuum diaphragm control ro trom transmission case Install vacuum diaphragm control od in ‘transmission case. Control Valve Body Removal 1. Raise vehicie ona hoist so transmission and pan isaccessible 2. Loosen pan attaching botts and drain thi from transmission, f the same fluids to be used ‘again, filter through a 100 mesh screen. Rous6 fluid only iit isin good condition. 3. Remove transmission fuid pan attaching bots, pan and gasket. Remove fiter scroen and O-rings. Remove loweverse servo cover, piston, spring and gasket 6. Disconnect two wires at the converter clutch solenoid and the two wares at the 3-4 shift solenoid. Technical Service Information 7. Remove bolts trom the control valve body. Note that the bolts are of different lengths and their locations are different from the bolt locations on other automatic transmissions. Carefully ease the body trom the case while unlocking and detaching the selector lever, ‘connecting rod. Seve coven Installation 1. Clean and inspect the valve body prior to installation, as detaled inthis section, 2. Attach and lock the selector lever connecting rod (Zink) to the manual valve and ease contral ody into the case. CAUTION: Use care not to bend selector lever connecting rod (Z-Link). 3. Insert correct length bots, finger-tight, in holes A ‘and B to position control body to case, 4, Ingert all remaining bolts (correct length) except fiter screen bott and tighten to specification. 6. Remove the bolt from hole A andinstall detent ‘spring fo bolt, thon reassemble and tighten A and Biocations to specification 6. _Installlow-reverse servo cover, piston, spring and gasket. 7. Connect the converter clutch solenoid wires. 8. Clean titer screen with solvent. Then install fiter screen O-ring and fter screen. 9. Using a new gasket, instal fuid pan. Tighten retaining bolts to 11-13.5Nem (8-10 fb). 10. Lower vehicle and fil transmission with proper ‘rade and quantity offi Pour in 2.8L (3 quarts) of fui. Run engine and ‘add fuid as required, 11, Operate vehicle and check for leaks. 45 (eaatse Technical Service Information convene gua VALVE BODY ISTALLATION © ® © omn-18 aan _ vai 00 011 Locanowsas oon Ytenna sequence = row age og @ Som ‘Gieran OF VaLve BODY TO OUTER EDGES. Technical Service Information Low-Reverse Servo Removal 1. Raise vehicle on a hoist. 2. Place a drain pan under transmission fd pan. ‘Starting at rear of pan and working toward front, loosen attaching botts and allow fi to drain. Remove allof the pan attaching botts except two ‘at the front to allow fhid to further drain. Finally, remove allof bolts and remove the pan. 3, Remove ol fiter screen and gasket. 4. Remove retaining screws, low-reverse servo ‘cover, piston, spring and gasket. 1. Installlow-reverse servo piston and spring inthe ‘servo housing, 2. Install servo cover and gasket. 3. Clean and replace fiter screen and gasket. 4. Position transmission fd pan and a new gasket retaining screws in two steps. transmission withthe proper grade and ‘quantity off. Pour in 2.81 (3 quarts) of uid. Run engine and add fluid as required, (Operate vehicle and check for leaks. Extension Housing Oil Seal Fomoval and Installation 1. Raise vehicle on a hoist. 2. Remove driveshatt. Driveline General Service. Make soribe marks on diveshatt end yoke and rear axle companion flange to aseure proper positioning of driveshaft during assembly. 8. Remove ol seal using Extension Housing Seal Flemover 17 1P-7657-A or equivalent. 4. Remove extension housing bushing using Extension Housing Bushing Remover ‘T77L-7697€ or equivalent. 5. _nstallnew extension housing bushing using {Extension Housing Bushing Replacer ‘T77L-7697-F or equivalent. 6. Before nstaling a new seal, inspect the sealing surface ofthe universal joint yoke for scores. scoring is found, replace yoke. TOOL NO TAP IEETA 7. Inspect counterbore of housing for burrs. Remove any burrs with crocus cloth, ‘8. Install new of sea using Extension Housing Seal Replacer T74P-77052°A or equivalent. Coat Inside dlameter atthe end of the rubber boot Portion of seal with Long-Life Lubricant G1AZ.19590-BA (ESA-M1C75.B) or equivalent Coat the front universal joint spline with Long-Life Lubricant C1AZ-19590-BA (ESAMIC75.B) or equivalent. 9. Install driveshaft using scribe mark as a guide to assure correct balance. 47 ATSG], Technical Service Information 10. Lower vehicie and check olllevel in transmission. Add oll necessary, Extension Housing Removal 1. Reise vehicle on a hoist. 2. Remove driveshatt Make soribe marks on 2 Tl i Onn et = 3 = 2 = - ® Gems = le OC} Simm “Th oan toe ae) 99, Install the reverse servo piston assombly into 101. Tighten servo tool adjusting screw to 4 Nem (35. ‘Servo bore along with a reverse servo check ino) reece eeaeanete ets 102, Install Dial Indicator with Bracketry 400. Install anew servo cover gasket and too! ‘TOOL-4201-C on transmission case and ‘T74P-77 190-A or equivalent and tighten with position inaicator on piston pad. Set cal Indleator to zero, three attaching bolts 83. Technical Service Information 103. Back out the servo tool adjusting screw unt Piston bottoms out on the tool. Record the ‘distance the servo piston traveled 104. If piston travelis betwoen 3 and 5.6mm (120 and.220 inch), itis within specification, 108. If piston travelis greater than 5.6mm (.220 inch), use the next longer piston and rod 108. If piston travel is less than 3mm (.120 inch), use the’ next shorter piston and rod, giana — neha i ‘HSS en 2120s Teo S180 mm Zoe 68 Ne Gre 8 1915 2 Gone 107. Using the above procedure. check the piston travel with the new selected piston and 0d Tequired) to make sure thatthe piston travelis Detween 3 and 5.6mm (.120 to 220 inch). 108. Remove the servo adiusting tool and the reverse servo piston checking spring, 109. Install the servo piston assembly, accumulator ‘Spring, gasket and cover. 110. Installfour 10mm servo retaining bolts and tighten to 10-13 Nem (7-10 16) 111. Installnew O-rings on the screen and lubricate with petroleum jel. 112, Install fiter screen and one tOmm bolt, Tighten toBetNem(7 1-97 int), 149, Remove any trace of old gasket on case and oll pan, 114. Position ol pan gasket on case and instal ol 146, Install 18-13mm oll pan cetaining bolts. Tighten to 11-13 Nem (8:10) 116. Remove any trace of old gasket on end of case and extension housing, Technical Service Information 1117. Install parking pawi andits return spring in the extension housing and preload, 118. Using a new gasket, install the extension housing. Be sure to correctly seat the operating parking rod in the extension guide cup. 119. Install six extension housing retaining fasteners. Tighten to 37-52 Nem (27-38 feb). mousne 120. Remove extension housing seal using Extension Housing Seal Remover 17 1P-7657-A or equivalent. 121. Remove extension housing bushing using Extension Housing Bushing Remover 177-7697 € or equivalent 122. Install extension housing bushing using Extension Housing Bushing Replacer T77L-7897-F or equivalent 123. Install extension housing seal using Extension Housing Seal Replacer T74P-77052.A or equivalent exten extension nousne Toone. tare rerove tae To head ceva Setup ad cske Sean Oa 2. With separator plate and gasket removed, note location of © Converter pressure relief valve and spring © TV pressure relief valve and spring «© Three shuttlo balls and one check ball ‘# Accumulator check valve (two) 85 Technical Service Information exgcx vate oor ‘Reem EATON Er VALVE CONVERTER PRESSURE EUR VALVE 1991 CHECKBALL LOCATION Valve Body Valve Identification “The following procedural steps detail the removal and installation of the ndivdual valves. Each valve body bbore has been assigned a reference number on the assembled view. Theilustrations have been assigned corresponding reference number. Each set of ilustrations contains the views necessary to remove and instal the components contained in a particular valve body bore. ‘© Fitter that is retained by the soparator plate at Converter clutch solenoid connector EARLY 1985 - 1987 HYDRAULIC 3-4 SHIFT CHECKBALL LOCATION © (im C: = i ete Ns = cavenec ae es Dee ee a SSS ) i c 2s =o C20 (eaats6), Technical Service Information LATE 1988-1990 ELECTRONIC 3-4 SHIFT CHECKBALL LOCATION 3-4 SHIFT ——"soLenoin ‘CONVERTER —— cH SOLENOID Automatic Transmission Service Group 88 Technical Service Information come cee RE gE RE AER BU re io dowrerren rox 5 nari Bolmsner vauve 200 MAW Ou Pressure goosreR tate tan St eboone aia Sa easune Bost vate BB aS const eonrnae v Seno menaron eS 89 (Caatsc), Technical Service Information Bore 2 100 (Eaatse), Technical Service Information Bore 201 TSG], Technical Service Information Bore 202 sone 22 sont ua SestSalk sear ano Mane SOO rm Bigger cute ry. woouaron 24 SHIT SOLENOID AETAINER 2 Technical Service Information ara, e me Bore 203 AETANING PLATE 93 ATSG), Technical Service Information Technical Service Information faze) <= Bees aoe he SEs oN SE) 20 = | 3 Ze eae ae I@AATSG] Technical Service Information Pl ASieonnaner one a Technical Service Information (€aarse), Technical Service Information Bore 211 wa BT 12 mango __— Tae saccour aacxour SADE Seana c ° = o — . ° - c ® ° > . o on a ° c = ° o KE Bore 212 100 (Caatse), Technical Service Information 102 MAATSG] Technical Service Information x a (Caatsc), Technical Service Information Technical Service Information Reverse-High Clutch Disassembly 1 Remove the pressure plate retaining ring Remove the plate pack. Inspect stee! clutch plates and clutch lning plates tor wear, d effects of overheating, Replace the entre setf necessary. new plates are tobe used, immerse them in transmission fluid for 30 minutes before assembly, "tance a Compress the compression springs using Clutch ‘Spring Compressor T6SL-77515-A or equivalent. Remove retaining ring and carefuly release pressure oa the spring Remove the spring and compression spring retainer 7. The piston s removed by air pressure as shown, Use finger to cose off opposite hole. 8 Apply air pressure to blow out clutch piston. CAUTION: Do not exceed 137 kPa (20 psi). Assembly 1. Install new seal rings on clutch piston. 2. Carefully install clutch piston nto clutch body. ‘3. Install compression spring and spring retainer. 4. Compress springs using Clutch Spring Compressor T65.-77515-A or equivalent. Install ‘the retaining rng. 5. alate ladon the sping ar renoe te 105 Technical Service Information 6. 10. 1 Install clutch plates beginning witha steel plate, then a friction plate tee! plate alternately, then the pressure plate. Secure with the retaining ring. a maresusona ME Use a feeler gauge 10 check the clearance ‘between the retaining ring and pressure plate. Push downward on the plates while making this check. The clearance should be to specification H clearance is not between 1.3 and 2.0mm (051 ‘and.079 inch), installa diferent suitable retaining ring Availabe retaining ring thicknesses are: 1.8Tmm (0539 inch) 1.7mm (0681 inch) 2.08mm ( 08:19 inch) 2.4mm (.0961 inch) Perform the air test by blocking hole with finger to prevent air leakage. Piston must apply when pressurized and release when airis removed. Forward Clutch Disassembly 1. Disassembly ofthe forward clutchis the same as the disassembly of the reverse and high clutch that has been previously covered with one. exception—removing the clutch piston, 2. The forward clutch piston is removed trom the forward clutch cylinder with air pressure, 4. Install the center support onthe forward clutch cylinder. ‘Sor wot ‘aro 106 Technical Service Information b. Apply ar pressure to the let (middle-sized) port in the center support as shown to force the piston assembly from the forward clutch Assembly 1. Rleassembiy of the forward clutchis the same as previously covered forthe reverse and bigh Clutch with the exception ofthe following: (© Arubber forward clutch cushion spring between piston and steel pate. (¢ Number of clutch plates: five steel and five friction 2. Install clutch plates begining witha stoe pate, then alternate fiction, steel, riction and 80 on Install pressure plate and retaining rng, Use a feeter gauge to check clearance between the retaining ring and pressure plate. 4. Push downward on the plates while making this ‘check. The clearance should be to specification. 5. clearance is not between 1.4 and 2. 1mm 055 and 083 inch), installa different suitable retaining ring. 6. Available retaining ring thicknesses are: 1.97mm (,0539 inch) 1.73mm (0681 inch) 2.08mm (0819 inch) 2.4mm (,0961 inch) 7. Pertocm the air test by instaling the center support on the forward clutch cylinder. Apply aie pressure to the eft (middle-sized) port, a8 shown, {o.check piston application Piston must apply when pressurized and release ‘when aris removed. Overdrive Clutch Disassembly 1. Disassembly of the overdrive cluichis the same 2s disassembly of the reverse and high clutch With the exception of removing the clutch piston Technical Service Information 2. The piston is removed by air pressure as shown. Use finger to close of air leak. Assembly 1, Reassembly of the overdrive clutch is the same ‘as previously covered forthe reverse and high Clutch with the exception ofthe following: «© Place return spriags around the assembly in ‘groups of three. ‘© Number of clutch plates: three steel and thr friction 2. Install clutch plates beginning witha steel plate, then alternate friction, steel, tiction. Then, install the pressure plate and retaining cip. 3. Usea teeter gauge to check clearance between the retaining ring and pressure plate 4, Push downward on the plates while making this ‘check. The clearance should be to specication, 5. clearance ig not between 1.4 and 2.1mm (055. and.083 inch), install acifferent suitable retaining ng 6. Available retaining ring thicknesses are: 1.37mm (.0539 inch) 1.73mm (.0681 inch) 2.08mm (.0819 inch) 2.4mm (.0861 inch) 7. Perform the ir test by blocking the hole with a finger to prevent air leakage. 8, Piston must apply when pressurized and release ‘when airis removed. Governor Disassembly and Assembly 1. Remove governor bady to cilcollector body attaching bots 108 Technical Service Information 2 3 4. nea NOTE: When the governor body attaching bolts are removed governor components are no longer retained in position o the governor body. Care ‘must be taken not to drop the governor body and Components when the attaching bolts are removed. Remove governor components from the governor body. Remove the counterweight. CClean aitparts. Replace parts that are worn or damaged. Assemble the outer weight spring and primary valve in the governor body. ‘Assemble governor body and counterweight 10 the oll collector body, Forward Geart 1 in Assembly ‘Assemble the forward clutch to the reverse and high clutch, positioning No. § (70428) thrust washer between ther, 2. Assemble the forward planet gear carrier tothe Internal gear, with needle bearing thrust washer No. 7 (7F374)in between ther. (On vehicles with 4.0 engines, position the No. 6 thrust bearing assembly on the gear carrier NOTE: To prevent damage tothe bearing needle ‘cage, it must be installed as shown (On2.3., 2.9L and 3.01 vehicles, postion No.6 Intogral thrust washer (7045) on forward planet carrier hub. Install the tront planet assembly into the forward clutch, Position needie bearing washer into forward planet gear carrer. Install clutch hub and sun Sear, 109 Technical Service Information GEIR Care SOE co So ge BSR yes soe Me avon | HE Gi ae we ey oureues 2 -Sitaon sa] ee He areves, s ; oN nm ty regio rage ase aes one-way Guten 7a beng ons ney ne anata L applications use a sprag type one-way led NO} cliteh that is not to be disassemble 1 2 Remove the snap ring using a screwdriver Lit out the cage with the springs and beating rolers asa unit Install the cage with springs. screwdriver and instal snap ring 10 ATSG), Technical Service Information 1989 LINE PRESSURE SPECIFICATIONS ide ‘Transmission 18 & WOT Stall ‘Trans, ‘Model/ Application Range Above 10" ‘Thru Detent AAD | 2.1 TPH Ranger D021 erica | 1ietoe 206286 R erisi | 18777 27804 PN 57-109 map | 2eveau 0,024 ar7e T4194 205286 Ranger (Be R sr1os | 157477 202.316 Aerostar PN 5778 AALD 2.3L Mustang D021 ST-47 90-110 180-210 R 6r77 124-144, (247-280 PN 8747 ‘ab nae SeeRETONS Teme i wear | wi Cacia ea Toon aegr Rano oan [Seat [are Tainan Bo sion | at Gor Anes cry | 9508 | er Gav Fowry vows | waai7 | Ee Gar tome e w tw sae | SET] TH Comrw Hone [neon had Soeeageeme fae | ae ia a area | ie ‘Ovecve Band Aang josie | A7S810 | S45 ‘Conair Housing and Pump to Case ees | 88 Case oa or aya a aa [ie ‘awri Bneai avn | TeTG | Be Sow tT cae oo [ ae Stee Ei aigh Gar [es |e Snare eal iaag a —[arer a] canna a Gal Gar Gece nae oe on va aaa arar air ie wGareew= tani] ware] ee Sipe Pa ai war} ae] Seale Cee em, ar Sergey eo | ae seats {UTOUATE TRANSMISSION AEFLL CAPACITY AAO a Tara Rl SR vse fe wow Ta aaa a Farge Za 2a 7 Bowe fo 2a 7 Re zac ‘80 48 eprint iy capaci, ee coe ard os FL lvl nai DOOM eds Getone Aca egavonei a Rad spe ‘Che nel tral opr tomperatse 00 NOT OVERFL. ite isrmcessry fo ao place Rts neon his whch hve bee eed by he sole as resng one ole Fars Mar Conoaryspecteaons Pombo "SAAC warrasen — Use ce masing scecieten Motrat MERCON WSPAUCIESA sus soee sreomcanons wanisee | Soar Vere septeon agen | To = ei a 7d | “To be fre aa nao | 0 ee aa io | “oe tet | Eo Caeeiaeeaee 23 MLD 1-1 inches 27 233 Ti Information Technical Service None Samp] Taramlaton Fo ng Piay| Part Naber icmees mm ny | “On waster Ciseat a ToT 7OOH 72 tout A paras ny OT TOOTAA 14 oss) + OT TOCA 16 0069) z ‘SOF 7OOH-CA 17 0.087) 3 OT. 7OOVDA GoM a OT TOOTEA 18.073) = SOT 7OOTFA 20 (ora, = 507 7OOV-GA Zi nes) 7 ‘BOTTDONEMA 22 (oe, 2 SOTTO 2a (ose) < 907 7OEKA 28 (10 3 SGOT TOOT 2a (0) = Te «Tr Wan GO| Ynsruion ew En Pay Cora Seat ose (012.02) ‘CLUTCH PLATES Formed Ch Reveraigh Guch ioe = Fete cores = eto Soares Peers 3 5 065-508 i = asim 2a 5 5 0065-5089 5 3 3081078 30k FI 5 5 0085.06 5 5 20s 3078 2 € . 0055.63 . . ouera078 exs wo AONSTHENTS ‘Gros c— — noe oo Fon Games] [rere Bert [asec ars) 22 A 2 ‘aowoacer || Tava Py a _| 0-5 wn (OTRO 200 EF ‘ere rt veda Bud] Fema ad ene 300cF z Z coasaceT —_}| Rican ea nose Tyson ao. 3 3 28-0087 Serotec ome ta Gaaawesale arm tt tener a ve ‘trai ad Hs VACUUM DUPHRAGM ASSEMBLY SPECIRCATION Bees ym Thala Vale Ros ‘Tomascn | Dagan boy Par Tie “io ey ang ‘canteen 7B SO__|_BOTISTIOBOG | esoTaA Te Saecion Nee 0] ROT aTrACSANB | eSGTAA wo. ROTIARTAGA TAA ‘S30 — Sige frm Dapp NiO — tr Ate Daatacre TORGUECOWERTER OOO-PLAY Cone Ea Pay ee Theo Rai Convair eed Convair ny = a a = aD Daa ew Tz Be wa SELECTIVE UP NGS. ‘Overs And ReversFigh Chach Forward Gch Ties | Diane ct J Pat amber Ton [ tctee | mm | bcs | Pat mer van [ete | mm] ch Fates tar | ose [sor | sr [eens var] case [ss] ase Eos 13 _| oan [toon | sz | eeames 173] eet [yas | ass eos: 2ce | ose | oor | sre Te eons 206 [ome | ras | ase Esa u_| coer | 1901] sae Le mones eee [ove | as | ames ‘Automatic Transmission Service Group m2

You might also like