Professional Documents
Culture Documents
The transmission fluid is water FLUID LEAKAGE along the drive hub and onto the
cooled; check the fluid lines and fit- CONVERTER AREA back of the impeller housing. Ex-
tings between the transmission and In diagnosing and correcting fluid cept in the case of a total seal fail-
the cooler in the radiator tank for leaks in the front pump and con- ure, fluid leakage by the lip of the
looseness, wear, or damage. If verter area, use the following pro- seal will be deposited on the inside
leakage cannot be stopped by tight- cedures to facilitate locating the of the converter housing only, near
ening a fitting, replace the defective exact cause of the leakage. Leakage the outside diameter of the housing.
parts. at the front of the transmission, as 2. Fluid leakage by the outside
Check the engine coolant in the evidenced by fluid around the con- diameter of the seal and front pump
radiator. If transmission fluid is verter housing, may have several body will follow the same path as
present in the coolant, the cooler sources. }Jy careful ob~ervation, it leaks by the front pump seal or may
in the radiator tank is probably leak- is possible, in many instances, to run down the face of the front pump.
ing. pinpoint the source of the leak be- 3. Fluid that leaks by a front
The cooler can be further checked fore removing the transmission from pump and converter housing to case
for leaks by disconnecting the lines the car. The paths which the fluid bolts will be deposited on the inside
at the cooler fittings and applying takes to reach the bottom of the of the converter housing only. Fluid
5 psi air pressure to the fittings. The converter housing are shown in Fig. will not be deposited on the back
radiator cap must be removed when 1. of the converter.
making this check to relieve the 1. Fluid leaking by the front 4. Leakage by the front pump to
pressure on the exterior side of the pump seal lip will tend to move case and a-ring seal may cause fluid
cooler. If the cooler is leaking and
will not hold this pressure, the radi-
~,,~
ator must be replaced. The cooler
':":'C;"';"""
cannot be replaced separately.
.If leakage is found at either the ~,{$~;:2,
throttle lever shaft or the manual ~~~~~;"f;,~,;i~.:~
,
lever shaft, replace either or both
seals.
Inspect the pipe plug in the case.
~,<i~~~:
"",.',,~'"
If the plug shows leakage, torque
the plug to specification. If tighten-
ing does not. stop the leaks, replace
the plug.
On a C6 transmissior. the TV
pressure port plug on the right rear
side of the case must also be in- j,~I~~~~gf;\~~~:4~~it~;
spected.
When converter drain plugs leak,
remove the two drain plugs with a
:\\' i
six-point wrench. Coat the threads .FRONT PUMP
,
with FoMoCo Perfect sealing
Compound or its equivalent, and in:'
FRONT PUMP
stall the plugs. Torque the drain AND CONVERTER
plugs to specification. Fluid leakage HOUSING TO
from the converter housing may be CASE BOLT LEAK
~
PART 7-1 GENERALTRANSMISSIONSERVICE 7-3
to be deposited on the outside lower from the engine or transmission. of the flywheel, back of the block
part of the converter housing as Unless a considerable amount of (in as far as possible), and inside
shown in Fig. 1. make-up fluid has been added or the converter housing (Fig. 1). Run
5. Fluid leakage from the con- the fluid has been changed, the red the engine until fluid leakage is evi-
verter drain plugs will appear at the color should assist in pinpointing the dent and the probable source of leak-
outside diameter of the converter. leak. age can be determined.
Engine oil leaks are sometimes Since road draft may causeleaking
CONVERTER LEAKAGE CHECK
improperly diagnosed as front pump valley cover oil to be present on the
seal leaks. The following areas of transmission, this leakage, if present, During the above fluid leakage
possible leakage should also be should be eliminated before per- checks, if there are indications that
checked to determine if engine oil forming work on the transmission. the welds on the torque converter are
leakage is causing the problem: (b) Remove the converter lower leaking, the converter will have to
(a) Leakage at the rocker arm housing cover. Clean off any fluid be removed and the following check
cover (valley cover) may allow oil from the top and bottom of the con- made before the unit is replaced:
to flow over the converter housing verter housing, front of the trans- A leak checking tool (Fig. 2),
or seep down between the con- mission case, and rear face of the can be made from standard parts.
verter housing and cylinder block engine and engine oil pan. Clean 1. Install the plug in the con-
causing oil to be present in or at the converter area by washing with verter (Fig. 3) and expand it by
the bottom of the converter housing. suitable non~flammable solvent, and tightening the wing nut. Attach the
(b) Oil gallery plug leaks will al- blow dry with compressedair. safety chains.
low oil to flow down'the rear face (c) Wash out the converter hous- 2. Install the air valve in one of the
of the block to the bottom of the ing, the front of the flywheel, and drain plug holes.
converter housing. the converter drain plugs. The con- 3. Introduce air pressure into the
(c) Leakage by the crankshaft seal verter housing may be washed out converter housing. Check the pres-
will work back to the flywheel, and using cleaning solvent and a squirt- sure with a tire gauge and adjust
then into the converter housing. type oil can. Blow all washed areas it to 20 psi.
Fluid leakage from other areas, dry with compressed air. 4. Place the converter in a tank
forward of the transmission could (d) Start and run the engine until of water. Observe the weld areas
cause fluid to be present around the the transmission reaches its normal for bubbles. If no bubbles are ob-
converter housing due to blow-back operating temperature. Observe the served, it may be assumed that the
or road draft. back of the block and top of the welds are not leaking.
The following procedure should be converter housing for evidence of ENGINE IDLE SPEED CHECK
used to determine the cause of leak- fluid leakage. Raise the car on a
hoist and run the engine at fast idle, Check and, if necessary, adjust
age before any repairs are made:
then at engine idle, occasionally the engine idle speed, using the pro-
(a) Remove the transmission dip-
stick and note the color of the fluid. shifting to the drive and reverse cedure given in Group 10.
ranges to increase pressures within If the idle speed is too low, the
Original factory fill fluid is dyed red
the transmission. Observe the front engine will run roughly. An idle
to aid in determining if leakage is
speed that is too high will cause
the car to creep when the trans-
mission is shifted into gear and will
3h2"STEEL PLATE HEX. HEAD SCREW
0/8" X 13/8", %"-24 X \12 cause rough transmission engage-
DISHEDOR DRILLTO SUIT ment.
FLAT WASHER
'~~#,,~~
13/4" O.D., 17132"
,~::~::~
HEX.NUT 3/8"-24
ANTI-STALL DASHPOT
CLEARANCE CHECK
WELD After the engine idle speed has
TOGETHER
been properly adjusted, check the
(()) '(0
. ,,' J"" 'IJ/
~ I@
~
~ PLUG
40 DUROMETER V2"-13 X 4V2"
LONG SQUARE
I
CHAIN, 10" LONG STANDARD , WELD TOGETHER THREAD
REMOVE END
HEAD
7-',.. '"
TIREVALVE SECURELY-MUST AND WELDTO "\ '---
NOT LEAK WASHER Tire Inflating Chuck
Tire Pressure Gauge
STANDARD FITTING-
- D1514-A
87971-8
VALVE D1067-A
FIG. 3-Typical Converterleak
FIG. 2-Converler leak CheckingTool Checking Tool
~
7-4 GROUP 7 - AUTOMATIC
TRANSMISSION
VACUUM DIAPHRAGM
D1643-A
FIG. 5-Vacuum Diaphragm and Control and TV Pressure Connecting FIG. 7-Testing Transmission
Points-C6 Transmission VacuumUnit for Leakage
PART 7-1 GENERALTRANSMISSIONSERVICE 7-5
sbifts and damage to the trans- formed to determine the exact cause and road speed over 30 mph, the
mission. of the trouble. transmission should shift to second
If the stall test speedsare 300 to gear when the selector lever is moved
STALL TEST 400 rpm below the specifications from D2 or Dl to L. The transmis-
Start the engine to allow it to shown in Table 3, and the car cruises sion will downshift from second or
reach its normal temperature. Apply properly but has very poor accelera- third to first gear when this same
both the parking and service brakes tion, the converter stator clutch is manual shift is made below approxi-
while making tests. slipping. mately 20 mph with a C4 transmis-
The stall test is made in D2, Dl, If the stall test speeds are 300 to sion or approximately 10 mph with
L, or R, at full throttle to check 400 rpm below the specified values, a C6 transmission. This check will
engine performance, converter clutch and the car drags at cruising speeds determine if the governor pressure
operation or installation, and the and acceleration is poor, the stator and shift control valves are function-
holding ability of the forward clutch, clutch could be installed backwards. ing properly.
reverse-high clutch and low-reverse Remove the converter and check During the shift check operation,
band and the gear train one-way the stator clutch as described in if the transmission does not shift
clutch. While making this test, do Cleaning and Inspection. within specifications or certain gear
not hold the throttle open for more When the stall test shows normal ranges cannot be obtained, refer to
than five seconds at a time. Then speeds, the acceleration is good, but the Diagnosis Guide to resolve the
move the selector lever to Neutral the car drags at cruising speeds, the problem.
and run engine at 1000 rpm for difficulty is due to a seized stator
about 15 seconds to cool the con- assembly. If the stator is defective, AIR PRESSURE CHECKS
verter before making the next test. replace the converter.
A NO DRIVE condition can
If the engine speed recorded by the exist, even with correct transmission
tachometer exceeds the maximum INITIAL ENGAGEMENT
fluid pressure, becauseof inoperative
limits specified in Table 3, release CHECKS
clutches, bands. The inoperative
the accelerator immediately because Initial engagement checks are units can be located through a series
clutch or band slippage is indicated. made to determine if initial band of checks by substituting air pressure
and clutch engagements are smooth. for the fluid pressure to determine
TABLE 3-Stall Speedlimits Run the engine until its normal the location of the malfunction.
operating temperature is reached. When the selector lever is at D2,
Engine Engine Trans- With the engine at the correct idle a NO DRIVE condition may be
Model Speed mission speed, shift the selector lever from caused by an inoperative forward
CID (rpm) Type N to D2, DI, L, and R. Observe clutch. A NO DRIVE condition at
the initial band and clutch engage- f D1 may be caused by an inoperative
170-1V 1450-1650 C4 ments. Band and clutch engagements forward clutch or one-way clutch.
200-1V 1600-1800 C4 should be smooth in all positions. When there is no drive in L, the
Rough initial engagements in DI, difficulty could be caused by im-
289-2V 1750-1950 C4 02, L, or R are caused by high en- proper functioning of the forward
289-4V 1800-2000 C4 gine idle speed or high control pres- clutch or low-reverse band and the
sures. one-way clutch in a C4, or the for-
390-2V 1750-1950 C6 ward clutch or low-reverse and one-
SHIFT POINT CHECKS
390-4V 1800-2000 C6 way clutches in the C6 transmission.
Check the light throttle upshifts in The low-reverse band in the C4
D I. The transmission should start in transmission and low-reverse in the
first gear, shift to second, and then C6 transmission cannot be checked
STALL SPEED TOO ffiGH shift to third within the shift points in L. If the low-reverse band or
If stall speed exceeds specifica- specified in the specifications section. clutch fails, the one-way clutch will
tions, band or clutch slippage is in- While the transmission is in third hold the gear train and operation
dicated, depending on transmission gear, depress the accelerator pedal will be normal except that there will
selector lever position. Excessive en- through the detent (to the floor). be no engine braking. Failure to
gine rpm only in DI, D2 and L indi- The transmission should shift from drive in reverse range could be
cates forward clutch slippage. Exces- third to second or third to first, de- caused by a malfunction of the re-
sive engine rpm only in R indicates pending on the car speed. verse-high clutch or low-reverse
either reverse-high clutch or low- Check the closed throttle down- band in the C4 transmission, or the
reverse band slippage in the C4 shift from third to first by coasting low-reverse clutch or the reverse-
transmission, and either reverse-high down from about 30 mph in third high clutch in the C6 transmission.
or low-reverse slippage in the C6 gear. The shift should occur within Erratic shifts could be caused by a
transmission. Excessive engine rpm the limits specified in the specifica- stuck governor valve.
only in DI indicates gear train one- tions section. To make the air pressure checks,
way clutch slippage. When the selector lever is at 02, drain the transmission fluid, and then
the transmission can operate only remove the oil pan and the control
STALL SPEED TOO LOW in second and third gears. Shift valve body assembly. The inoperative
When the stall test speedsare low points for second to third and third units can be located by introducing
and the engine is properly tuned, to second are the same in both 02 air pressure into the transmission
converter stator clutch problems are and DI. case passagesleading to the clutches,
indicated. A road test must be per- With the transmission in third gear servos, and JZovernor.
7-8 GROUP 7 AUTOMATIC
TRANSMISSION
FORWARD CLUTCH
Apply air pressure to the transmis-
sion case forward clutch passage
(Fig. 9). A dull thud can be heard
when the clutch piston is applied. If
no noise is heard, place the finger
tips on the input shell and again
apply air pressure to the forward
clutch passage. Movement of the
piston can be felt as the clutch is
applied.
GOVERNOR
Apply air pressure to the control
pressure to governor passage and
listen for a sharp clicking or whistl-
ing noise. The noise indicates sec-
ondary governor valve movement.
REVERSE-HIGH CLUTCH
Apply air pressure to the reverse-
high clutch passage (Fig. 9). A dull
thud indicates that the reverse-high
clutch piston has moved to the ap-
plied position. If no noise is heard,
place the finger tips on the clutch
drum and again apply air pressure to
detect movement of the piston.
INTERMEDIATE SERVO
FIG. 9-0il Pressure
Passage
Holes
Hold the air nozzle in the inter-
mediate servo apply passage (Fig.
LOW.REVERSE SERVO- DIAGNOSIS GUIDE
9). Operation of the servo is indi-
C4 TRANSMISSION
cated by a tightening of the inter- The Transmission Diagnosis
mediate band around the drum. Apply air pressure to the low-re-
Guide lists the most common trou-
Continue to apply air pressure into verse apply passage(Fig. 8). The low-
ble symptoms that may be found in
the intermediate servo apply pas- reverse band should tighten around
the transmission, and gives the items
sage, and introduce air pressure the drum if the servo is operating
that should be checked to find the
into the intermediate servo release properly.
passage. The intermediate servo cause of the trouble.
If the servos do not operate, dis-
should release the band against the assemble, clean and inspect them to The items to check for each
apply pressure. locate the source of the trouble. trouble symptom are arranged in a
If air pressure applied to any logical sequence which should be
LOW-REVERSE CLUTCH- followed for quickest results. The
C6 TRANSMISSION clutch passage fails to operate the
clutch or operates more than one letter symbols for each item are ex-
Apply air pressure to the low- plained in the Key to the Diagnosis
clutch at once, remove and, with
reverse clutch apply pressure pas- Guide.
sage. A dull thud indicates that the air pressure, check the fluid passages
in the case and front pump to detect If items A, B, C, D, E, and the
piston has moved to the apply po-
sition. If no thud is heard, apply obstructions. stall test have already been checked
air pressure again while holding the If the passagesare clear, remove during the preliminary checks and
palm of the hand on the exterior at the clutch assemblies, and clean and adjustments, they need not be re-
the rear of the case to detect clutch inspect the malfunctioning clutch to peated when following the Diagnosis
apply movement. locate the trouble. Guide.
transmission. Loosen and remove all 1. After installing a new or re- lines at the cooler and the cooler
but two of the oil pan bolts, from built automatic transmission and inlet line (converter out) to the
the front of the case and drop the converter assembly in the car, Do transmission.
rear edge of the oil pan to drain the Not Connect the Cooler Return line 9. Start the engine and check
fluid. Remove and thoroughly clean to the Transmission. Place the trans- the fluid flow. If the transmission
the oil pan and screen. Discard the mission selector lever in the P fluid flows freely, proceed with steps
oil pan gasket. (park) position and connect the 3 through 6. If there is no fluid flow,
2. Place a new gasket on the oil cooler inlet (converter out) line to check for pinched cooler lines. If
pan, and install the screen and pan the transmission. Place a pan under the flow is restricted, replace cooler
on the transmission. the end of the cooler return line that lines and/or the radiator.
3. Add three quarts of fluid to the will hold transmission fluid. Do Not 10. Shut off the engine, and con-
transmission through the filler tube. Start the Engine. nect the cooler return line to the
4. Run the engine at idle speed for 2. Install 5 quarts of automatic transmission. Check the transmission
about two minutes. Check the fluid transmission fluid meeting Ford fluid level as indicated under head-
level, and add fluid if necessary.Run Specification. ing Transmission Fluid Level Check.
the engine at fast idle speed (about 3. Start the engine and allow it Add or remove transmission fluid as
1200 rpm) until it reaches its nor- to run at normal idle speed for 3 required until the proper fluid level
mal operating temperature. Do not minutes with the selector lever in is obtained on the dipstick. DO NOT
race the engine. P (park) position. Stop the engine OVERFILL THE TRANSMIS-
5. Shift the selector lever through and add additional transmission fluid SION.
all the positions, place it at P, and required to complete total fill. Start 11. Do not attempt to correct
check the fluid level. If necessary, the engine and allow it to run at cooler or cooler line leaks by closing
add enough fluid to the transmission normal idle speed. off the lines.
to raise the level to the F (Full) 4. Allow approximately two
mark on the dipstick. Do not overfill quarts of transmission fluid to drain OIL COOLER TUBE
the transmission. into the pan placed under the end REPLACEMENT
of the cooler return line. When fluid leakage is found at
OIL COOLER FLUSHING 5. If the fluid does not run clean the oil cooler, the entire radiator
PROCEDURE after draining two quarts of it must be replaced. The oil cooler
When a clutch or band failure or through the cooler, shut off the en- cannot be removed from the radia-
other internal trouble has occurred gine and add two additional quarts tor for replacement.
in the transmission, any metal par- of transmission fluid. When one or more of the fluid
ticles or clutch plate or band mate- 6. Repeat steps 3 through 5 until cooler steel tubes must be replaced,
rial that may have been carried into the transmission fluid flowing out each replacement tube must be fabri-
the cooler should be removed from of the cooler return line is clean. cated from the same size steel tubing
the system by flushing the cooler 7. If there is no fluid flow or the as the original line.
and lines before the transmission is fluid does not flow freely, shut off
put back into service. In no case Using the old tube as a: guide,
the engine and disconnect both
should an automatic transmission cooler lines from the transmission bend the new tube as required. Add
having a clutch or band failure or and cooler. the necessary fittings, and install the
other internal trouble resulting in 8. Use an air hose with not more tube.
fluid contamination, be put back into than 100 psi air pressure to reverse After the fittings have been tight-
service without first flushing the flush the cooler lines and the cooler. ened, add fluid as needed, and check
transmission oil cooler. After reverse flushing, connect both for fluid leaks.
Torque Wrench
Torque Wrench
Tool-T59p.7902.8 or 7937.8
Metal Ring
Too/-T63P-7902-A
TURBINEHUB
T001- T64L- 7902-A
(4-(6 TRANSM5SION
STATOR CLUTCH CHECK
D 1516-C
and install them in their normal run- be installed,soak them in automatic planet assemblies should be checked
ning position in the clutch drum. transmissionfluid for at least 15 min- for loose fit and/ or complete dis-
Then check the ring gaps. This ring utes before assemblingthem in the engagement. Replacement, using a
gap clearance should be between clutch drum. This soakingprevents new planet assembly, should be
0.002 and 0.009 inch. damage to the plates during the made if either condition is found to
4. Inspect the input shaft bush- transmissionfluid fill period and in- exist.
ings in the stator support shaft for itial running-in. 2. Inspect the pinion gears for
wear. 2. Inspect the steelclutch plates. damaged or excessively worn areas.
Check the oil ring grooves in the These clutch plates should also be 3. Check for free rotation of the
stator support for nicks, burrs or flat. If they are not flat, they should pinion gears.
damaged edges. Check the gasket be replaced. 4. Inspect the C4 transmission
mating surface of the pump body for 3. Inspect the clutch release front planet thrust surface for ex-
damaged surface. springs for being broken or dis- cessive wear.
5. Inspect the converter pump torted.
drive hub bushing in the front pump SERVO-ASSEMBLIES
housing. Inspect the pump seal in the
4. Inspect the clutch piston ball 1. Inspect the servo piston and
pump housing for defects that would
check valve for free movementand seals for defectsthat would cause
proper seating.Make surethe orifice
cause fluid leakage.
in the clutch piston is open. hydraulic leakage.
2. Inspectthe cover seal and gas-
GOVERNOR 5. Inspect the clutch drum bush- ket cover sealingsurfacefor defects.
1. Inspect the governor valves ing for wear.
and housing for wear. Crocus cloth CASE
may be used to polish the valves CONTROL VALVE BODY 1. Inspect the case for cracks.
if care is taken to avoid rounding 1. Inspectall valveand plug bores 2. With an air hose,checkall fluid
the sharp edges. for scores.Check all fluid passages passagesfor obstruction or cross
2. Install the governor valves in for obstruction. Inspect the check leakage.
the governor housing and check valvesfor free movement.Inspectall 3. Checkall caselinkagepartsfor
them for free movement. Each valve mating surfacesfor burrs or distor- free travel and proper engagement.
should fall of its own weight when tion. Inspectall plugs and valvesfor 4. Check the vent passagefor
dry. burrs and scores.Crocus cloth can obstructionswith an air hose.
be usedto polish valvesand plugsif
CLUTCH ASSEMBLY care is taken to avoid rounding the ONE-WAY CLUTCH
1. Inspect the composition clutch sharpedgesof the valvesand plugs. 1. Inspect the outer and inner
plates for damage. These plates 2. Inspect all springs for distor- racesfor scoresor darnagedsurface
should be fiat. If the plates are not tion. Check all valvesand plugs for area where the rollers contact the
fiat, they must be replaced. If the free movement in their respective races.
old plates are to be re-used, they bores. Valves and plugs, when dry,
must not be cleaned in a vapor de- must fall from their own weight in 2. Inspect the rollers and springs
greaser or cleaned with any type of their respectivebores. for excessivewear or darnage.
detergent solution. Wipe them clean 3. Inspect the spring and roller
with lint-free towels. PINION CARRIERS cage for bent or darnagedspring
If new composition plates are to 1. The pins and shafts in the retainers.
7-15
C4 AUTOMATIC
DUAL RANGE TRANSMISSION
Section Page Section Page
1 Description and Operation Low-Reverse Servo Piston Replacement. . . . . . .7-32
Description 7-15 Extension Housing Bushing and Rear
Operation 7-15 SeaIReplacement 7-32
Extension Housing and Governor Replacement.7-32
2 In-Car Adjustments and Repairs
Control Linkage Adjustments. . . . . . . . . . . . . . . .7-24 3 Removal and Installation
Throttle and Downshift Linkage Adjustments. . .7-24 Removal 7-33
Manual Linkage Adjustment. . . . . . . . . . . . . . . . .7-28 Installation 7-33
Neutral Start Switch Adjustment. . . . . . . . . . . . .7-30
Neutral Start Switch Replacement 7-31 4 Major Repair Operations
BandAdjustments 7-31 Disassembly of Transmission. . . . . . . . . . . . . . . . .7-34
Oil Pan and Control Valve Body Replacement.. 7-31 Parts Repair or Replacement. . . . . . . . . . . . . . . . .7-38
Intermediate Servo Repair. . . . . . . . . . . . . . . . . . .7-31 Assembly of Transmission. . . . . . . . . . . . . . . . . . .7-47
I SLEEVE SEAL
LOW-REVERSEDRUM { ONE.WAY
\.i CLUTCH OJTPUTSHAFT
:
GOVERNOR
FORWARDCLUTCH
!1!.. I HUB AND RING GEAR
INPUT I;:-BUTOR ~~
~ SHELL ~
" .
SPLINE SEAL
EXTENSION
~
HOUSING
. --~~..~ ..
t-
~ '>RIVE GEAR
\~(
\rf' GOVERN~:
\~
\
. _ANET CARRIER
PLANET CARRIER
\:
~~
!'. ,-.
T',c
," ," '
~!
.. REVERSE-HIGH CLUTCH
STATOR . Ca-ITROL VALVE
IWEL1-ER
. BODY
,
D 1474-A
Reverse-High Clutch. When hy- return spring to tighten the inter- expands to release the piston and the
draulic pressure is directed to the mediate band around the reverse- low-reverse band.
clutch piston, the piston moves high clutch drum.
against the release springs (Fig. 4). To release the servo piston, hy- POWER FLOW
The piston movement locks the steel draulic pressure is directed to the re- All Gear Rotations are viewed
and rotating composition clutch lease side of the piston. The release from the front of transmission. Table
plates together. The steel clutch pressure is assisted by the com- 2 shows the gear ratios obtained in
plates drive the reverse-high clutch pressed return spring to move the the different selector lever positions.
drum which is splined to the input servo piston and intermediate band Power Flow Neutral. In neutral
shell. Rotation of the input shell to the OFF position. The interme- (Fig. 7) the clutches or bands are
drives the sun gear which is splined diate servo and band are applied only not applied, therefore, no power is
to the input shell. during the intermediate gear oper- transmitted to the output shaft.
To release the reverse-high clutch, ation. Power Flow First Gear. In low
hydraulic pressure is exhausted from Low-Reverse Servo and Band. gear (Fig. 7), the forward clutch is
the apply side of the piston. The re- The low-reverse servo is machined applied, and the planet one-way
turn springs move the piston to the into the transmission case and the clutch or low-reverse band is holding
released position. The steel and com- band has an external adjustment the low-reverse drum and reverse
position clutch plates are now re- screw (Fig. 6). To apply the servo, planet carrier from rotating. The
leased to stop rotation of the reverse- hydraulic pressure is directed from power flow is through the input
high clutch drum, input shell and the control valve body through a shaft and into the forward clutch.
sun gear. hole in the case to a hole in the The input shaft is splined to and
InteTDlediate Servo and Band. The piston stem. The pressure then drives the forward clutch cylinder.
intermediate servo is machined into passes through the center of the Rotation of the forward clutch
the transmission case and the band piston stem to the apply area of the drives the forward clutch hub and
has an external adjustment screw servo piston. The apply pressure ring gear. The ring gear rotates the
(Fig. 5). To apply the servo, hy- force moves the piston against the forward planet gears clockwise to
draulic pressure is directed from the piston return spring to tighten the cause the sun gear to rotate counter-
control valve body, through a hole in low-reverse band around the low- clockwise.
the case to the hole in the servo reverse drum. Counterclockwise rotation of the
piston stem. The pressure passes To release the servo piston and sun gear turns the reverse planet
through the center of the piston stem band, the hydraulic pressure is ex- gear clockwise. The reverse planet
and then to the apply side of the hausted from the apply side of the carrier being splined to the low-
piston. The piston moves against the piston. The compressedreturn spring reverse drum is held from rotating
7-18 GROUP 7 AUTOMATIC
TRANSMISSION
the power flow through the input In addition, fluid is also directed manual linkage according to mode
shell to the sun gear. With the sun to the primary throttle valve, which of operation desired, to direct fluid
gear and the forward clutch hub ring is located in the rear of the case. out of two or more of the line
gear driven at the same speed the Fluid delivered to these valves is at passageswhich lead from the manual
forward planet assembly (that is a pressure controlled by the main valve. The five passages (Fig. 8)
splined to the output shaft) is forced oil pressure regulator valve. leading from the manual valve (from
to rotate the output shaft at the same Main Oil Pressure Regulator left to right) are:
speed and direction to provide high Valve. The main regulator valve 1. D2
gear. assembly consists of the main oil 2. Dl
Power Flow Reverse. In reverse pressure regulator valve and spring, 3. D
(Fig. 7), the reverse-high clutch and retainer, main oil pressure booster 4. L-R
low-reverse band are applied. The valve, spring and sleeve, located 5. R
power flow is through the input in one bore in the main control The D2 passageis chargedin D2
shaft, reverse-high clutch, input shell assembly (Fig. 8). range only.
and to the sun gear. Clockwise rota- Fluid is delivered to three valleys The Dl passageis chargedin D2
tion of the sun gear causescounter- of the main regulator valve, from the and Dl ranges.
clockwise rotation of the reverse front pump. The difference in diam- The D passageis charged in all
planet gears. eter between the end land and the forward ranges, (including manual
The low-reverse band, holding the second land provides an area differ- low).
low-reverse drum and reverse planet ential for regulation. Fluid pressure The L-R passageis chargedin L
carrier from turning, causes the re- in this area tends to move the valve and R ranges.
verse planet gears to rotate counter- against spring force. Spring force is The R passageis chargedin re-
clockwise. such that at approximately 60 psi verse range only.
This rotates the reverse ring gear front pump pressure, the main valve In Park and Neutral the valve
and hub counterclockwise. The hub will move so that the third land un- blocks the flow of control pressure
splined to the output shaft rotates covers .the converter feed port, al- and exhauststhe five passageslead-
the output shaft counterclockwise at lowing additional pump volume to be ing from the manual valve.
a reduction in speed and at an in- used to charge the converter. If vol- The D passagesuppliesfluid pres-
crease in torque for reverse gear. ume supplied by the front pump is sure to the governor secondary
greater than that required to main- valve, D2 valve and forward clutch.
HYDRAULIC CONTROL tain 60 psi line pressure, and con- The D2 passage supplies fluid to
SYSTEM verter and lube requirements, the the adjoining ends of the D2 and 1-2
shift valves. '
The hydraulic system described be- valve will move further allowing the
low (Fig. 8) includes all models. fourth land to uncover the port The D 1 passagesupplies fluid to
Front Pump. Fluid for operation which allows excesspump volume to the 2-3 shift valve.
of the hydraulic control system is be discharged into the sump. the Land R passage supplies
supplied by one gear type pump Pressures over 60 psi which are fluid to the lower end of the inter-
mounted on the front of the trans- required under various operating mediate band accumulator valve,
mission case. Pump intake is through conditions are obtained by delivering end of the manual low valve, through
a screen which is part of the main fluid under pressure to the pressure the downshift valve, to and through
control assembly, into the case cast- booster valve, where it will cause the throttle modulator valve bore,
ing and pump. Discharge is through the pressure booster valve to assist under the 2-3 shift valve and to the
the case into the main control as- the main regulator valve spring in in- underside of the first land of the
sembly. Fluid from the front pump creasing regulated line pressure. 1-2 shift valve.
is directed to the following valves in Source of these pressures which In addition, fluid is supplied to the
the main control assembly: cause variations in control pressure D2 valve and through the valve
Main Oil Pressure Regulator are discussed later. when it is in the closed (up) position,
Valve Manual Valve. Two passagesde- to the Low and Reverse Servo, ap-
Throttle Booster Valve liver control pressure to the manual plying the low and reverse band. The
Manual Valve valve. The valve is positioned by the same fiuid is also directed to the
7-20 GROUP 7 - AUTOMATIC
TRANSMISSION
SECOND GEAR
OUTPUT SHAFT
HIGH GEAR
D1476-A
FIG. 7-PnwPcr Flnw
PART 7-2 - C4 AUTOMATIC
DUALRANGE
TRANSMISSION 7-21
\\\-.
~~
REVERSE
INTERMEDIATE ~ ~ lOW ANO
AND
DIRECT SERVO I REVERSE
SERVO SECONDARY
CLUTCH GOVERNOR
ON
- -..
VALVE
~tON=-
VERTER
PRESSURE
RELIEF
-
,VALVE <::k=== ,-- VALVE
-
GAUGE r-
I CON-
NECTION
~-~
1-2 SHIFT
SERVO VALVE
CHECK THROTTLE
02 VALVE - - --
VALVE
VALVE EXHAUST
INTER-
MEOIATE
BAND ~ ~
ACCUMU- "',.~. ._-
LATOR BOOST VALVE
VALVE
\'
DOWNSHIFT
VALVE
- ~ - MANIFOLD VACUUM
DE -' PRIMARY...
1
SUMP
~~
I PRESsUiE-
BOOSTER
VALVE
-
"Dl
THROTTLE VACUUM
VALVEICASE)DIAPHRAGM
~ ~~~
~
I I
-'
PRND,D,L LoR
D lS89-A
spring end (opposite governor) of the Governor move the primary governor valve in,
D2 valve. AT REST (0 MPH). Control pres- closing the line leakage exhaust port
The R passage supplies fluid to sure (line) is fed to the secondary at the primary valve. Pressure in the
the middle valley of the pressure line leakage passage will become
governor valve through the center
booster valve, through the 2-3 shift equal to line pressure, forcing the
passage in the valve body. Because
valve to the reverse and direct clutch, of the differential in area of the secondary governor valve in. This
applying it, and to the release side of inner and outer lands of the valve, action shuts off line pressure feed
the intermediate servo. Fluid is also the valve will be forced inward, to the governor passageand exhausts
supplied to the end of the 2-3 back- shutting off line pressure feed to the the governor circuit.
out valve, and to the intermediate When the secondary governor
governor passage and allowing this
band accumulator valve. valve is regulating, governor pressure
passageto be opened to exhaust, at
Primary Throttle Valve. The pri- will be delivered to the cut-back
the inner end of the valve. At the
mary throttle valve is actuated by valve, end of the 2-3 shift valve and
same time, line pressure will pass
changes in manifold vacuum. Pri~ by two flats on the outer end of the the 1-2 shift valve. Figure 10 shows
mary throttle pressure starts at 20" valve, pressurizing the line leakage th(; r:.lationship between governor
(nominal) of mercury vacuum. Pri- pres,ure and output shaft RPM.
passage leading to the primary gov-
mary throttle pressure is delivered ernor valve. At rest, the spring on "1brottle Booster Valve. Throttle
to the: plate openings above 50° provide
the outer end of the primary gov-
1. End of the pressure booster very little change in engiBe vacuum
ernor valve holds the primary gov-
valve. as compared to throttle plate open-
ernor valve inward, blocking further
2. Upper valley of pressure boost- ings below 50°. The throttle booster
flow of the fluid in the line leakage
er valve (through cutback valve). valve is provided to boost throttle
passage. This causes pres"ure in the
3. Downshift valve and throttle pressure and provide the necessary
line leakage passage to build to me
modulator valve (through throttle same value as line pressure. A$ a shift delay for engine throttle plate
booster valve). consequence,the secondary governor openings above 50°.
4. End of the throttle booster Below approximately 60 PSI
valve is held in and there is no pres-
valve. sure in the governor circuit. primary TV pressure, TV pressure
5. Spring end of the 2-3 back-out flows to and through the throttle
ABOVE 10 MPH. When vehicle
valve and manual low valve. Figure boost valve unaffected, working on
speedreachesapproximately 10 mph,
9 shows how primary throttle pres- the end of the boost valve and on
centrifugal force on the primary
sure varies with engine vacuum. the area differential on the spring
governor valve overcomes spring
Pressure Booster Valve. T.V. pres- side of the boost valve. As a con-
force, and the valve moves outward,
sure is delivered to the upper valley opening the line leakage passage sequence, TV pressure passes
of the pressure booster valve and through the throttle boost valve un-
to exhaust. This action reduces the
to the end of the pressure booster affected.
pressure on the end of the secon-
valve. When force created on the When TV pressure increasesabove
dary governor valve to zero (0),
booster valve by T.V. pressures in 60 psi, the force created by TV
allowing the secondary valve to also
these two areas exceeds pressure move outward, due to spring force pressure acting on the end of the
booster valve spring force, the force and centrifugal force. When the sec- throttle boost valve, minus the force
will be added to the main regulator ondary valve moves outward, it of TV pressure acting on the area
valve spring force transmitted to closes the governor exhaust passage, differential on the spring side, will
the main regulator valve. This will and allows line pressure to enter the exceed the force of the spring. This
provide increased control pressures governor passage.As pressure builds causes the valve to move against the
required to compensate for increased in the governor passageit will create spring, closing off primary TV pres-
throttle openings and engine torque a force on the secondary governor sure to the area differential on the
output. Figure 9 shows how control valve due to the differential in areas spring side and permitting this area
pressure varies with engine vacuum of the inner and outer lands of the to be fed from line pressure, causing
at 0 output shaft rpm. valve. This force tends to move the a boost in the pressure used for shift
valve inward. When the force on the delay only. Because the area of the
valve created by pressure in the
governor passage exceeds the cen-
trifugal force plus spring force, the
valve will move inward, allowing
governor pressure to exhaust, and
close the passage between line pres-
sure and governor pressure. When
-' 100
governor pressure is reduced, the
vi
secondary valve will again move out- n. 60
ward, closing the governor exhaust
- - - -
20 0 port and opening the line pressure
15 10 5
to governor passage.Above 10 mph, ~ I [, I I I I .
MANIFOLD VACUUM
0 5 10 15 20 25 30
governor pressure is regulated in this
manner, and will vary with vehicle OUTPUTSHAFTRPMx 100 DI5S9-A
D1558.A
speeds.
FIG. 9-Throttle Pressure If vehicle speed drops below J0 FIG. 10-Governor Pressure
Regulation mph, the primary valve spring will Regulator
PART 7-2 C4 AUTOMATICDUAL RANGETRANSMISSION 7-23
end of the throttle boost valve ex- the D2 valve is moved downward the throttle modulator valve is held
ceeds the area differential on the D fluid is exhausted from the differ- down cutting off modulated throttle
spring side by 21/2 to 1, throttle ential in areas provided by the lower pressure to the 2-3 shift valve and
boost pressure above 60 psi primary two lands of the D2 valve. This ac- 1-2 shift valve. In addition, the
TV pressure will increase 2.5 psi, tion eliminates the force created by port which delivered D1 fluid to the
per 1 psi primary TV. D fluid which tends to hold the 1-2 differential in area of the shift valve
TV pressure from the throttle shift valve train closed. lands, is closed.
booster valve is delivered to the If governor pressure is reduced to The shift valve will be reopened
downshift valve and throttle mod- the point where spring force and (moved up) causing a downshift
ulator valve. modulated throttle pressure force under one or more of the following
Figure 9 shows the relationship exceeds governor pressure force, the conditions:
between primary TV pressure and 1-2 shift valve train will move up GOVERNOR PRESSURE RE-
boosted throttle pressure. (close) cutting off the flow of D DUCED. If governor pressure is re-
Throttle Modulator Valve. The fluid through the valve and opening duced to the point where it can no
throttle modulator valve, located in the exhaust port allowing a down- longer hold the shift valve down
the end of the 2-3 shift valve bore shift to low gear. against spring force and TV pres-
reduces throttle pressure which acts If the throttle is open to the point sure force, the valve will move up
on the ends of the 2-3 shift valve where modulated throttle pressure causing a downshift. Under closed
and on the area differential of the acting on the 1-2 shift valve plus the throttle conditions, the 2-3 shift
1-2 shift valve. Modulated throttle 1-2 shift valve spring force creates valve will close at approximately 10
pressure in these areas provides shift a force greater than that provided mph (speed at which governor pres-
delay in relation to throttle opening. by governor pressure, the 1-2 shift sure is cut off). Since governor
Cut Back Valve. Increased line pres~ure is cut off at this speed the
valve train will be closed, providing
pressure is required to prevent clutch a torque demand downshift to low. 1-2 shift valve train also closes at
and band slippage under stall condi- If the throttle is open through the same time. This will provide a
tions. Dependent upon car speed, detent, the downshift valve moves to 3-1 downshift when coasting in D1
the requirements for increased line allow boosted throttle pressure to range.
pressure are considerably reduced. enter the modulated throttle pres- THROTTLE PRESSURE IN-
When governor pressure acting on sure passage at the 1-2 shift valve CREASE. If throttle pressure is
the end of the cutback valve exceeds to provide a forced 2-1 downshift. increased sufficiently, it will move
the force of TV pressure acting on the throttle modulator valve and
L RANGE. In L range L-R fluid
its area opposing governor, the cut- consequently the 2-3 shift valve up,
enters the modulated throttle pres-
back valve will move cutting off causing a 3-2 torque demand down-
sure passage to provide a manual
primary TV pressure being fed to shift.
low downshift to first gear. Once
the upper valley of the pressure THROTTLE PRESSURE IN-
the transmission is in low gear L-R
booster valve. This action reduces TRODUCED BELOW 2-3 SHIFT
fluid, which is directed to the D2
the assist that the pressure booster VALVE. If the downshift valve is
valve, passes through the D2 valve
valve provides to the main regulator moved through detent, boosted
and is delivered to the spring end
valve spring. The cutback valve throttle pressure is directed to the
of the D2 valve preventing an up-
movement will therefore vary with undersize of the 2-3 shift valve,
shift. L-R fluid which passesthrough forcing the valve up and causing a
engine throttle opening and car the D2 valve also applies the re-
forced 3-2 downshift. Maximum 3-2
speed. verse and low servo. forced downshift speed is controlled
1-2 Shift Valve Train. The 1-2 D2 RANGE. In D2 range, D2 fluid
shift valve train is composed of the is introduced between the 1-2 shift by governor pressure.
1-2 shift valve, the D2 valve, and and D2 valves. This action opens EXHAUSTING D1 FLUID
the 1-2 shift valve spring. the D2 valve and holds it open, pro- FEED TO THE 2-3 SHIFT
D-l RANGE. In Dl range the viding a second gear start and pre- VALVE. If manual valve is moved
1-2 shift valve is held closed (up) by venting a 2-1 downshift. to L range, the D1 passage which
modulated throttle pressure acting 2.3 Shift Valve. The 2-3 shift feeds oil to the 2-3 shift valve will
on the differential area between valve is held closed by throttle mod- be opened to exhaust allowing di-
the two lands of the 1-2 shift ulator valve spring force, modulated rect clutch apply-intermediate servo
valve, by D fluid' pressure acting throttle pressure force, and by DI release fluid to exhaust, permitting
on the differential in area be- fluid pressure force acting on the the intermediate band to apply,
tween the two lands at the spring differential in area of the lands of causing a 3-2 downshift.
end of the D2 valve, and by the the valve to which it is delivered. 2-3 Back-Out Valve. The purpose
1-2 shift valve spring. Governor Governor pressure tends to open of the 2-3 back-out valve is to pro-
pressure tends to move the 1-2 shift the 2-3 shift valve. When force vide smooth upshifts, when the
valve train against these forces. created by governor pressure exceeds throttle is suddenly closed while
When force created by governor the forces holding the valve closed, accelerating in second gear. Opera-
pressure exceeds the forces holding the valve will move downward (open) tion is as follows:
the 1-2 shift valve train closed, the closing the exhaust passage(through NORMAL THROTTLE-ON 2-3
1-2 shift valve and D2 valve will be the manual valve) and opening the UPSHIFTS. When the 2-3 shift
opened (moved downward), closing D1 passage to allow Dl fluid to valve moves to cause a 2-3 upshift,
the exhaust port and allowing D apply the reverse-high clutch and D 1 fluid passesthrough the valve to
fluid to pass through the D2 valve release the intermediate servo. apply the direct clutch and release
to accomplish the 1-2 shift. When With the shift valve open (down) the intermediate servo. This same
7-24 GROUP 7 - AUTOMATIC
TRANSMISSION
fluid is also directed to the end out valve will be moved up the fluid which is trapped in the inter-
of the 2-3 back-out valve. However, instant that pressure drops in the mediate servo release passageto be
with throttle open, primary throttle direct clutch apply-intermediate pressurized. This pressure acting on
pressure on the opposite end of the servo release circuit, when a shift the area differential of the interme-
2-3 back-out valve, assists spring to manual low range is made or a diate servo accumulator valve will
force in holding the valve up, so forced downshift is made, from high cause the accumulator valve to move
that there will be no valve move- gear. This is accomplished by di- against its spring to exhaust, to
ment until after the 2-3 shift has recting control pressure to the end maintain a certain level of pressure
been completed. of the manual low valve, when L on the release side of the inter-
BACK-OUT 2-3 UPSHIFTS. range is selected or, by directing mediate servo until it has completely
When the throttle is closed during a TV pressure to the end of the man- stroked, applying the band. Force
2-3 upshift, and before the shift is ual low valve, when the downshift created by this pressure on the re-
completed, there may be enough valve is moved to the downshift lease side of the servo, plus spring
pressure in the direct clutch cylinder position. force, is subtracted from the force
to apply the clutch at the reduced Intennediate Band Accumwator of control pressure acting on the
engine torque input, but not enough Valve. The intermediate band ac- apply side of the servo, thereby con-
pressure to release the intermediate cumulator valve train is composed of trolling the servo apply force during
servo. This condition could cause a the intermediate band accumulator any condition requiring the inter"
harsh 2-3 shift. However, if the valve and spring. The intermediate mediate band to be on in DI or D2
throttle is closed during a 2-3 shift, band accumulator valve train in con- ranges.
primary throttle pressure will be junction with the intermediate servo (LOW RANGE) (3-2 DOWN-
reduced to zero (0), and reverse and check valve controls intermediate SHIFT). Low and reverse pressure
direct clutch apply pressure on the servo apply force on all applications acting on the end of the intermediate
end of the 2-3 back-out valve will of the intermediate band, under all servo accumulator valve will move
move the valve down against spring operating conditions, in D1 and D2 the valve against the accumulator
force. This action immediately con- ranges. In low range the intermediate valve spring to insure that the fluid
nects the clutch apply circuit to the servo accumulator valve provides no in the release side of the intermediate
intermediate servo apply circuit, re- control on the application of the servo can exhaust freely.
ducing the pressure on apply side of intermediate band on 3-2 downshifts. (DI AND D2 RANGES) (2-3 UP-
the servo to the same value as in SHIFTS). During a 2-3 upshift, DI
the direct clutch (and also on the Operation is as follows: fluid from the 2-3 shift valve will un-
release side of the intermediate (D1 AND D2 RANGES) (1-2 seat the intermediate servo check
servo). When this happens, the inter- UPSHIFTS AND 3-2 DOWN- valve, bypassing the intermediate
mediate band is released, to provide SHIFTS). Fluid pressure from the servo accumulator valve, allowing
a smooth 2-3 shift. D2 valve acting on the apply side the release side of intermediate servo
Manual Low Valve. The manual of the intermediate servo piston tend- to be pressurized at the same pres-
low valve insures that the 2-3 back- ing to apply the servo, causes the sure level as the direct clutch.
D 1585 - A
9825
LUBRICATIONPOINTS.
D lS86-A
. LUBRICATION
POINTS D 1625-A
rod to bring the pedal height within 7. Remove the four bolts that
specifications. Connect the carburetor secure the selector lever control
rod and tighten the jam nut. Install housing to the console. Lift the
the return spring. selector lever housing from the con-
On V -8 engines, disconnect the sole.
carburetor return spring and the car- 8. It is necessary to disassemble
buretor rod at point C (Fig. 15). the quadrant to adjust the selector
Adjust the length of the rod to bring lever. To disassemble the quadrant,
the pedal height within specifications. remove the two retainers from the
Connect the carburetor rod and re- underside of the dial and the two
turn spring. attaching screws from the opposite
4. If necessary, adjust the trans- side. Separate the dial, insulators,
mission kickdown linkage as fol- retainer, pointer and the plate from
lows: the housing.
D1568.B 9. Install the selector lever handle.
On six-cylinder engines, discon-
nect the kickdown cable return FIG. 16-Manual Linkage- 10. Position the selector lever as
spring at the transmission. Dis- shown in Figure 19. With a feeler
connect the carburetor return spring Typical gauge, check the clearance between
at the manifold. Disconnect the the detent pawl and plate. The clear-
kickdown cable at Point A (Fig. transmission into the D1 detent po-
ance should be 0.005 to 0.010 inch.
sition, second from the rear.
15). If necessary adjust the height of the
4. Tighten the clamp on the shift
Position the kickdown lever in the detent pawl as shown in Figure 19.
rod at point A.
downshift position (carburetor-wide 5. Check the pointer alignment 11. Remove the handle from the
open position). Hold the kickdown and transmission operation for all selector lever.
lever on the transmission against the selector lever detent positions. 12. Position the plate, pointer,
stop, in a counterclockwise direction retainer, insulators and the dial on
(kickdown position). Console Shift Transmission. Be- the control housing. Secure these
Adjust the trunnion at point A fore adjusting the manual linkage, items with two screws and two re-
on the kickdown cable so it aligns check the starter neutral switch tainers.
with the hole in the kickdown lever operation. If the switch needs adjust- 13. Position the selector lever
and install the attaching clip. In- ing the adjustment can be made at housing in the console. Install the
stall the return springs. the time the manual linkage is ad- four attaching bolts (Fig. 17).
On eight-cylinder engines, dis- justed. The handle must be tight
14. Connect the quadrant lamp
connect the kickdown return spring on the selector lever.
wires to their connectors.
at the bellcrank. Disconnect the car- 1. Move the selector lever to the
buretor return spring (Fig. 15). D1 detent position against the stop. 15. Po~ition the console plate and
Disconnect the kickdown lever 2. Raise the car and loosen the secure it with the attaching screws.
rod at point B. Hold the carburetor manual linkage rod attaching nut 16. Install the handle and the but-
rod in the wide open throttle posi- (Fig. 17). Move the transmission ton on the selector lever. Secure the
tion. The step in the rod should place manual lever to the D1 position, handle with the lock screw.
the bellcrank in the downshift posi- second from the rear. The last de- 17. Secure the manual linkage rod
tion. Hold the kickdown lever rod in tent position is low position. to the arm with two insulating wash-
the downward position. This posi- 3. With the selector lever and the ers, a flat washer and a retainer
tions the transmission lever in the transmission manual lever in the D 1 (Fig. 17).
downshift position. position, tighten the rod attaching 18. Adjust the linkage as re-
Adjust the kickdown lever trun- nut to specifications. quired. Lower the car.
nion at point B so it aligns with
the hole in the bellcrank. Install the Selector Lever Removal, MUSTANG
trunnion and retaining clip. Release Adjustment and Installation. Linkage Adjustment.
the levers and install the carburetor 1. Raise the car on a hoist or 1. Position the transmission se-
rod and bellcrank return springs. jack stands. lector lever in Dl (large dot) position
2. Remove the retainer that se- (Fig. 18).
MANUAL LINKAGE
cures the manual linkage rod to the 2. Raise the car and loosen the
ADJUSTMENT lower end of the manual lever (Fig. manual lever control rod retaining
COMET, FALCON, FAIRLANE 17). nut. Move the transmission manual
Column Shift Transmission. 3. Remove the flat washer and lever to the D 1 position, second de-
1. With the engine stopped, loosen two insulator washers and discon- tent position from the back of the
the clamp at the shift lever at point nect the rod from the arm. transmission. The last detent position
A so that the shift rod is free to 4. Working from inside of the is manual low.
slide in the clamp (Fig. 16). car, remove the selector lever handle 3. With the transmission selector
2. Position the transmission se- attaching screw. Lift the handle off lever against the stop and manual
lector lever into the Dl (large dot) the selector lever. lever in the DI positions, torque the
position making sure that the selector 5. Remove the console trim panel attaching nut 20 to 25 ft-ibs.
lever is against the D, stop on the from the top of the console. 4. Check the operation of the
selector plate. 6. Disconnect the quadrant lamp transmission in each selector lever
3. Shift the manual lever at the wires from the harness. position.
PART 7-2 C4 AUTOMATICDUAL RANGETRANSMISSION 7-29
,HANDLE
7256
PLUG -
374949-58
-f' J
'SELECTORLEVER
! I?-'
--~--,",'
HOUSING
7200
~~
NUT
374717-5
---~ - ~ 7341
FLAT WASHER
7353"
372285-58
MANUAL LINKAGE
"
7341
ROD 7340
BUSHING
7343
VIEWZ
D-1626-A
ing.
7. Remove the selector lever to FIG. 19-5elector LeverDetent Pawl Adjustment-Mustang
housingattachingnut (Fig. 19). Re-
move the lever from the housing.
8. Install the selector lever in the
housing and install the attaching nut.
Torque the nut to 20 to 25 ft-lbs.
9. Install th~ dial indicator light.
10. Install the selector lever
handle.
11. Position the selector lever as
shown in Figure 19. With a feeler
gauge check the clearance between
the detent pawl and plate. The clear-
ance should be 0.005 to 0.010 inch.
If necessary adjust the height of the
detent pawl as shown in Figure 19.
12. Remove the handle from the
selector lever.
13. Install the selector housing and
lever assembly as shown in Figure
f8. Torque the attaching bolts 8-12
ft-lbs.
14. Connect the dial indicator light
wires.
15. Install the selector lever plate
and tighten the attaching screws.
16. Install the dial housing and
tighten the attaching screws.
17. Install the selector lever handle
and tighten the attaching screw.
18. Position the selector lever in
the Dl (large dot) position.
19. Raise the car. Install the trans-
mission manual lever rod to the
selector lever. Adjust the manual
linkage.
20. Lower the car and check the
transmission operation in each se-
lector lever detent position.
start only with the transmission se- tool handle clicks. The tool is a pre-
lector lever in N (neutral) and P set torque wrench which clicks and
(park). overruns when the torque on the
adjusting screw reaches 10 ft-ibs.
BAND ADJUSTMENTS 3. Back off the adjusting screw
INTERMEDIATE BAND exactly 3 full turns.
1. Clean all the dirt from the band 4. Hold the adjusting screw from
adjusting screw area. Loosen the turning and torque the lock nut to
lock nut several turns. specification.
2. With the tool shown in Fig. 21;
tighten the adjusting screw until the OIL PAN AND CONTROL
tool handle clicks. The tool is a pre- VALVE BODY REPLACEMENT
set torque wrench which clicks and 1. Raise the car so the transmis-
overruns when the torque on the
sion oil pan is accessible.
adjusting screw reaches 10 ft-lbs. 2. Loosen the oil pan retaining
Too/-T59P.77370-B or 7345 bolts and lower one edge of the oil
pan to drain the transmission oil. If
the same fluid is to be used again,
filter the fluid through a 100 mesh
FIG. 20-Neutral Start Switch screen. Re-use the fluid only if it
is in good condition.
has to be inserted to a full 31f64 3. Remove the transmission oil
inch into the three holes of the pan attaching bolts, oil pan and
switch ~ig. 20). gasket.
3. Torque the two switch attach- 4. Remove the valve body to case
ing bolts to specification. Remove attaching bolts (Fig. 33). Remove
the gauge pin from the switch. the valve body from the case and
4. Check the operation of the the transmission inner control levers.
switch. The engine should start only 5. Refer to the Major Repair
with the transmission selector lever Operation for control valve body re-
in Neutral and Park. pair operation.
-~- ~
the servo piston in the cover. 11. lA>vverthe car and check the seal should be firmly seated in the
5. Install the piston return spring transmission fluid level. bore. Coat the inside diameter of the
in the case. Place a new gasket on fiber portion of the seal with B8A-
the cover. Install the piston and EXTENSION HOUSING 19589-A lubricant.
cover into the transmission case BUSHING AND REAR SEAL 7. Coat the front universal joint
making sure that the slotted end of REPLACEMENT spline with B8A-19589-A lubricant
the piston is in a horizontal position 1. Disconnect the drive shaft from and install the drive shaft.
so that it will engage the strut. the transmission.
Use two 5I16-18xl V4 bolts, 1800 2. When only the rear seal needs EXTENSION HOUSING AND
apart to position the cover against replacing, carefully remove it with GOVERNOR REPLACEMENT
the case. a tapered chisel or the tools shown 1. Raise the car on the hoist.
6. Install the two servo cover in Fig. 23. Remove the bushing as 2. Remove the drive shaft. Posi-
attaching bolts. Remove the two shown in Fig. 24. Use the bushing tion the transmission jack to support
11/4-inch bolts and install two at- remover carefully so that the spline the transmission.
taching bolts. Torque the bolts to seal is not damaged. 3. Remove the speedometer cable
specification.
7. Adjust the intermediate band.
Lower the car and check the trans-
mission fluid level.
8. If the band cannot be adjusted
properly, the struts are not in posi-
tion. Remove the oil pan and valve
body. Install the struts, valve body,
oil pan, and adjust the band. Refill
the transmission with fluid.
LOW-REVERSE SERVO
PISTON REPLACEMENT
1. Raise the car on a hoist.
2. Loosen the reverse band adjust-
ing screw lock nut. Tighten the re-
verse band adjusting screw to 10 EXTENSIONHOUSING
from the extension housing.
ft-lbs torque. (Tightening the screw 4. Remove the extension housing
will insure that the band strut will Too/-T57P-7697-A
or 7000-G or AD to crossmember mount attaching
be held against the case by the band, bolts. Raise the transmission and re-
preventing it from falling down move the mounting pad between the
when the reverse servo piston as- extension housing and the crossmem-
sembly is removed). ber.
3. Remove the four servo cover to D1025.8
5. Loosen the extension housing
case attaching bolts. Remove the FIG. 24-Removing Extension attaching bolts to drain the trans-
identification tag and vent tube re- mission fluid. Disconnect the exhaust
taining clip. Remove the servo cover HousingBushing
inlet pipes at the manifold and lower
and seal from the case. the inlet pipes.
4. Remove the reverse servo piston
3. When installing a new bushing
use the special tool shown in Fig. 6. Remove the six extension hous-
and stem from the case as an as- ing-to-case attaching bolts and re-
25.
sembly. move the extension housing.
5. Insert a small screwdriver in BUSHING
7. Remove the governor housing-
the hole of the piston stem (Fig. 52). to-governor distributor attaching
Remove the piston attaching nut. bolts (Fig. 27). Remove the gov-
6. Remove the servo piston from ernor housing from the distributor.
the stem. The piston seal cannot be 8. Refer to Major Repair Opera-
replaced without replacing the pis- tions for governor repair operations.
ton. The seal is bonded to the piston. 9. Install the governor housing on
7. Install a new piston on the EXTENSION HOUSING 01026-B the governor distributor (Fig. 27).
stem. Install the attaching nut. Install the attaching bolts and torque
FIG. 25-lnstolling Extension
the bolts to specification.
Torq~e the nut to specification.
Housing Bushinq 10. Install a new extension hous-
8. Install the reverse servo pis-
ing gasket on the case. Install the
ton assembly in the case. Make sure 4. Before installing a new seal, extension housing and six attaching
that the release spring is in position. inspect the sealing surface of the bolts. Torque the bolts to specifica-
9. Install the reverse servo cover universal joint yoke ~or scores. If tion.
and a new seal, positioning the scores are found, replace the yoke. 11. Install the transmission mount-
breather tube clip and service identi- 5. Inspect the counterbore of the ing pad to the crossmember. Lower
fication tag under the proper cover- housing for burrs and remove with the transmission and install the ex-
to-case bolts. Torque the bolts to crocus cloth. tension housing-to-crossmember at-
specification. 6. Install the seal into the housing taching bolts. Torque the attaching
10. Adjust the reverse band. with the tool shown in Fig. 26. The bolts to specification. Remove the
PART 7-2 - C4 AUTOMATIC
DUALRANGE
TRANSMISSION
7-33
D1027-C
FIG. 26-lnstalling ExtensionHousing Seal
transmissionjack. manifold.
1'2. Connect the speedometer 14. Lower the car and fill the
cable to the extensionhousing. In- transmissionwith fluid.
stall the drive shaft. 15. Check the extension housing
13. Install the inlet pipes on the area for fluid leakage. FIG. 27-Governor Installed
Connect the vacuum hose to the transmission downshift and manual 14. Install the starter and torque
transmission"vacuum unit. Install control levers. the bolts to specification. Connect
the vacuum line retaining clip. 10. Connect the speedometer ca- the starter cable.
7. Install the transmission fluid ble to the extension housing. 15. Install the drive shaft. Torque
filler tube. Connectthe fluid cooling 11. Connect the exhaust inlet pipes the companion flange U-bolt nuts
lines to the transmissioncase. to the manifolds. to specification.
8. Connect the neutral start switch 12. Install and adjust the parking 16. Lower the car and fill the
wires to their respective connectors brake cable at the equalizer lever. transmission with fluid. Adjust the
and secure the harness in the retain- 13. Install the converter housing manual and kickdown linkage.
ing clamps. cover and torque the attaching bolts
9. Connectthe linkagerods to the to specification.
INTERMEDIA TE INTERMEDIATE BAND gear train toward the back of the REMOVAL OF CASE.AND
BAND STRUTS ADJUSTING SCREW
transmission case. EXTENSION HOUSING PARTS
4. With the dial indicator contact- 1. Rotate the holding fixture to
ing the end of the input shaft, set put the transmission in a vertical
the indicator at zero (Fig. 35).
position with the converter housing
5. Insert a screwdriver behind the
input shell (Fig. 35). Move the input up.
shell and the front part of the gear 2. Remove the six converter hous-
train forward. ing and front pump to case retaining
6. Record the dial indicator read- bolts. Remove the converter housing
ing. The end play should be 0.008 from the front pump.
to 0.042 inch. If the end play is not 3. Remove the front pump by in-
within specifications, the selective serting a screwdriver behind the in-
thrust washer (Fig. 31) must be re- put shell (Fig. 38), Move the input
placed. shell forward until the front pump
When it is necessary to change seal is above the edge of the case.
a thrust washer, use the selective Remove the front pump and gasket
LOW.REVERSEBAND LOW.REVERSE thickness of thrust washer No.2 to from the case. If the selective thrust
ADJUSTING SCREW BAND STRUTS D 1384-B
obtain the proper end play. Fig. 36 washer No.1 did not come out'wit1i
FIG. 34-Band Adjusting Studs shows the selectivity that is available 'the front pump, remove it from the
and Struts to obtain the correct selective thrust top of the reverse-high clutch.
washers. 4. Remove the intermediate arid
the intermediate band struts ~om
the case. Loosen the low-reverse
band adjusting screw and remove
the low-reverse band struts (Fig. 34).
TRANSMISSION END
PLAY CHECK
1. To keep the output shaft in
alignment during the end play check,
install the extension housing oil seal
replacer tool or a front universal
joint yoke in the extension housing.
2. Remove one of the front pump-
to-case attaching bolts and mount thE'
dial indicator as shown in Fig. 35.
3. The input shaft is a loose part
and has to be properly engaged with
the spline of the forward clutch hub
during the end play checking pro-
cedure. Move the input ,shaff.. and
INPUTSHAFT D1387-A
solution. Clean the band with a lint forward clutch hub and ring gear
free cloth. (Fig. 43).
5. Using a screwdriver between 9. If thrust washer No.3 (Fig.
the input shell and rear planet carrier 42) did not come out with the for-
(Fig. 40) lift the input shell upward ward clutch, remove the thrust
and remove the forward part of the washer from the forward clutch hub.
gear train as an assembly (Fig. 41). 10. Remove the forward clutch
-'
INTERMEDIATEBANDCLEARANCE
hub and ring gear from the front
HOLE IN CASE D1389-A planet carrier (Fig. 43).
11. Remove thrust washer No.4
FIG. 39-Removing or Installing and the front planet carrier from the
Intermediate Band input shell.
12. Remove the input shell, sun
gear and thrust washer No.5 from
the holding fixture (Fig. 43).
13. From inside the transmission
case, remove thrust washer No.6
SUN GEAR
\\c
THRUST WASHER
NO.3 THRUST WASHER
NO.4
REVERSE-HIGH CLUTCH THRUST WASHER
NO.5
D1393-A
FIG. 43-Forward Partof GearTrainDisassembled
PART 7-2 - C4 AUTOMATICDUAL RANGETRANSMISSION 7-37
THRUST NO.9
THRUSTWASHER NO.8
REVERSE CARRIER
REVERSERINGGEAR SPRING RETAINER
AND HUB
RACE
~'j'"
if
~f
...
THRUSTWASHER NO.7
g~
ONE-WAY
CLUTCH
LOW AND REVERSEDRUM OUTER RACE
THRUST WASHER NO.6 SPRINGS (12)
AND ROLLERS (12)
D1394-A
(Fig. 44) from the top of the re- retainer from the outer race (Fig.
verse planet carrier. 44). Do not lose or damage any of
14. Remove the reverse planet the 12 springs or rollers. The outer
carrier and thrust washer No.7 race of the one-way clutch cannot
from the reverse ring gear and hub be removed from the case until the
(Fig. 44). extension housing, output shaft
15. Move the output shaft for- and governor distributor sleeve
ward and with the tool shown in are removed.
Fig. 45 remove the reverse ring gear 21. Remove the transmission from
hub to output shaft retaining ring. the holding fixture. Position the
FIG. 46-Removing or Installing transmission on the bench in a ver-
Low-Reverse
Band tical position with the extension
housing up. Remove the four exten-
sion housing-to-case attaching bolts.
Remove the extension housing and
gasket from the case.
22. Pull outward on the output
shaft and remove the output shaft
and governor distributor assembly
from the governor distributor sleeve
(Fig. 47).
23. Remove the governor distribu-
tor lock ring from the output shaft
(Fig. 48). Remove the governor dis-
tributor from the output shaft.
24. Remove the four' distributor
HUB RETAINING RING D1395-A sleeve-to-case attaching bolts. Re-
move the distributor sleeve from the
FIG. 45-Removing or Installing case. Do not bend or distort the oil
ReverseRing Gear Hub Retaining tubes as the tubes are removed
Ring
16. Remove the reverse ring gear
and hub from the output shaft. Re-
move thrust washer No.8 from the
low and reverse drum.
17. Remove the low-reverse band
from the case (Fig. 46).
18. R1Jmovethe low-reverse drum
from the one-way clutch inner race
(Fig. 44).
19. Remove the one-way clutch
inner race by rotating the race clock-
wise as it is removed.
FIG. 47-Removing or Installing D1398-B
/" --- --
transmission identification tag, vent
tube and retaining clip from the case.
2. Remove the servo cover, cover
seal, servo piston and piston return
spring from the case (Fig. 51).
3. The servo piston seal is bonded
SPRING to the piston. If the seal has to be
D1401-A
PISTON
COVER D1583-A
Engine DIA. B
INSIDE
DIA.C
INSIDE
DIA.D
DIA.A
3.3265 2.3765 3.340 2.390
4. Remove the seal rings from the ~
servo piston and cover. I CFFM I 289-2V,4V I PCW-AN,AS&AR - 3.3265 2.4865 2.500
3.7875 2.8265 "NmE"" 2.840
S. Install a new seal on the cover I FAIRLANE I 289-4V H.P. 3.7875 : 3.1175 NONE 3.131
and servo piston. Figure 55 shows ~
the correct servo piston and cover
for each transmission model. Lubri- FIG. 55-Intermediate ServoPistonand Cfter Identification
7-40 GROUP 7 - AUTOMATIC
TRANSMISSION
D1408-A
FIG. 60-Removing Manual
Lever Seal
1001-77288
D1409-A
attachingnut and lever. Removethe
outer manual lever from the case. FIG. 61-lnstalling Manual
7. To remove the manual lever LeverSeal
seal,use the tools shownin Fig. 60.
To install the new seal,use the tool 10. Install the parking pawl link
shownin Fig. 61. on the case retaining pin. Install the
8. Install the outer manual lever flat washer and link retaining ring
in the case.Install the inner manual (Fig. 57).
lever and attaching nut (Fig. 56). 11. Position the inner manual
Torque the nut to specification. lever behind the manual lever link,
9. From the back of the transmis- with the cam of the lever contact-
sion case,install the parking toggle ing the lower link pin (Fig. 62).
rod and link assemblyinto the case 12. Install the upper end of the
(Fig. 58). manual lever link on the case re-
coil. Tap the tool sharply with a body. Removethe spring and detent
MANUAL
hammer so that the blade cuts into plunger.
LINK the insert. Exert downward pressure
on the tool and turn it counterclock-
wise until the insert is removed.
CONTROL VALVE
Disassembly
1. Remove the screws that attach
the oil screen to the body and re-
move the screen (Fig. 63).
2. Remove the lower valve body
attaching screws and separate the
- lower valve body, separator plate,
MANUAL ; LEVER D141008 gasket and hold-down plates (Fig.
64) from the upper valve body.
FIG. 62-Inner Manual Lever 3. Depress the manual valve de-
Location tent spring with the. tool shown in
Fig. 65. Remove the spring retaining
taining pin. Install the flat washer pin (roll pin) from the upper valve
and retaining ring.
13. Operate the manual lever and
check for correct linkage operation.
J.4. Install the neutral start switch. I nWFR VALVE BODY UPPER VALVE BODY
15. Install the inner and outer
downshift levers. Torque the attach- ,FPARATOR PLATE
ing nut to specifications.
Thread Repair-Case. Thread serv-
ice kits may be purchased from local
jobbers or the Heli-Coil Corporation.
To repair a damaged thread, the fol..
lowing procedures should be care.
fully followed.
1. Drill out the damaged threads,
using the same driIl size as the
thread OD. For example, use a %6-
inch drill for a 0/16-18thread.
2. Select the proper special tap
and tap the drilled hole. The tap is
marked for the size of the thread
being repaired. Thus, the special tap GASKET
marked %6-18 will not cut the same
thread as a standard %6-18 tap. It D 1561-8
does cut a thread large enough to
accommodate the insert, and after FIG. 63-Upper and Lower V.alveBodiesDisassembled
the insert is installed the original
thread size (0/16-18) is restored.
3. Select the proper coil inserting CHECK VALV~
tool. These tools are marked with ~EPARATOR PLATE
the thread size being repaired. Place
the insert on the tool and adjust
the sleeve to the length of the insert
being used.
Press the insert against the face
of the tapped hole. Turn the tool
clockwise and wind the insert into
the hole until the insert is 1/2 turn
below the face.
4. Working through the insert,
bend the insert tang straight up and
down until it breaks off at the notch.
5. If the inserts are not properly
installed, they can be removed with
the extractor tool. Place the extrac-
tor tool in the insert so that the LOWER VALVE BOOY D1562. A
blade rests against the top coil 1/4
to 1/2turn away from the end of the FIG. 64-Separating Upperand LowerValveBodies
7-42 GROUP 7 - AUTOMATIC
TRANSMISSION
4. Slide the manual valve out of 14. Remove the pressure booster 8. Place the throttle modulator
the body. valve, washer, s(!rings and the main valve, spring, and 2-3 shift valve in
5. Remove the cut-back and the regulator valve. the body.
back-out valve cover plate from the 15. Carefully pry the downshift 9. Secure the 1-2 shift valve
valve body (Fig. 66). valve retainer from the body, then and the 2-3 valve cover plate to the
6. Remove the cut-back valve remove the spring and valve. body and torque the screws to speci-
from the body. 16. Hold the upper valve body fications.
7. Remove the 2-3 back-out valve, as shown in Fig. 67 and depress the 10. Place the manual low valve,
spring and the manual low valve throttle booster valve plug to release spring, and the 2-3 back-out valve
from the body. the retaining pin. Remove the plug, in the body.
8. Rer:novethe 1-2 shift valve and valve and the spring. 11. Place the cut-back valve in
the 2-3 shift valve cover plate from 17. Remove the two hold-down the body.
the valve body. plates and the separator plate from 12. Secure the cut-back and the
9. Rem'Ovethe 2-3 shift valve and the lower valve body. back-out cover plate to the body
the throttle modulator valve from with two screws. Torque the screws
the body. Assembly to specifications.
10. Remove the 1-2 shift valve, 1. Position the separator plate and 13. Slide the manual valve into
D2 valve and the spring from the the two hold-down plates on the the body making sure that the notch
body. lower valve body and install the four for the manual lever is toward the
11. Remove the intermediate band attaching screws and torque them to inside and that the detent notches
accumulator valve cover plate from are facing upward.
specification. 14. Place the detent plunger and
the valve body. 2. Place the throttle booster valve
12. Remove the spring and the spring, valve (long end into spring) spring in the body. Depress the..
intermediate band accumulator and the plug (Fig. 66). Depress the spring and install a new roll piq:
valve. plug and install the retaining pin. 15. Position a new rubber cn~ck
13. Remove the pressure booster 3. Insert the downshift valve into valve in the upper valve body (Fig
valve cover plate (Fig. 66). the body with the large diameter fac- 64).
ing inward. Install the downshift 16. Place a new gasket, separator
valve spring and the retainer (Fig. plate and the lower valve body in
place on the upper valve body and
66).
4. Place the main regulator valve secure them with the attaching
in the body with the large diameter screws. Torque the screws to speci-
facing inward. Install the two springs fications.
and the spacer, pressure booster 17. Secure the oil screen to the
valve and sleeve. body with the attaching ScCrew's,
5. Hold the pressure booster valve Torque the screws to spe-cifications
cover plate in place and install the
three attaching screws and torque FRONT PUMP
them to specification. 1. Remove the four seal rings
6. Position the intermediate band from the stator support and the 0-
accumulator valve and spring in the ring seal from the pump housing.
-
Dl564-A
body. Secure the cover to the body
with the attaching screw. Torque the
2. Removethe five bolts that at-
tach the stator support to ~e front
screw to specifications. pump housing. RemQ,;jethe stator
FIG. 67 -Removing Throttle 7. Position the spring, D2 valve support from the pump housing
BGosterValve and the 1-2 shift valve in the body. (Fig. 68).
PUMP HOUSING
FRONT PUMP SEAL STATOR SUPPORT
SEAL RINGS
GEAR 1
DRIVEN GEAR
THRUST WASHERS
GASKET
C-RING SEAL
D1417-A
3. Remove the drive and driven gear has an identification mark on REVERSE.HIGH CLUTCH
gearsfrom the front pump housing. the side of the gear teeth that are 1. Remove the pressure clutch
4. Install the drive and driven chamfered.' The chamfered side plate retaining snap ring (Fig. 71).
gears in the pump housing. Each with the identification mark has to 2. Remove the pressure plate, and
be positioned downward against the the drive and driven clutch plates.
face of the pump housing. (Fig. 72). If the composition clutch
5. Place the stator support in the plates are to be reused, do not clean
pump housing and install the five the plates in a vapor degreaser or
attaching bolts. Torque the bolts to with a detergent solution. Wipe the
specifications. plates clean with lint-free cloth.
6. Install the four seal rings on 3. To remove the piston spring
the stator support. Two large rings retainer sn!!cpring, place the clutch
are assembled first in the ring hub in the arbor press. With the
grooves toward the front of the tools shown in Fig. 73, compress
D1418-A
stator support. Install the a-ring seal the piston return springs and re-
FIG. 69-Removing FrontPump on the pump housing (Fig. 68). move the snap ring. When the arbol
7. Check the pump gears for free press ram is released, guide the
Seal rotation by placing the pump on the spring retainer to clear the snap
converter drive hub in its normal ring groove of the drum.
running position and turning the 4. Remove the spring retainer
pump housing. and ten piston return springs.
8. If the front pump seal must be 5. Remove the piston by inserting
replaced, mount the pump in the air pressure in the piston apply hole
transmission case and remove the of the clutch hub (Fig. 74).
seal with the tool shown in Fig. 69. 6. Remove the piston outer seal
To install the new seal use the tool from the piston and the piston inner
shown in Fig. 70. seal from the clutch drum.
REVERSE- HIGH
SPRING
CLUTCH DRUM
FIG. 70-lnstalling FrontPump RETAINER
CLUTCH
Seal piSTON
-
Tool T65L-77515-A
Toot T6SL-77SIS-A
D1591-A
7. Install a new inner seai in the the correct size snap ring and re-
clutch drum and a new outer seal check the clearance.
on the clutch piston (Fig. 71). Lu-
bricate the seals with clean trans- FORWARD CLUTCH
mission fluid and install the piston 1. Remove the clutch pressure
into the clutch drum. plate retaining snap ring (Fig. 76).
8. Place the ten clutch piston 2. Remove the pressure plate, and
springs into position on the clutch the drive and driven clutch plates
piston. Place the spring retainer on from the clutch hub (Fig. 77).
top of the springs. To install the 3. Remove the disc spring re-
snap ring, use the tools shown in taining snap ring (Fig. 78).
Fig. 73. As the press ram is moved
downward, make sure the spring
FIG. 74-Removing Reverse- retainer is centered to clear the
HighClutchPiston drum. Install the snap ring. Before
the press ram is released make sure
the snap ring is positioned inside
of the four snap ring guides on the
spring retainer.
9. When new composition clutch
plates are used, soak the plates in
transmission oil for fifteen minutes
before the plates are assembled. In-
stall the clutch plates alternately by
starting first with a steel plate then
D1550-A
a non-metallic plate (Fig. 72). The
FIG. 75-Checking Reverse-High last plate installed is the pressure
ClutchSnapRing Clearance plate. For the correct number of
clutch plates required for each trans-
mission model, refer to Part 7-4.
10. Install the pressure plate re-
taining snap ring (Fig. 71). Make
sure the snap ring is fully seated in
the snap ring groove of the clutch
hub.
11. With a feeler gauge, check
the clearance between the snap
ring and the pressure plate (Fig. 75).
12. The pressure plate should be
held downward as the clearance is
checked. The clearance should be
0.050-0.060 inch. If the clearance
is not within specifications, selective
thickness snap rings are available in
these thicknesses, 0.102-0.106,
FIG. 76-Removing Forward 0.088-0.092, 0.074-0.078, 0.060- FIG. 79-Removing Forward
ClutchPressurePlate Snap Ring 0.064 and 0.102-0.106 inch. Install ClutchPiston
4. Apply air pressure at the clutch FORWARD CLUTCH HUB 3. Install the forward clutch hub
piston pressure hole (Fig. 79), to AND RING GEAR in the ring gear. Make sure the hub
remove the piston from the clutch 1. Remove the forward clutch is bottomed in the groove of the
hub. hub retaining snap ring (Fig. 81). ring gear.
5. Remove the clutch piston out- 4. Install the front clutch hub re-
er seal and the inner seal from the taining snap ring. Make sure the
clutch hub (Fig. 77). snap ring is fully seatedin the snap
6. Install new clutch piston seals ring groove of the ring gear.
on the clutch piston and drum. Lu-
bricate the seals with clean trans-
INPUT SHELL AND SUN GEAR
mission fluid.
1. Removethe external snapring
7. Install the clutch piston into from -thesun gear(Fig. 82).
the clutch hub. Install the steel ring 2. Remove thrust washer No.5
on the piston. Install the disc spring from the input shell and sun gear
and retaining snap ring (Fig. 78). (Fig. 83).
8. Install the lower pressure 3. From insidethe input shell,re-
plate with the flat side up and r~dius ,~ .... move the sun gear. Removethe in-
side downward. CLUTCH HUB D1428-A ternal snap ring from the sun gear.
Install one non-metallic clutch 4. Install the internal snap ring
plate and alternately install the drive FIG. 81-Forward Clutch Hub on the sun gear. Install the sun gear
and driven plates. The last plate in- and Ring Gear Disassembled in the input shell.
stalled will be the top pressure plate.
S. Install thrust washerNo.5 on
(Fig. 77). Refer to Specification Sec- 2. Remove the forward clutch the sun gear and input shell (Fig.
tion for the correct number of clutch hub from the ring gear. 83).
plates for the applicable model 6. Install the external snap ring
transmission. on the sun gear (Fig. 82).
9. Install the pressure plate re- REVERSE RING GEAR
taining snap ring (Fig. 76). Make AND HUB
sure the snap ring is fully seated in 1. Removethe hub retaining snap
the ring groove of the clutch hub. ring from the reversering gear.
10. With a feeler gauge, check 2. Removethe hub from the re-
the clearance between the snap ring versering gear(Fig. 84).
and the pressure plate (Fig. 80). 3. Install the hub in the reverse
Downward pressure on the plate ring gear.Make surethe hub is fully
should be used when making this seatedin the grooveof the ring gear.
check. The clearance should be 4. Install the snapring in the re-
0.020-0.036 inch for transmissions versering gear. Make sure the snap
having four internal splined clutch ring is fully seatedin the snap ring
plates and 0.026-0.042 inch for groove of the ring gear.
transmissions having five internal
splined clutch plates. GOVERNOR AND On..
DISTRIBUTOR
FIG. 82-Removing or Installing 1. Remove the rings from the
SunGearExternalSnapRing governor oil distributor (Fig. 85).
FIG. SO-CheckingForward
Clutch Snap Ring Clearance
~~, / SPACE~,,-
\
~
(Fig. 47).
10. Place a new extension housing
gasket on the case. Install the ex-
SPRING~~~~?f~..t~\~ tension housing, vacuum tube clip,
"1rir!pp"11B
;( :, SPRING
RETAIN: CLIP
f't
and the extension housing-to-case
attaching bolts. Torque the bolts to
specification.
11. Place the transmission in the
SPRING- A~ ""1 holding fixture with the front pump
SECONDARY
GOVERNOR VALVE- ;~~V
c" ,
"
"
,,'
mounting face of the case up. Make
sure thrust washer No.9 is still
, " located at the bottom of the trans-
I "
\ // mission case (Fig. 88).
'-
12. Install the one-way clutch
spring retainer into the outer race
FIG. 8S-Governor and Oil Distributor (Fig. 93).
7-48 GROUP 7 - AUTOMATIC
TRANSMISSION
7
4 8
6
1 5
j
n
!
~ I
,~
/- - - - - - - - - - - - - - -.- - - - - - - - - - - - - - - - - - - - - - -
'-' '
i
I
\ - -- '\
-~~ ~-
~~--~~-~~
'-- ~ .. """
~,
~
"1.f
'"
,. -- -=~ 26
.
27
,.-.,
28
":.;.--'"
,',
301
J
I
\
" ---
,\
~;;~
~
32 -.. ~- 35
37 3'6 - I
.I
31
,.-
(
""-
/
I -- =-~ =-I
""
40 L
"'"
FIG. 87-TransmissionSub-Assemblies
~
PART 7-2 - C4 AUTOMATIC
DUALRANGE
TRANSMISSION 7-49
THRUST WASHER NO.9 PARKING GEAR been assembledrotate the inner race
clockwise to center the rollers and
springs. Install the low and reverse
drum (Fig. 87). The splines of the
drum have to engage with the splines
of the one-way clutch inner race.
Check the one-way clutch operation
by rotating the low and reverse
drum. The drum should rotate clock-
wise but should not rotate counter-
clockwise.
17. Install thrust washer No.8 on
top of the low and reverse drum
(Fig. 94). Install the low-reverse
band in the case, with the end of
the band for the small strut toward
the low-reverse servo (Fig. 39).
--- ---~-- 18. Install the reverse ring gear
BOTTOM and hub on the output shaft.
OF CASE D1437-A NO. 10 D1441-A
19. Move the output shaft for-
FIG. SS-Number 9 Thrust FIG. 91-Number 10 Thrust ward and install the reverse ring
WasherLocation ~
gear hub to output shaft retaining
WasherLocation
ring (Fig. 43).
20. Place thrust washers Nos. 6
and 7 on the reverse planet carrier
(Fig. 95).
21. Install the planet carrier in
the reverse ring gear and engage the
tabs of the carrier with the slots in
the low-reverse drum.
22. On the bench, install the for-
ward clutch in the reverse-high
clutch by rotating the units to mesh
the reverse-high clutch plates with
RETAINS REVERSE RING GEAR AND
HUB TD DUTPUT SHAFT
the splines of the forward clutch
(Fig. 96).
23. Using the end play check
reading that was obtained during the
transmission disassembly to deter-
mine which No.2 steel backed thrust
FIG. 89-lnstalling One-Way wash"er is required, proceed as fol-
Clutch Outer Race Attaching Bolt lows:
a. Position the stator support ver-
tically on the work bench and install
the correct No.2 thrustwasher to
RETAINS GOVERNOR DISTRIBUTOR
bring the end play within specifica-
TOOUTPUTSHAFT tions.
D1549-A b. Install the r.everse-high clutch
~jhe forward clutch on the stator
FIG. 92-Governor and Reverse Silpport.
Ring Gearand Hub SnapRing c. Invert the complete unit mal'-
Identification iog sure that the intermediate brake
drum bushing is seated on the for-
ward clutch mating surface.
13. Install the inner race inside of d. Select the thickest fiber washer
the spring retainer. (No.1) that can be inserted between
14. Install the individual springs the stator support and the inter-
between the inner and outer race as mediate brake drum thrust surfaces
shown in Fig. 93. and still maintain a slight clearance.
15. Starting at the back of the Do not select a y.'asher that must
transmission case, install the one-way
be forced between the stator support
clutch rollers by slightly compress-
ing each spring and positioning the and intermediate brake d~m.
roller between .,the spring and the e. Remove the intermediate brake
spring retainer., drum and forward clutch~nit from
16. After toe one-way clutch has the stator support.
7-50 GROUP 7 - AUTOMATICTRANSMISSION
-- ---"-
SPRINGS(12) STEP.3
INSTALL 12 SPRINGS
f. Install the selected Nos. 1 and on the forward clutch hub (Fig. 98). gear on the gear train (Fig. 101).
2 thrustwashers on the front pump 26. Install thrust washer No.4 Rotate the input shell to engage the
stator support (Fig. 34) using on the front planet carrier (Fig. 99). drive lugs of the reverse-high clutch.
enough vaseline to hold the thrust Install the front planet carrier into If the drive lugs will not engage,
washers in position during the front the forward clutch hub and ring the outer race inside the forward
pump installation. gear. Check the forward thrust bear- planet carrier is not centered to en-
24. Install thrust washer No.3 ing race inside the planet carrier for gage the end of the sun gear inside
on the forward clutch (Fig. 97). proper location against the thrust the input shell. Center the thrust
25. Install the forward clutch hub bearing. Make sure the race is cen- bearing race and install the input
and ring in the forward clutch by tered for alignment with the sun shell.
rotating the units to mesh the for- gear on the input shell (Fig. 100). 28. Hold the gear train together
ward clutch plates with the splines 27. Install the input shell and sun and install the forward part of the
PART 7-2 - C4 AUTOMATICDUAL RANGETRANSMISSION 7-51
DESCRIPTION Only one (intermediate) band is stator. This flow produces a maxi-
Figure 1 shows the location of the used in the C6 transmission. This mum torque increase of about 2
converter, front pump, clutches, along with the forward clutch is to 1 when the turbine is stalled.
gear train and most of the internal used to obtain intermediate gear. When enough torque is developed
parts used in the C6 transmission. The only adjustments on the trans- by the impeller, the turbine begins
The identification tag (Fig. 2) at- mission proper, are for the inter- to rotate, turning the turbine shaft
tached by the servo cover bolt, in- mediate band and the neutral safety (input shaft).
cludes the model prefix and suffiX, switch. The converter torque multiplica-
as well as a service identification The fluid is drained from the tion gradually tapers off as turbine
number and serial number. The transmission by loosening the pan speed approaches impeller speed,and
service identification number indi- bolts and allowing it to drain. Then it becomes 1 to 1 when the turbine
cates changes to service details which by finally removing all bolts except is being driven at %0 impeller speed.
affect interchangeability when the two from the front. This will allow This is known as the "coupling
transmission model is not changed. the pan to drain more thoroughly. point."
For interpretation of this number, When the turbine is rotating at
see the Master Parts Catalog. OPERATION less than %0 impeller speed, the
Table 1 shows the engine and TORQUE CONVERTER converter is multiplying torque. The
transmission model applications. The hydraulic torque converter fluid leaving the turbine blades
The C6 transmission is a three (Fig. 3) consists of an impeller strikes the front face of the stator
speed dual range unit capable of (pump), a turbine, and a stator. All blades. These blades are held station-
transmitting the higher torque out- these parts are enclosed and operate ary by the action of the one-way
put of the new improved engines. in a fluid-filled housing. clutch (Fig. 3) as long as the fluid
The converter housing and the fixed When the engine is running, the is directed against the front face of.
splines which engage the splined aD fluid in the torque converter flows the blades.
of the low-reverse clutch steel plates, from the impeller to the turbine and When the turbine rotates {aster
are both cast integrally into the case. back to the impeller through the than %0 impeller speed the convert-
er no longer multiplies torque. The
fluid is directed against the back face
TABLE 1 .Engineand TransmissionApplication of the stator blades. As the one-way
Transmission Engine clutch permits the stator to rotate
Car Model Model Model only in the direction of impeller ro-
tation, the stator begins to turn with
Comet-Fairlane (Col. Shift) 390-2V the impeller and turbine. The con-
PDD:Jc. ,;
Comet-Fairlane (Fl. Shift) PDD-P ..,,~ 390-2V verter operates as an efficient fluid
coupling as long as the turbine speed
Comet-Fairlane (Col. Shift) PDD-E 390-4V remains greater than %0 impeller
Comet-Fairlane(Fl. Shift) PDD-R 390-4V speed.
A constant flow of fluid into and
7-54 GROUP 7 - AUTOMATIC
TRANSMISSION
D1593-A
out of the converter is maintained. high clutch is applied, the external gether. The low-reverse clutch hub
The fluid coming out of the con- area of the clutch hub is splined to can be held from rotating by the
verter is forced through a cooler and drives the input shell to rotate reverse clutch. In Dl the low-reverse
located in the radiator tank. the sun gear. When the forward clutch hub is also held from rotating
clutch is applied, the composition by a roller type one-way clutch.
PLANETARY GEAR TRAIN, clutch plates drive the forward clutch The forward planet carrier, re-
CLUTCHES, BAND, hub and ring gear. The ring gear verse ring gear hub, park gear and
AND SERVO rotates the forward planet gears.
Planetary Gear Train. The gear When applied, the intermediate
train consists of an input shaft that band holds the reverse-high clutch
is splined to the turbine of the con- drum, input shell and sun gear from
verter and the forward clutch cylin- rotating. TURBINE
-HOUSING
der (Fig. 4). The forward clutch cyl- The sun gear, which is driven by
inder rotates the steel internal clutch the input shell, is meshed with the (PUMP)
plates of the forward clutch and the forward and reverse planet gears.
composition clutch plates of the re- The reverse planet carrier and low STATOR
verse-high clutch. When the reverse reverse clutch hub are locked to-
ONE-WAY
TRANSMISSI~ DETAIL
CLUTCH
MODEL CHANGES
-.
(TURBINE)
SHAFT
/
SERIAL NO.
~ ~ ../ D1004-A
D 1628-A
FIG. 3-Sectional Viewof
FIG. 2-ldentification Tag TorqueConverter-Typical
PART 7-3 C6 AUTOMATICDUAL RANGETRANSMISSrON 7-55
governor distributor are all splined drum which is splined to the input Intermediate Servo and Band. The
to the output shaft. shell. Rotation of 'the input shell intermediate servo is machined into
Forward Clutch. The input shaft drives the sun gear which is splined the transmission case and the band
is splined to and drives the forward to the input shell. has an external adjustment screw
clutch cylinder (Fig. 4). Rotation of To release the reverse-high clutch, (Fig. 5). To apply the servo, hy-
the cylinder drives the steel clutch hydraulic pressure is exhausted from draulic pressure is directed from the
plates in the forward clutch and the the apply side of the piston. The re- control valve body, through a hole
composition clutch plates of the re- turn springs move the piston to the in the case to the hole in the servo
verse-high clutch. released position. The steel and com- piston stem. The pressure passes
When the forward clutch piston position clutch plates are now re- through the center of the piston
is applied by hydraulic pressure, the leased to stop rotation of the re- stem and then to the apply side of
movement of the piston against the verse-high clutch drum, input shell the piston. The piston moves against
disc spring locks the steel and com- and sun gear. the return spring to tighten the in-
position clutch plates together to
drive the forward clutch hub and
ring gear.
When hydraulic pressure is re-
leased from the piston, the disc
spring moves the piston to the re-
leased position. As the disc spring
moves, the steel and composition
clutch plates are released. This stops
the rotation of the forward clutch
hub and ring gear (Fig. 4). The for-
ward clutch is applied in all forward
drive gear ratios.
Reverse-High Clutch. When hy-
draulic pressure is directed to the
clutch piston, the piston moves
against the release springs (Fig. 4).
The piston movement locks the steel
and rotating composition clutch
plates together. The steel clutch
plates drive the reverse high clutch
7-56 GROUP 7 - AUTOMATIC
TRANSMISSION
termediate band around the reverse- gear ratio (torque multiplication) is gears.
high clutch drum. a combination of the ratios provided The reverse-clutch, holding the
To release the servo piston, hy- by the forward and reverse planet reverse planet carrier from turning,
draulic pressure is directed to the assemblies. causes the reverse planet gears to
release side of the piston. The re- Power Flow Intermediate Gear. rotate counterclockwise.
lease pressure is assisted by the In intermediate gear (Fig. 6), the This rotates the reverse ring gear
compressed return spring to move forward clutch is applied and the and hub counterclockwise. The hub
the servo piston and intermediate intermediate band is holding the splined to the output shaft rotates
band to the OFF position. The in- reverse-high clutch drum, input shell the output shaft counterclockwise at
termediate servo and band are ap- and sun gear from turning. a reduction in speed and at an in-
plied only during the intermediate The power flow is through the in- crease in torque for reverse gear.
gear operation. put shaft into the forward clutch HYD~ULIC CONTROL
and forward planet assembly ring SYSTEM
POWER FLOW gear. The sun gear is held from ro-
tating by the intermediate band. This Front Pump. Fluid for operation
All Gear Rotations are viewed of the hydraulic control system (Fig.
from the front of transmission. Table causes the forward planet pinions to
rotate (walk) around the sun gear, 7) is supplied by a gear type pump
2 shows the gear ratios obtained in mounted on the front of the trans-
the different selector lever positions. carrying the forward planet carrier
with them. The forward planet car- mission case. Pump intake is through
Power Flow Neutral. In neutral a screen which is part of the main
(Fig. 6) the clutches or bands are rier, being splined to the output
control assembly, into the case cast-
not applied, therefore, no power is shaft, causes clockwise rotation of
the output shaft at a reduction in ing and pump. Discharge is through
transmitted to the output shaft. the case into the main control assem-
Power Flow First Gear. In low speed compared to the speed of the
bly. Fluid from the front pump is
gear (Fig 6), the forward clutch is input shaft, and at an increase in
directed to the main oil pressure
applied, and the planet one-way torque. regulator valve, throttle booster
clutch or reverse clutch is holding Clockwise rotation of the output valve, manual valve, 1-2 accumula-
the reverse planet carrier from ro- ~ laft causes clockwise rotation of tor valve.
tating. The power flow is through t:.1eoutput shaft ring gear, causing In addition, fluid is also directed
the input shaft and into the forward the reverse planet pinions to also to the primary throttle valve, which
clutch. The input shaft is splined to rotate (walk) around the sun gear is located in the rear of the case.
and drives the forward clutch cylin- in a clockwise direction. The reverse
Fluid delivered to these valves is at
der. Rotation of the forward clutch planet carrier will also rotate clock- a pressure controlled by the main oil
drives the forward clutch hub and wise and the one-way clutch inner pressure regulator valve.
ring gear. The ring gear rotates the race, being splined to the reverse Main Oil Pressure Regulator
forward planet gears clockwise to planet carrier, will overrun. Valve. The main regulator valve
cause the sun gear to rotate counter- Power Flow High Gear. In high assembly consists of the main oil
clockwise. gear (Fig. 6), the forward and re- pressure regulator valve and spring,
Counterclockwise rotation of the verse-high clutches are applied. The main oil pressure booster valve,
sun gear turns the reverse planet power flow is through the input spring and sleeve. This assembly is
gear clockwise. The reverse planet shaft into the forward clutch cylin- located in one bore of the main con-
carrier being splined to the low- der. (The forward clutch cylinder trol assembly.
reverse clutch hub is held from rotates the steel clutch plates of the Fluid is delivered to two valleys
rotating by the one-way clutch or forward clutch and the composition of the main regulator valve from the
reverse clutch. clutch plates of the reverse-high front pump. The difference in dia-
With the reverse planet carrier clutch). The forward clutch directs meter between the end land and the
held stationary, the clockwise rota- the power flow through the forward second land provides an area differ-
tion of the reverse planet gears ro- clutch hub and ring gear to the ential for regulation. Fluid pressure
tates the reverse ring gear. The hub forward planet carrier. in this area tends to move the valve
of the reverse ring gear is splined to The reverse-high clutch directs against spring force. Spring force is
the output shaft and rotates the out- the power flow through the input such that at approximately 60 psi
put shaft clockwise. shell to the sun gear. With the sun front pump pressure, the main valve
The output shaft rotation is at a gear and the forward clutch hub will move so that the fourth land
reduced speed, compared to the in- ring gear driven at the same speed uncovers the converter feed port,
put shaft rotation, but at an in- the forward planet assembly (that allowing additional pump volume to
creased torque. is splined to the output shaft) is be used to charge the converter and
The output shaft rotation at a re- forced to rotate the output shaft at provide fluid for cooling and lub-
duced speed is caused by the fact the same speed and direction to pro- rication. If volume supplied by the
that the forward planet carrier ro- vide high gear. front pump is greater than,.that re-
tates at the same speed of the output Power Flow Reverse. In reverse quired to maintain 60 psi line pres-
shaft and in the same direction since (Fig. 6), the reverse-high clutch and sure and converter and lube require-
the carrier is splined to the output reverse clutch are applied. The pow- ments, the valve will move further
shaft. The forward ring gear and er flow is through the input shaft, allowing the third land to uncover
planet assembly are rotating in the reverse-high clutch, input shell and the port which allows excess pump
same direction, but the planet carrier to the sun gear. Clockwise rotation volume to be discharged into the
is rotating at a slower speed than of the sun gear causes counterclock- sump.
the rine: e:ear. Therefore. the low wise rotation of the reverse Dlanet Pressures over 60 Dsi which are
PART 7-3 C6 AUTOMATICDUAL RANGETRANSMISSION 7-57
NEUTRAL
HIGH GEAR
THE REVERSE AND HIGH CLUTCH js APPLIED. THE INPUT SHAFT IS LOCKED
TD THE REVERSE AND HIGH CLUTCH DRUM, THE INPUT SHELL AND THE
SUN GEAR
--
THE LOWAND REVERSE CLUTCH (LOW RANGE) OR THE ONE. WAY CLUTCH
(D! RANGE) IS HOLDING THE REVERSE UNIT PLANET CARRIER STATIONARY.
FIRST GEAR
- -~ --- -
THE LOW AND REVERSE CLUTCH IS APPLIED. THE REVERSE UNIT PLANET
CARRIER IS HELD STATIONARY.
THE INTERMEDIATE BAND IS APPLIED. THE REVERSE AND HIGH CLUTCH
DRUM, THE INPUT SHELL AND THE SUN GEAR ARE HELD STATIDNARY. REVERSE
GEAR RATIOS
,I FIRST 2.46:1
SEC~D 1.46:1
HIGH 1.00:1
THE FORWARD CLUTCH IS APPLIED. THE FRONT PLANETARY UNIT RING
GEAR IS LOCKED TO THE INPUT SHAFT. REVERSE 2.17:1
SECOND GEAR
D1596-A
Pressure Booster Valve off line pressure feed to the gover- valve will move inward, allowing
nor passage and allowing this pas- governor pressure to exhaust, and
FORWARD DRIVING close the passage between line pres-
sage to be ~pened to exhaust, at the
RANGES (D1, D2, L) inner end of the valve. At the same sure and governor pressure. When
TV pressure is delivered to the time, line pressure will pass by two governor pressure is reduced, the
lower valley of the pressure booster flats on the outer end of the valve, secondary valve will again move out-
valve and to the end of the pressure pressurizing the line leakage pas- ward, closing the governor exhaust
booster valve. When force created port and opening the line pressure
sageleading to the primary governor
on the booster valve by TV pressures valve. At rest, the spring on -the out- to governor passage.Above 10 mph,
in these two areas exceeds pressure er end of the primary governor governor pressure is regulated in this
booster valve spring force, the force manner, and will vary with the car
valve holds the primary governor
will be added to the main regulator valve inward, blocking furtQer flow speeds.
valve spring force transmitted to the of the fluid in the line leakage pas- If the car speed drops below 10
main regulator valve. This will pro- sage. This causes pressure in the mph, the primary valve spring will
vide increased control pressures re- line leakage passage to build to the move the primary governor valve
quired to compensate for increased same value as line pressure. As a in, closing the line leakage exhaust
throttle openings and engine torque consequence, the secondary gover- port at the primary valve. Pressure
output. Fig. 10 shows how control nor valve is held in and there is no in the line leakage passage will be-
pressure varies with engine vacuum pressure in the governor circuit. come equal to line pressure, forcing
at zero output shaft rpm. ABOVE 10 MPR. When speed the secondary governor valve in.
REVERSE (R). Additional fluid reaches approximately 10 mph, cen- This action shuts off line pressure
pressure is required in reverse to pre- trifugal force on the primary gover- feed to the governor passage and
vent clutch and/ or band slippage nor valve overcome spring force, exhausts the governor circuit.
under stall or partial stall conditions. and the valve moves outward, open- When the secondary governor
This additional pressure is provided ing the line leakage passage to ex- valve is regulating, governor pres-
by directing line pressure to the haust. This action reduces the pres- sure will be delivered to the cutback
upper valley of the pressure booster sure on the end of the secondary valve, end of the 2-3 shift valve, 1-2
valve when reverse range is selected. governor valve to zero (0), allowing shift valve and end of the line pres-
The differential in area between the the secondary valve to also move sure coasting boost valve and 3-2
lands of this valve provides a force outward, due to spring force and coasting control valve. Fig. 10 shows
which is added to the TV pressure centrifugal force. When the secon- the relationship between governor
forces present in the lower valley dary valve moves outward, it closes pressure and output shaft rpm.
and on the end of the valve, to the governor exhaust passage, and Throttle Booster Valve. Throttle
boost line pressure to a higher value allows line pressure to enter the gov- plate openings above 50° provide
than is available in the forward driv- ernor passage.As pressure builds in very little change in engine vacuum
ing ranges. the governor passage,it will create a as compared to throttle plate open-
force on the secondary governor ings below 50°. The throttle booster
Governor valve due to the differential in areas valve is used to boost throttle pres-
AT REST (0 MPH). Control pres- of the inner and outer lands of the sure and provide the necessary shift
sure (line) is fed to the secondary valve. This force tends to move the delay for engine throttle plate open-
governor valve through the center ings above 50°.
valve inward. When the force on
passage in the valve body. Because Below approximately 65 psi pri-
of the differential in area of the inner the valve created by pressure in the
mary 11{ pressure, 11{ pressure
~d outer lands of the valve, the governor passage exceed the cen- flows to and through the throttle
valve will be forced inward, shutting trifugal force plus spring force, the boost valve unaffected, working on
the end of the boost valve and on
the area differential in the first valley.
When TV pressure increasesabove
65 psi, the force created by 11{
pressure acting on the end of the
throttle boost valve, minus the force
of TV pressure acting on the area
differential in the first valley will
exceed the force of the spring. This
causes the valve to move against
the spring, closing off primary TV
pressure to the area differential and
permitting this area to be fed from
line pressure, causing a boost in the
pressure used for shift delay only.
Because the area of the end of the
throttle boost valve exceeds the area
differential in the first valley by 3
to 1, throttle boost pressure above
FIG. 1 a-Control Line Pressureand GovernorPressureVersusOutput 65 psi primary 11{ pressure will
increase 3 psi for each 1 psi increase
Shaftrpm
PART 7-3 - C6 AUTOMATIC
DUALRANGE
TRANSMISSION 7-61
in primary TV. Dl RANGE. In Dl range the 1-2 sure is present on the end of the 1-2
Figure 8 shows the relationship shift valve is held closed (up) by accumulator valve and holds the
between primary TV pressure and modulated throttle pressure acting valve up in its bore against spring
boosted throttle pressure. on the differential area between the pressure.
Throtde Modulator Valve. The two lands of the 1-2 shift valve, by When the 1-2 shift valve train
throttle modulator valve, located in D fluid pressure acting on the dif- moves to make a 1-2 shift, line pres-
the end of the 2-3 shift valve bore ferential in area between the two sure passes thru the D-2 valve and
reduces throttle pressure which acts lands at the spring end of the D2 goes to the 1-2 scheduling valve.
on the end of the 2-3 shift valve and valve, and by the 1-2 shift valve This pressure passes thru the sched-
on the area differential of the 1-2 spring. Governor pressure tends to uling valve bore, goes to the differen-
shift valve. Modulated throttle pres- move the 1-2 shift valve train against tial in area between the two lands
sure in these areas provides shift these forces. When force created by of the 1-2 accumulator valve and
delay in relation to throttle opening. governor pressure exceeds the forces thru the 2-3 backout valve to apply
Cutback Valve. Increased line holding the 1-2 shift valve train the intermediate servo. This same
pressure is required to prevent closed, the 1-2 shift valve and D2 fluid also passes thru a hole in the
clutch and band slippage under stall valve will be opened (move down- center of the 1-2 scheduling valve
ward), closing the exhaust port and to the end of the valve, and also
conditions. Dependent upon car
speed,the requirements for increased allowing D fluid to pass through the thru an orifice which feeds the fluid
line pressure are considerably re- D2 valve to accomplish the 1-2 to the spring ends of the 1-2 accum-
duced. When governor pressure shift. When the D2 valve is moved ulator and 1-2 scheduling valves.
acting on the end of the cutback downward, D fluid is exhausted The fluid which passes thru the
from the differential in areas pro- center of the 1-2 scheduling valve
valve exceeds the force of TV pres-
vided by the lower two lands of the tends to move the valve upward
sure acting on its area opposing gov-
ernor, the cutback valve will move D2 valve and modulated throttle against spring force. However, the
pressure from area differential on spring effort and fluid pressure cre-
cutting off primary TV pressure
1-2 valve. This action eliminates the ated by the fluid which has passed
being fed to the lower valley of the
force created by D fluid which thru the orifice to the spring end of
pressure booster valve, thtu the
tends to hold the 1-2 shift valve the valve will hold the valve down.
coasting boost valve. This action
reduces the assist that the pressure train closed. As fluid flows thru the orifice to
booster valve provides to the main If governor pressure is reduced the spring ends of the 1-2 accumu-
to the point where spring force ex- lator and scheduling valves, and
regulator valve spring. The cutback
valve movement will therefore vary ceeds governor pressure force, the pressure increaseson the spring ends
1-2 shift valve train will move up of the valves, the 1-2 accumulator
with engine throttle opening and
car speed. Figure 10 shows how (close) cutting off the flow of D valve starts to move downward. This
line pressure varies with output shaft fluid through the valve and opening movement of the 1-2 accumulator
the exhaust port allowing a down- valve causes a flow of fluid thru the
rpm (car speed) at constant vac-
shift to low gear. orifice, resulting in a lower pressure
uum values.
If the throttle is opened through existing on the spring sides of the
Coasting Boost Valve. When using valves.
manual low 10 force a 3-2 coasting detent, the downshift valve moves
to allow line pressure to enter the As a consequence, the fluid pres-
(throttle closed) downshift in order sure on the end of the 1-2 scheduling
to use the engine as a brake, addi- modulated throttle pressure passage
at the 1-2 shift valve to provide a valve opposite the spring will be
tional pressure may be required to higher than the pressureon the spring
insure positive band applications. forced 2-1 downshift.
L-RANGE. Once the transmission end of the valve, causing the valve
With the throttle closed there will to move upward. This action cuts
be no TV pressure present at the is in low gear L-R fluid, which is
directed to the D2 valve, passes off fluid supply to the intermediate
pressure booster valve. servo (and thru the orifice) and
through the D2 valve and is deliv-
At speeds above approximately ered to the spring end of the D2 opens an exhaust port at the end of
55 mph, additional pressure is ob- valve, preventing an upshift. L-R the 1-2 scheduling valve. When the
tained thru the U3e of the coasting fluid which passes through the D2 exhaust port opens, the pressure on
boost valve. When the manual valve valve also applies the reverse clutch. the end of the 1-2 scheduling valve
is shifted to manual low (L), line Coasting downshifts to first gear are opposite the spring is reduced, allow-
pressure is exhausted from the end not possible above approximately 10 ing the valve to again move down-
of the coasting boost valve, allow- mph in low range. ward and opening the line to the
ing governor pressure to move the D2 RANGE. In D2 range, D2 intermediate servo apply.
valve downward. This action blocks fluid is introduced between the 1-2 In this manner, the 1-2 schedul-
the TV pressure passage from the shift and D2 valves. This action ing valve regulates to control the
cut-back control valve and allows in- opens the D2 valve and holds it intermediate servo apply during a
termediate servo apply pressure to open, providing a second gear start 1-2 shift, until the 1-2 accumulator
pass thru the coasting boost valve and preventing a 2-1 downshift. valve has fully bottomed in its bore
to the lower valley of the pressure 1-2 Scheduling Valve and 1-2 Ac- and there is no more fluid flow thru
booster valve, increasing main line cumulator Valve. The 1-2 scheduling tile orifice.
pressure. and 1-2 accumulator valves are used 2.3 Shift Valve. The 2-3 shift
1-2 Shift Valve Train. The 1-2 to control the rate of band applica- valve is held closed by throttle mod-
shift valve train is composed of the tion during a 1-2 shift. ulator valve spring force, modulated
1-2 shift valve, the D2 valve, and During operation in first gear throttle pressure force, and by D1
the 1-2 shift valve spring. prior to the 1-2 shift, control pres- fluid pressure force acting on the
7-62 GROUP 7 - AUTOMATIC
TRANSMISSION
differential in area of the lands of 2-3 shift valve, forcing the valve up force. This action immediately con-
the valve to which it is delivered. and causing a forced 3-2 downshift. nects the clutch apply circuit to the
Governor pressure tends to open Maximum 3-2 forced downshift intermediate servo apply circuit, re-
the 2-3 shift valve. When force speed is controlled by governor ducing the pressure on apply side of
created by governor pressure exceeds pressure. the servo to the same valve as in the
the forces holding the valve closed, In addition to the above, a 3-2 reverse-high clutch (and also on the
the valve will move downward downshift will occur when the manu- release side of the intermediate
(open) closing the exhaust passage al valve is moved to L range. The servo). When this happens, the inter-
(through the manual valve) and DI passagewhich feeds fluid to the mediate band is released, to provide
opening the Dl passageto allow Dl 2-3 shift valve will then be opened a smooth 2-3 shift.
fluid to apply the reverse-high clutch to exhaust, allowing reverse-high 3.2 Coasting Control Valve. The
and release the intermediate servo. clutch apply-intermediated servo re- 3-2 coasting control valve controls
With the shift valve open (down) lease fluid to exhaust and causing the intermediate servo apply force
the throttle modulator valve is held a 3-2 downshift. to provide acceptable 3-2 downshifts
down cutting off modulated throttle 2.3 Backout Valve. The purpose under both coasting and throttle-on
pressure to the 2-3 shift valve and of the 2-3 back-out valve it to pro- conditions.
1-2 shift valve. In addition, the port vide smooth upshifts, when the throt- THRO1TLE-ON 3-2 SHIFT.
which delivered Dl fluid to the dif- tle is suddenly closed while accele- During a 3-2 throttle-on downshift,
ferential in area of the shift valve rating in second gear. Operation is car speed will be such that governor
lands, is closed. as follows: pressure will hold the 3-2 coasting
The shift valve will be reopened NORMAL THROTTLE ON 2-3 control valve bottomed in its bore
(moved up) causing a downshift UPSHIFTS. When the 2-3 shift against its spring. In this position,
under one or more of the following valve moves to cause a 2-3 upshift, intermediate servo release fluid ex-
conditions: D I fluid passesthrough the valve to hausts through the coasting control
GOVERNOR PRESSURE RE- apply the direct clutch and release valve and 2-3 shift valve during a
DUCED. If governor pressure is the intermediate servo. This same 3-2 downshift, allowing a rapid ap-
reduced to the point where it can fluid is also directed to the end of ply of the intermediate band.
no longer hold the shift valve down the 2-3 back-out valve. However, COASTING 3-2 SHIFT ( D2
against spring force, the valve will with throttle open, primary throttle RANGE). At the 3-2 coasting down-
move up causing a downshift. Under pressure on the opposite end of the shift speed, governor pressure is re-
closed throttle conditions, the 2-3 2-3 back-out valve, assists spring duced to zero and the 3-2 coasting
shift valve will close at approxi- force in holding the valve up, so control valve will be moved by spring
mately 10 mph, (speed at which gov- that there will be no valve move- force to the bottom of its bore. This
ernor pressure is cut off). Si~ce ment until after the 2-3 shift has blocks the direct passage of inter-
governor pressure is cut off at this been completed. mediate servo release fluid to exhaust
speed, the 1-2 shift valve train also BACK-OUT 2-3 UPSHIFTS. and requires that this fluid be ex-
closes at the same time. This will When the throttle is closed during hausted through a controlling orifice.
provide a 3-1 downshift when coast- a 2-3 upshift, and before the shift is Therefore, the band application is
ing in Dl range. completed, there may be enough cushioned during a 3-2 coasting
THROTTLE PRESSURE IN- pressure in the reverse-high clutch downshift, resulting in a smooth
CREASED. If throttle pressure is cylinder to apply the clutch at the re- shift.
increased sufficiently, it will move duced engine torque input, but not Manual Low Valve. The manual
the throttle modulator valve and enough pressure to release the inter- low valve insures that the 2-3 back-
consequently the 2-3 shift valve up, mediate servo. This condition could out valve will be moved up the in-
causing a 3-2 torque demand down- cause a harsh 2-3 shift. However, if stant that pressure drops in the
shift. the throttle is closed during a 2-3 reverse-high clutch apply-intermedi-
LINE PRESSURE INTRO- shift, primary throttle pressure will ate servo release circuit, when a shift
DUCED BELOW 2-3 SHIFT be reduced to zero (0), and reverse- to manual low range is made. This
VALVE. If the downshift valve is high clutch apply pressure on the is accomplished by directing control
n1()vedthrough detent, line pressure end of the 2-3 back-out valve will pressure to the end of the manual
is directed to the underside of the move the valve down against spring low valve, when L range is selected.
""'-',
-~ ,,' c, ,
,', ,
., I
r \
'""lt
roo
! ~
-
VIEWZ
\
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~ r ""-::::-::---""
.~~~---
~, "
-"""'-;:'\'~--
,
!\ '"
J
I '\ \'\
TRANSMISSION. SELECTOR
MANUALLEVER LEVER
\
..
I \
I
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,,~
'...,
, ~ _:~::::::::::=/
-
,/"
200AND289ENG
NEUTRAL
STARTSWITCH
C4TRANSMISSION
D-1626.A
PART 7-3 - C6 AUTOMATIC
DUALRANGE
TRANSMISSION 7-65
BAND ADJUSTMENT
1. Raise the car on a hoist or
jack stands.
2. Clean the threads of the inter-
mediate band adjustment screw.
3. Loosen the adjustment screw
lock nut.
4. Tighten the band adjustment
screw as shown in Fig. 16 until the
wrench overruns, then back it off
11/8 turns. Tighten the adjustment
FIG. 14-Selector Lever Detent Pawl Adjustment screw lock nut to specification being
7-66 GROUP 7 AUTOMATIC
TRANSMISSION
'"
",.
r
the output shaft. remover carefully so that the spline
14. Secure the governor (Fig. 18) seal is not damaged.
to the distributor flange with the Tool-T61L-7657-B
c~
'CCCCCC ,
gasket on the transmission. C ~ ~c. Cc
INPUT
SHELL
D 1608 - A
OUTER
INNER
MANUAL.
LEVER
PARKING
DDWNSHIFT I. PAWL ACTUATING
LEVER ROD
LOW- REVERSE CLUTCH
APPLY PASSAGE D1611-A
-~-~~-~.. DI6J2-A
FIG. 31-RemovingLow- FIG. 32-Downshift and Manual linkage
ReverseClutch Piston
lever to the transmissionand remove shaft. Slide the outer lever and shaft
piston from the case as shown in the lever. from the case.
Fig. 31. 2. Removethe two bolts that se- 6. Removethe seaifrom the case
cure the neutral safety switch to the with Tools T59L-IOO-Band T58L-
PARTS REPAIR OR case. Insert a screwdriver between lOl-A or 7600-E.
REPLACEMENT the switch and caseas closeaspossi- 7. Dip the new seal in transmis-
During the repair of the subas- ble to the shaft. Gently pry the sion fluid and install it in the caseas
semblies, certain general instructions switch from the case. shownin Fig. 33.
which apply to all units of the trans- 3. Slide the downshift lever out 8. Slide the outer m~nual lever
mission must be followed. Following from the inside of the case (Fig. and shaft in the transmissioncase.
these instructions will avoid unneces- 32). Removethe sealfrom the recess 9. Position the inner lever on the
sary repetition. in the manuallever shift. shaft and install the attaching nut.
All transmission parts must be 4. Removethe C-ring that secures Tighten the nut to specification.In-
handled carefully to avoid nicking the parking pawl actuating rod to stall the parking pawl actuatingrod
or burring the bearing or mating the manual lever. Remove the rod and secure it to the inner manual
surfaces. from the case. lever with a C-washer.
Lubricate all internal parts of the 5. Remove the nut that secures 10. Install a new downshift lever
transmission with clean automatic the inner manual lever to the shaft. seal in the recessof the outer lever
transm:ssion fluid before assembling Remove the inner lever from the shaft. Slide the downshift lever and
them.
Do not use any other lubricants GUIDEPLATE PIN SPRING CUPPED PLUG
except on gaskets and thrust wash-
ers. These may be coated with vase-
line to facilitate assembly. Always
use new gaskets and seals when as-
sembling a transmission.
Tighten all bolts and screws to the
recommended torque as outlined in
the Specification Section.
TRANSMISSION CASE AND
LINKAGE
Downshift and Manual Linkage
1. Remove the nut ..nd lock wash-
er that secures the outer downshift
D1614-A
shaft into position. 12. Place the outer downshift Hook the end of the spring over the
11. Position the neutral safety lever on the shaft and secure it with pin on the park plate.
switch on the manual lever and se- a lock washer and nut. 7. Install a new cupped washer
cure it with the two attaching bolts. (Fig. 34) to retain the shaft.
Leave the attaching bolts loose to Parking Pawl Linkage 8. Install the parking pawl shaft
adjust the switch after installing the 1. Remove the bolts that secure in the case. Slip the parking pawl
control valve. the parking pawl guide plate to the and spring into place on the shaft.
case (Fig. 34). Remove the plate. 9. Position the guide plate on the
2. Remove the spring, parking case making sure that the actuating
pawl and shaft from the case. rod is seated in the slot of the plate.
3. Working from the pan mount- Secure the plate with two bolts and
ing surface, drill a Ys inch diameter lock washers.
hole through the center of the
cupped plug. Pull the plug from the Servo Apply Lever
case with a wire hook. 1. Working from inside of the
4. Lift the end of the spring off transmission case, carefully drive on
the park plate pin to relieve the the servo apply lever shaft to remove
tension. the ball. The shaft (Fig. 36) can be
5. Thread a Y4-20 inch screw withdrawn from the case by hand.
(Fig. 35) into the park plate shaft. 2. Hold the servo apply lever in
Pull the shaft from the case with position and install the new shaft.
the screw. 3. Press the ball into position and
6. Position the spring and park stake it in two places as shown in
plate in the case and install the shaft. Fig. 36.
PARK PLATE PARK
SHAFT PLATE Thread Repair Case. Thread serv-
D1629-A ice kits may be purchased from local
jobbers or the Heli-Coil Corpora-
FIG. 35-Removing Park Plate tion. To repair a damaged thread,
Shaft the following procedures should be
carefully followed.
TRANSMISSION SERVO APPLY LEVER 1. Drill out the damaged threads
CASE
using the same size threads as the
CONVERTER thread on. For example, use a %6-
HOUSING
inch drill when repairing a %6-18
\--.0 inch thread.
Fri3;
-
2. Select the proper special tap
and tap the drilled hole. The tap is
FRONT OF TRANS. marked for the size of the thread
being repaired. Thus, the special tap
BALL
supplied with the repair kit marked
STAKEBALLSECURELY,.
%6-18 will not cut the same thread
-2-PLACES ASSHOWN -Y VIEWA as a standard %6-inch tap. It will
ANYRADIALLOCATIC)'! D 161S-A D1617.A cut a thread large enough to accom-
modate the insert, and after the in-
FIG. 36-Servo Apply Lever FIG. 38-Removing Manual sert is installed, the original thread
Installation Valve size (%6-16 inch) is restored.
SEPARATOR
PLATE
7AOO8
D
1616
FIG. 37-Upper and Lower Valve BodiesDisassembled
PART 7-3 C6 AUTOMATICDUAL RANGETRANSMISSION 7-73
~"..,
~
SPRING
~
"PRESSURE
BOOST
VALVE
SLEEVE
PLATE
I, I, D1618-A
3. Select the proper coil inserting the eight attaching screws. valve body and install the detent
tool. These tools are marked with 10. Hold the valve body so that plug, spring and the retaining pin in
the thread size being repaired. Place the plate is facing upward. Slowly the body.
the insert on the tool and adjust the release the pressure and remove the 13. Place the valve body on a
sleeve to the length of the insert plate. clean surface with the passage side
being used. 11. When removing the various facing up. Place the converter relief
Press the insert against the face of valves from the control valve body, valve spring in its bore (Fig. 40).
the tapped hole. Turn the tool clock- keep all ports covered with your fin-
wise and wind the insert into the gers except the bore the valve is be-
hole until the insert is one half turn ing removed from. Remove the 1-2
below the face. shift capacity scheduling and accu-
4. Working through the insert, mulator valves and springs (Fig. 39)
bend the insert tang straight up and from the valve body.
down until it breaks off at the notch. 12. Remove the 2-3 back-out
5. If the inserts are not properly valve, spring and the manual low
installed, they can be removed with valve.
the extractor tool. Place the ex- 13. Remove the 2-3 shift valve,
tractor tool in the insert so that the spring and the throttle modulator
blade rests against the top coil 1/4-Y2 valve.
turn away from the end of the coil. 14. Remove the 1-2 shift valve,
Tap the tool sharply with. a hammer D2 shift valve and the spring from
so that the blade cuts into the insert. the valve body.
Exert downward pressure on the tool 15. Remove the coasting boost
and turn it counterclockwise until valve and the spring from the body.
the insert is removed. 16. Remove the cut back control
valve to complete the disassembly of D 1630- A
plates on the separator plate and gear has an identification mark on from the piston and the inner seal
torque the screws to specification. one face. The identification mark on from the clutch drum (Fig. 46).
each gear must be toward the front
FRONT PUMP of the pump housing.
Assembly
The front seal can be replaced 2. Position the .pump support in
the pump housing and install and 1. Dip the new seals in trans-
(Figs.41 and 42) after the pump has
torque the five attaching bolts to mission fluid and install one on the
been installed on the transmission.
drum and one on the piston.
specification.
3. Carefully install two new seal 2. Install the piston in the clutch
rings on the pump support. Make drum.
sure that the ends of the rings are 3. Position the piston return
engaged to lock them in place. springs in the piston sockets. Place
4. Install the selective thrust the spring retainer on the springs.
washer. Make sure that the correct 4. Install Tool T65L-77515-A
thickness selective washer is being (Fig. 47) and compress the springs.
used to obtain the specified end play. Make certain that the spring retainer
5. Place the pump on converter is centered while compressing the
making sure that the drive gear en- springs. Install the snap ring. Before
gages the converter hub. Rotate the releasing the pressure on the tool,
pump to make sure that the gears make certain that the snap ring is
rotate freely. positioned inside of the four snap
ring guides on the spring retainer.
REVERSE-ffiGH CLUTCH 5. Dip the clutch plates in clean
Tool- T63L-77837-A transmission fluid. Install the clutch
Disassembly plates alternately starting with a
D 1637. A 1. Separate the drive train as steel drive plate and a composition
shown in Fig. 44. Remove the pres- plate (Fig. 46).
FIG. 42-lnstalling Front Pump sure plate retaining snap ring from 6. After all clutch plates have
Seal the reverse-high clutch as shown in been installed, position the pressure
Fig. 45. plate in the clutch drum with the
Disassembly 2. Remove the pressure plate and chamfered side facing up. Install
the drive and driven clutch plates the pressure plate snap ring.
1. Removethe two sealrings and
the selectivethrust washer(Fig. 43). (Fig. 46). 7. With a feeler gauge, check the
3. Install Tool T65L- 77515-A clearanc~ between the pressure plate
2. Remove the O-ring seal from (Fig. 47) on the reverse-high clutch
the pump housing. and snap ring (Fig. 49).
drum. Make sure that the legs clear 8. The pressure plate should be
3. Removethe five bolts that se- the snap ring enough to permit ex-
cure the pump support to the pump held downward as the clearance is
panding it enough for removing it. checked. The clearance should be
housing. Lift the support from the Remove the snap ring and remove
housing. the tool. 0.022-0.036. If the clearance is not
4. Removethe drive and the driv- within specifications, selective thick-
4. Remove the spring retainer and
en gearfrom the housing. the piston return springs. ness snap rings are available in the
5. Apply air pressure to the piston following thicknesses: 0.065-0.069,
Assembly apply hole in the clutch hub (Fig. 0.074-0.078, 0.083-0.087. Install the
1. Install the drive and driven 48) and remove the piston. correct size snap ring and recheck
gears in the pump housing. Each 6. Remove the piston outer seal the clearance.
D 1619
6
8
11
10 14
12
- -- - - -
d
- ""
- - - - -- \
" -- ""
16
17 18
19
20
?1
-- - - - -_/
/
22
26 '7
J J J.
28
0
/
-- - --- - 0 -"
I \
\ /
/
'"
" '- -
1. FRONT PUMP SEAL RING 11. FORWARDCLUTCH HUB 20. REVERSE RING GEAR AND SPRING RETAINER
2. FRONT PUMP ASSEMBLY HUB RETAINING RING 30. RETURN SPRING
3. GASKET 12. NUMBER 5 THRUST WASHER 21. REVERSE RING GEAR AND HUB 31. LOW-REVERSE PISTON
4. SEAL 13. FORWARDPLANET ASSEMBLY 22. NUMBER 9 THRUST WASHER 32. CASE
5. NUMBERI THRUSTWASHER 14. INPUT SHELL AND SUN 23. LOW-REVERSE CLUTCH HUB 33. NUMBER 10 THRUST WASHER
(SELECTIVE) GEAR ASSEMBLY 24. ONE-WAY CLUTCH 34. PARKING GEAR
6. REVERSE-HIGH CLUTCH 15. NUMBER 6 THRUST WASHER 2S. ONE-WAY CLUTCH INNER RACE 35. GOVERNORDISTRIBUTOR SLEEVE
ASSEMBLY 16. SNAP RING 26. SNAP RING 36. SNAP RING
7. NUMBER 2 THRUST WASHER 17. NUMBER 7 THRUST WASHER 27. LOW-REVERSE CLUTCH 37. GOVERNORDISTRIBUTOR
8. FORWARDCLUTCH ASSEMBLY 18. REVERSE PLANET ASSEMBLY 28. SNAP RING 38. GOVERNOR
9. NUMBER 3 THRUST WASHER 19. NUMBER 8 THRUST WASHER 29. LOW- REVERSE PISTON RETURN 39. OUTPUT SHAFT
10. NUMBER 4 THRUST WASHER
D1620-A
FORWARD CLUTCH 2. Removethe rear.pressureplate, that secures the disc spring in the
the drive and driven plates and the clutch cylinder. Remove the disc
Disassembly. forward pressure plate from the spring.
1. Remove the clutch pressure clutch hub (Fig. 51). 4. Apply air pressure to the clutch
plate retaining snap ring (Fig. 50). 3. Removethe snapring (Fig. 52) apply passage in the cylinder (Fig.
53) to remove the piston.
5. Remove the seal from the pis-
ton and the seal from the clutch hub
(Fig. 51).
Assembly
1. Dip two new seals in trans-
mission fluid. Install the smaller seal
on the clutch hub and the other seal
on the clutch piston.
2. Install the clutch piston in the
cylinder.
3. Make sure that the steel pres-
sure ring is in the groove on the pis-
ton. Position the disc spring in the
cylinder with the conv.ex face down-
FIG. 45-Removing Reverse-HighPressurePlate SnapRing ward. Install the spring as shown in
SPRING
f
7Bf°'\
f
SPRING
RETAINER
EXTERNAL
SPLINE PRESSURE
PLATE PLATE
70427 78442 78066 D1631-A
5. With a feeler gauge, check the size snap ring and recheck the
clearance between the snap ring and clearance.
the pressure plate (Fig. 54). Down-
ward pressure on the plate should
be maintained when making this INPUT SHELL AND SUN GEAR
check. The clearance should be
0.048-0.061 inch. Disassembly
6. If the clearance is not within 1. Removethe rear snapring from
D1550-A specifications, selective snap rings the sun gear as shown in Fig. 55.
are available in the following thick- 2. Removethe thrust washerfrom
FIG. 49-Checking Reverse- nesses:0.065-0.069,0.074-0.078, and the input shell and sun gear (Fig.
High Clutch Snap Ring Clearance 0.083-0.087 inch. Insert the correct 55).
INNER SEAL
PISTON
7A262 STEEL
,
SNAP
.
SELECTIVE
377130894 RING RING EXTERNAL SPLINE
7D256 PLATE-7B442 SNAP RING
377127-5 377126-5
D1632-A
LOWANDREVERSE
cLyrcH DRUM.7D390
FIG. 55-Removing or Installing ONE.WAY
2. Make sure that all of the roll- SERVO 2. Working from the front end of
ers are in place and that the springs the output shaft, slide the governor
contact them properly. Disassembly distributor into place on the shaft.
3. Place the low-reverse clutch 1. Apply air pressure to the port Install the snap ring to secure it.
hub on the bench with the one-way in the servo cover to remove the Make sure that the snap ring is
clutch race facing upward. piston and stem. seated in the groove.
4. Place the one-way clutch on 1. Remove the seals from the pis-
3. Position the governor on the
the hub so that the springs load the too.
distributor (Fig. 60) and secure them
rollers in a counterclockwise direc- 3. Remove the seal from the
with the attaching screws.
tion when looking downward at the cover.
unit (Fi£. 59). ASSEMBLY OF TRANSMISSION
Assembly
1. Dip the new sealsin transmis- 1. Place the transmission case in
sion fluid. a holding fixture.
2. Install the new seals on the 2. Tap the reverse clutch piston
piston. into place in the case with a clean
3. Install the new seal on the rubber hammer.
cover. 3. Hold the one-way clutch inner
4. Dip the piston in transmission race in position and install and
fluid and install it in the cover. torque the attaching bolts to speci-
fication.
WW-REVERSE CLUTCH
PISTON 4. Install a low-reverse clutch re-
turn spring in each pocket in the
Disassembly clutch piston. Press the springs firmly
1. Remove the inner and the into the piston to prevent them
outer seal from the reverse clutch from falling out.
piston. 5. Position the spring retainer over
the springs and position the retainer
Assembly snap ring in place on the one-way
D1622-A
1. Dip the two new seals in clean clutch inner race.
transmission fluid.
6. Install the compressing tool
FIG. 59-Installing One-Way 2. Install the seals on the piston.
shown in Fig. 31 and compress the
Clutch OUTPUT SHAFT springs just enough to install the
low-reverse clutch piston retainer
5. Work each roller inward just Disassembly snap ring.
enough to enter it in the ramp. Do 1. Remove the governor attaching 7. Install the snap ring, then re-
this to each individual roller until bolts and remove the governor. move the compressing tool.
the one-way clutch is positioned in 2. Remove the snap ring that se-
8. Place the transmission case on
the race. Placing a rubber band cures the governor distributor on the
the bench with the front end facing
around the clutch as shown in Fig. output shaft (Fig. 60) and slide it
downward.
59 helps to contract the rollers to off the front of the shaft.
permit installation. After all of the 3. Remove the seal rings from the 9. Position the parking gear thrust
rollers have started, remove the rub- distributor. washer and the gear on the case
ber band. (Fig. 34).
6. Install the snap ring at the rear Assembly 10. Position the oil distributor and
of the low-reverse clutch hub to se- 1. Carefully install new seal rings tubes in place on the rear of the
cure the one-way clutch. on the distributor. case. Install and torque the attach-
SNAP SEAL
RING RING
GOVERNOR
..t. ~ >
) )!
D1623-A
ing bolts to specification. ring in the groove in the output shaft. into the case around the direct
11. Install the output shaft and 17. Assemble the front and rear clutch cylinder with the narrow band
governor as an assembly. thrust washers onto the reverse end facing toward the servo apply
12. Place a new gasket on the planet assembly. Retain them with level. Install the struts and tighten
rear of the transmission case. Po- vaseline, and insert the assembly the band adjusting screw sufficiently
sition the extension housing on the into the ring gear. Install the snap to retain the band.
case and install the attaching bolts. ring in the ring gear. 23. Place a selective thickness
Torque the attaching bolts to speci- 18. Set the reverse-high clutch on bronze thrust washer on the rear
fication. the bench, with the front end facing shoulder of the stator support and
13. Place the case in the holding down. Install the thrust washer on retain it with vaseline. Lay a new
fixture. the rear end of the reverse-high gasket on the rear mounting face of
14. Align the low-reverse clutch clutch assembly. Retain the thrust the pump and position the pump on
hub and one-way clutch with the washer with vaseline and insert the the case being careful not to damage
inner race at the rear of the case. splined end of forward clutch into the O-ring. Install six of the seven
Rotate the low-reverse clutch hub the open end of the reverse-high mounting bolts and torque them to
clockwise while applying pressure clutch so that the splines engage the specification.
to seat it on the inner race. reverse-high friction plates (Fig. 46). 24. Adjust the intermediate band
15. Install the low-reverse clutch 19. Install the thrust washer and as detailed in Section 2 and install
plates, starting with a steel plate and retain it with vaseline, on the front the input shaft.
following with friction and steel end of the forward planet ring gear 25. Install tool 4201-C at the sev-
plates alternately. If new compo- and hub. Insert the ring gear into enth pump mounting bolt (Fig 25)
sition plates are being used, soak the forward clutch. and check the transmission end play.
them in clean transmission fluid for 20. Install the thrust washer on Remove the tool.
fifteen minutes before installation. the front end of the forward planet 26. Install the control valve in the
Install the pressure plate and the assembly. Retain the washer with case, making sure that the levers
snap ring. Test the operation of the vaseline and insert the assembly into engage the valves properly.
low-reverse clutch by applying air the ring gear. Install the input shell 27. Install the primary throttle
pressure at the clutch pressure apply and sun gear assembly. valve, rod, and the vacuum diaph-
hole in the case. The transmission 21. Install the reverse-high clutch, ragm in the case.
casesare machined to accommodate forward clutch, forward planet as- 28. Install a new pan gasket and
a five-plate clutch pack. sembly and input shell and sun gear the oil pan.
16. Install the reverse planet ring as an assembly into the transmission 29. Install the converter assembly.
gear thrust washer and the ring gear case. 30. Install the transmission in the
and hub assembly. Insert the snap 22. Insert the intermediate band car.
7-82
SPECIFICATIONS
11.078-0.074
I rJ.O64-0.060
Reverse-HighClutch Pressure 0.060-0.080inch
Plate to Snap Ring Clearance Selective Snap Ring Thicknesses
0.092-0.088
0.078-0.074
0.064-0.060
0.102-0.106(2)
@Use with PCWand PCS models.
SELECTIVE THRUSTWASHERS-
CONTROL TRANSMISSION END PLAY@
(No.1 and 2)
Thrust WasherNo.1 Thrust WasherNo.2
- -
Composition Color No. Stamped Metal
Thrust of on Thrust
Washer
0.108-0.104
Washer
-
L
Rlue
Washer
-5 Washer
0.109-0.107
0.091-0.087 .-,
VAliow 4 0.092-0.090
0.074-0.070 -.
Rlack 3 0.075-0.073
LUBRICANT REFILL CAPACITY 0.057-0.053 .
Tan 2 0.058-0.056
Models Capacity 0.042-0.038 -.
Green 1 0.043-0.041
PCS-V,Y, Wand AA
0.121-0.125 ..
Red
7qts250z
0.138-0.142 Purple
PCW-AN, AR, AS, AY and AZ 8 qts 27 oz
@Selectionin pairsnot applicable.
PART 7-4 - SPECIFICATIONS
AND SERVICE
TOOLS 7-83
Range Shift 1 2 3 4 5 6 7 8
L 2-1 19 19 20 20 21 22 23 23
-
Use
Engine Axle Column
Car CID Ratio Tire Size No.
Comet or 6.95x 14 1
200-IV 3.50:1
Falcon
7.35x 14or 7.75x 14 2
Falcon I70-IV
-
3.25:1 6.50x 13 2
I70-IVor 7.35 x 14 or 7.75 x 14 4
Falcon 200-IV 6.95x 14 3
3.20:1 6.50x 13or 6.95x 14 3
2.83:1
Falcon 170-1V or 6.50x 13 6
2.80:1
Cometor 200-1V 6.95 x 14or 7.35x 14 7
Falcon
Range Shift 1 2 3 4 5 6 7 8
-
Use
Engine Axle Jlun.
Car CID Ratio Tire Size No.
7.35 x 14 or 7.75 x 14 4
Fairlane 3.00:1 6.95x 14 5
289-4V 7.35 x 14 or 7.75 x 14 6
(Cant'd) 2.80:1 6.95 x 14 7
7.35 x 14 8
-
3.20:1 6.95x 14 4
3.00:1 6.95x 14 5
Mustang 289.4V 2.80:1 6.95x 14 7
or
2.83:1
200-6-Cyl. 1600-1800
289-2V 1750-1950
289-4V 1800-2000
CLUTCH PLATES
Reverse-High Clutch Forward Clutch
Transmission
Model Steel Composition Steel Composition
Plates Plates Plates Plates
-
PCS-I70, 3 3 3 4
200-IV
- -
PCW-289-2V 4 4 4 5
289-4V
C6 TRANSMISSION
TORQUE LIMITS
C6 TRANSMISSION SHIFT SPEEDS (Approximate)
- -
Range fK=
1-2
hift 2 - -
01 7-13 6-12
Minimum 01 2-3 11-21 11-20
Throttle 02 3-2 7-9 6-8
I 01 3-1 7-9 6-8
i L 2-1 7-9
-6.8
~ 1 1-2 38.45 35-42
Maximum 01,02 2-3 72.82 66-76
Throttle , 01,02
01 3-2 64.73 59-68
2-1 or 26.34 24-31
3-1
-
Use
Engine Axle Tire Column
Car Displacement Ratio Size No.
Comet-Fairlane
390-2V 3.00:1 7.35x 15 1
390-4V 3.25:1 7.75x 15 2
PART 7-4 - SPECIFICATIONS
ANDSERVICE
TOOLS 7-85
TOOL-1175-AB
LOW-REVERSE CLUTCH PLATES TOOL-3552-H 3552-H Special Jaws for 7600-E
- TOOL-4201-C 4201-C Differential Backlash and Runout
Transmission Steel Composition Gauge, with Universal Bracket,
Model Plates Plates
- Dial Indicator and Bracket
PDD-E,J,P,R 5 5 TOOL-7000-DD 7000-00 Air Nozzle Rubber Tip Assembly
T52L-7000-GAE 7000-G Transmission Extension Housing
Rear Bearing Remover
REVERSE-HIGH CLUTCH PLATES T52L-7000-HAE 7000-HF Transmission Extension Housing
- Rear Bearing Remover
Transmission Steel Composition T64L-6001-A Transmission Holding Fixture
Model Plates Plates T64P-7A128-A
i Manual Valve Detent Spring
- T64P-7B456-A and Clutch Raceto Case Bolt Socket
PDD-E,J,P,R 3 3 T65P-7B456-B !
T58L-IOI-A and 7600-E Seal Remover(Head and Hammer)
T59L-IOO-B
FORWARD CLUTCH PLATES T61L-7657-A 7657-AA Transmission Extension Housing
- Oil Seal Replacer
Transmission Steel Composition T61L-7657-B 7657-AB Transmission Extension Housing
Model Plates
-
Plates
T57P-7697-A
Oil Seal Replacer
Transmission Extension Housing
POO-E,J, P, R 3 4 Bushing Remover
T57P-7697-B Transmission Extension Housing
INTERMEDIATE BAND WIDTH (Inches) Bushing Replacer
T60-K-7697-A 7000-AF Transmission Extension Housing
Transmission Bushing Remover
PDD-E,J,P,R T59P-7902-B 7937-8 Welded Converter Sprag Driver
Mode! 113;16
n R
PISTON
Di , . Inches
Mode!. Pm.n Cover A B I c D
C6AP- C6AP.
PDD.E,R
7D021.A 7DO27.A I 2.075 2.980 2.971 2.066
D II;A?R