Home

904 & 727 Techtrain Manual

Contents

1. NEW UPDATES INCLUDED EBNHEBEESE BEN TUUM No returns on EHE I 4atsc TRANSMISSION SERVICE 9 toup o TORQUEFLIGHT A 727 A 904 We thank the Chrysler Corporation for the illustrations that have made this booklet possible This booklet contains the general description of the lock up converter A special tool section is included The teardown and assembly is fully covered In car service procedures are outlined ROBERT D CHERRNAY DALE ENGLAND TECHNICAL DIRECTOR FIELD SERVICE CONSULTANT FRANK MIETUS WAYNE COLONNA TECHNICAL CONSULTANT TECHNICAL SUPERVISOR PETE LUBIN TECHNICAL CONSULTANT AUTOMATIC TRANSMISSION SERVICE GROUP 18639 SW 107 AVENUE MIAMI FLORIDA 33157 305 670 4161 PDHHHHHHHHHHH GUHEVMVMMMNMREHHEWREBEXEIEREXHHENHM INTRODUCTION DIAGNOSIS AND TESTS 9 20 SERVICE IN VEHICLE o m Mr M 23 AA AECA 28 SERVICE OUT OF THE VEHICLE 33 SPECIFICATIONS 58 TECHNICAL SERVICE INFORMATION 60 TORQUE CONVERTER INFORMATION 67 79 Co gt m BA RAS ATA RA
2. 2 Loosen adissc z serew nut and back off lock nut 1 Fig 5 Test adjust ing screw for free z the lever 3 Using wrench T gt A tighten band ad justing screw to 72 in M 512 adjusting screw in this position and tighten o 25 ft lbs 84 N m 5 Reinstal new gasket Tighten oil pan bolts to 150 in Ibs 17 Nem TO COOLER BAND ADJUSTING SCREW BACK UP LAMP AND NEUTRAL PARK STARTING SWITCH THROTTLE LEVER GEARSHIFT CONTROL LEVER Fig 4 Externa Comtrots scd Adjustments 6 transmss Automatic Transz g HYDRAULIC ADJUSTMENTS Line Pressure An incorrect L cause incorrect line presz line pressure adjustmer sect and correct throttle presec s z e me zZiusting the line pressure approxima e z zies meas LOW REVERSE BAND ACE Fig 5 Low Revecss tr eent 2720277 TRANSMISSION SERVICE GROL 22 PA4ATSG Technical Service Information Fig 6 Line Pressure Adjustment ured from valve body to inner edge of adjusting nut Fig 6 However due to manufacturing tolerances the adjustment can be varied to obtain specified line pressure The adjusting screw may be turned with an Allen wrench
3. LONG END MUST BE TOWARD LOCK UP MODULE LOCK UP MODULE FAIL SAFE SPRING FAIL SAFE VALVE e ps SCREW 2 LOCK UP VALVE Z LOCK UP SPRING ENO PLATE VALVE BODY FIGURE 1 AUTOMATIC TRANSMISSION SERVICE GROUP w nTSG Technical Service Information Reinstall valve body and torque screws to 100 inch pounds Reinstall transmission oil pan using supplied gasket PN 4295875 Reconnect shift and kickdown linkage Lower vehicle and refill using transmission fluid PN 4318077 Adjust shift and kickdown linkages per the service manual procedures Remove ESA and replace with supplied ESA PN 4379255 Type Authorized Modification Label PN 4275086 as shown in Figure 2 and attach near VECI label AUTOMATIC TRANSMISSION SERVICE GROUP 64 CAATSG Technical Service Information SHUDDER SYMPTOM CONDITION Part throttle surge warm at 30 40 mph following transmission lock up DIAGNOSIS Road test the vehicle and verify the condition If surge is stil present at steady speeds between 30 and 40 mph with the engine fully warmed up and after all warm driveability diagnostic procedures have been followed do the following REPAIR PROCEDURE Parts Required 1 Spring PN 4202672 1 Lock Up Body PN 4202209 Refer to Step 2 of Repair Procedure for usage of this part 1 Remove transmission oil pan 2 Remove valve body and inspect the lock up valve body A If lock up valve body is the old style lock up body
4. z pei z can have z RT ns below nec directly on outer pon aos diameter 7 1 converter front cover With torque converter from vehicle replacement of the gear gs Removal 1 Cut threzen welt material at rear side of ring gear with hacx sew grinding wheel Fig 2 Be careful not to cuz cr gc zZ inte front cover stamping 2 Scribe a heavy iine on the front cover next to front face of ring gear tc 28 27 locating the new gear 3 Support torque convercer front cover next to the lugs with blocks of wood to prevent altering lug position The torque converter musz mot rest on the front cover hub during this operazion Using a blunt chisel or drift and hammer downward on ring gear near welded areas to break remaining weld material Fig 2 Tap around ring gear until it comes off the torque converter 4 Smooth off weld areas on the cover with a file installation Any of the following methods may be used to heat and expand starter ring gear for installation on the torque converter Oven Place ring gear in Oven and set temperature at 276 degrees F 93 degrees Celsius Allow ring gear BRASS DRIFT l e ove Starter Ring Gear wz cck Up Only AUTOMATIC a 2525 00 S 5 to remain in oven for 15 to 20 minutes Boiling Water Place ring gear in a shallow con tainer a
5. Engine idle speed too low Aerated fluid sel x x x Worn or broken input shaft 52 seal rings Faulty oil pump x x Cil filter clogged x xi incorrect gearshift control linkage adjustment 9 s 24 gt lt Low fluid level x x wel gt lt s lt Low reverse servo band or linkage maitunction 25 25 or maifunction x x x x x x x x x x Low reverse band out of 52 adjustment Aaa pressures x sel Sel 52 ise 52 T Engine idle speed too high ml x gt Stuck lock up valve N Stuck switch valve e z o gt lt o 51 5 iz gt gt o z 5 z z a lt og I Tolo ac x zz 212 S 94 28 a 5 Sie o E gt s lt gt sri amp o gt oH E lt 2 0 do On d gt e 21652 5 Ol z wi S z tu 2 2505 2 es52 le z S955 2 55 851 e sl z zE z Z 325 Size 9 9 525 20150 SEZ X uS 2 6552 5 ez 2 2 2 55 zo z z 2 20 gt gt gt mr 5 gt Z 6 262 o o xEw X 8 Sloe 2 Fes amp 58 2 Ze COS 2 sled 25 SEE lt 0 z cee ol Sits up t 5E 2 2 498 520 d 21 226 2 Gl 5166 alio Fl sn nTSG Technical Service Information DIAGNOSIS CHART LOCK UP
6. 2s5sem Shuttle Valve and Governor Plugs Fe 1 Turn valve body over 2 2 sme valve cover plate 2 Remove governtr scc rs and slide out the shuttle valve 1 7 T LF icc pring the 1 2 shift valve z z z 1 2 shift AFE SPRING FAIL SAFE VALVE Pel SCREW 2 LOCK UP SPRING END PLATE lt 9 PU9B AUTOMATIC TRANSMISSION SERVICE GROUP 28 CA4ATSG TRANS ER PLATE SPRING RETAINER AND LINE PRESSURE ADJUSTING SCREW BRACKET FLUID Z 225 S S SS REPAIR STAND THROTTLE LEVER ADJUSTING SCREW AND SHAFT MANUAL VER ASSEMBLY kt gt PU5 Fig 1 Valve Body Assembly 2 Drive a new seal into the case with a 15 16 inch socket and hammer Fig 13 This seal can be replaced without removing the DETENT BALL AND SPRING ASSEMBLY THROTTLE Technical Service Information valve body from transmission by using a small screw driver to pry seal out of its bore Be careful not to scratch manual lever shaft or the seal bore in transmission VALVE BODY DISASSEMBLY Tag all springs as they are removed for reassem bly identification Do not clamp any portion of valve body or transfer plate in a vise Any slight distortion of the aluminum body or transfer plate wil result in sticking valves excessive leakage or both When removing or install ing valves or plugs slide them in or out carefully Do not use force Remove E clip and park
7. 5 Install the speedometer pinion and adapter 6 Carefully guide front universal joint yoke into extension housing and on the output shaft splines Align marks made at removal and connect propeller shaft to rear axle pinion shaft yoke 7 Add automatic transmission fluid to transmis sion to bring up to proper level GOVERNOR AND PARKING GEAR Removal 1 Remove extension housing and output shaft bearing as previously described 2 Carefully pry snap ring from weight end of governor valve shaft Fig 10 Slide valve and sha assembly out of governor body 3 Remove large snap ring from weight 27 governor body lift out governor weight assem v 4 Remove snap ring from inside governor weigh remove inner weight and spring from che cuter TOOL INSTALLING BUSHING END BUSHING TOOL Fig 9 Repiace Extension Housing Bushing Technical Service GOVERNOR SUPPORT AND PARKING Fig 10 Governor Sraz weight Figure 11 shows a dissss amp c c 778 governor assembly 5 Remove snap ring from e p m then slide governor and surp ze 7 ve output shaft Remove the iit m e governor body and screen from tar 27 or Cleaning and Inspection Figure 11 shows cisass 7 c0 00 rr v nor assembly Insepct all parts rics itl we oser Dc weight for free moreret wm mmer weight for free e
8. 6 Lubricate all clutch plates install one lined disc followed by a steel plate until all plates are installed Install outer pressure plate and selective snap ring 7 Measure rear clutch plate clearance by having an assistant press down firmly on outer pressure plate then insert a feeler gauge between the plate and snap ring Fig 29 See Specifications for allowed clearance If neces sary install a new snap ring of proper thickness to obtain specified clearance Low limit clearance is desirable Rear clutch plate clearance is very impor tant in obtaining proper clutch operation Clearance can be adjusted by the use of various thickness outer snap rings Snap rings are available in 060 SELECTIVE SNAP RING FEELER GAUGE RH295 Fig 29 Measure Rear Clutch Plate Clearance AUTOMATIC TRANSMISSION SERVICE GROUP 46 076 and 098 inch thickness 8 Grease cupped side of 3 thrust plate and install cupped side over input shaft REAR CLUTCH A 727 Disassembly Figure 30 shows a disassembled view of the rear clutch assembly 1 Remove large selective snap ring that secures pressure plate in clutch retainer Lift pressure plate clutch plates and inner pressure plate out of the retainer 2 Carefully pry one end of wave spring out of its groove in clutch retainer then remove wave spring spacer ring and clutch piston spring 3 Invert clutch piston retainer assembly and bump it on a wooden block to r
9. AUTOMATIC TRANSMISSION SERVICE GROUP 60 SJATSG Technical Service Information 1986 Truck Ramcharger Ram Van Wagon Part Engine Transmission Torque Converter Number 225 3 7L A 904 High staTl lock up 4431115 225 3 7L A 904 High stall non lock up 4431117 225 3 7L 727 High stall lock up 4431125 318 5 21 999 Low stall lock up 4431113 318 5 2L 999 High stall lock up 4431119 318 5 2L 727 Low stall non lock up 4431123 360 5 9L 727 High stall non lock up 4431121 360 5 9L A 727 Low stall non lock up 4431127 REPAIR PROCEDURE This repair involves the replacement of the torque converter l Check engine for any driveability problems Low carburetor air flow early EGR valve operation etc have been found to be a contributor to reverse shake in some vehicles Perform a propane adjustment and or correct any other driveability problems that may exist with the vehicle using the appropriate Driveability Test Procedure If correcting any driveability problems with the vehicles does not eliminate the reverse shake then it will be necessary to replace the torque converter with new one Select the appropriate torque converter for the vehicle from the parts list Replace the torque converter per the appropriate service manual instructions Road test the vehicle and check for leaks AUTOMATIC SERVICE GROUP P4ATSG Technical Service Information SURGING This bulletin supersede
10. GROMMET ASSEMBLY TORQUE SHAFT BUSHING az BRACKET GEARS Fe SOFA WASHER 22 Was RETAINER Fig 1 Column Gearshift Linkage Adjus AUTOMATIC TRANS SON SERVICE GROUP PA4ATSG 4 Tighten adjustment swivel lock bolt to 90 in lbs 10 5 Check adjustment as follows a Detent position for neutral and drive should be within limits of hand lever gate stops ib Key start must occur only when shift lever is in park or neutral positions THROTTLE ROD ADJUSTMENT With engine at operating temperature and carbu retor off fast idle cam adjust idle speed of engine using a tachometer Refer to Fuel System Group 14 for idle speed Specifications and carburetor linkage adjustment ADJUSTMENT PROCEDURE Figs 2 or 3 1 Perform transmission throttle rod adjustment while engine is at normal operating temperature otherwise make sure carburetor is not on fast idle cam 2 Raise vehicle on hoist to make adjustment at transmission throttle lever 3 Loosen adjustment swivel lock screw 4 To insure proper adjustment swivel must be free to slide along flat end of throttle rod so that preload spring action is not restricted Disassemble and clean or repair parts to assure free action if BRACKET ASSEMBLY FRONT PU 488 M CLIP WASHER Technical Service Information necessary 5 Hold transmission lever firmly forward against its internal stop and tighten swivel lock scre
11. Second 1 45 X X 1 LOW First 2 45 X X AUTOMATIC SHIFT SPEEDS AND GOVERNOR PRESSURE CHART APPROXIMATE MILES PER HOUR Carline HNFG HNFG RW SX C Engine Cu In EE 225 318 360 4 360 2 400 2 400 4 Hi Perf 400 4 amp 440 Hi Perf Axle Ratio 2 76 2 45 321 2 45 2 71 21 Tire Size bad on Be las 6 95x14 E78x14 H78x14 GR78x15 HR78x15 JR78x15 Throttle Minimum 1 2 Upshift 9 16 8 16 8 15 9 16 9 16 8 15 2 3 Upshift 15 25 15 25 15 23 17 25 15 25 15 23 3 1 Downshift 8 13 9 14 8 13 9 14 8 13 8 13 Throttle Wide Open 1 2 eerte xe 31 43 39 54 43 56 41 57 37 52 38 53 2 3 Upshift 63 76 79 95 78 93 83 100 77 92 77 93 Kickdown Limit 3 2 WOT Downshift 60 73 76 92 75 90 79 96 73 89 74 90 3 2 Part Throttle Downshift 46 61 30 56 34 57 31 58 30 56 29 54 3 1 WOT Downshift 28 35 30 44 34 47 31 46 29 43 29 43 Lock up Limit Minimum in Direct 27 37 24 29 26 30 26 30 23 26 None Governor Pressure 15 psit Ee AERE 20 22 21 23 20 22 22 24 21 23 21 23 40 DSI on Ici gene Rr utu s o ERES 47 53 60 66 60 66 62 69 59 66 58 65 wea eas 66 72 83 90 81 88 87 94 82 90 81 88 Governor pressure should be from zero to 1 5 psi at stand still or downshift may not occur NOTE Figures given are typical for oth
12. sage through the transmission input shaft I Fig 12 New oil passage through input shaft provides hydraulic control of lock up piston AUTOMATIC TRANSMISION SERVICE GROUP 2 5 In the unlocked mode transmission converter pressure is applied through the shaft The oil flows around the unlocked piston face back through the converter and out between the reaction shaft and the input shaft When the conditions are right for lock up the Switch valve vents the pressure on the front TESTING FOR LOCK UP OPERATION To test for lock up operation it s necessary to take the car on the road road test will tell you Fig 13 A road test is required to check for proper lock up operation LOCK UP CONVERTER SERVICING You can test the lock up converter for proper stator clutch operation and the holding ability of the transmission clutches just as you would with any other converter by using the famil iar stall test This test tells if the stator is holding and providing the torque multiplica tion necessary for good acceleration Technical Service Information side of the piston This causes the line pressure behind the piston to force it into lock The lock up friction material and an O ring at the 1 0 of the piston provide a pressure seal across the piston face to keep the converter in the locked up mode There is an additional lip sea located the 1 0 of the turbine hub
13. 1 Place drain pan under speedometer adapter 2 Remove bolt and retainer securing speedometer pinion adapter in the extension housing Fig 1 3 With cable housing connected carefully work adapter and pinion out of the extension housing 4 If transmission fluid is found in cable housing replace seal in the adapter Fig 2 Start seal and retainer ring in the adapter then push them into adapter with Tool C 4004 until tool bottoms Fig 3 AUTOMATIC TRANSMISSION SERVICE GROUP 23 ADAPTER 6 O CLOCK POSITION RH260 Fig 1 Speedometer Pinion and Adapter Before installing pinion and adapter assembly make sure adapter flange and its mating area on extension housing are perfectly clean Dirt or sand will cause misalignment resulting in speedometer pinion gear noise 5 Note number of gear teeth and install speedome ter pinion gear into adapter 6 Rotate the speedometer pinion gear and adapter assembly so that the number on the adapter corre sponding to the number of teeth on the gear is in the 6 o clock position as the assembly is installed Fig 1 7 Install retainer and bolt with retainer tangs in adapter positioning slots Tap adapter firmly into the extension housing and tighten retainer bolt to 100 in Ibs 11 N m Refill transmission NEUTRAL STARTING AND BACK UP LAMP SWITCH Fig 4 Replacement and Test The neutral starting switch is the center terminal of the 3 terminal switch It provides
14. 1 Remove low reverse drum loosen rear band adjuster remove band strut and link remove band from the case Double Wrap Band Loosen band adjusting screw then remove band and low reverse drum Overrunning Clutch 1 Note position of overrunning clutch rollers springs before disassembly to assist in reassembly ou TRANSMISSION VENT Fig 7 Remove Oil Pump Technical Service Information 2 Carefully slide out clutch hub and remove roll ers and springs Kickdown Servo Front 1 Compress kickdown servo spring by using engine valve spring compressor Tool C 3422A remove snap ring Fig 8 2 Remove rod guide spring and piston assembly from the case Be careful not to damage piston rod or guide during removal 3 Withdraw piston from the transmission case Low Reverse Servo Rear 1 Compress low and reverse servo piston spring by using engine valve spring compressor Tool C 3422A then remove the snap ring 2 Remove spring retainer spring and servo piston and plug assembly from the case RECONDITION SUBASSEMBLIES The following procedures cover disassembly inspec tion repair and assembly of each subassembly as removed from the transmission Heli Coil inserts are recommended for repairing damaged stripped or worn threads in aluminum parts Presized service bushings are available for replace ment for most all bushings in the LoadFlite transmis sions The two bushings in sun gear a
15. 15 Disconnect throttle rod from lever at the left side of transmission Remove linkage bellcrank from transmission if so equipped 16 Remove oil filler tube and speedometer cable 17 Install engine support fixture Tool C 3487 A with frame hooks or a suitable substitute that will support rear of the engine Fig 1 18 Raise transmission slightly with service jack to relieve load on the supports 19 Remove bolts securing transmission mount to crossmember and crossmember to frame then remove crossmember 20 Remove all bell housing bolts 21 Carefully work transmission and torque con verter assembly rearward off engine block dowels and disengage torque converter hub from end of crank shaft Attach a small clamp to edge of bell housing to hold torque converter in place during transmission removal 22 Lower transmission and remove assembly from under the vehicle 23 To remove torque converter assembly remove clamp from edge of bel housing then carefully slide assembly out of the transmission TOOL ASSEMBLY gt RH274 Fig 1 Engine Support Fixture Typical Technical Service Information TT x STARTER RING REPLACEMENT NOTE enm e coeverters with starter gez coi r 7 zrement should be rec acecow ziir 77 52 25 assembly This is to Breve 4 21 Tm iT izmege while weld ng Tew f geo rin NOTE 2 i te ce see converters with Starlet
16. One complete turn of the adjusting screw changes closed throttle line pressure approximately 1 2 3 psi Turning adjusting screw counterclockwise increases pressure and clockwise decreases pressure Throttle Pressure Throttle pressures cannot be tested accurately therefore the adjustment should be measured if a Fig 7 Throttie Pressure Adjustment malfunction is evident 1 Insert gauge pin of Tool C 3763 between the throttle lever cam and kickdown valve Fig 7 2 By pushing in on tool compress kickdown valve against its spring so throttle valve is completely bottomed inside the valve body 3 As force is being exerted to compress spring turn throttle lever stop screw with allen wrench until head of screw touches the throttle lever tang with throttle lever cam touching tool and the throttle valve bottomed Be sure adjustment is made with spring fully compressed and valve bottomed in the valve body SERVICE IN VEHICLE GENERAL INFORMATION Various transmission components can be removed for repairs without removing the transmission from the vehicle The removal reconditioning and installa tion procedures for these components are covered here SPEEDOMETER PINION GEAR Any time the speedometer pinion adapter is re moved a NEW ring black in cofor must be installed on the outside diameter of the adapter Removal and Installation Rear axle gear ratio and tire size determines pinion gear requirements
17. and A 999 or Tool C 3881 A 727 until the two small holes in handle are vertical Fig 51 2 Carefully slide torque converter assembly over input shaft and reaction shaft Make sure torque converter hub slots are also vertical and fully engage pump inner gear lugs Test for full engagement by placing a straightedge on face of the case Fig 52 The surface of torque SPECIAL TOOL ALIGNMENT HOLES VERTICAL RH315 Fig 51 Align Pump inner Gear Lugs AUTOMATIC TRANSMISSION SERVICE GROUP 56 STRAIGHTEDGE Fig 52 Measure Torque Converter for Full Engagement into Transmission converter front cover lug should be at least 1 2 inch to rear of straightedge when torque converter is pushed all the way into transmission 3 Attach a small C clamp to edge of torque con verter housing to hoid torque converter in place during transmission installation 4 Inspect torque converter drive plate for distor tion or cracks and replace if necessary Torque the drive plate to crankshaft bolts to 55 ft Ibs 75 When drive plate replacement has been necessary make sure both transmission dowel pins are in engine block and they are protruding far enough to hold transmission in alignment 5 Coat torque converter hub hole in crankshaft with Multipurpose grease Place transmission and torque converter assembly on a service jack and position assembly under vehicle for installation Raise or tilt as necessary until trans
18. in the Chart may vary somewhat due to production tolerances and rear axle ratios The quality of the shifts is very important All shifts should be smooth and positive with no noticeable engine runaway See Diagnosis and Tests for chart Gearshift and Parking Lock Controls The transmission is controlled by a lever type gearshift incorporated within the steering column The control has six selector lever positions P park R reverse N neutral D drive 2 second and 1 first The parking lock is applied by moving the selector lever past a gate to the P park position Do not apply the parking lock until the vehicle has stopped otherwise a severe ratcheting noise will occur Starting the Engine The engine will start with the selector lever in either the P park or N neutral positions As a safety precaution when starting in the N neutral position apply the parking or foot brake The LoadFlite trans mission will not permit starting the engine by pushing or towing AUTOMATIC TRANSMISSION SERVICE GROUP 7 nTSG ing the cooler tubes and placing the rear cooler tube into a 1 quart container Overfill the transmission by 1 quart Watching a clock start engine run at curb idle and run in neutral for exactly 20 seconds If cooler flow is less than 1 quart in 20 seconds replace the radiator or have the radiator bottorn cooler profes sionally reconditioned Manual Linkage Normal operation of the neutral
19. s2c gt s valve for free Siste g s e weights ang velts z 7 5 col 22 DIES wren clean and 15 wiih crocus iso premo s Core sea riers CIT 1 27 4727 ic aga Tn amps um h c7 her tices 7 Se o ean z gt ce 77 477 VALVE SHAFT SNAP RINGS VALVE INNER WEIGHT FILTER SCREEN SNAP RING mH270 Fig 11 Governor Assembly AUTOMATIC IRANON ION SERVICE GROUP SATSE Installation 1 Assemble governor body and screen to the sup port and tighter bolts finger tight Make sure oil passage of governor body aligns with passage in the support 2 Position support and governor assembly on the output shaft Align assembly so valve shaft hole in governor body aligns with hole in the output shaft then slide assembly into place Install snap ring behind governor body Fig 10 Tighten the body to support bolts to 95 in lbs 11 N m The support bolts have a self locking nylon patch and can be reused 3 Assemble governor weights and spring and secure with snap ring inside of large governor weight Place weight assembly in governor body and install snap ring 4 Place governor valve on the valve shaft insert assembly into the body and through governor weights Install val
20. shop air 4 Treat the cooler lines separately and insure they are clear by flowing mineral spirits or automatic transmission fluid through them 5 Remove leftover mineral spirits from cooler and cooler lines by flowing automatic transmission fluid through them 6 Cooler flow should now be checked by connect AUTOMATIC TRANSMISSION SERVICE GROUP 9 nTSG Technical Service Information ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER Clutches Bands Lever Standard Wide Start Parking Front Over Lock up Kickdown Low Pe Position Ratio Ratio d Sprag running Front Rea P PARK Pan ayat SSESE ee R REVERSE 221 221 r Ee Pee ee x N NEUTRAL D DRIVE First 2 45 2 74 X Second 1 45 1 54 X X Direct 1 00 1 00 X X 2 SECOND First 2 45 2 74 X Second 1 45 1 54 X X 1 LOW Firs 245 24 E Test One Selector in 1 1 Attach gauges to line and rear servo ports 2 Operate engine at 1000 rpm for tests 3 Move selector lever on transmission all the way forward 1 position 4 Read pressures on both gauges as throttle lever on transmission is moved from full forward position to full rearward position b Line pressure should read 54 to 60 psi 372 to 414 kPa with throttle lever forward and gradually increase as lever is moved rearward to 90 to 96 psi 621 to 662 kPa 6 Rear servo pressure sho
21. 3 Install 3 screws in separator plate 4 Place transfer plate assembly on valve body Be careful to align filter screen as the 17 shorter screws installed finger tight the three longer screws are for oil filter St Starting at the center and working outward tighten screws to 35 in Ibs 4 N m 6 Slide switch valve and line pressure valves and springs into their bores Fig 2 7 Install pressure adjusting screw and bracket assembly on the springs and fasten with one screw for now Use screw which goes into side of valve body This screw is to be tightened first after starting the top and bottom screws 8 Install oil filter and tighten screws to 35 in Ibs 4 N m 9 Install lock up valve and spring then install fail safe spring and valve into the lock up module Fig 3 Install lock up module to transfer and separator plate assembly with three screws Install stiffener plate on nonlock up valve body 10 Insert lock up solenoid nozzle with O ring into bore in transfer plate and install retaining screw Route lock up solenoid wire between solenoid and limit valve housing cover and underneath edge of oil filter Correct wire routing is VERY IMPORTANT The wire must be routed away from the low reverse band lever 11 After valve body has been serviced and com pletely assembled measure throttle and line pressure adjustments see Maintenance and Adjustments However if pressures were satisfactory prior
22. C 3283A into threaded holes of reaction shaft support flange 2 Assemble and place pump gears in center of the support 3 Lower pump body over the pilot studs insert Tool C 3756 through pump body and engage pump inner gear Rotate the pump gears with tool to center gears in pump body then with pump body firm against reaction shaft support tighten clamping tool securely 4 Invert pump and reaction shaft support assem bly with clamping tool intact Install support to pump body bolts and tighten to 175 in lbs 20 N m Remove clamping tool pilot studs and gear alignment tool 5 Place a new oil seal in opening of pump housing lip of seal facing inward Using Tool C 4193 and handle Tool C 4171 drive seal into housing until tool bottoms AUTOMATIC TRANSMISSION SERVICE GROUP 39 nTSG ALIGNING TOOL PILOT STUDS 2 REACTION SHAFT PUMP GEARS Fig 13 Assemble Pump and Reaction Shaft Support A 904T and A 999 OIL PUMP AND REACTION SHAFT SUPPORT A 727 It is important that the oil pump be within the clearance limits as specified Also note that the oii pump bushing should be replaced in any overhaul OIL PUMP BODY VENT BAFFLE OIL SEAL O RING OUTER GEAR Technical Service Information Disassembly Figure 14 shows the oil pump and reaction shaft support disassembled 1 Remove bolts from rear side of reaction shaft support and lift support off the pump 2
23. Figure 1 replace it with new style Lock Up Body Figure 2 PN 4202209 and replace the present lock up spring with a new Lock Up Spring PN 4202672 Re use the existing lock up valve fail safe valve and spring cover and screws If the lock up valve body is the new style lock up body Figure 2 install only the new Lock Up Spring PN 4202672 ds usd the valve body and torque screws to 35 inch pounds 4 Nm AUTOMATIC TRANSMISSION SERVICE GROUP w nTSG Technical Service Information 4 Install the transmission oil pan and fill with ATF fluid 5 Adjust shift and throttle linkage as necessary ADNAN 5 AS cw B 24 ES SSS SAN AX Ne NN N N FIGURE 1 FIGURE 2 OLD STYLE VENT ADDED TO LOCK UP BODY NEW STYLE 66 SZATSG IS BASICALLY TWO FANS The two fan example of a fluid coupling is technically just the same as a torque converter If you use a denser fluid oil instead of air you get a firmer more powerful drive with less slip page but the principle is the same Keeping this principle in mind will help you understand the automotive torque converter and why the lock up feature is desirable Fig 1 A torque converter is similar to two fans one powering the other IMPELLER ALWAYS DRIVES THE TURBINE In a conventional torque converter Fig 2 the driving fan welded to the converter shell is always turning at the same speed as the engine And although tha
24. NEUTRAL START SWITCH PAN GASKET OIL COOLER FITTINGS EXTENSION HOUSING TO_CASE GASKET EXTENSION HOUSING TO CASE BOLTS EXTENSION HOUSING YOKE SEAL SPEEDOMETER ADAPTER O RING FRONT BAND ADJUSTING SCREW AUTOMATIC TRANSMISSION SERVICE GROUP 17 PUS68 ATSG Technical Service Information POSSIBLE CAUSE LOADFLITE DIAGNOSIS CHART GENERAL x x x x x Faulty fock up clutch Overrunning clutch inner race damaged Overrunning clutch worn broken or seized Planetary gear sets broken or seized Rear cluth dragging X X Worn or faulty rear clutch Insufficient clutch plate clearance Faulty cooling system Kickdown band adjustment too tight Hydraulic pressure too high Breather clogged X X X X oe M X High fluid level Worn or faulty front clutch Kickdown servo band or linkage malfunction Governor malfunction Worn or broken reaction IO 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 X X X X X X Se x tasa x x X Xx x shaft support seal rings aep 2 gt 25 gt Governor support seal rings broken or worn gt lt Output shaft bearing and or bushing damaged Overrunning clutch not 52 sd holding Kickdown band out of T sl 2 adjustment Incorrect throttle linkage 52 adjustment
25. Technical Service Information throttle acceleration The nonlock up A 904T used in California has a threaded plug in the rear of the transmission case in place of the lock up wiring connector The fail safe valve restricts feed to the lock up clutch if front clutch pressure drops It permits lock up only in direct gear and provides a fast lock up release during a kickdown The switch valve directs oil to apply the lock up clutch in one position and releases it in the other as well as directs oil to the cooling and lube circuits The switch valve also regulates the oil pressure to the torque converter and limits the maximum oil pressure to 130 psi Clutches Band Servos and Accumulator The front and rear clutch pistons and both servo pistons are moved hydraulically to engage the clutches and apply the bands The pistons are released by spring tension when hydraulic pressure is released On the 2 3 upshift the kickdown servo piston is released by spring tension and hydraulic pressure and the lock up piston is applied by pressure within the torque converter The accumulator controls the hydraulic pressure on the apply side of the kickdown servo during the 1 2 shift thereby cushioning the appli cation at any throttle position OPERATING INSTRUCTIONS The transmission will automatically upshift and downshift at approximately the speeds shown in the Automatic Shift Speed Chart shift speeds given
26. and A 999 Vent Plug Retainer 15 Technical Service Information VENT PLUG RETAINER RETAINER TORQUE CONVERTER PLUG MADE FRO HUB SEAL CUP OLD FILLER TUBE RH255 Fig 12 Transmission Prepared for Test hub seal cup over input shaft and through the torque converter hub seal until the cup bottoms against the pump gear lugs Secure with cup retainer strap Fig 9 using torque converter housing to engine block retaining bolts 4 Attach and clamp hose from nozzle of Tool C 4080 to tubing which is on the rear cooler line fitting Fig 13 5 Pressurize the transmission using Tool C 4080 until the pressure gauge reads 8 psi Position trans mission so that pump housing and case front may be covered with soapy solution or water Leaks are some times caused by porosity in the case or pump housing CAUTION Do not under any circumstances pres surize a transmission to more than 10 psi If a leak source is located that part and all associ ated seals and gaskets should be replaced with new parts FLARE CAP FLARED TUBE ON COOLER LINE FITTING RY254 Fig 13 Pressurizing Transmission PA4ATSG Technical Service Information DIAGNOSIS GUIDE ABNORMAL NOISE INSPECT ANO CORRECT THE TRANSMISSION FLUID LEVEL ROAD TEST TO VERIFY THAT AN ABNORMAL NOISE EXISTS IDENTIFY THE TYPE OF NOISE DRIVING RANGES AND CONDITIONS WHEN THE NOISE OCCURS WHINE OR BUZZ NOISE LISTEN TO T
27. and throttle valve operating levers and shafts for being bent worn or loose If a lever is loose on its shaft the lever and shaft assembly should be replaced Do not attempt to straighten bent levers Inspect lock up solenoid assembly for cut or broken wire melted or distorted coil cut or nicked O rings etc Shake solenoid to verify that plunger is free to travel Replace solenoid if plunger is stuck Check orifice in solenoid nozzle and drilled crosshole at solenoid bore in transfer plate for dirt or foreign material To check solenoid operation hold solenoid with nozzle pointing up and apply 12 volts between solenoid wire and solenoid frame at screw hole Plunger should travel up and down when 12 volts power is turned on and off Inspect all mating surfaces for burrs nicks and scratches Minor blemishes may be removed with crocus cloth using only a very light pressure Using a straightedge inspect all mating surfaces for warpage or distortion Slight distortion may be corrected using a surface plate Make sure all metering holes in steel plate and valve body are open Using a pen light inspect bores in valve body for scores scratches pits and irregularities Make sure orifice referred to in Fig 5 is open by inserting a 1 32 inch diameter drill through it into the 1 2 shift control valve bore Inspect all valve springs for distortion and collapsed coils Inspect all valves and plugs for burrs nicks and scores Small
28. connector at rear of transmission case if so 4 Remove the 10 hex head valve t2 mrarsr sion bolts Remove E clip securing parang ims rot to the valve body manual lever 5 While lifting valve upward 27 trexst sion case disconnect parking tock red 172 lever Accumulator Piston and Spring 1 Lift spring off accumulator piston and withdraw piston from the case Extension Housing or Adapter on 4 W D Before removing extension housing pull parking lock rod forward out of the case Rotate output shaft DIAL INDICATOR Fig 5 Measuring input Shaft End Play Z RH278 Technical Service i T S bo SHE i x E STAND A B RH279 Tu Repair Stand coe z z and sprag to permit ec gt mM tess the sprag sweedi 2te7 onion and adapter 10 transmission bolts 2 gasket from bottom of 2 Spread large snap 3 snap ring spread ex ension housing off ze p Using mar rz pliers remove out put shaft bearing rear snar Remove bearing from shaft then remove ron snap ring A 727 The A 904T and A 999 transmissions have no front snap ring 5 On 4 W D vehicles use Tool L 4450 inverted with Handle C 4171 to drive out bearing from adapter if necessary Governor and Support 1 Carefully pry snap ring fro
29. for distor tion or breakage Inspect teflon and or cast iron seal rings on input shaft for wear Fig 27 If required replacement rings AUTOMATIC Lae SION SERVICE GROUP w nTSG LARGE SEAL RING SMALL SEAL RING INPUT SHAFT NON LOCK UP 2 THRUST WASHER PISTON Technical Service Information PISTON SEAL OUTER SNAP RING ELECTIVE DRIVING DISCS WAVE SPRING PRESSURE PLATE PISTON PRESSURE PLATE SPRING CLUTCH PLATES PISTON SEAL INNER RH293 Fig 27 Rear Clutch A 904T and A 999 Nonlock Up wil be cast iron hooked joint type Do not remove rings unless conditions warrant Inspect rear clutch to front clutch 2 thrust washer for wear Washer thickness should be 061 to 063 inch replace if necessary Assembly 1 If removed press input shaft into piston re tainer and install snap ring 2 Lubricate and install inner and outer seals on clutch piston Make sure seal lips face toward input shaft and seals are properly seated in piston grooves Fig 27 3 Place piston assembly in retainer and with a twisting motion seat piston in bottom of retainer 4 Place clutch piston spring on top of piston in clutch retainer Start one end of wave spring in retainer groove Fig 28 then progressively push or tap spring into place making sure it is fully seated in the groove 5 Install inner pressure plate in clutch retainer with raised portion of plate resting on the spring
30. ground for the starter solenoid circuit through the selector lever in only Park and Neutral positions 1 To test switch remove wiring connector from switch and test for continuity between center pin of switch and transmission case Continuity should exist TRANSMISSION lt NS FRONT FEASTS SPEEDOMETER ADAPTER gt sien CABLE OIL SEAL GEAR BOLT O RING RETAINER RING sou CLAMP RATIO ADAPTER REQUIRED ON SOME MODELS RH261 Fig 2 Speedometer Drive Technical Service Information ADAPTER LOCK RING A OIL SEAL RH263 Fig 3 Install Speedometer Pinion Seal only when transmission is in Park or Neutral 2 Check gearshift linkage adjustment before replacing a switch that tests bad 3 Unscrew switch from transmission case allowing fluid to drain into a container Move selector lever to Park and then to Neutra positions and inspect to see that the switch operating lever fingers are centered in switch opening in the case 4 Screw switch with new seal into transmission case and tighten to 25 ft lbs 34 N m Retest switch with the test lamp 5 Add automatic transmission fluid to transmis sion to bring up to proper level 6 The back up lamp switch circuit is through the two outside terminals of the 3 terminal switch 7 To test switch remove wiring connector from Switch and test for continuity between the two outside pins 8 Continuity should e
31. inch replace if necessary Input Shaft Bushing Replacement A 727 only 1 Clamp input shaft in a vise with soft jaws being careful not to clamp on seal ring lands or bearing journals 2 Assemble the remover Tool SP 3630 cup Tool SP 3633 and hex nut Tool SP 1191 Fig 31 3 With cup held firmly against clutch piston re tainer thread remover into bushing as far as possible by hand 4 Using a wrench screw remover into bushing 3 to 4 additional turns to firmly engage threads in the bushing 5 Turn hex nut down against cup to pull bushing from input shaft 6 Thoroughly clean input shaft to remove chips made by remover threads Make certain small lubrica SNAP RING SELECTIVE DRIVING DISCS PRESSURE INPUT SHAFT PLATE CLUTCH RETAINER M m SEAL RINGS 2 PLATES WAVE SPRING SPACER RING PISTON NYLON PISTON SEAL SEAL OUTER RING 2 THRUST SNAP RING ASHER RH296 Fig 30 Rear Clutch A 727 AUTOMATIC TRANSMISSION SERVICE GROUP w nTSG HEX NUT SP 1191 TOOL HANDLE C 4171 REMOVER SP 3630 REMOVAL CUP SP 3633 INSTALLING REAR CLUTCH HEAD RETAINER SP 3636 INPUT SHAFT RN38 Fig 31 Replacing Input Shaft Bushing A 727 tion hole next to ball in end of shaft is not plugged with chips Be sure no chips are lodged next to the steel ball 7 Slide a new bushing on installing head Tool SP 3636 and start them in the bore of input shaft
32. it can be read under the vehicle Disconnect throttle rod and shift rod from transmis sion levers so they can be controlled under the vehicle Attach 100 psi gauges C 3292 to ports required for test being conducted A 300 psi gauge C 3293 is required for reverse pressure test at rear servo Test port locations are shown in Figs 1 and 2 AUTOMATIC TRANSMISION SERVICE GROUP wAnTSG Mountain Driving When driving in the mountains with either heavy loads or when pulling trailers the 2 second or 1 low position should be selected on upgrades which require heavy throttle for 1 2 mile or more This reduces possibility of overheating the transmission and torque converter under these conditions Towing Vehicle Transmission Inoperative Tow the vehicle with a Technical Service Information rear end pickup or remove the propeller shaft Transmission Operating Properly The vehicle may be towed safely in N neutral with rear wheels on the ground at a speed not to exceed 30 mph 48 km h If the vehicle is to be towed for extended distances it should be done with a rear end pickup or the propeller shaft removed Because the transmission receives lubrication only when the engine is running itis good practice to always tow a disabled vehicle with a rear end pickup or remove the propeller shaft DIAGNOSIS AND TESTS DIAGNOSIS GENERAL Automatic transmission malfunctions may be caused by four general conditions poor en
33. pan to break it loose allowing fluid to drain then remove oil pan 3 Loosen clamp bolts and remove throttle and shift levers from transmission 4 Pull wire connector from combination back up lamp neutral start switch 5 Unscrew and remove switch from transmission case Fig 4 6 Disconnect electronic lock up solenoid wire from inside of wiring connector at rear of transmission case if so equipped 7 Place drain pan under transmission then remove the ten hex head valve body transmission case bolts Hold valve body in position while removing the bolts 8 While lowering valve body down out of transmis sion case pull it forward out of the case If necessary rotate propeller shaft to align parking gear and sprag to permit knob on end of parking control rod to pass the sprag 9 Remove accumulator piston and spring from transmission case Inspect piston for nicks scores and wear Inspect spring for distortion Inspect rings for freedom in piston grooves and wear or breakage Replace parts as required Manual Lever Shaft Seal 1 If valve body manual lever shaft oil seal requires replacement drive it out of the case with a punch 15 16 SOCKET SN Fig 13 Install Manual Lever Shaft Seal SEAL AUTOMATIC TRANSMISSION SERVICE GROUP 27 wAnTSG 2 Remove top and bottom screws from spring retainer and adjustment screw bracket 3 Hold spring retainer firmly against spring force while rem
34. place Install low reverse drum Be sure long link and anchor assembly is installed as shown in Figure 42 to provide running clearance for the low reverse drum Double wrap Low Reverse Band A 904T and A 999 Figs 46 and 47 1 Push band reaction pin with new O ring into case flush with gasket surface 2 Place band into case resting two lugs against band reaction pin 3 Install low reverse drum into overrunning clutch and band 4 Install operating lever with pivot pin flush in case and adjusting screw touching center lug on band ADJUSTING SCREW LOCKNUT LEVER SHORT LINK AND ANCHOR RH309 Fig 45 Low Reverse Band and Linkage A 727 AUTOMATIC TRANSMISSION SERVICE 54 Technical Service Information LOCKNUT LEVER ADJUSTING SCREW PIVOT PIN 5 BAND SON REACTION O RING Fig 46 Double Wrap Band Linkage A 904T and A 999 Kickdown Servo Fig 43 1 Carefully push servo piston assembly into the case bore Install spring guide and snap ring 2 Compress kickdown servo springs by using en gine valve spring compressor Tool C 3422 A then install snap ring Planetary Gear Assemblies Sun Gear and Driving Shell 1 While supporting assembly in the case insert output shaft through rear support Carefully work assembly rearward engaging rear planetary carrier lugs into low reverse drum slots Be very careful not to damage ground surfaces or output s
35. reverse line pressure All automatic transmissions in 1978 are equipped with modulated reverse line pressure that provides controlled pressure in reverse gear Previously reverse line pressure was a constant 260 psi 1793 kPa throughout the full range of throttle operation This pressure is now modulated from 150 psi 1034 kPa at idle speeds to 260 psi at full throttle operation This change reduces the pressure to which the front clutch seals and reaction shaft seals are subjected providing a beneficial effect on transmission durability and reliability This improvement is accomplished by routing the reverse control fluid to the regulator valve reducing the fluid pressure at closed throttle to 150 psi At wide open throttle the regulator valve provides the 260 psi needed during heavy duty reverse operation such as backing up grades or parking a heavy trailer However during normal reverse operation such as backing out of a parking space or a driveway the system is only subjected to a pressure of about 160 psi 1103 kPa AUTOMATIC TRANSMISSION SERVICE GROUP ATSG Technical Service Information ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER Clutches Bands Lever Gear Start Parking Front Rear Over Lock up Kickdown Low Rev Position Ratio Safety Sprag running Front Rear P PARK X X R REVERSE 2 21 X X N NEUTRAL X D DRIVE First 2 45 X Second 1 45 X X Direct 1 00 X X 2 SECOND First 2 45 X X
36. to prevent internal leakage if the lock up clutch is actually locking up and whether it is holding or slipping USE A TACHOMETER Hook up an accurate engine tachometer and watch the engine speed in direct drive Watch the tachometer as you press the acceler ator to detent position just short of kickdown above 50 miles per hour The tachometer should indicate little or no increase in RPM if the lock up clutch is holding properly SLIGHT SLIPPAGE IS OK Some lock up torque converters may show a slight momentary increase in RPM during ac celeration in direct gear If the momentary increase is not more than 250 RPM the converter may be considered normal WHAT THE STALL TEST DOES The stall test applies full engine power against an unmoving or stalled turbine stator and transmission The stall test is done only in di rect drive Since the impeller is putting full engine power AUTOMATIC TRANSMISSION SERVICE GROUP PA4ATSG into the converter and it can t get out because of the stalled turbine the transmission oil is very quickly heated to the danger point For that reason do not exceed wide open throttle for longer than necessary to get the maximum RPM reading and never longer than five seconds at a time During the stall test maximum engine speed is limited by the restriction of the oil flow as it is forced through the locked stator That deter mines the engine speed you re looking for in th
37. to disas sembly use origina setings 12 Insta parking oz and E clip retainer to manua lever my SATSE Technical Service Information VALVE BODY AND ACCUMULATOR PISTON INSTALLATION 1 Make sure combination back up lamp neutral start switch is not installed in transmission case 2 Place valve body manual lever in manual low position to move parking rod to rear position 3 Use a screwdriver to push the park sprag into engagement with parking gear turning output shaft to verify engagement This will allow knob on end of parking rod to move past the sprag as valve body is installed 4 Install accumulator piston in the transmission case 5 Position accumulator spring between piston and valve body 6 Place valve body in position working park rod through opening and past sprag Install retaining bolts finger tight 7 With neutral starting switch installed place manual lever in the neutral position Shift valve body if necessary to center neutral finger over the neutral switch plunger Snug bolts down evenly then tighten to 105 in lbs 12 N m 8 Connect lock up solenoid wire to wiring connec SERVICE OUT TRANSMISSION AND CONVERTER REMOVAL Remove Transfer Case if so equipped Refer to Transfer Case Removal for procedure 1 The transmission and torque converter must be removed as an assembly otherwise the torque con verter drive plate pump bushing or oil sea
38. turn the stator backward but a one way clutch pre vents backward rotation of the stator t m Re E Ld 54 a E mm Fig 5 In a torque converter the stator re directs the driving oil in a helping direction back into the impeller MULTIPLICATION Technical Service Information TTIW p if w Fig 4 In a simple fluid coupling the driving oi can flow back and interfere with the driving fan STATOR PROVIDES OIL FLOW DURING ACCELERATION When the engine speeds up for acceleration in low gear the impeller of course speeds up the same as the engine In the torque converter the oil is forced violently into and out of the turbine and against the front of the stator vanes This forces the stator into lock and the stator vanes now re direct the oil flow in a helping direction back into the impeller The impeller in turn uses the re directed oil to push the turbine and the cycle is repeated TORQUE MULTIPLICATION With the addition of the stator the total push finally given to the impeller is greatly increased When the turbine is turning slowly and the impeller is turning fast the torque at the reac tion shaft may be several times the torque input from the engine You can remember it this way When there is a great difference between impeller speed and turbine speed the oil flow locks the stator and torque multiplication occurs AUTOMAT
39. 01 113 60 67 97 108 Kickdown Range 3 2 Downshift 3 1 Downshift Governor Pressure 50 57 80 92 25 27 40 43 25 27 40 43 16 18 26 29 50 57 80 92 60 68 97 109 30 32 48 52 16 18 26 29 19 21 36 41 58 66 36 41 58 66 43 49 69 79 40 45 64 72 43 49 69 79 41 47 66 76 54 59 87 95 54 59 87 95 64 70 103 113 59 65 95 105 62 68 100 110 59 65 95 105 55 63 89 101 158 65 93 101j55 62 89 100 28 30 45 48 27 35 43 56 26 33 42 53 31 34 17 19 27 31 17 20 27 32 16 19 26 31 Governor pressure should be from zero to 1 5 psi at standstill or downshift may not occur NOTE Figures given are typical for the axle ratio and tire size combination Changes in tire size or axle ratio will cause shift points occur at correspondingly higher or lower vehicle speeds AUTOMATIC TRANSMISSION SERVICE GROUP 11 SATSE pressure take off point located at lower left side of extension near the mounting flange Fig 2 2 Operate transmission in third gear to read pres sures and compare speeds shown in chart If governor pressures are incorrect at the given vehicle speeds the governor valve and or weights are probably sticking The governor pressure should re spond smoothly to changes in mph and should return to 0 to 1 1 2 psi 10 kPa when vehicle is stopped High pressure above 2 psi when vehicle is stopped will prevent the transmission from downshifting Throttle Pressure No gauge port is provided for throttle
40. 5 Remove cooler lines at Transmission 6 Remove starter motor and cooler line bracket 7 Remove torque converter access cover 8 Loosen oil pan bolts tap the pan to break it loose allowing fluid to drain 9 Reinstall pan 10 Mark torque converter and drive plate to aid in reassembly The crankshaft flange bolt circle inner and outer circle of holes in the drive plate and the four tapped holes in front face of the torque converter al have one hole offset so these parts will be installed in the original position This maintains balance of the engine and torque converter 11 Rotate engine clockwise with socket wrench on vibration dampener bolt to position the bolts attach ing torque converter to drive plate and remove bolts AUTOMATIC TRANSMISSION SERVICE GROUP 33 nTSG 12 Mark parts for reassembly then disconnec propeller shaft at rear universal joint Carefully 2 7 shaft assembly out of the extension housing 13 Disconnect wire connector from the back ur lamp and neutral starting switch and lock up solenoic wiring connector if so equipped 14 Disconnect gearshift rod and torque shaf assembly from transmission When it is necessary to disassemble linkage rods from levers that use plastic grommets as retainers the grommets should be replaced with new ones Use a prying tool to force rod from grommet in lever then cut away old grommet Use pliers to snap new grommet into lever and rod into grommet
41. 8 Stand input shaft upright on a clean smooth surface and install handle Tool C 4171 in the install ing head Fig 31 Drive bushing into shaft until tool bottoms 9 Thoroughly clean input shaft and clutch piston retainer before assembly and installation Assembly 1 If removed press input shaft into clutch piston retainer and install snap ring 2 Lubricate and install inner and outer seals on clutch piston Make sure seal lips face toward input shaft and seals are properly seated in piston grooves Fig 30 3 Place piston assembly in retainer and with a twisting motion seat piston in bottom of the retainer 4 Position clutch retainer over piston retainer splines and support the assembly so clutch retainer remains in place 5 Place clutch piston spring and spacer ring on top of piston in clutch retainer make sure spring and spacer ring are positioned in the retainer recess Start one end of wave spring in retainer groove Fig 28 then progressively push or tap spring into place mak ing sure it is fully seated in the groove 6 Install inner pressure plate in clutch retainer with raised portion of plate resting on the spring 7 Lubricate all clutch plates install one lined disc followed by a steel plate until all plates are installed Install outer pressure plate and selective snap ring 8 Measure rear clutch plate clearance by having an assistant press downward firmly on outer pressure plate then insert
42. ELY MOVE THE SELECTOR TO A FORWARD E MOVE TRANSMISSION DRIVE RANGE AND OBSERVE THE AND CONVERTER AS AN ASSEMBLY DISASSEMBLE CLEAN AND INSPECT ALL ides PARTS CLEAN THE VALVE BODY INSTAL ALL NEW SEALS RINGS AND GASKETS REPLACE WORN OR DEFECTIVE PARTS HAFT T PROPELLER SHAFT DOES BUT REAR WHEELS NOT TURN DO NOT TURN INSPECT REMOVE THE FOR BROKEN REAR TRANSMISSION OIL PAN AXLE PARTS INSPECT FOR DEBRIS DEBRIS IS PRESENT REMOVE THETRANSMISSION AND CONVERTER AS AN ASSEMBLY DISASSEMBLE CLEAN AND INSPECT NO DEBRIS REMOVE VALVE BODY DISASSEMBLE CLEAN AND INSPECT ALL PARTS ALL PARTS CLEAN VALVE BODY INSTALL ALL NEW SEALS RINGS AND GASKETS REPLACE WORN OR DEFECTIVE PARTS PU567 REASSEMBLE INSTALL AND CHECK PRESSURES AND OPERATION DIAGNOSIS GUIDE FLUID LEAKS VISUALLY INSPECT FOR SOURCE OF LEAK IF THE SOURCE OF LEAK CANNOT BE READILY DETERMINED CLEAN THE EXTERIOR OF THE TRANSMISSION CHECK TRANSMISSION FLUID LEVEL CORRECT IF NECESSARY THE FOLLOWING LEAKS REQUIRE REMOVAL OF THE TRANSMISSION AND TORQUE CONVERTER FOR CORRECTION TRANSMISSION FLUID LEAKING FROM THE LOWER EDGE OF THE CONVERTER HOUSING CAUSED BY FRONT PUMP SEAL PUMP TO CASE SEAL OR TORQUE CONVERTER WELD CRACKED OR POROUS TRANSMISSION CASE THE FOLLOWING LEAKS MAY BE CORRECTED WITHOUT REMOVING THE TRANSMISSION MANUAL LEVER SHAFT SEAL FILLER TUBE O RING PRESSURE GAUGE PLUG
43. Engine Bolt 30 41 150 17 Valve Body Screw 35 4 Valve Body to Transmission 150 17 Case Bolt 105 12 inch Pounds Inch Pounds AUTOMATIC TRANSMISSION SERVICE GROUP 59 nTSG Technical Service Information STALL SPEED SYMPTOM CONDITION Vehicle shakes during breakaway in reverse with medium to heavy throttle application i e backing very slowly up a steep grade or backing up a trailer DIAGNOSIS Warm vehicle to normal operating temperature Locate a relatively steep grade where it is safe to stop and back up Try backing the vehicle up very slowly from a full stop If a sufficiently steep grade is not avail able move the vehicle to an open flat paved area where it is safe to stop and back up Apply the parking brake about half way Shift to re verse and slowly open the throttle until the vehicle just begins to move Vehicle speed should be no more than a slow walking pace Extreme care must be taken not to overheat the transmission during this test Do not open the throttle more than 10 seconds at a time Alow the transmission to cool by running at a fast idle in neutral for at least three minutes between attempts to breakaway during either of these tests do the fol lowing repair PARTS REQUIRED 1986 Passenger Car Application Fifth Avenue Gran Fury and Diplomat Part Engine Transmission Torque Converter Number 318 5 2L A 999 Low stall lock up 4431113
44. HOD o Water Heat Exchanger LUBRICATION isco Ghee eh E eae ee oy Pump Gear Type GEAR RATIOS Lui a eee Ae C Cae ee First Second Third Reverse 7277 dovere 2 45 to 1 1 45 to 1 1to1 2 21 to 1 A 904T A 999 2 74 to 1 1 54 to 1 2 21 to 1 PUMP CLEARANCES Outer Gear to Case Bore 0035 to 0075 inch Outer to Inner Tip 0045 to 0095 inch End Clearance Gears 0004 to 0025 inch 001 to 003 inch GEAR TRAIN END PLAY 005 to 048 inch 006 to 048 inch INPUT SHAFT END PLAY 022 to 091 inch 034 to 084 inch SNAP RINGS Rear Clutch Snap Ring Selective a verme Gana Ses Bet 060 to 062 inch 060 to 062 inch 068 to 070 inch 074 to 076 inch 076 to 078 inch 088 to 090 inch 098 to 100 inch 106 to 018 inch Output Shaft Forward End 040 to 044 inch 048 to 052 inch 062 to 066 inch 055 0 059 inch 082 to 086 inch 062 to 066 inch CLUTCH PLATE CLEARANCE Front Clutch x esL 4 Disc 067 to 134 inch 4 Disc 082 to 151 inch 5 Disc 075 to 152 inch Rear CIatch te y wheat e s lenses aig Mw ENIM 4 Disc 032 to 055 inch 4 Disc 025 to 045 inch A 904T A 999 A 727 CLUTCHES Engine Cu In 225 318 318 360 Number of Front Clutch Plates 4 5 4 Number of Front C
45. IC TRANSMISSION SERVICE GROUP 68 wA RnTSC On the other hand when the impeller and tur bine speeds are closer together the oil flow tends to the stator in the forward direction The stators overrunning clutch now permits forwart rotation of the stator in effect let stator coast along with the oil flow FLUID COUPLINGS ALL SLIP A LITTLE sugh fluid couplings provide smooth CHRYSLER S LOCK UP With a conventional converter in direct drive both the impeller and the turbine are rotating at approximately the same speed The stator is freewheeling and no torque multiplication is produced or needed However as we have noted the fluid coupling part of the torque converter still allows a slight amount of slip page between its members If we can now lock the turbine and the impeller together we can achieve a condition of zero slippage in direct drive NEW PISTON LOCKS TURBINE TO IMPELLER Chrysler engineers added a moveable piston to the turbine and opposite the piston they added friction material to the inside of the impeller housing IMPELLER THRUST WASHER IMPELLER FRONT ASSEMBLY COVER PISTON TURBINE STATOR Fig 6 New lock up converter has clutch to lock turbine to impeller in direct drive TORQUE CONVERTER Technical Service Information shock free power and torque transfer it is nat ural for all fluid drives to slip somewhat even in direct drive In the p
46. L NOISE MOVE THE SELECTOR TO A FORWARD DRIVE RANGE AND OBSERVE THE PROPELLER SHAFT FOR TURNING PROPELLER SHAFT DOES NOT TURN REMOVE THE TRANSMISSION OIL PAN INSPECT FOR DEBRIS PROPELLER SHAFT TURNS BUT REAR WHEELS DO NOT TURN INSPECT FOR BROKEN REAR AXLE PARTS DEBRIS IS PRESENT REMOVE TRANSMISSION AND CONVERTER AS AN ASSEMBLY DISASSEMBLE CLEAN AND INSPECT ALL PARTS CLEAN THS VALVE BODY INSTALL ALL NEw SEALS RINGS AND GASKETS REPLACE WORN OR DEFECTIVE PARTS NO DEBRIS REMOVE VALVE BODY DISASSEMBLE CLEAN AND INSPECT ALL PARTS REASSEMBLE INSTALL AND CHECK PRESSURES AND OPERATION AUTOMATIC TRANSMISSION SERVICE GROUP 78 OMATIC TRANSMISSION SERVICE GRO DODD PR PRINTED IN U S A E
47. LADANA LA NIENTE 0197919191979 AAAA AUTOMATIC TRANSMISSION SERVICE GROUP ERIS N 79 9 9 9 9 9 9 9 9 91919 9 3 9 9 919 9 91919 919 9 3 9 9 19 9 5 ATSGI technical Service Information TORQUEFLITE A 727 GENERAL INFOR 277 Safety goggles s 7 22 2 times when working on tra7s ss 77s The idenzi ezt 7 Sairi the Load Flite Transm s Because of the s servicing the transmiss eni e ma combined in this res occur application is indirz s 2 Transmission operatic are differ ent for each 272 e z e combination and some internal parts 5e c erert to provide for this Therefore when 2 c refer to the seven digit part number sta rec side of the transmission oil pan flange All A 904T and A 999 transmissions are equipped with a wide ratio gear set Low is 2 74 to 1 The sun gear and front planetary cear set is unique to the wide ratio transmission T e rear plan Sans etary gear set remains the same as previous models The transmission combines a orgue convener and a fully automatic 3 speed gear svstem The torque converter housing and transmission gral aluminum casting The multiple disc clutches an and bands and 2 planetary gear sets 12 Sroxvice t
48. LEn 2 FX TS Z q TNA Ose Jus j r T DN d 3i w z lt gt dies ed 29 52 M P 2 2 55 55 Qu Technical Service Information AUTOMATIC TRANSMISSION SERVICE GROUP OIL FILTER SUN GEAR DRIVING SHELL KICKDOWN ERONT BAND FLEXIBLE DRIVE PLATE Torque Converter A 904T 1 LoadFlite Transmission Technical Service Information nTSC 14VHS 108100 ONIX dVNS 666 v pue 1 06 Aiqwassy siean K1ejouejd 2 614 83HS V A ISNYHL 9 4v3O SNINNNY Z SNINNNY 1 YIHSVM LSNYHL 01 YIHSVM LSNYHL 5 2 45 STS NIRS TAS Z BELTS A AYID nns ONIY dVNS x i MV f U SY YIVISNI u Wis vA LSOHHI vil MV O SONNY wv 10427272 A WWJSSV P P 4 OW ANS Jd AD NV d 2 180440 YVIO SMIANNY 1 VS WIJHSVAA 15 1 6i LZZ 222727722272 13315 31 14 LSNYHL 8 13315 31 14 LSNYHL 4 TWHS ONIARIG AUTOMATIC TRANSMISSION SERVICE GROUP P4ATSG IMPELLER OIL PUMP STATOR FRONT CLUTCH TURBINE LOCK UP CLUTCH REAR CLUTCH FRONT PLANETARY GEAR SET Technical Service Information BUSHING SEAL EXTENSION HOUSING OUTPUT SHAFT BEARING PARKING LOCK ASSEMBLY GOVERNOR VALVE BODY LOW AND REVERSE REAR BAND REAR PLANETARY GEAR SET OVER
49. Locknut Kickdown Lever Shaft Plug Lock up Solenoid Wiring Connector ever ne ehh s s P n n teta rm eire m on c v og n nn A 904T A 999 225 318 CID 1 061 to 063 inch 2 061 to 063 inch 024 to 026 inch 3 Selective 052 to 054 inch Tin 068 to 070 inch Red 083 to 086 inch Green 4 121 to 125 inch A 727 ALL 1 Selective 061 to 063 inch Natural 084 to 086 inch Red 102 to 104 inch Yellow 2 061 to 3 062 to 063 inch Natural 064 inch 030 to 032 inch 5 048 to 050 inch 4 059 to 062 inch 5 059 to 062 inch 6 048 to 050 inch 7 050 to 052 inch 8 050 to 052 inch 6 034 to 036 inch 9 048 to 050 inch 7 059 to 062 inch 8 034 to 036 inch 10 048 to 040 inch TIGHTENING REFERENCE Ft Lbs N m Ft Lbs 155 18 Neutral Starter Switch 25 34 85 10 Oil Pan Bolt ecce yes 150 T Oil Pump Housing to Transmission 75 Case Bolt gine 700 Output Shaft Support Bolt 150 17 270 31 Overrunning Clutch Cam Set Screw 40 5 Pressure Test Take Off Plug 120 14 32 43 Reaction Shaft Support to Pump Bolt 175 20 50 68 Reverse Band Adjusting Screw TI Boi up aee v 25 34 Speedometer Drive Clamp Screw 100 11 30 41 Transmission to
50. N SERVICE GROUP 13 Fig 5 Pump Housing Area housing area Fig 5 7 Remove the transmission and torque converter assembly from vehicle for further investigation The fluid should be drained from the transmission Rein stall oil pan with new gasket at specified torque Possible sources of transmission pump housing area fluid leakage shown in Fig 5 are 1 Torque converter hub seal a Seal lip cut check torque converter hub finish b Bushing moved and or worn c Oil return hole in front pump housing plugged or omitted d Seal worn out high mileage vehicles 2 Fluid leakage at the outside diameter from pump housing O ring seal 3 Fluid leakage at the front pump to case bolts 4 Fluid leakage due to case or front pump housing porosity 5 Oil leakage out the vent 6 Kickdown lever shaft access plug TORQUE CONVERTER HUB WELD OUTSIDE RH254 Fig 6 Torque Converter Nonlock up STARTER RING GEAR Technical Service Information WELD OR BREAK EDGE oe BRAZE 1 8 SEAL THIS END AIR TIGHT ERES 5 1 4 1 873 POLISH 1 87 OUTSIDE OF END FOR THIS MATERIAL 1 7 8 INCH THIN WALLED STEEL TUBING DISTANCE ON TUTE AND 1 8 INCH STEEL DISC PY304 Fig 7 A 727 Hub Seal Cup Torque Converter Leakage Fig 6 Possible sources of torque converter leakage are a Torque converter weld leaks at the outside c ameter perip
51. NG GOVERNOR PRESSURE PORT REAR SERV APPLY PRESSURE PORT Fig 2 Pressure Test Locations AUTOMATIC TRANSMISSION SERVICE GROUP w nTSG 4 Read pressures on both gauges as throttle lever on transmission is moved from full forward position to full rearward position 5 Line pressure should read 54 to 60 psi 372 to 414 kPa with throttle lever forward and gradually increase as lever is moved rearward 6 Front servo release is pressurized only in direct drive and should be same as line pressure within 3 psi 21 kPa up to downshift point 7 This tests pump output pressure regulation and condition of rear clutch front clutch and lock up clutch hydraulic circuits Test Four Selector in Reverse 1 Attach 300 psi gauge to rear servo apply port 2 Operate engine at 1600 rpm for test 3 Move the selector lever on transmission four detents rearward from full forward position This is selector R position 4 Rear servo pressure should read 145 to 175 psi with throttle lever forward and increase gradually to 230 280 psi as throttle lever is moved rearward 5 This tests pump output pressure regulation and condition of front clutch and rear servo hydraulic Technical Service Information circuits 6 Move selector lever on transmission to D posi tion to check that rear servo pressure drops to zero 7 This tests for leakage into rear servo due to case porosity which can cause reverse b
52. NO NEW RING GEAR OR BALANCE WEIGHT REPLACEMENTS In the past it was acceptable for a ring gear to be replaced on a torque converter by grinding away the welds breaking off the gear and re welding a new gear in place This is not recom mended for the lock up converter The same restriction applies to the converter balance weights on the front cover In the photo Fig 14 you can see the normal heat scars from the original ring gear welds at the factory You can also see the bonded friction material close by which was installed after the welding opera tion If you attempted to re weld a new ring gear or balance weights the rewelding opera tion could easily overheat the friction material causing it to fail Therefore in the event of a ring gear failure the entire lock up converter should be replaced Fig 14 Welding heat scars show why ring gear re placement is not recommended NO EXCHANGE APPLICATIONS Even though the overall dimensions are about the same there is no way to use the new lock up torque converter or the new lock up valve body with any other transmission LOCK UP COMPONENTS NOT THE SAME FOR ALL ENGINES You ll also see that lock up components speci fied for one engine may not be suitable for another car engine application even if it too is a lock up Ce Fig 15 Lock up and non lock up components are not interchangeable 75 Peta Fig 16 Deca shows converter engine
53. NSMISSION SERVICE GROUP 77 RnTSG Technical Service Information DIAGNOSIS GUIDE FLUID LEAKS VISUALLY INSPECT FOR SOURCE OF LEAK IF THE SOURCE OF LEAK CANNOT BE READILY DETERMINED CLEAN THE EXTERIOR OF THE TRANSMISSION CHECK TRANSMISSION FLUID LEVEL CORRECT IF NECESSARY THE FOLLOWING LEAKS MAY BE CORRECTED WITHOUT REMOVING THE TRANSMISSION THE FOLLOWING LEAKS REQUIRE REMOVAL CF THE TRANSMISSION AND TORQUE CONVERTE MANUAL LEVER SHAFT SEAL FOR CORRECTION FILLER TUBE O RING TRANSMISSION FLUID LEAKING FROM THE PRESSURE GAUGE PLUG LOWER EDGE OF THE CONVERTER HOUSING NEUTRAL START SWITCH CAUSED BY FRONT PUMP SEAL PUMP TO CASE PAN GASKET SEAL OR TORQUE CONVERTER WELD OIL COOLER FITTINGS CRACKED OR POROUS EXTENSION MOUSING TO CASE GASKET TRANSMISSION CASE EXTENSION HOUSING TO CASE BOLTS EXTENSION HOUSING YOKE SEAL SPEEDOMETER ADAPTER O RING FRONT BAND ADJUSTING SCREW DIAGNOSIS GUIDE VEHICLE WILL NOT MOVE CHECK THE TRANSMISSION FLUID LEVEL BEFORE STARTING THE ENGINE IF NOIFLUID 15 VISIBLE ON THE DIP STICK ADD FLUID TO THE L MARK BEFORE STARTING THE ENGINE THEN START THE ENGINE WITH THE TRANSMISSION IN NEUTRAL AND LISTEN FOR NOISE ABNORMAL NOISE STOP ENGINE IMMEDIATELY REMOVE THE TRANSMISSION AND CONVERTER AS AN ASSEMBLY DISASSEMBLE CLEAN AND INSPECT ALL PARTS CLEAN VALVE BODYAJINSTALL ALL NEW SEALS RINGS AND GASKETS REPLACE WORN OR DEFECTIVE PARTS NO ABNORMA
54. RANSMISSION AND GEAR NOISE KNOCK CLICK Of OR GRINDING SCRAPE NOISE REMOVE THE TRANSMISSION AND CONVERTER ASSEMBLY DISASSEMBLE CLEAN AND INSPECT ALL PARTS CLEAN REMOVE TORQUE CONVERTER AND FOR LOOSE OR CRAT CONVERTER DRIVE INSPECT FOR CONTAT gt THE STARTER DRIVE THE STARTING RING 22 THE VALVE BODY INSTALL ALL NEW SEALS RINGS AND GASKETS REPLACE WORN OR DEFECTIVE PARTS CONVERTER FOR SOURCE OF NOISE TRANSMISSION MAS CONVERTER HAS Loc BUZZ OR WHINE BUZZ OR WHINE REMOVE THE TRANSMISSION PAN INSPECT FOR DEBRIS INDICATING WORN OR FAILED PARTS REPLACE TORQUE CONVERTER DEBRIS PRESENT REMOVE TRANSM SL w AND CONVERTER AS ASSEMBLY DISASSEs 1 CLEAN AND INSPEC PARTS CLEAN THE BODY INSTALL ALL SEALS RINGS AND GASKETS REPLACE Wie OR DEFECTIVE PARTS NO DEBRIS PRESENT REMOVE VALVE BODY DISASSEMBLE CLEAN AND INSPECT PARTS REASSEMBLE INSTALL CHECK OPERATION AND PRESSURES PUS AUTOMATIC TRANSMISSION SERVICE GROUP wAnTSG Technical Service Information DIAGNOSIS GUIDE VEHICLE WILL NOT MOVE CHECK THE TRANSMISSION FLUID LEVEL BEFORE STARTING THE ENGINE IF NO FLUID IS VISIBLE ON THE DIP STICK ADD FLUID TO THE MARK BEFOR STARTING THE ENGINE THEN START THE ENGINE WITH THE TRANSMISSION IN ABNORMAL NOISE NO ABNORMAL NOISE STOP ENGINE IMMEDIAT
55. RUNNING CLUTCH SUN GEAR DRIVING SHELL D 52 u lt 5 5 2 o z x Ot x lt v _ 2 n Z FLEXIBLE DRIVE PLATE ENGINE CRANKSHAFT AUTOMATIC SON SERVICE GROUP Fig 3 LoadFlite Transmission and Torque Converter A 727 Pressure Supply System The pressure supply system consists of an oil pump driven by the engine through the torque converter The single front pump furnishes pressure for all the hydraulic and lubrication requirements Pressure Regulating Valves The regulator valve controls line pressure depen dent on throttle opening The governor valve controls governor pressure to the transmission which varies with vehicle speed to control upshift downshift and lock up speeds The throttle valve controls throttle pressure to the transmission which varies with throttle position to control upshift and downshift speeds Flow Control Valves The manual valve provides the different transmis sion drive ranges as selected by the vehicle operator The 1 2 shift valve automatically shifts the trans mission from low to second or from second to low depending on the vehicle operation The 2 3 shift valve automatically shifts the trans mission from second to direct or from direct to second depending on the vehicle operation The kickdown valve makes possible a forced down shift from direct to second second to breakaway or direct to breakaway depending on vehic
56. Remove rubber seal ring from pump body flange 3 Drive out oil seal with a blunt punch Inspection Inspect interlocking seal rings Fig 14 on reaction shaft support for wear or broken locks make sure they turn freely in the grooves Inspect machined surfaces on pump body and reaction shaft support for nicks and burrs Inspect pump body and reaction shaft support bushings for wear or scores Inspect pump gears for scoring or pitting With gears cleaned and installed in pump body place a straightedge across face of gears and pump body Use a feeler gauge to measure clearance between straightedge and face of gears Clearance limits are from 001 to 0025 inch Also measure gear tip clearance between inner and outer teeth Clearance limits are from 005 to 010 inch Clearance between outer gear and its bore in oil pump body should be 004 to 008 inch Pump Bushing Replacement A 727 1 Place pump housing on a clean smooth surface REACTION SHAFT SEAE RINGS SUPPORT INNER GEAR 1 THRUST WASHER SELECTIVE BOLTS 6 22270 Fig 14 01 Pump and Reaction Shaft Support A 727 AUTOMATIC TRANSMISSION SERVICE GROUP gear cavity down 21 Place removing head Tool SP 3550 in bushing ard install handle Tool C 4171 in the removing head Fig 15 3 Drive bushing straight down and out of the bore e careful not to cock tool in the bore 4 Position a new bushing on installing head Tool 27 5118 5 With pump
57. TORQUE CONVERTER POSSIBLE CAUSE FAULTY OIL PUMP STICKING GOVERNOR VALVE PLUGGED COOLER LINES OR FITTINGS VALVE BODY MALFUNCTION STUCK SWITCH VALVE STUCK LOCK UP VALVE STUCK FAIL SAFE VALVE STUCK LOCK UP SOLENOID SOLENOID WIRING DISCONNECTED FAILED LOCK UP SOLENOID FAILED LOCK UP RELAY FAULTY TORQUE CONVERTER OUT OF BALANCE FAILED LOCKING CLUTCH LEAKING TURBINE HUB SEAL ALIGN EXHAUST SYSTEM TUNE ENGINE FAULTY INPUT SHAFT OR SEAL RING THROTTLE LINKAGE MISADJUSTED CONDITION C eee TAT AE c d suu uc a S S ONT ES a gt TO au vr x obi 15 Bie 2 tee lt g 32 gt gt 5 2 42 5 28 5 2 53 af az o u zw P D e te mE Ee lt 2 OO iz COZ wz Ei e o az gt 2 z lt 2 elena 9 25 5g 28 55 85 522 ws 2 o 22 e 2 gt rS 9 s 2 29 3 az8 S2a lt x lt zzz Ox lt oz lt gt 225 559 mo 52 25 z z 59 99 5e 550 558 59 zz 59 AUTOMATIC TRANSMISSION SERVICE GROUP 19 nTSG LUBRICATION Inspect fluid level on dipstick every six months with engine idling and transmission in neutral position and vehicle on level ground properly filled transmission will read near the add mark when fluid tempera ture is 70 degree fa
58. a disassembled view of the rear clutch assembly 1 Remove large selective snap ring that secures pressure plate in clutch piston retainer Lift pressure plate clutch plates and inner pressure plate out of the retainer 2 Carefully pry one end of wave spring out of its groove in clutch retainer then remove wave spring and clutch piston spring 3 Invert clutch piston retainer assembly and bump it on a wooden block to remove piston Remove seals from piston 4 If necessary remove snap ring and press input shaft from piston retainer Inspection Inspect facing material on all driving discs Replace discs that are charred glazed or heavily pitted Discs Should also be replaced if they show evidence of material flaking off or if facing material can be scraped off easily Inspect driving disc splines for wear or other damage Inspect steel plate and pressure plate surfaces for burning scoring or damaged driving lugs Replace if necessary Inspect plates and discs for flatness they must not be warped or cone shaped Inspect steel plate lug grooves in clutch retainer for smooth surfaces plates must travel freely in the grooves Note ball check in clutch retainer make sure ball moves freely Inspect seal rings surfaces in clutch retainer for nicks or deep scratches Light scratches will not interfere with sealing of the seals Inspect neoprene seal rings for deterioration wear and hard ness Inspect piston spring and wave spring
59. a feeler gauge between the plate and snap ring Fig 29 See Specifications for al lowed clearance If necessary install a new snap ring NSTALLATION Technical Service Information of proper thickness to obtain specified clearance Low limit clearance is desirable Rear clutch plate clear ance is very important in obtaining proper clutch Operation The clearance can be adjusted by the use of various thickness outer snap rings Snap rings are available in 060 074 088 and 106 inch thickness 9 Install 3 thrust washer on rear end of input shaft using grease to hold in place PLANETARY GEAR TRAIN A S04T and A 999 End Play Measure end play of planetary gear assemblies sun gear and driving shell before removing these parts from output shaft Stand assembly upright with for ward end of output shaft on a wooden block so that all parts will move forward against selective snap ring at front of shaft Insert a feeler gauge between rear annulus gear support hub and shoulder on output shaft Fig 32 The clearance should be 005 to 048 inch If clearance exceeds specifications replace thrust washers and or necessary parts Disassembly Fig 33 1 Remove selective 3 thrust washer from for ward end of output shaft 2 Remove selective snap ring from forward end of output shaft then slide front planetary assembly off the shaft 3 Remove snap ring and 4 thrust washer from forward hub of front planetary gear
60. ainer Apply a coating of wax type lubricant or Door Ease to outer edge of seals and press seal to bottom of its groove around piston diameter for easier installation of piston assem bly Place piston assembly in retainer and carefully seat piston in bottom of retainer 3 Place spring on piston hub and position spring retainer and snap ring on the spring Compress spring with Tool C 3575A Fig 19 and seat snap ring in hub groove Remove compressor tool 4 Lubricate all clutch plates install one steel plate followed by a lined plate disc until the number given in specifications is installed Install pressure plate and snap ring Make sure snap ring is properly seated 5 Insert a feeler gauge between pressure plate and waved snap ring to measure maximum clearance where snap ring is waved away from pressure plate Fig 21 See Specifications for allowed clearance TOOL HANDLE C 4171 TOOL HANDLE amp C 4171 REMOVING HEAD INSTALLING HEAD SP 3626 FRONT SP 3627 CLUTCH RETAINER FRONT CLUTCH RETAINER BUSHING INSTALLATION RN34 REMOVAL Fig 20 Front Clutch Retainer Bushing A 904T and A 999 AUTOMATIC TRANSMISSI Technical Service Information FEELER GAUGE FEELER GAUGE RH288 Fig 21 Measure Front Clutch Plate Clearance FRONT CLUTCH A 727 Disassembly Figure 22 shows a disassembled view of the front clutch assembly 1 Remove large waved snap ring t
61. ainer for scores Note ball check in clutch retainer make sure ball moves freely Inspect seal surfaces in clutch retainer for nicks or deep scratches Light scratches will not interfere with sealing of seals Inspect clutch retainer bushing for wear or scores Inspect inside bore of piston for score marks if light remove with crocus cloth Inspect seal grooves for nicks and burrs Inspect rubber seals for deteriora SPECIAL 44 tion wear and hardness Inspect all piston springs retainer and snap ring for distortion Front Clutch Retainer Bushing Replacement A 727 1 Lay clutch retainer open end down on a clean smooth surface and place removing head Tool SP 3629 in the bushing Install handle Tool C 4171 in remov ing head Fig 24 2 Drive bushing straight down and out of clutch retainer bore Be careful not to cock tool in the bore REMOVER HEAD SP 3629 TOOL HANDLE C 4171 FRONT CLUTCH RETAINER REMOVAL INSTALLING HEAD SP 5511 TOOL HANDLE C 4171 INSTALLATION SoS 7 22 x 22 Z 2 5 3 Lay clutch retainer open end up on clean smooth surface Slide a new bushing on installing head Tool SP 5511 and start them in clutch retainer bore 4 Install handle in the installer Drive bushing into clutch retainer until tool bottoms 5 Thoroughly clean clutch retainer before assem bly and installation Assembly 1 Lubricate and install inner seal
62. and burn out Test Resuit Indications 1 If proper line pressure minimum to maximum is found in any one test the pump and pressure regulator are working properly 2 Low pressure in D 1 and 2 but correct pres sure in R indicates rear clutch circuit leakage 3 Low pressure in D and R but correct pressure in 1 indicates front clutch circuit leakage 4 Low pressure in R and 1 but correct pressure in 2 indicates rear servo circuit leakage 5 Low line pressure in all positions indicates a defective pump a clogged transmission oil filter or a stuck pressure regulator valve Governor Pressure Test only if transmission shifts at wrong vehicle speeds when throttle rod is correctly adjusted 1 Connect a 0 100 psi pressure gauge to governor AUTOMATIC SHIFT SPEEDS AND GOVERNOR PRESSURE CHART APPROXIMATE MILES PER HOUR AT ROAD LOAD km h kilometers per hour Engine C D 150 250 350 Axle Ratio 2 71 2 94 3 21 3 54 Tire Size Throttle Closed mph mph km h mph km h mph km h 1 2 Upshift 1519 1316 13 16 516 13 16 10 12 16 19 9 11 14 9 9 11 14 19 8 11 13 18 2 3 Upshift 11 14 18 23 3 1 Downshift 8 10 13 16 13 16 10 12 16 19 9 11 14 19 9 11 14 19 Throttle Wide Open 1 2 Upshift 29 36 46 57 ven wale 42 55 68 31 39 50 63 36 43 58 69 34 41 55 66 2 3 Upshift 55 61 89 98 55 61 89 98 65 73 105 118 60 67 97 108 63 70 1
63. application and indicates high stall or low stall stator AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information PARTSG At this writing there are 12 different lock up converters All of these converters can be iden tified by a decal mounted just inboard of the 2 offset drive lug on the converter shell The decal is visible by removing the transmis sion dust shield and rotating the converter to 7e correct hole in the drive plate Color coded decals indicate whether the converter has a high stail HS stator or low stall LS stator Therefore follow the background color and stall code of the decal to match the converter to the correct engine RED 360 and 400 C I D engine BLUE 225 C I D engine WHITE 318 C I D engine Input shafts to the transmission are also differ ent for the lock up converter Conventional shafts can not be used for any application NEW OWNERS ADVISED ABOUT LOCK UP Owners of new cars equipped with the lock up torque converter will be provided information in the Operator s Manual Literature Package advising them that they might feel the lock up engagement when it occurs Although most drivers will not be aware of the lock up action some owners may notice it and may require additional assurance that the Fig 17 Lock up converters require lock up transmis S j transmission is operating properly sion input shafts You ll find a change in
64. assembly slide front annulus gear and support off planetary gear assembly Remove 5 thrust washer from front side of planetary gear assembly Remove 6 thrust washer from rear side of planetary gear assembly If necessary remove snap ring from front of annulus gear to separate support from annulus gear OUTPUT SHAFT REAR ANNULUS GEAR REAR PLANETARY GEAR ASSEMBLY DRIVING SHELL RH297 Fig 32 Measure End Play of Planetary Gear Train AUTOMATIC TRANSMISSION SERVICE GROUP 48 RINGS FRONT FRONT PLANETARY GEAR ASSEMBLY 4 PINION 7 THRUST SUN GEAR PLATE STEEL 4 THRUST WASHER FRONT ANNULUS GEAR 5 THRUST WASHER 6 THRUST WASHER SPACER REAR PLANETARY GEAR ASSEMBLY 8 THRUST 3 PINION PLATE STEEL SNAP RING 10 THRUST WASHER DRIVING SHELL 9 THRUST WASHER RY185 Fig 33 Wide HRatio Planetary Gear Train 4 Slide sun gear driving shell and rear planetary assembly off the output shaft B Lift sun gear and driving shell off rear planetary assembly Remove snap ring and 8 thrust plate from sun gear rear side of driving shell Slide sun gear out of driving shell and remove spacer Fig 33 and 7 thrust plate from opposite end of sun gear if necessary 6 Remove 9 thrust washer from forward side of rear planetary assembly and remove planetary gear assembly from rear annulus gear Remove 10 thrust washer from rear side of planetar
65. ast a small amount of slippage in direct drive was tolerated because the potential sav ings in fuel did not justify the added expense of a lock up feature Present conditions however have changed that understanding SQ FRICTION MATERIAL Fig 7 Lock up friction material is bonded inside impel ler front cover Now by means of oil pressure the turbine pis ton can be forced against the impeller friction material resulting in total converter lock up This is done in direct drive only The result is a straight through 1 1 mechanical connection of the engine and transmission plus the elimination of all hydraulic fluid slip page in direct drive TORSIONAL VIBRATION DAMPERS ADDED Since the locked up mode has eliminated the vibration damping effect of the conventional fluid coupling any torsional vibration load transmitted by the engine is now absorbed by ten damper springs between the iock up piston and the turbine AUTOMATIC TRANSMISSION SERVICE GROUP 69 Technical SATSE Fig 8 Ten damper springs absorb any torsional vibra tion load from the engine THREE DIFFERENT SPRING RATES You can t see them but the springs are color coded red white or blue Each engine applica tion with a lock up torque converter has its own specification on damper springs There fore only the identical lock up converter may be used for replacement COLOR CODED IDENTIFICATION Lock up torque converters are identified b
66. cock tool in the bore 4 Position new bushing on installing head Tool SP 5117 5 With pump housing on a smooth clean surface start bushing and installing head in the bushing bore Install handle in the installing head Fig 10 6 Drive bushing into housing until tool bottoms in the pump cavity Be careful not to cock tool during installation 7 Stake bushing in place by using a blunt punch or similar tool Fig 11 A gentle tap at each stake slot location will suffice 8 Using a narrow bladed knife or similar tool remove high points or burrs around staked area Fig 11 Do not use a file or similar tool that will remove more metal than is necessary Fig 9 Oil Pump and Reaction Shaft Support A 904T and A 999 AUTOMATIC TRANSMISSION SERVICE GROUP 8 w nTSt TOOL HANDLE C 4171 REMOVAL REMOVING HEAD SP 3551 TOOL HANDLE C 4171 INSTALLING HEAD SP 5117 INSTALLATION MS gt BUSHING RN32 Fig 10 Replace Pump Bushing A 904T and A 999 Reaction Shaft Bushing Replacement A 904T and A 999 For identification purposes lock up reaction shaft support has 3 steel balls in the support at outside diameter of reaction shaft and nonlock up has 2 steel balls In case of a reacton shaft bushing failure always inspect the support for wear from the input shaft seal ring lands If worn or grooved replace support assembly 1 Assemble the remover Tool SP 5324 cup Tool SP 3633 and
67. control rod from manual lever Filter Transfer Plate and Pressure Regulators 1 Place valve body assembly on repair stand Tool C 3749 Fig 1 Remove three screws from the fluid filter and lift off filter A VALVE SPRING SWITCH VALVE SWITCH VALVE SPRING LINE PRESSURE REGULATOR VALVE LINE PRESSURE REGULATOR SPRING SPRING RETAINER AND ADJUSTING SCREW BRACKET MANUAL LEVER WASHER CLIP ASSEMBLY 3 SEAL MANUAL VALVE KICKDOWN KICKDOWN DETENT 2 LINE PRESSURE ADJUSTING SCREW ASSEMBLY THROTTLE PRESSURE ADJUSTING SCREW PU8A Fig 2 Pressure Regulators and Manual Control AUTOMATIC TRANSMISSION SERVICE GROUP Technical Se 1 4 INCH DIAMETER 0 cemove the secondary BALLS ooo wens waned by E clip SMALL ORIFICE INTO 1 2 SHIFT CONTROL BORE Marca am e Lever shaft 2 rom shaft then their Bore wt 0 75 c similar tool slide ballarzsz z 2 Slide 7 ue 3 Sits tlc cree gt em vVlxdown valve rod gt eg ree ccce gcn ee Shift Valves ard V2 ve Pressure Sensing Plugs 1 1 5 72 mr 1 4 INCH DIAMETER BALLS 11 32 INCH DIAMETER BALL PUTI plate Fig 7 enti sg zs c mer 1227 z sleeve line pressure pluz _m 2 2 string Fig 5 Steel Ball Locations 2 Remove 1 2 2 2 ru 1 1 0a clusing assemb
68. dd water and heat for approximately eight minutes after water has come to a boil Steam Place ring gear on a flat surface and direct flow around gear for approximately two minutes Flame Place ring gear squarely on a flat surface Using a medium size tip direct a slow flame evenly around inner rim of the gear Do not apply flame to the gear teeth Place a few drops of water on face of gear at intervals during heating process When gear is hot enough to just boil the water installation of gear on the torque converter can be made 1 After ring gear is expanded by heating place the gear in position on torque converter front cover Tap gear on the cover evenly with a plastic or rawhide mallet until face of gear is even with scribed line made during removal on the front cover Make sure gear is even with scribed line around full circumfer ence of the front cover 2 Reweld ring gear to torque converter front cover being careful to place as nearly as possible same amount of weld material in exactly same loca tion as was used in original weld This is necessary in order to maintain proper balance of the unit Place welds alternately on opposite sides of torque converter to minimize distortion 3 The following suggestions are offered as an aid in making the weld a Do not gas weld b Use a D C welder that is set at straight polarity an welder if the proper electrode is available c Use a 1 8 inch diameter weld
69. e chart in the Service Manual Either faster or slower engine speeds than those shown in the chart indicate torque converter or other trans mission problems If the stall speed is above the specification it indicates that something is not holding the Technical Service Information engine back as it should and only transmis sion clutch slippage can be the cause You ll have to make transmission oil pressure and air pressure checks as shown in the Service Man ual to determine the cause of the slippage before running the test a slower than speci fied stall figure indicates a stator clutch prob lem You ll have to make a road test to deter mine the cause If the stall speeds are 350 to 500 RPM below specification and the vehicle operates prop erly at highway speeds but acceleration through the gears is poor the stator overrun ning clutch is slipping The torque converter should be replaced if this fault is confirmed TORQUEFLITE TRANSMISSION STALL SPEED CHART Engine Transmission Cu In Type 225 A 904 318 CAL Hi Alt A 904 LA 318 FED A 904 LA 225 A 904 HD 318 CAL Hi Ait A 727 318 FED A 727 360 4 H D A 727 360 2 A 904 LA 360 2 A 727 360 4 CAL Hi Alt A 904 LA 400 4 A 727 400 4 H D A 727 440 4 A 727 440 4 H P A 727 During the stall test a whining or siren like noise caused by fluid flow is normal with some torque converters However if you hear definite metallic noises such as
70. eeds for the various modes of operation are shown in the Automatic Shift Speeds and Governor Pres sure chart Observe closely for slipping or engine speed flare up Slipping or flare up in any gear usually indicates clutch band or overrunning clutch problems If the condition is far advanced an overhaul will probably be necessary to restore normal operation In most cases the clutch or band that is slipping can be determined by noting the transmission oper ation in all selector positions and by comparing which internal units are applied in those positions The Elements in Use Chart provides a basis for road test Technical Service Information analysis By observing that the rear clutch is applied in bot the D first gear and 1 first gear positions but tha the overrunning clutch is applied in D first and the low and reverse band is applied in 1 first if th transmission slips in D range first gear but does nc slip in 1 first gear the overrunning clutch must be the unit that is slipping Similarly if the transmission slips in any two forward gears the rear clutch is the slipping unit Using the same procedure the rear clutch and fron clutch are applied in D third gear If the transmis sion slips in third gear either the front clutch or the rear clutch is slipping By selecting another gear which does not use one of those units the unit whic is slipping can be determined If the transmission al
71. ehicles 1 Install a snap ring in the front groove A 727 only on output shaft Install bearing on shaft with its outer race ring groove toward front Press or tap bearing tight against front snap ring or shoulder on A 904T and A 999 then install rear snap ring 2 On 4 W D vehicles use door ease lubricant on output shaft bearing O ring Drive the bearing into adapter using Tool C 4203 inverted with Handle C 4171 3 Place a new extension housing gasket on the transmission case Position output shaft bearing re taining snap ring as far as possible then carefully tap extension housing or adapter into place Make sure snap ring is fully seated in the bearing groove 4 Install and tighten extension housing or adapter bolts to 32 ft lbs 43 N m 5 Install gasket plate and screws on bottom of extension housing mounting pad Measure input shaft end play as described under Disassembly Subassembly Removal Correct if nec essary Fig 5 Valve Body Assembly and Accumulator Piston 1 Make sure combination back up lamp neutral start switch is not installed in transmission case 2 Place valve body manual lever in low position to move parking rod to rear position 3 Use a screwdriver to push park sprag into en gagement with parking gear turning output shaft to verify engagement This will allow knob on end of parking rod to move past the sprag as valve body is installed 4 Install accumulator piston in t
72. emove piston Remove seals from the piston 4 If necessary remove snap ring and press input shaft from clutch piston retainer Inspection Inspect plates and discs for flatness They must not be warped or cone shaped Inspect facing material on all driving discs Replace discs that are charred glazed or heavily pitted Discs should also be replaced if they show evidence of material flaking off or if facing material can be scraped off easily Inspect driving disc splines for wear or other damage Inspect steel plate and pressure plate surfaces for burning scoring or damaged driving lugs Replace if necessary PISTON SEAL INNER PISTON RETAINER PISTON SPRING Technical Service Information Inspect steel plate lug grooves in clutch retainer for smooth surfaces plates must travel freely in the grooves Note ball check in the piston make sure ball moves freely Inspect seal surfaces in clutch retainer for nicks or deep scratches Light scratches will not interfere with sealing of seals Inspect seals for deteri oration wear and hardness Inspect piston spring wave spring and spacer for distortion or breakage Inspect seal rings Fig 30 on input shaft for wear or broken locks make sure they turn freely in the grooves Do not remove rings unless conditions war rant Inspect bushing in input shaft for wear or scores Inspect rear clutch to front clutch 2 thrust washer for wear Washer thickness should be 061 to 063
73. er models Changes in tire size or axle ratio will cause shift points to occur at corresponding higher or lower vehicle speeds AUTOMATIC TRANSMISSION SERVICE GROUP 76 wAnTSG Technical Service Information DIAGNOSIS GUIDE ABNORMAL NOISE INSPECT AND CORRECT THE TRANSMISSION FLUID LEVEL ROAD TEST TO VERIFY THAT AN ABNORMAL NOISEEXISTS IDENTIF THE TYPE OF NOISE DRIVING RANGES AND CONDITIONS WHEN THE NOISE OCCURS KNOCK CLICK GEAR NOISE OR GRINDING WHINE OR 8UZZ NOISE OR SCRAPE NOISE REMOVE THE TRANSMISSION REMOVE TORQUE CONVERTER AND CONVERTER ASSEMBLY AND INSPECT FOR LOOSE DISASSEMBLE CLEAN AND LISTEN TO TRANSMISSION OR CRACKED CONVERTER INSPECT ALL PARTS CLEAN AND CONVERTER FOR DRIVE PLATE INSPECT FOR THE VALVE BODY INSTALL SOURCE OF NOISE CONTACT OF THE STARTER ALL NEW SEALS RINGS AND DRIVE WITH THE GASKETS REPLACE WORN STARTER RING GEAR QR DEFECTIVE PARTS TRANSMISSION HAS BUZZ CONVERTER HAS LOUD OR WHINE BUZZ OR WHINE REMOVE THE TRANSMISSION PAN INSPECT FOR DEBRIS INDICATING WORN OR FAILEO PARTS REPLACE TORQUE CONVERTER NO DEBRIS PRESENT REMOVE VALWE BOOY OISASSEMBLE CLEAN AND INSPECT PARTS REASSEMBLE INSTALL CHECK OPERATION AND PRESSURES DEBRIS PRESENT REMOVE TRANSMISSION AND CONVERTER AS AN ASSEMBLY DISASSEMBLE CLEAN AND INSPECT ALL PARTS CLEAN THE VALVE BODY INSTALL ALL NEW SEALS RINGS GASKETS REPLACE WORN OR DEFECTIVE PARTS AUTOMATIC TRA
74. er than rear 6 Remove 7 thrust washer from forward side of rear planetary gear assembly remove planetary gear set and 8 thrust plate from rear annulus gear Inspection Inspect bearing surfaces on output shaft for nicks burrs scores or other damage Light scratches small nicks or burrs can be removed with crocus cloth or a fine stone Inspect speedometer drive gear for any nicks or burrs and remove with a sharp edged stone Make sure all oil passages in shaft are open and clean Inspect bushings in sun gear for wear or scores replace sun gear assembly if bushings are damaged Inspect all thrust washers for wear and scores replace if damaged or worn below specifications Inspect thrust faces of planetary gear carriers for wear scores or other damage replace as required Inspect plane tary gear carrier for cracks and pinions for broken or worn gear teeth and for broken pinion shaft lock pins Inspect annulus gear and driving gear teeth for dam age Replace distorted lock rings Assembly Refer to Figure 34 for parts identification 1 Install rear annulus gear on the output shaft Apply a thin coat of grease on 8 thrust plate place it on the shaft and in the annulus gear making sure teeth are over the shaft splines 2 Position rear planetary gear assembly in the rear annulus gear Place 7 thrust washer on front side of planetary gear assembly 3 Install snap ring in front groove of sun gear long end of gear Ins
75. ert sun gear through front side of driving shell install rear 6 thrust plate and snap ring 4 Carefully slide driving shell and sun gear assem bly on output shaft engaging sun gear teeth with rear AUTOMATIC TRANSMISSION SERVICE GROUP w nTsG planetary pinion teeth Place 5 thrust washer inside the front driving shell 5 Place 4 thrust washer on rear hub of front planetary gear assembly then slide assembly into front annulus gear 6 Carefully work front planetary and annulus gear assembly on output shaft meshing planetary pinions with the sun gear teeth 7 With all components properly positioned install selective snap ring on front end of output shaft Remeasure end play of the assembly The clearance can be adjusted by the use of various thickness snap rings Snap rings are available in 048 055 and 062 inch thickness OVERRUNNING CLUTCH Inspection Inspect clutch rollers for smooth round surfaces they must be free of flat spots and chipped edges Inspect roller contacting surfaces in the cam and race for brinelling Inspect roller springs for distortion wear or other damage A 727 Inspect cam set screw for tightness If loose tighten and restake the case around screw Overrunning Clutch Replacement A 904T and A 999 If overrunning clutch cam or spring retainer are found damaged they can be replaced with a service replacement cam spring retainer and retaining bolts Fig 35 The se
76. fication If stall speed exceeds the maximum speci chart by more than 200 rpm transmission slippage is indicated Follow the transmission sure and air pressure checks outlined in this determine the cause of slippage Stall Speed Below Specification Low stall speeds with a properly tuned indicate torque converter stator clutch problem road test will be necessary to identify the problem If stall speeds are 250 350 rpm below specific and the vehicle operates properly at highway but has poor through gear acceleration the overrunning clutch is slipping lock up and nor up torque converters If stall speed and acceleration are norma abnormally high throttle opening is required to tain highway speeds the stator clutch has seizec lock up torque converter only Both of these stator defects require replaceme gt the torque converter Noise A whining or siren like noise due to fluid normal during stall operation with some torqus verters however loud metallic noises from loose or interference within the assembly indicate a tive torque converter To confirm that the noise nates within the torque converter operate the at light throttle in D and on hoist and under the transmission bell housing CLUTCH AND SERVO AIR PRESSURE TESTS NO DRIVE condition might exist ever correct fluid pressure because of ino
77. ghten oil pan bolts to 150 in lbs 17 N m 6 Pour four quarts of MOPAR ATF PLUS Auto matic Transmission Fluid Type 7176 through the filler tube 7 Start engine and allow to idle for at least two minutes Then with parking brake on move selector Technical Service Information lever momentarily to each position endirz neutral position 8 Add sufficient fluid to bring level to the t7 mark Recheck fluid level after transmission is a operating temperature The level should be 7 the FULL mark and ADD mark with ve level ground To prevent dirt from entering certain that dipstick cap is fully seated onto tube GEARSHIFT LINKAGE ADJUSTMENT Column Shift Fig 1 When it is necessary to disassemble from levers which use plastic grommets as ers the grommets should be replaced w ones Use a prying tool to force rod from lever pry only where grommet and rod atiz on the rod itself then cut away old grom pliers to snap new grommet into lever and m grommet 1 To insure proper adjustment make sure z able swivel block is free to turn on shift rod D ble and clean or repair parts to assure free av necessary 2 Place gearshift lever in P park posi 3 With all linkage assembled and the ac swivel lock bolt loose move shift lever on trans all the way to rear detent park position
78. gine per formance improper adjustments hydraulic malfunc tions and mechanical malfunctions Diagnosis of these problems should always begin by checking the easily accessible variables fluid level and condition manual linkage adjustment and throttle linkage ad justment Then perform a road test to determine whether the problem has been corrected or that more diagnosis is necessary If the problem exists after the preliminary tests and corrections are completed hydraulic pressure tests should be performed Fluid Level and Condition If a failure of any kind has contaminated the transmission fluid the oil cooler and cooler tubes must be reverse flushed see Oil Cooler and Cooler Tubes Flushing Before removing the dipstick wipe all dirt off of the protective cap and top of the filler tube Since the torque converter fills more slowly in the P Park position place the selector lever in N Neutral to be sure that the fluid level check is accurate The vehicle must be on level ground The engine should be running at idle speed The fluid should be at normal operating temperature approxi mately 175 F The fluid level is correct if it is between the Full and Add marks on the dipstick Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid As in any hydraulic system air bubbles make the fluid spongy therefore pressures will be low and build up slowly Imprope
79. haft during installation Front and Rear Clutch Assemblies The front and rear clutches front band pumr and reaction shaft support are more easily installec with transmission in an upright position ADJUSTING SCREW BAND REACTION PIN RH311 Fig 47 Doubie Wrap Band and Linkage A 904T and A 999 GROUP P nRTSG ne metn d to support transmission is outlined in Steps 1 and 2 1 Cut a 3 1 2 inch 89 mm diameter hole in a bench in the end of a small oil drum or a large wooden box strong enough to support transmission Cut or file notches at edge of the 3 1 2 inch 89 mm hole so output shaft support will fit and lay flat in the hole 2 Carefully insert output shaft into hole to sup port the transmission upright with its weight resting on flange of the output shaft support 3 A 904T and A 999 Apply a light coat of grease to selective thrust washer and install washer on front end of the output shaft Apply a light coat of grease to input shaft thrust plate and install over input shaft If input shaft end play was not within specifications 022 to 091 inch when tested before disassembly replace thrust washer with one of proper thickness Refer to thrust washer number 3 in Specifications for sizes available A 727 Apply a coat of grease on the input to output shaft thrust plate Number 3 Fig 34 and install plate on front end of the output shaft Apply a light coat of grease to the 3 tab thrus
80. hat secures pressure plate in clutch piston retainer Lift pressure plate and clutch plates out of the retainer Snap ring in 5 disc clutch is not waved 2 Install compressor Tool C 3863A over piston spring retainer Fig 23 Compress springs and re move snap ring then slowly release tool until spring retainer is free of hub Remove tool retainer and springs 3 Invert clutch retainer assembly and bump it on a wooden block to remove piston Remove seals from piston and clutch retainer hub Inspection Inspect plates and discs for flatness They must not be warped or cone shaped Inspect facing material on all driving discs Replace discs that charred glazed or heavily pitted Discs Should also be replaced if they show evidence of material flaking off or if facing material can be scraped off easily Inspect driving disc splines for wear or other damage Inspect steel plate and pressure plate surfaces for burning scoring or damaged driving lugs Replace if necessary Inspect steel plate lug grooves in clutch retainer for smooth surfaces must travel freely in the ON SERVICE GROUP PISTON SEAL INNER PISTON PISTON SPRINGS RETAINER ASSEMBLY PISTON SEAL OUTER SPRING RETAINER Technical Service Information CLUTCH PLATES SNAP RING WAVED SNAP RING DRIVING DISCS PRESSURE PLATE RH289 Fig 22 Front Clutch A 727 grooves Inspect band contacting surface on clutch ret
81. he same manner with Tool C 3974 3 A 904T and A 999 Slide a new bushing on installing end of Tool C 3996 Align oil hole in bushing with oil slot in the housing then press or drive bushing into place Fig 9 A 727 Using Tool C 3974 install a new bushing in same manner 4 A 904T and A 999 Drive a new oil seal into housing with Tool C 3995 Fig 6 A 727 Using Tool C 3972 install a new oil seal in same manner Extension Installation 1 Place new extension housing gasket on the transmission case Position the output shaft bearing retaining snap ring in extension housing Slide exten sion housing on output shaft guiding the parking lock Fig 7 Remove or Install Extension Housing AUTOMATIC TRANSMISSION SERVICE GROUP 25 nTSG BEARING SNAP RING GROOVE PARK LOCK SNAP CONTROL ROD RING Fig 8 Output Shaft Bearing contro rod knob past the parking sprag While spreading large snap ring in housing Fig 7 carefully tap housing into place then release the snap ring Make sure snap ring is fully seated in bearing outer race ring groove 2 Install and tighten extension housing bolts to 32 ft Ibs 43 3 Install gasket plate and screws on bottom of the extension housing mounting pad 4 Install the center crossmember and rear mount assembly tighten retaining bolts Lower transmission to install extension housing to support bolts and tighten to 50 ft lbs 68 N m
82. he transmission case Fig 50 5 Place valve body in position working park rod through opening and past sprag Install retaining bolts finger tight 7 With neutralstarting switch installed place manual lever in the neutral position Shift valve body if necessary to center neutral finger over the neutral switch plunger Snug bolts down evenly then tighten to 105 in Ibs 12 N m 8 Connect lock up solenoid wire to wiring connec tor at rear of transmission case if so equipped 9 Install gearshift lever and tighten clamp bolt Check lever shaft for binding in the case by meving Technical Service Information RETURN SPRING ACCUMULATOR PISTON SEAL RINGS RH314 Fig 50 Accumulator Piston and Spring lever through all detent positions If binding exists loosen valve body bolts and realign 10 Make sure throttle shaft seal is in place then install flat washer and throttle lever and tighten the clamp bolt 11 Position the round magnet over the bump in the front right hand corner of the oil pan 12 Install oil pan and a new gasket TRANSMISSION TORQUE CONVERTER AND DRIVE PLATE INSTALLATION The transmission and torque converter must be installed as an assembly otherwise the torque con verter drive plate pump bushing and oil seal will be damaged None of the weight of transmission should be allowed to rest on the plate during installation 1 Rotate pump gears with Tool C 3756 A 904T
83. heral weld b Torque converter hub weld Air Pressure Test of Transmission Fabricate equipment needed for test as shown Figs 7 through 11 WELD BREAK EDGE 1 16 OR BRAZE POLISH 6 OUTSIDE lt OF OPEN Les END FOR 1 498 THIS DISTANCE ON TUBE MATERIAL 1 1 2 INCH THIN WALLED STEEL TUBING AND 1 8 INCH STEEL DISC PY305 Fig 8 A 904T and A 999 Hub Seal Cup 15 32 DRILL 4 HOLES 17 19 32 20 MATERIAL 1 4 STEEL STOCK 1 1 4 WIDE PY306 Fig 9 Hub Seal Cup Retaining Strap AUTOMATIC TRANSMISSION SERVICE GROUP nTSG 3 8 DRILL 2 HOLES WELD OR BRAZE 1 4 ROD 1 4 ROD 4 21 32 RADIUS 5 RADIUS MATERIAL 3 16 STEEL STOCK Fig 10 A 727 Vent Plug Retainer PY307 The transmission should be prepared for pressure test as follows after removal of the torque converter 1 Install filler tube bore plug propeller shaft yoke tie in with cord or wire flared tube fitting cap on front cooler line fitting and a short piece of tubing flared at one end on the rear cooler line fitting Figs 12 and 13 2 Remove necessary front pump housing bolts Install vent plug rubber stopper and vent plug retainer preferably using longer bolts than those removed 3 With rotary motion install torque converter 13 32 DRILL 2 HOLES WELD OR BRAZE 1 4 ROD MATERIAL 3 16 STEEL STOCK PY308 Fig 11 A 904T
84. hex nut Tool SP 1191 Fig 12 Do not clamp any part of reaction shaft or support in a vise 2 With cup held firmly against reaction shaft thread remover into bushing as far as possible by hand 8 Using a wrench screw remover into bushing 3 to 4 additional turns to firmly engage threads in the BLUNT PUNCH Fig 11 Stake Pump Bushing 904 and A 999 Technical Service Information HEX NUT SP 1191 REMOVER SP 5324 INSTALLING HEAD SP 5325 REACTION SHAFT SUPPORT INSTALLATION REACTION REMOVAL SHAFT RN33 Fig 12 Replacing Reaction Shaft Bushing A 904T and A 999 bushing 4 Turn hex nut down against cup to pull bushing from reaction shaft Thoroughly clean reaction shaft to remove chips made by remover threads 5 Lightly grip bushing in a vise or with pliers and back tool out of the bushing Be careful not to damage threads on bushing remover 6 Slide new bushing on installing head Tool SP 5325 and start them in the bore of reaction shaft Fig 12 7 Support reaction shaft upright on a clean smooth surface and install handle C 4171 in installing head Drive bushing into the shaft until tool bottoms 8 Thoroughly clean reaction shaft support assem bly before installation Assembly 1 Place reaction shaft support in assembling Tool C 3759 with hub of support and tool resting on a smooth flat surface bench Fig 13 Screw two pilot studs Tool
85. housing on a smooth clean surface sub end down start bushing and installing head in the bushing bore Install handle in installing head 51 Drive bushing into housing until tool bottoms in 1 pump cavity Be careful not to cock tool during 7 Stake the bushing in place by using a blunt anch or similar tool Fig 16 gentle tap at each zke slot location will suffice Using a narrow bladed knife or similar tool ove high points or burrs around staked area Do use a file or similar tool that will remove more lt a than is necessary Thoroughly clean pump housing before 1 Beaction Shaft Bushing Replacement A 727 Assemble the remover Tool SP 5301 cup Tool 22 2533 and hex nut Tool SP 1191 Fig 17 lt not clamp any part of reaction shaft or support vise With cup held firmly against reaction shaft Use a wrench to screw remover into bushing 3 to 2 e2Zitional turns to firmly engage threads in the ea HANDLE 4171 REMOVAL REMOVING HEAD SP 3550 1 lt 7 PUMP HOUSING WOOL HANDLE C 4171 RN35 Fig 15 Replacing Pump Bushing A 727 Technical Service Information NARROW cio Fig 16 Stake Pump Bushing A 727 4 Turn hex nut down against the cup to pull bushing from reaction shaft Thoroughly clean reac tion shaft to remove chips made by remover threads 5 Lightly grip bushing in a vise or with pliers and back tool ou
86. hree forward ratios and a reverse razic The common sun gear of the planetary gear sets is connected to the front clutch by a driving she which is splined to the sun gear and engages the fren clutch retainer The hydraulic system consists of an 22 pump and a single valve body assembly which contains ai of the valves except the governor vaive Venting of the transmissicn is accomplished by a passage through the upper part of the oil pump housing The torque converter is attached to the crankshaft through a flexible driving piate Cooling of the torque converter is accomplished bx circulating the transmis sion fluid through an oil to water type cooler located in the radiator lower tank The torque converter A 904 assembly is a sealed unit which cannot be disassem bled A lock up clutch is located inside most torque converters The transmission fluid is filtered by an internal Dacron Type filter attached to the lower side of the valve body assembly Engine torque is transmitted to the torque con verter then through the input shaft to the multiple disc clutches in the transmission The power flow depends on the application of the clutches and bands Refer to Elements in Use Chart in Diagnosis and Tests section Lock up Torque Converter The A 904T except California models and A 999 transmissions are both equipped with lock up torque converters The A 727 transmission is non lockup The lock up mode is activated o
87. hrenheit 21 degrees Celsius and near but not over the full mark at 180 degrees fahrenheit 82 degrees Celsius average operating temperature Fluid and Filter Changes Refer to Lubrication and Maintenance Group O for mileage intervals Severe usage as defined below requires that fluid and filter be changed and bands adjusted every 12 000 miles 19 000 kilometers 1 More than 50 operation in heavy city traffic during hot weather above 90 F 32 C 2 Police Taxi Limousine Commercial Type Oper ation and Trailer Tow NOTES 1 When the factory fill fluid is changed as recom mended above MOPAR ATF PLUS Automatic Trans mission Fluid Type 7176 should be used band adjustment and filter change should be made at the time of the oil change 2 If the transmission is disassembled for any rea son the fluid and filter should be changed and the bands adjusted Drain and Refill 1 Raise vehicle on a hoise Place a drain container with a large opening under transmission oil pan 2 Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain then remove the oil pan 3 If necessary adjust the reverse band 4 Install a new filter on bottom of the valve body and tighten retaining screws to 35 in Ibs 4 N m 5 Clean the oil pan Make sure the round magnet is located over the bump in the front right hand corner of the oil pan Install oil pan using a new gasket Ti
88. ing rod and welding current of 80 to 125 amps d Direct the arc at intersection of the gear and front cover from an angle of 45 degrees from rear face of the gear 4 Inspect gear teeth and remove all nicks where metal is raised weld metal splatter etc in order to insure quiet starter operation OIL COOLER AND TUBES FLUSHING See Diagnosis and Tests PUMP OIL SEAL Replacement The pump oil seal can be replaced without removing pump and reaction shaft support assembly from the transmission case 1 A 904T and A 999 Screw seal remover Tool C 3981 into seal Fig 3 then tighten screw portion of tool to withdraw the seal A 727 Using Tool C 3861 remove seal in the same manner 2 A 904T and A 999 To install a new seal place seal in opening of the pump housing lip side facing Technical Service Information SEAL REMOVER RH276 Fig 3 Remove Pump Seal inward Using Tool C 4193 and handle Tool C 4171 drive seal into housing until tool bottoms Fig 4 A 727 Using Tool C 3860 A and handle Tool C 4171 install new seal in the same manner DISASSEMBLY SUBASSEMBLY REMOVAL Prior to removing any transmission subassemblies plug all openings and thoroughly clean exterior of the unit preferably by steam Cleanliness through entire disassembly and assembly cannot be overemphasized When disassembling each part should be washed in a suitable solvent then dried by compressed air Do not wipe part
89. l may be damaged The drive plate will not support a load therefore none of the weight of the transmission should be allowed to rest on the plate during removal 2 Disconnect negative ground cable from the battery for safety 3 Some models require that the exhaust system be dropped for clearance see Group 11 4 Remove engine to transmission struts if so equipped tor pin at rear of transmission case if so equipped 9 Install gearshift lever and tighten clamp bolt Check lever shaft for binding in the case by moving lever through all detent positions If binding exists loosen valve body bolts and realign 10 Make sure throttle shaft seal is in place then install flat washer and throttle lever and tighten the clamp bolt Connect throttle and gearshift linkage and adjust as required 11 Install oil pan with a new gasket Add trans mission fluid to bring it up to proper level ALUMINUM THREAD REPAIR Damaged or worn threads in the aluminum trans mission case and valve body can be repaired by the use of Heli Coils or equivalent Essentially this repair consists of drilling out the worn or damaged threads tapping the hole with a special Heli Coil tap or equivalent and installing a Heli Coil insert or equivalent into the tapped hole This brings the hole back to its original thread size Heli Coil or equivalent tools and inserts are readily available from most automotive parts suppliers OF VEHICLE
90. le speed by depressing the accelerator pedal past the detent feel near wide open throttle The throttle pressure plug at the end of the 2 3 shift valve provides a 3 2 downshift with varying throttle openings depending upon vehicle speed The 1 2 shift control valve transmits 1 2 shift con trol pressure to the transmission accumulator piston to control the kickdown band capacity on 1 2 upshifts and 3 2 downshifts The limit valve determines the maximum speed at which a 3 2 part throttle kickdown can be made Some transmissions do not have the Limit Valve and the maximum speed for the 3 2 kickdown is at the detent position The shuttle valve has two separate functions and performs each independently of the other The first is that of providing fast release of the kickdown band and smooth front clutch engagement when the driver makes a lift foot upshift from second to direct The second function of the shuttle valve is to regulate the application of the kickdown servo and band when making direct to second kickdowns The lock up valve automatically applies the torque converter lock up clutch when fed with line pressure from the lock up solenoid The lock up solenoid is controlled by the engine electronics through an elec trical connector in the rear of the transmission case Electronic control of the torque converter lock up includes unlocking the torque converter at closed throttle during engine warm up and during part
91. lutch Discs 4 5 4 Number of Rear Clutch Plates 3 3 3 Number of Rear Clutch Discs 4 4 4 Number of Front Clutch Springs 1 1 11 BAND ADJUSTMENTS Kickdown Front Turns 2 1 2 2 1 2 2 1 2 Low Reverse Internal Turns 4 4 2 Backed off from 72 inch pounds 8 AUTOMATIC TRANSMISSION SERVICE GROUP 58 56 Technical Service Information SPECIFICATIONS THRUST WASHERS zngine Reaction Shaft Support Thrust Washer Rear Clutch Retainer Thrust Washer nput Shaft Thrust Plate Output Shaft Thrust Washer n Output Shaft Thrust Plate ront Annulus Thrust Washer ront Carrier To Annulus Thrust Washer 2rive Sheli To Front Annulus Thrust Washer ront Carrier To Drive Shell Thrust Washer Sun Gear Drive Shell Thrust Plate te rtt ron e n e vans t n9 Rear Carrier To Drive Shell Thrust Washer Rear Carrier To Annulus Thrust Plate Rear Carrier To Annulus Thrust Washer woes vob Rh a god 444 m o sona Automatic LoadFlite 4 904T A 999 A 727 cooler Line Fitting Cooler Line Nut id Drive Plate to Crankshaft olt converter Drive Plate to Torque Converter Bolt Sxtension Housing to Transmission Case Bolt Extension Housing to Insulator Mounting Bolt Governor Body to Support Bolt Kickdown Band Adjusting Screw
92. ly valve governor plug 3 Re Here Sarees us Se 3 Remove shuttle valve clip and slide shuttle 1 2 SHIFT VALVE GOVERNOR PLUG 4 SHUTTLE we GOVERNOR PLUG x END PLATE 2 SM TT VALVE 5s i n e SHITE VALVE PRIMARY SPRING SHUTTLE VALVE THROTTLE PLUG SCREW S PUI2 Fig 6 8Shuttle Valve and Governor Plugs AUTOMATIC TRANSMISSION SERVICE GROUP 30 7 07i from throttle lever while c s iT ball and spring manta ewer g 003 2c i Femove the detent SATSE 2 3 SHIFT VALVE 1 2 SHIFT VALVE 1 2 SHIFT CONTROL VALVE REGULATOR VALVE THROTTLE PRESSURE PLUG SPRING 2 3 SHIFT SPRING 1 2 SHIFT SPRING 1 2 SHIFT CONTROL SPRING REGULATOR VALVE LINE PRESSURE Technical Service Information THROTTLE PLUG HOUSING END PLATE PLUG 3 2 DOWNSHIFT AND LIMIT VALVE ASSEMBLY USED ON SOME V 8 MODELS REGULATOR VALVE SLEEVE THROTTLE PRESSURE RETAINER RYISIA PLUG END PLATE Fig 7 Shift Valves and Pressure Regulator Valve Plugs 4 Slide retainer from housing and remove limit valve and spring 5 Remove the three springs and shift valves from the valve body Cleaning and Inspection Allow all parts to soak a few minutes in a suitable clean solvent Wash thoroughly and blow dry with compressed air Make sure all passages are clean and free from obstructions Inspect manual
93. m weight end of governor valve shaft Slide valve and shaft assembly out of the governor body 2 Remove snap ring from behind governor body then slide governor body and support assembly off the output shaft Oil Pump and Reaction Shaft Support 1 Tighten front band adjusting screw until band is tight on front clutch retainer This prevents clutch retainer from coming out with pump which might cause unnecessary damage to the clutches 2 Remove oil pump housing retaining bolts AUTOMATIC ON SERVICE GROUP 6 w AnTSG 3 Attach Tool C 3752 to pump housing flange Fig 7 in threaded holes in the flange 4 Bump outward evenly with the two knocker weights to withdraw oil pump and reaction shaft support assembly from the case Front Band and Front Clutch 1 Loosen front band adjuster remove band strut and A 727 anchor and slide band out of the case 2 Slide front clutch assembly out of the case Input Shaft and Rear Clutch 1 Grasp input shaft and slide input shaft and rear clutch assembly out of the case Be careful not to lose thrust washer located between rear end of input shaft and forward end of the output shaft Planetary Gear Assemblies sun Gear and Driving Shell 1 While supporting output shaft and driving shell carefully slide assembly forward and out through the case Be very careful not to damage ground surfaces on output shaft during removal Rear Band and Low Reverse Drum
94. mission is aligned with engine 6 Rotate torque converter so mark on torque con verter made during removal will align with mark on drive plate The offset holes in plate are located next to 1 8 inch hole in the inner circle of plate Carefully work transmission assembly forward over engine block dowels with torque converter hub entering the crankshaft opening 7 After transmission is in position install torque converter housing bolts and tighten to 30 ft Ibs 41 N m 8 Install crossmember to frame and lower trans mission to install mount on extension to the cross member Tighten all bolts 9 Remove the engine support fixture Fig 1 10 Install oil filler tube and speedometer cable 11 Connect throttle rod to transmission lever 12 Connect gearshift rod and torque shaft assem 57 Fig 53 Torque Converter and Drive Plate Markings bly to transmission lever and frame When it is necessary to disassemble linkage rods from levers which use plastic grommets as retain ers the grommets should be replaced with new ones Use a prying tool to force rod from grommet in lever then cut away old grommet Use pliers to snap new grommet into lever and rod into grommet 13 Place wire connector on the combination back up lamp and neutral park starter switch 14 Connect wiring to lock up solenoid wiring con nector at rear of transmission case if so equipped 15 Rotate engine clockwise with socket wrench o
95. n vibration dampener bolt as needed to install torque converter to drive plate bolts matching marks made at removal Tighten to 270 in lbs 31 N m 16 Install torque converter ac ess cover 17 Install starter motor and cooler line bracket 18 Connect cooler lines to transmission fittings 19 Install engine to transmission struts if so equipped Tighten bolts holding strut to transmission before strut to engine bolts 20 Install transfer case if so equipped Refer to Transfer Case Installation for procedure 21 Replace exhaust system if it was disturbed for clearance 22 Carefully guide sliding yoke into extension housing and on the output shaft splines Align marks made at removal then connect propeller shaft s tc axle pinion shaft yoke s 23 Adjust gearshaft and throttle linkage 24 Refill transmission with MOPAR ATF PLUS Automatic Transmission Fluid Type 7176 P4ATSG Technical Service Information SPECIFICATIONS LOADFLITE TRANSMISSIONS Transmission Models A 904T A 999 A 727 Dl ACE UDIN DE Automatic Three Speed with Torque Converter TORQUE CONVERTER DIAMETER Standard 10 3 4 inches 10 3 4 inches U S Metric U S Metric Measure Measure Measure Measure OIL CAPACITY TRANSMISSION AND TORQUE CONVERTER Lock up 17 1 Pts 8 1 Liter 16 7 Pts 7 9 Liter Nonlock up 17 1 Pts 8 1 Liter Use DEXRON II Type Automatic Transmission Fluid COOLING MET
96. nd play of the assembly The clearance can be adjusted by the use of various thickness snap rings Snap rings are available in 042 064 and 084 inch thickness PLANETARY GEAR TRAIN A 727 Fig 34 End Play Measure end play of planetary gear assemblies sun gear and driving shell before removing these parts from output shaft Stand assembly upright with for ward end of output shaft on a wooden block so that all parts will move forward against selective snap ring at front of shaft Insert a feeler gauge between rear annulus gear support hub and shoulder on output shaft Fig 32 The clearance should be 006 to 048 inch If clearance exceeds specifications replace thrust washers and or necessary parts Disassembly 1 Remove 3 thrust plate from forward end of output shaft Fig 34 2 Remove selective snap ring from forward end of output shaft then slide front planetary assembly off the shaft 3 Slide front annulus gear off planetary gear assembly Remove 4 thrust washer from rear side of planetary gear assembly 4 Slide sun gear driving shell and rear planetary assembly off output shaft 5 Lift sun gear and driving shell off rear planetary gear assembly Remove 5 thrust washer from inside the driving shell Remove snap ring and 6 thrust plate from sun gear rear side of driving shell and slide sun gear out of the shell Remove front snap ring from sun gear if necessary Note that front end of sun gear is long
97. nds and inspect system for excessive oil leaks Rear Clutch Apply air pressure to rear clutch apply passage and listen for a dull thud which indicates that rear clutch is operating Also inspect for excessive oil leaks If a dull thud cannot be heard in the clutches place finger tips on clutch housing and again apply air pressure Movement of piston can be felt as the clutch is applied Kickdown Servo Front Direct air pressure into front servo apply passage Operation of servo is indicated by a tightening of front band Spring tension on servo piston should release the band Low Reverse Servo Rear Direct air pressure into rear servo apply passage Operation of servo is indicated by a tightening of rear band Spring tension on servo piston should release the band If clutches and servos operate properly no upshift or erratic shift conditions indicate that malfunctions exist in the valve body Technical Service Information FLUID LEAKAGE TRANSMISSION TORQUE CONVERTER HOUSING AREA 1 Check for Source of Leakage Since fluid leakage at or around the torque con verter area may originate from an engine oil leak the area should be examined closely Factory fill fluid is dyed red and therefore can be distinguished frorn engine oil 2 Prior to removing the transmission perform the following checks When leakage is determined to originate from the transmission check fluid level prior to removal of
98. ng sure retainer lugs snap firmly into notches on the cam 5 Position cam in the case with cam serrations aligned with those in the case Tap cam evenly into the case as far as possible with a soft faced hammer 8 Install Tool C 3863A and Adapter SP 5124 as shown in Figure 41 tighten nut on tool to seat cam into the case Make cure cam is firmly bottomed then install cam retaining set screw Stake the case around set screw to prevent it coming loose 7 Remove cam installing tool Remove pilot studs install bolts and tighten to 150 in lbs 17 N m Stake the case around cam in 12 places with a blunt chisel Fig 42 ADAPTER SET SCREW Bc gt a 4 Fig 41 Instalf Overrunning Clutch Cam A 727 AUTOMATIC TRANSMISSION SERVICE GROUP 52 CA4ATSG SPRING ROLLER LOW AND REVERSE LINK STAKE 12 PLACES RH306 HUB RACE Fig 42 Overrunning Clutch Low Reverse Band Link KICKDOWN SERVO AND BAND Disassembly Disassemble controlled load servo piston by remov ing small snap ring from servo piston Then remove washer spring and piston rod assembly from servo piston Inspection Inspect piston and guide seal rings for wear and make sure they turn freely in the grooves It is not necessary to remove seal rings unless conditions war rant Inspect piston for cracks burrs scores and wear Inspect piston bore in the case for scores or other damage Inspect fit of guide on pist
99. nicks and scores may be removed with crocus cloth providing extreme care is taken not to round off sharp edges The sharpness of these edges is vitally important because it prevents foreign matter from lodging between valve and valve body thus reducing possibility of sticking Inspect all valves and plugs for freedom of operation in valve body bores When bores valves and plugs are clean and dry the valves and plugs should fall freely in the bores The valve body bores do not change dimensionally with use Therefore a valve body assembly that was functioning properly when vehicle was new will oper AUTOMATIC TRANSMISSION SERVICE GROUP Technica ate correctly if it is properly and thorough s There is no need to replace valve 5oc zs unless it is damaged in handling VALVE BODY REASSEMBLY Tighten all valve body screws to 35 inch pour s 4 Newton meters Shift Valves and Regulator Valve Pressure Sensing Plugs Fig 7 1 Slide shift valves and springs into proper gt ve body bores 2 Subassemble the 3 2 limit valve housing zs e bly as follows a Insert limit valve and spring into heusine b Slide spring retainer into groove in c c Insert throttle plug in housing bore 22s assembly against the shift valve springs Omit step 2 when no 3 2 limit valve housing assem bly is used 3 Install end plate and tighten screws 4 Install throttle pressure spring ard plug ine pressure plug and
100. nly in direct drive and is controlled by the engine electronics A lock up solenoid on the valve body transfer plate is powered by the engine ESA module to activate torque cor verter lock up Lock up and non lock up torque converters and transmissions are not intermixable HYDRAULIC CONTROL SYSTEM The hydraulic control circuits diagrams show the position of the various valves with color coded sages to indicate those under hydraulic pressure for all operations of the transmission The hydraulic control system makes the transmis sion fully automatic and has four important functions to perform In a general way the components of any automatic transmission control system be grouped into the following basic groups The pressure supply system the pressure regulat ing valves the flow control valves the clutches and band servos Taking each of these basic groups or systems in turn the control system may be described as follows AUTOMATIC TRANSMISSION SERVICE GROUP P4ATSG REAR PLANETARY GEAR SET FRONT PLANETARY GEAR SET FRONT CLUTCH TURBINE LOW AND REVERSE REAR BAND STATOR REAR CLUTCH IMPELLER o 5 z o 5 2 E z o v z 25 5 5 lt 5 3 9 pa a o o 573 2 x a a gt lt X x a 8 Z 9 2 2 gt 2 lt gt gt B ba gt d ls s n d lt 5 w Ui Z E
101. nspection Inspect interlocking seal rings Fig 9 on reaction shaft support for wear or broken locks make sure they turn freely in the grooves Seal rings have to be removed to allow clearance for 1 thrust washer removal or installation Inspect front clutch piston retainer to reaction shaft support thrust washer for OUTER GEAR PUMP HOUSING O RING REACTION SHAFT SUPPORT INNER GEAR Technical Service Information wear Washer thickness should be 061 to 063 inch replace if necessary Inspect machined surfaces on pump body and reaction shaft support for nicks and burrs Inspect pump body and reaction shaft support bushings for wear or scores Inspect pump gears for scoring or pitting With gears cleaned and installed in pump body place a straightedge across face of gears and pump body Use a feeler gauge to measure clear ance between straightedge and face of gears Clear ance limits are from 001 to 0025 inch Also measure gear tip clearance between inner and outer gear teeth Clearance limits are from 0045 to 0095 inch Clear ance between outer gear and its bore in oil pump body should be 0035 to 0075 inch Pump Bushing Replacement A 904T and A 999 1 Place pump housing seal face down on a smooth firm surface 2 Place removing head Tool SP 3551 in bushing and install handle Tool C 4171 in the removing head Fig 10 3 Drive bushing straight down and out of pump housing bore Be careful not to
102. on hub of clutch retainer Make sure lip of seal faces down and seal is properly seated in the groove 2 Install outer seal on the clutch piston with lip of seal toward bottom of clutch retainer Apply a coating of wax type lubricant or Door Ease to outer edge of seals and press seal to bottom of its groove around piston diameter for easier installation of piston assem bly Place piston assembly in retainer and carefully seat piston in bottom of retainer 3 Refer to Specifications and install proper number of springs on piston exactly as shown in Figure 25 or 26 Position spring retainer and snap ring over the springs Compress springs with Tool C 3863 A Fig 23 and seat snap ring in hub groove Remove compressor tool 4 Lubricate all clutch plates install one steel plate followed by a lined plate disc until the number given in specifications is installed Install pressure plate and snap ring Make sure snap ring is properly seated 5 Insert a feeler gauge between pressure plate and waved snap ring to measure maximum clearance where snap ring is waved away from pressure plate Fig 21 See Specifications for allowed clearance SPRINGS 9 RH291 Fig 25 Front Clutch Spring Location 9 Springs Technical Service Information OMIT THESE TWO SPRINGS FOR 11 SPRING CLUTCH Fig 26 Front Clutch Spring Location 11 and 13 Springs REAR CLUTCH A 904T and A 999 Disassembly Figure 27 shows
103. on rod Inspect piston spring for distortion For controlled load servo inspect bore in piston and ring on piston rod Inspect band lining for wear and bond of lining to the band Inspect lining for black burn marks glazing non uniform wear pattery and flaking If lining is worn So grooves are not visible at ends or any portion of the bands replace the band Inspect band for distortion or cracked ends Assembly Assemble controlled load servo piston as follows Fig 43 1 Grease O ring and install piston rod 2 Install piston rod into servo piston 3 Install spring flat washer and snap ring to complete the assembly Technical Service Information PISTON RINGS 2 2 PISTON ROD Z SERVO PISTON SPRING WASHER 0 Mm SNAP RING PISTON ROD GUIDE PISTON ROD A 727 ONLY SERVO SPRING SEAL RING SNAP RING RH307 Fig 43 Kickdown Servo LOW REVERSE SERVO AND BAND Diassembly 1 Remove snap ring from piston and remove the piston plug and cushion spring Fig 44 inspection Inspect seal for deterioration wear and hardness Inspect piston and piston plug for cracks burrs scores and wear piston plug must operate freely in the piston Inspect piston bore in the case for scores or other damage Inspect springs for distortion Inspect band lining for wear and bond of lining to the band If lining is worn so grooves are not visible at ends or any portion of the band replace
104. oving last retaining screw from side of valve body 4 Remove spring retainer with line and throttle pressure adjusting screws do not disturb setting and the line pressure and switch valve regulator springs 5 Slide switch valve and regulator valve out of their bores 6 Remove screws from lock up module or stiffener plate and carefully remove tube and lock up module or stiffener plate Disassemble lock up module tag ging springs Nonlock up A 904T for California mod els use an empty lock up body instead of a stiffener plate 7 Remove transfer plate retaining screws and lift off transfer plate and separator plate assembly 8 Remove lock up solenoid retaining screw and pull solenoid from its bore in transfer plate if so equipped 9 Remove three screws from separator plate and separate parts for cleaning Fig 4 10 Remove rear clutch ball check reverse servo ball check and line pressure regulator valve screen from separator plate for cleaning Fig 4 11 Remove the seven balls from valve body as shown in Figure 5 LOCK UP MODULE Fig 3 1 Remove end cover VALVE BODY LOCK UP VALVE Technical Service Information PRESSURE REGULATOR FILTER SCREEN 1 HN REAR CLUTCH BALL CHECK VALVE Fig 4 Transfer Pats ac s Sate 2 Remove lock up sz z gt 3 Remove fail saft valve gn Tag these springs as they m bly identification vee
105. perative clu or bands The inoperative units clutches bands servos can be located through a series of substituting air pressure for fluid pressure Fig The front and rear clutches kickdown serve z low reverse servo may be tested by applying air z sure to their respective passages after the valve assembly has been removed To make air press_ tests proceed as follows LOADFLITE TRANSMISSION STALL SPEED CHART Carburetor BBLS Engine C I D 10 3 4 inch 10 3 4 inch Engine Stall Speed rpm 1800 2100 1700 2000 1700 2000 Torque Converter Diameter AUTOMATIC TRANSMISSION SERVICE GROUP RTSG FRONT SERVO APPLY FRONT REAR SERVO APPLY 222 9 SERVO gt RELEASE 292 UJ PUMP LINE PRESSURE TO ot A Z ic ACCUMULATOR c E H NOU PUMP l APRESSURE CI y T it Ale FRONT E L L cturcH EY APPLY REAR fa Ltr cure js A A APPLY NITO ToRQUE GOVERNOR Vo CONVERTOR PRESSURE FROM TORQUE PYF CONVERTER TO Se ee GOVERNOR TO COOLER CRH252 Fig 3 Air Pressure Tests Compressed air supply must be free of all dirt or moisture Use a pressure of 30 psi Front Ciutch Apply air pressure to front clutch apply passage and listen for a dull thud which indicates that front clutch is operating Hold air pressure on for a few seco
106. pressure Incorrect throttle pressure should only be suspected if part throttle upshift speeds are either delayed or occur too early in relation to vehicle speeds Engine runaway on either upshifts or downshifts can also be an indicator of incorrect low throttle pressure setting In no case should throttle pressure be adjusted until the transmission throttle linkage adjustment has been verified to be correct TORQUE CONVERTER STALL TEST WARNING DO NOT LET ANYONE STAND IN FRONT OF VEHICLE DURING TEST The stall test consists of determining the engine speed obtained at full throttle in D position only This test checks the torque converter stator clutch oper ation and the holding ability of the transmission clutches The transmission oil level should be checked and the engine brought to normal operating tempera ture before stall operation Both the parking and service brakes must be fully applied and front wheels blocked while making this test Do not hold the throttle open any longer than is necessary to obtain a maximum engine speed reading and never longer than five seconds at a time If more than one stall check is required operate the engine at approximately 1 000 rpm in neutral for 20 seconds to cool the transmission fluid between runs If engine speed exceeds the maximum limits shown release the accelerator immediately since transmission clutch slippage is indicated Technical Service Information Stall Speed Above Speci
107. r filing can also raise the fluid level too high When the transmission has too much fluid the gears churn up foam and cause the same conditions which occur with a low fluid level In either case the air bubbles can cause overheat ing fluid oxidation and varnishing which can inter fere with normal valve clutch and servo operation Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak Along with fluid level it is important to check the condition of the fluid When the fluid smells burned and is contaminated with metal or friction material particles a complete transmission overhaul is needed and because the torque converter cannot be flushed it should be replaced Be sure to examine the fluid on the dipstick closely If there is any doubt about its condition drain out a sample for a double check After the fluid has been checked seat the dipstick fully to seal out water and dirt OIL COOLERS AND TUBES ELUSHING When a transmission or lock up clutch failure has contaminated the fluid the oil cooler s should be reverse flushed to insure that metal particles or sludged oil are not later transferred back into the reconditioned transmission 1 Disconnect both cooler lines at radiator 2 Dislodge any foreign material at the inlet side of the cooler with a small screwdriver 3 Reverse flush the cooler with a combination of mineral spirits and pulsating air under pressure
108. re not serviced because of the low cost of sun gear assembly If bushings are found worn or scored they should be replaced as outlined in the following reconditioning procedures Fig 8 Compress Kickdown Servo Spring AUTOMATIC TRANSMISSION SERVICE GROUP 37 w RTSG The bushing replacement tools listed by SP num bers are part of Tool Kit C 3887B The use of crocus cloth is permissible where neces sary providing it is used carefully When used on valves use extreme care to avoid rounding off the sharp edges The sharp edge is vitally important to this type of valve Sharp edges prevent dirt and foreign matter from getting between the valve and body thus reducing possibility of sticking When it becomes necessary to recondition transmission and vehicle has accumulated considerable mileage install new seal rings on parts requiring their usage Coat each part with automatic transmission fluid during assembly OIL PUMP AND REACTION SHAFT SUPPORT A 904T and A 999 Due to the lock up torque converter it is impor tant that the oil pump be within the clearance limits as specified Also note that the oil pump bushing should be replaced in any overhaui Disassembly Figure 9 shows the oil pump and reaction shaft support disassembled 1 Remove bolts from rear side of reaction shaft support and lift support off the pump 2 Remove rubber seal ring from pump body flange 3 Drive out oil seal with a blunt punch I
109. retainer inner bore surface for wear from reaction shaft sup port seal rings Inspect clutch retainer bushing for wear or scores Inspect inside bore of piston for score marks if light remove with crocus cloth Inspect seal grooves for nicks and burrs Inspect seals for deterioration wear and hardness Inspect piston spring retainer and snap ring for distortion SPECIAL TOOL C 3575A SPRING RETAINER Fig 19 Front Clutch Spring Retaining Snap Ring A 904T and A 999 AUTOMATIC TRANSMISSION SERVICE GROUP SATSE Front Clutch Retainer Bushing Replacement A 904T and A 999 1 Lay clutch retainer open end down on a clean smooth surface and place removing head Too SP 3627 in the bushing Fig 20 Install handle Tool C 4171 in removing head 2 Drive bushing straight down and out of clutch retainer bore Be careful not to cock tool in the bore 3 Lay clutch retainer open end up on a clean smooth surface Slide a new bushing on installing head Tool SP 3626 and start them in clutch retainer bore 4 Install handle in installing head Drive bushing into clutch retainer until tool bottoms 5 Thoroughly clean clutch retainer before assem bly and installation Assembly 1 Lubricate and install inner seal on hub of clutch retainer Make sure lip of seal faces down and seal is properly seated in the groove Fig 18 2 Install outer seal on the clutch piston with lip of seal toward bottom of clutch ret
110. rge waved snap ring that secures pressure plate in the clutch piston retainer Lift pressure plate and clutch plates out of the retainer 2 Install compressor Tool C 3575A over piston spring retainer Fig 19 Compress spring and remove snap ring then slowly release tool until spring re tainer is free of the hub Remove tool retainer and spring 3 Invert clutch retainer assembly and bump it on a wooden block to remove the piston Remove seals from the piston and clutch retainer hub Inspection Inspect plates and discs for flatness They must not be warped or cone shaped Inspect facing material on all driving discs Replace discs that are charred glazed or heavily pitted Discs should also be replaced if they show evidence of material flaking off or if facing material can be scraped off easily Inspect driving disc splines for wear or other damage Inspect steel plate and pressure plate surfaces for burning scoring or damaged driving lugs Replace if necessary Inspect steel plate lug grooves in clutch retainer for smooth surfaces plates must travel freely in grooves Inspect band contacting surface on clutch retainer for scores the contact surface should be protected from damage during disassembly and handling Note ball check in clutch retainer make sure ball moves freely Inspect piston seal surfaces in clutch retainer for nicks or deep scratches Light scratches will not interfere with sealing of seals Inspect clutch
111. rvice Information PLUG po STRUT ANCHOR A 727 ONLY LEVER FLEX BAND A 904 LEVER SHAFT AND ADJUSTING SCREW AND LOCKNUT RH312 Fig 48 Kickdown Band and Linkage 1 Serew two pilot studs Tool C 3288 B in pump opening in the case Fig 49 Install a new gasket over the pilot studs 2 Place a new rubber seal ring in the groove on outer flange of pump housing Make sure seal ring is not twisted Coat seal ring with grease for easy installation 3 Install pump assembly in the case tap it lightly with soft mallet if necessary Remove pilot studs install bolts and snug down evenly Rotate input and output shafts to see if any binding exists then tighten bolts to 175 in lbs 20 N m Check shafts again for free rotation 4 Adjust both bands as described in Maintenance and Adjustments Section Governor and Support 1 Position support and governor body assembly on the output shaft Align assembly so governor valve TRANSMISSION VENT OIL SEAL Fig 49 Installing Oil Pump nTSG shatt hole in governor body aligns with hole in output shaft then slide assembly into place Install snap ring behind the governor body Tighten body to support self locking bolts to 95 in Ibs 11 N m 2 Place governor valve on valve shaft insert as sembly into body and through governor weights In stall valve shaft retaining snap ring Output Shaft Bearing and Extension Housing or Adapter on 4 W D V
112. rvice parts are retained in the case with bolts instead of rivets To install proceed as follows 1 Remove four bolts securing output shaft support to rear of the transmission case Tap support rear ward out of the case with a soft faced hammer 2 Center punch the rivets exactly in center of each rivet head Fig 36 i 3 Drill through each rivet head with a 3 8 inch drill Be careful not to drill into the transmission case BOLT AND WASHER 7 SPRING CAM RETAINER RH299 Fig 35 Overrunning Clutch Service Replacement Cam A 904T and A 999 Technical Service Information CENTER PUNCH 7 RIVET HEADS Fig 36 Center Punch Rivet Heads A 904T and A 999 Chip off rivet heads with a small chisel then drive rivets and cam from the case with a blunt punch of proper size 4 Carefully enlarge rivet holes in the case with a 17 64 inch drill Remove all chips and foreign matter from the case make sure cam area is free of chips and burrs 5 To install position cam and roller spring re tainer in the case Align cam bolt holes with holes in the case then thread all seven retaining bolt and washer assemblies into cam a few turns The cone washers must be installed so inner diameter is coned toward the bolt head Fig 37 6 Tap cam firmly into the case if necessary Draw retaining bolts down evenly then tighten to 100 in lbs 11 N m T Screw two pilot studs Tool C 3288 B into the case Fig 38 Position
113. s slips in reverse the front clutch is slipping If the transmission does not slip in reverse the rear clutc is slipping This process of elimination can be used to detec any unit which slips and to confirm proper operatic of good units However although road test analys can usually diagnose slipping units the actual cause of the malfunction usually cannot be decided Prac cally any condition can be caused by leaking hydrau lic circuits or sticking valves Therefore unless the condition is obvious like nc drive in D range first gear only the transmission should never be disassembled until hydraulic pres sure tests have been performed An engine tachometer can be used to determine the lock up clutch in the torque converter is func tioning An instantaneous rise in engine speed more than 150 rpm at 60 mph 97 km h when the throttle is opened just short of kickdown indicates that the lock up clutch is slipping more than normal HYDRAULIC PRESSURE TESTS Pressure testing is a very impUrtant step in the diagnostic procedure These tests usually reveal the cause of most transmission problems Before performing pressure tests be certain that fluid level and condition and control linkage adjust ments have been checked and approved Fluid must be at operating temperature 150 to 200 degrees F Install an engine tachometer raise vehicle on hoist which allows rear wheels to turn and position the tachometer so
114. s Technical Service Bulletin 18 55 86 whick should be removed from your files This repair only applies to subject vehicles equipped with a Federal Emission Package It does not apply to 5 2L 2BBL heav duty engines identified by a d in the engine character of the VIN SYMPTOM CONDITION Vehicle may exhibit a surge between steady speeds of 35 and 55 mph with engine at full operating temperature DIAGNOSIS Road test the vehicle at a steady speed between 35 and 55 mph to verify surge condition Engine must be at full operating temper ature The surge normally is worse just after transmission lock up engagement PARTS REQUIRED Drive Package PN 4419440 Consists of 1 ESA EFC Module PN 4379255 1 6 2 Transmission Lock Up Spring PN 4202672 1 Transmission Pan Gasket PN 4295875 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE This repair involves replacement of the transmission lock up spring and a revised ESA EFC module The lock up speed will be raised from approximately 43 mph to 53 mph AUTOMATIC TRANSMISSION SERVICE GROUP 62 nTSG Technical Service Information 1 Raise vehicle on hoist remove shift linkage and kickdown linkage drain transmission fluid and remove transmission pan 2 Lower valve body just enough to remove torque converter lock up spring replace with supplied spring PN 4202672 Re use the existing lock up valve fail safe valve and spring cover and screws Figure 1
115. s with shop towels All mating surfaces in the transmission are accurately machined therefore careful handling of parts must be exercised to avoid nicks or burrs Input Shaft End Play Measuring input shaft end play before disassembly will usually indicate when a thrust washer change is required except when major parts are replaced The TRANSMISSION VENT OIL SEAL INSTALLER SPECIAL TOOL HANDLE C 4171 RH277 Fig 4 Install Pump Seal AUTOMATIC TRANSMISSION SERVICE GROUP 35 w nTSG thrust washer is located between reaction shaft sup port and front clutch retainer on A 727 transmissions The thrust washer is located between input and out put shafts on A 904T and A 999 transmissions 1 Attach a dial indicator to transmission bell housing with its plunger seated against end of input shaft Fig 5 Move input shaft in and out to obtain end play reading End play specifications are 022 to 091 inch for A 904T and A 999 transmission and 034 to 084 inch for A 727 transmissions 2 Record indicator reading for reference wher reassembling the transmission Oil Pan 1 Place transmission assembly in repair stanc Tool C 3750 A Fig 6 2 Remove oil pan bolts and remove oil pan gasket Valve Body Assembly 1 Loosen clamp bolts and remove throttle and gearshift levers from the transmission 2 Remove back up lamp neutral start switch 3 Disconnect lock up solenoid wire from wirrz
116. safety switch pro vides a quick check to confirm proper manual linkage adjustment Move the selector lever slowly upward until it clicks into the P Park notch in the selector gate If the starter will operate the P position is correct After checking P position move the selector slowly toward N Neutral position until the lever drops at the end of the N stop in the selector gate If the starter will also operate at this point the manual linkage is properly adjusted If adjustment is required refer to Gearshift Linkage Adjustment in Maintenance and Adjustments Throttle Linkage The throttle rod adjustment is very important to proper transmission operation This adjustment posi tions a valve which controls shift speed shift quality and part throttle downshift sensitivity If the setting is too short early shifts and slippage between shifts may occur If the setting is too long shifts may be delayed and part throttle downshifts may be very sensitive Refer to Throttle Rod Adjustment in Maintenance and Adjustments Road Test Prior to performing a road test be certain that the fluid level and condition and control linkage adjust ments have been checked and approved During the road test the transmission should be operated in each position to check for slipping and any variation in shifting Note whether the shifts are harsh or spongy and check the speeds where the upshifts and downshifts occur Approximate shift sp
117. sion housing to the crossmember Raise transmission slightly with service jack then remove center crossmember and support assembly 4 Remove extension housing to transmission bolts When removing or installing extension housing step 6 the gearshift lever must be in 1 low position This positions parking lock control rod rear ward so it can be disengaged or engaged with the parking lock sprag 5 Remove screws plate and gasket from bottom of extension housing mounting pad Spread large snap ring from output shaft bearing Fig 7 With snap ring spread as far as possible carefully tap extension hosuing off the output shaft bearing Carefully pull extension housing rearward to allow parking lock control rod knob to clear parking sprag then remove the housing Bearing Replacement 1 Using heavy duty snap ring pliers remove the output shaft bearing rear snap ring and remove SPECIAL RH77 Fig 5 Remove Extension Housing Yoke Seal Technical Service Information SPECIAL TOOL RH78 Fig 6 Install Extension Housing Yoke Seal bearing from the shaft Fig 8 2 Install a new bearing on shaft with outer race ring groove toward front then install rear snap ring A 727 has a snap ring in front of bearing A 904T and 999 do not Bushing Replacement 1 Remove oil seal with Tool C 3985 Fig 5 2 A 904T and A 999 Press or drive out bushing with Tool C 3996 Fig 9 A 727 Remove bushing in t
118. sleeve then fasten plate 72 valve body Shuttle Valve and Governor Plugs Fig 6 1 Place 1 2 and 2 3 shift valve governor plugs in their respective bores 2 Install shuttle valve and hold it in bore with index finger while installing the secondary spring with guides and retaining E clip 3 Install primary shuttle valve spring and throttle plug 4 Install governor plug end plate and tighten the retaining screws 5 Install shuttle valve cover plate and tighten the retaining screws Manual Lever and Throttle Lever Fig 2 1 Install throttle valve throttle valve spring kick down valve and kickdown detent sleeve 2 Slide manual valve into its bore 3 Install throttle lever and shaft on valve body Insert detent spring and ball in its bore in valve body Depress ball and spring with Tool C 3765 Fig 8 or similar tool and slide manual lever over throttle shaft so that it engages manual valve and detent ball Install seal retaining washer and E clip on throttle shaft Filter Transfer Plate Lock up Solenoid and Pressure Regulators 1 Install the 7 balls in valve body as shown in Figure 5 2 Install rear clutch ball check and low reverse servo ball check Fig 4 in transfer plate and regula tor valve screen in separator plate Fig 4 AUTOMATIC TRANS SS Fig 8 Install Detent Spring and Bali The low reverse servo ball check is used ONLY with A 904T and A 999 transmissions
119. support over the pilot studs and tap it firmly into the case with a soft faced hammer RETAINING BOLTS 7 RH301 Fig 37 Cam Retaining Bolts A 904T and A 999 OUTPUT SHAFT SUPPORT RH302 Fig 38 Install Output Shaft Support A 904T and A 999 8 Remove pilot studs install bolts and tighten to 150 in Ibs 17 N m Overrunning Clutch Cam Replacement A 727 If overrunning clutch cam and or roller spring retainer are found damaged replace cam and spring retainer in the following manner 1 Remove set screw from the case below clutch cam 2 Remove bolts securing output shaft support to rear of transmission case Insert a punch through bolt holes and drive cam from the case Fig 39 Alternate punch from one bolt hole to another so cam will be driven evenly from the case The output shaft support must be in the case to install the overrunning clutch cam If the support requires replacement tap support lt 2 N Ach gt e OUTPUT SHAFT SUPPORT RH303 Fig 39 Remove Overrunning Clutch Cam A 727 OUTPUT SHAFT SUPPORT Fig 40 Install Output Shaft Support A 727 rearward with a soft faced hammer To install screw two C 3288B pilot studs into the case Fig 40 Posi tion support over the pilot studs and tap it firmly into the case with a soft faced hammer 3 Clean all burrs and chips from cam area in the case 4 Place spring retainer on the cam maki
120. t neck sticking out on the right looks like it s driving the transmission it s not It just drives the front oil pump in the transmission nothing else The actual output of the converter and input to the transmission is a splined shaft inside the neck Technical Service Information A TORQUE CONVERTER ENGINE Cc ROTATION Fig 2 Torque converter shell is bolted directly to the engine turns at engine speed CONVENTIONAL TORQUE CONVERTER IS A TRUE FLUID COUPLING I In a conventional converter Fig 3 notice that the impeller Fan 1 drives the turbine Fan 2 by means of an oil coupling only There s no direct mechanical link at all between the engine and the transmission 2 72 4 TINN 3 t wy Fig 3 Conventional converter has oil coupling only there s no direct mechanical link AUTOMATIC TRANSMISSION SERVICE GROUP 5 OIL CAN CAUSE A DRAG A simple fluid coupling however can suffer certain power losses if the driving oil flows back and impedes the driving fan This prob lem is overcome by adding a third element to the system the stator TORQUE As its name suggests the stator works while it s standing still Although the stator is free to rotate forward when the oil flow hits the back sides of the stator vanes direct drive during acceleration the oil flow is on the front sides of the stator vanes This oil pressure tries to
121. t of the bushing Be careful not to damage threads on bushing remover 6 Slide new bushing chamfered end first on installing head Tool SP 5302 and start them in the bore of reaction shaft Fig 17 7 Support reaction shaft upright on a clean smooth surface and install handle Tool C 4171 in installing head Drive bushing into shaft until tool bottoms 8 Thoroughly clean the reaction shaft support assembly before installation Assembly 1 Assemble pump gears and ring in the pump housing Fig 14 2 Install reaction shaft support Install retaining bolts and tighten to 175 in Ibs 20 N m HEX NUT TOOL HANDLE 4171 INSTALLING HEAD SP 5302 TS BE BUSHING im 2796 ew a REACTION SHAFT REACTION SHAFT SUPPORT REMOVAL INSTALLATION N37 Fig 17 Replacing Reaction Shaft Bushing A 727 AUTOMATIC TRANSMISSION SERVICE GROUP PISTON RETAINER ASSEMBLY PISTON SEAL OUTER RETURN SPRING Service Information PRESSURE DRIVING DISCS PLATE SNAP RING WAVED SPRING RETAINER CLUTCH PLATES RH286 Fig 18 Front Clutch A 904T and A 999 3 Place a new oil seal in opening of pump housing lip of seal facing inward using Tool C 3860A and Handle C 4171 drive seal into housing until tool bottoms FRONT CLUTCH A 904T and A 999 Disassembly Figure 18 shows a disassembled view of the front clutch assembly 1 Remove la
122. t washer and install in rear clutch piston retainer 4 Align front clutch plate inner splines and place assembly in position on the rear clutch Make sure plate splines are fully engaged on rear clutch splines 5 Align rear clutch plate inner splines grasp input shaft and lower the two clutch assemblies into the transmission case 6 Carefully work clutch assemblies in a circular motion to engage rear clutch splines over splines of front annulus gear Make sure front clutch drive lugs are fully engaged in slots in the driving shell Kickdown Band Fig 48 1 Slide band over front clutch assembly 2 Install band strut screw in adjuster just enough to hold strut and anchor in place Oil Pump and Reaction Shaft Support If difficulty was encountered in removing pump assembly due to an exceptionally tight fit in the case it may be necessary to expand the case with heat during pump installation Using a suitable heat lamp heat the case in area of pump for a few minutes prior to instaling pump and reaction shaft support assembly A 904T and A 999 Install number one thrust washer on reaction shaft support hub Fig 9 A 727 If input shaft end play was not within specifications 034 to 084 inch when measured be fore disassembly replace thrust washer on reaction shaft support hub with one of proper thickness Fig 14 Refer to thrust washer number one in Specifica tions for sizes available Technical Se
123. the transmission and torque converter High oil level can result in oil leakage out the vent located at the top of the front pump housing If the fluid level is high adjust to proper level After performing this operation inspect for leak age If a leak persists perform the following operation on the vehicle to determine whether it is the torque converter or transmission that is leaking Leakage Test Probe 1 Remove torque converter housing dust shield 2 Position vehicle with front lower than back so that accumulated fluid in torque converter housing will drain out Wipe inside of torque converter hous ing as dry as possible solvent spray followed by compressed air drying is recommended 3 Fabricate and fasten test probe Fig 4 securely to convenient dust shield bolt hole Make certain torque converter is cleared by test probe Tool must be clean and dry 4 Run engine at approximately 2 500 rpm with transmission in neutral for about 2 minutes Trans mission must be at operating temperature 5 Stop engine and carefully remove tool 6 If upper surface of test probe is dry there is no torque converter leak A path of fluid across probe indicates a torque converter leak Oil leaking under the probe is coming from the transmission pump 5 1 2 BOTTOM OF CONVERTER HOUSING DUST SHIELD MATERIAL 5 1 2 X 1 1 2 X BOLT 1 32 SHEET METAL PY300 Fig 4 Leak Locating Test Probe Tool AUTOMATIC TRANSMISSIO
124. the band Inspect band for distortion or cracked ends Assembly 1 Lubricate and insert piston plug and cushion Spring in the piston and secure with snap ring ASSEMBLY SUBASSEMBLY INSTALLATION The assembly procedures given h Ye include instal lation of subassemblies in the transmission case and adjusting input shaft end play Do not use force to assemble mating parts If parts do not assemble freely investigate the cause and correct the trouble before SEAL RING PISTON SNAP RING SPRING PISTON PISTON PLUG SNAP RING SPRING RETAINER Fig 44 Low Reverse Servo AUTOMATIC TRANSMISSION SERVICE GROUP proceeding with assembly procedures Always use new gaskets during assembly operations Use only automatic transmission fluid to lubricate transmission parts during assembly Overrunning Clutch 1 With transmission case in an upright position insert clutch hub inside the cam Install overrunning clutch rollers and springs as shown in Figure 42 Low Reverse Servo Band and Linkage A 727 Fig 45 1 Carefully work servo piston assembly into the case with a twisting motion Place spring retainer and snap ring over the piston Fig 44 2 Compress low reverse servo piston spring by using engine valve spring compressor Tool C 3422A then install snap ring 3 Position rear band in the case install short strut then connect long link and ancbor to the band Screw in band adjuster just enough to hold strut in
125. uld read the same as line pressure within 3 psi 7 This tests pump output pressure regulation and condition of rear clutch and rear servo hydraulic circuits Test Two Selector in 2 1 Attach gauge to line pressure port and tee into rear cooler line fitting to read lubrication LINE PRESSURE PORT REAR SERVO APPLY PORT FRONT SERVO RELEASE PORT RH250 Fig 1 Pressure Test Locations pressure 2 Operate engine at 1000 rpm for test 3 Move the selector lever on transmission detent rearward from full forward position 1 selector 2 position 4 Read pressures on both gauges as throttle on transmission is moved from full forward posit full rearward position 5 Line pressure should read 54 to 60 psi 27 414 kPa with throttle lever forward and grac increase as lever is moved rearward to 90 to 621 to 662 kPa 6 Lubrication pressure should be 5 to 15 psi 2 103 kPa with lever forward and 10 to 30 psi 68 22 kPa with lever rearward 7 This tests pump output pressure regulation condition of rear clutch and lubrication hydrz circuits Test Three Selector in D 1 Attach gauges to line and front servo lease ports 2 Operate engine at 1600 rpm for test 3 Move the selector lever on transmission gt detents rearward from full forward position This selector D position LUBRICATION PRESSURE PORT COOLER RETURN FITTI
126. up and unlock are completely automatic and are controlled by new circuits in the trans mission valve body The spool valve you knew in the past as the torque converter control valve has been modified for the lock up system and is now called the switch valve The switch valve provides both the and off oil pressures which move the lock up piston SWITCH VALVE CONTROLLED BY NEW LOCK UP MODULE The switch valve will not operate to activate the lock up piston until two other control valves are switched These two valves are housed in a new lock up control valve body The LOCK UP VALVE reacts to prop shaft speed and automatically directs the switch valve to lock up if the vehicle is above a certain speed The FAIL SAFE VALVE will permit lock up in direct gear only when the transmission front clutch has sufficient pressure et Mox 8 Fig 10 New lock up module on valve body holds lock up valve fail safe valve Technical Service Information 224 FAIL SAFE VALVE 2 P TE Fig 11 Both these valves must switch before switch valve will operate The fail safe valve also provides fast lock up release during a kickdown The smooth sensing actions of both the lock up valve and the fail safe valve are necessary for good shift quality NEW OIL PASSAGES In order to provide the oil pressures needed to move the lock up piston there s a new oil pas
127. us gear support 4 Install 7 thrust plate and spacer on wide ratio transmissions Fig 33 on one end of sun gear Insert sun gear through front side of driving shell install 8 thrust plate and snap ring 5 Carefully slide driving shell sun gear assem bly on the output shaft engaging sun gear teeth with rear planetary pinion teeth 6 Place front annulus gear support in the annulus gear and install snap ring 7 Position 5 thrust washer on front side of front planetary gear assembly Position front planetary gear assembly in front annulus gear place 4 thrust washer over planetary gear assembly hub and install snap ring Position 6 thrust washer on rear side of planetary gear assembly 8 Carefully work front planetary and annulus gear assembly on output shaft meshing planetary pinions with sun gear teeth 9 With all components properly positioned install selective snap ring on front end of output shaft AUTOMATIC TRANSMISSION SERVICE GROUP w nTSG SNAP RING FRONT SELECTIVE p ANNULUS GEAR ASHER ASSEMBLY DRIVING SHELL SUN GEAR 5 THRUST PLANETARY GEAR WASHER ASSEMBLY 3 THRUST PLATE OUTPUT SHAFT Technical Service Information 6 THRUST REAR REAR ANNULUS PLATE STEEL PLANETARY GEAR STEEL Urat GEAR ASSEMBLY 7 THRUST WASHER 8 THRUST PLATE SSSSSSS Low AND REVERSE DRUM RH298 Fig 34 Planetary Gear Train and Output Shaft A 727 Remeasure e
128. ve shaft retaining snap ring Inspect valve and weight assembly for free movement after installation 5 Install output shaft bearing and extension housing as previously described PARKING LOCK COMPONENTS Removal 1 Remove extension housing as previously described 2 Slide shaft out of extension housing to remove the parking sprag and spring Fig 12 Remove snap ring and slide the reaction plug and pin assembly out of the housing 3 To replace the parking lock control rod refer to Valve Body Removal and Installation inspection Inspect sprag shaft for scores and free movement in the housing and sprag Inspect sprag and control rod springs for distortion and tension Inspect square lug on sprag for broken edges also lugs on parking gear for damage Inspect knob on end of control rod for nicks burrs and free turning EXTENSION wy FAMILY 8 HOUSING C SPRAG 6 SPRING SNAP RING PLUG AND PIN CONTROL ROD Fig 12 Parking Lock Components Technical Service Information Assembly 1 Install reaction plug and pin assembly in the housing and secure with snap ring Fig 12 2 Position sprag and spring in housing and insert the shaft Make sure square lug on sprag is toward parking gear and spring is positioned so it moves sprag away from the gear 3 Install extension housing VALVE BODY AND ACCUMULATOR PISTON REMOVAL 1 Raise vehicle on a hoist 2 Loosen oil pan bolts tap the
129. w to 100 in lbs 11 6 The adjustment is finished and linkage backlash was automatically removed by the preload spring 7 If lubrication is required refer to Lubrication Group 0 8 Lower vehicle reconnect choke if disconnected and test linkage freedom of operation by moving throttle rod rearward slowly releasing it to confirm it will return fully forward BAND ADJUSTMENTS Kickdown Band Front The kickdown band adjusting screw is located on left side of the transmission case Fig 4 1 Loosen lock nut and back off lock nut approxi mately five turns Test adjusting screw for free turn ing in the transmission case 2 Using wrench Tool C 3380 A with adapter C 3705 tighten band adjusting screw 47 to 50 in lbs 5 N m If adapter C 3705 is not used tighten adjust ing screw to 72 in lbs 8 which is the true torque 3 Back off adjusting screw the number of turns listed in Specifications Hold adjusting screw in this position and tighten lock nut to 30 ft Ibs 41 N m RETURN SPRING THROTTLE ROD ADJUSTABLE SWIVEL SWIVEL LOCK SCREW SPRING THROTTLE LEVER Fig 2 Throttle Rod Adjustment 6 Cylinder Models AUTOMATIC TRANSMISSION SERVICE GROUP 21 RETURN SPRING THROTTLE BRACKET ASSEMBLY PU490 Fig 3 Throttie Rod Adjustment 8 Cylinder Modes Low Heverse Band Bear 1 Raise vehicle irain Transmission fluid from loosened oil and gt
130. would be caused by loose parts or interference inside the torque converter you may have a defective unit To confirm that the noise does originate within the converter oper ate the vehicle at light throttle on a hoist with the transmission in DRIVE or NEUTRAL Then listen for the noise under the transmission bell Converter Stall Diameter R P M 10 3 4 1800 2100 10 3 4 2125 2425 10 3 4 1700 2000 10 3 4 1800 2100 10 3 4 2125 2425 10 3 4 1700 2000 10 3 4 2150 2450 10 3 4 1775 2075 10 3 4 1775 2075 10 3 4 2150 2450 10 3 4 1850 2150 10 3 4 2300 2600 10 3 4 1950 2250 10 3 4 2500 2800 housing The stall test can be hazardous to perform since the engine is in DRIVE and throttle is wide open Be certain to follow the exact pro cedure and precautions given in your Service Manual whenever performing stall tests Overheating the transmission fluid and damag ing the converter or transmission can also re sult if the test is not conducted properly Again follow the Service Manual directions exactly AUTOMATIC TRANSI SIUN SERVICE GROUP 3 Technical Service Information THAT S THE SERVICE STORY ON TORQUE CONVERTERS w nTSG The lock up torque converter allows no other service operations While in the past you may have flushed a converter or replaced a ring gear these procedures are no longer recom mended in fact you ll not find a drain plug on any Chrysler torque converter lock up or conventional
131. xist only with transmission in Reverse position 9 No continuity should exist from either pin to the case EXTENSION HOUSING YOKE SEAL Replacement 1 Mark parts for reassembly then disconnect the propeller shaft at rear universal joint Carefully pull SEE Gh rel Pu N SWITCH PLUNGER IN S fu REVERSE POSITION CUm e CONTACT SWITCH RH266 Fig 4 Start and Back Up Lamp Switch AUTOMATIC TRANSMISSION SERVICE GROUP lt shaft yoke out of the transmission extension housing Be careful not to scratch or nick ground surface on sliding spline yoke during removal and installa tion of the shaft assembly 2 Remove oil seal with Tool C 3985 Fig 5 3 To install a new seal position seal in opening of extension housing and drive it into the housing with Tool C 3995 or C 3972 Fig 6 4 Carefully guide front universal joint yoke into extension housing and on the mainshaft splines Align marks made at removal and connect propeller shaft to rear axle pinion shaft yoke EXTENSION HOUSING BUSHING AND OUTPUT SHAFT BEARING Extension Removal 1 Mark parts for reassembly then disconnect pro peller shaft at rear universal joint Carefully pull shaft assembly out of the extension housing 2 Remove speedometer pinion and adapter assem bly Fig 1 Drain approximately two quarts of fluid from the transmission 8 Remove bolts securing exten
132. y a decal applied at the factory and visible near the offset lug on the converter The decal iden WHEN LOCK UP OCCURS The lock up mode is activated only in direct drive Even though there is some hydraulic slippage in all gears the lock up feature can not be applied in low and second gears be cause lock up eliminates the torque multiplica tion necessary for acceleration This means lock up only occurs after the 2 3 upshift In order to prevent engine lugging due to lock Service Information Fig 9 Lock up converter has color coded identifica tion decal near offset lug tifies the converter as lock up and indicates whether stall speed is HIGH HS or LOW LS Also the color of the decal matches the damper spring color and indicates the engine application RED 360 and 400 C I D engine WHITE 318 C I D engine BLUE 225 C I D engine Decals with other colors Green and Orange indicate non lock up torque converters up at too low an engine speed the minimum lock up and disengagement points are approx imately 24 to 34 mph depending on engine size and axle ratio This means that the minimum 2 3 shift light throttle will occur earlier than the minimum lock up shift At heavier throttle where the 2 3 shift occurs above the minimum lock up speed the lock up shift will occur immediately after the 2 3 shift AUTOMATIC TRANSMISSION SERVICE GROUP 70 CA4ATSG LOCK UP CONTROL Lock
133. y assembly If neces sary remove snap ring from rear of annulus gear to separate support from annulus gear Inspection Inspect bearing surfaces on output shaft for nicks burrs scores or other damage Light scratches small nicks or burrs can be removed with crocus cloth or a fine stone Inspect speedometer drive gear for any nicks or burrs and remove with a sharp edged stone Make sure all oil passages in shaft are open and clean Inspect bushings in sun gear for wear or scores replace sun gear assembly if bushings are damaged Inspect all thrust washers for wear and scores replace if damaged or worn below specifications Inspect thrust faces of planetary gear carriers for wear scores or other damage replace as required Inspect plane tary gear carrier for cracks and pinions for broken or worn gear teeth and for broken pinion shaft welds Inspect annulus gear and driving gear teeth for dam age Replace distorted lock rings Assembly Refer to Figure 33 for parts reference 1 Place rear annulus gear support in annulus gear and install snap ring 2 Position 10 thrust washer on rear side of rear planetary gear assembly and install in rear annulus gear Install 9 thrust washer on front side of rear planetary gear assembly 3 Insert output shaft in rear opening of rear annulus gear Carefully work shaft through annulus gear support and planetary gear assembly Make sure shaft splines are fully engaged in splines of annul

Download Pdf Manuals

Related Search

Related Contents

Chapitre Cuisine Part 2  none 8239204117 Installation Guide  présomption d`innocence  User Guide for running 'Chess Mentor'  Pyle Car Stereos User Manual  JVC RX-F10S User's Manual  MANUAL DEL USUARIO  MSI Gaming GT80-2QES16SR221BW (Titan SLI)  縦置きスタンド 取扱説明書  

Copyright © All rights reserved. Failed to retrieve file