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ISSION O`MATIC

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1. DO 2 iF ous 29 HOIvanWnoov H91012 1NO HH DM DRE UHOImo uv3H co c C gt 5 OAH3S Hv3H Eo HONH3AO9 OAH3S LNOYS B i gt A 21 70 1 00706 rae ih OR VALVE Em PUN ERE BEAHCEUIGH Lus dul SERVO FRONT CLUTCH ACCUMULATOR i en d 7 E e C 2 HE j 2 Ti 2 o m 2 lt m cC COOLER gt COF e LUBRICATION 2 7 2 TO FRONT MANUAL VALVE CLUTCH o iu 18 pe UE 5 Xem m 2 steel 4 LINE MU a PUMPSUCTION LUBRICATION THROTTLE TORQUE CONVERTER OIL FILTER IC 800706 E manoa varve p GOVERNOR VALVE OIL FILTER SCREEN REAR CLUTCH 00000 REAR SERVO LINE PUMP SUCTION FRONT CLUTCH FRONT SERVO HYDRAULIC PRESSURE EH GOVERNOR AU 7 wuarication NAC ACCUMULATOR COOLER TO LUBRICATION TO FRONT CLUTCH LUBRICATION E TORQUE CONVERTER Un gt O m o m 2 lt O 4 1 NOISSINSNVYL DILVWOLnY 3 21 600706 REAR SERVO FRONT SERVO GOVERNOR VALVE FRONT CLUTCH ACCUMULATOR REAR CLUTCH
2. 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 10 Using snap ring pliers remove output shaft bearing snap ring and remove bearing from shaft 11 Carefully pry snap ring from weight end of governor valve 5 shaft Slide valve and shaft assembly out of governor V M parking gear body S ut 12 Remove snap ring from behind governor body then slide governor and support assembly off output shaft 904030 Snap ring Snap ring Governor body 904030 21 76 COMPONENT SERVICE AUTOMATIC TRANSMISSION 13 Tighten kickdown band adjusting screw until band is tight on front clutch retainer This prevents front clutch retainer from coming out with pump which might cause unnecessary damage to clutches 14 Remove oil pump housing retaining bolts 15 Attach two Special Tools 904046 to pump housing flange in threaded holes in flange 16 Bump outward evenly with two weights to withdraw pump and reaction shaft support assembly from the case 17 Loosen Kickdown band adjusting screw remove band strut and slide band out of the case 904090 18 Slide front clutch assembly out of the case 19 Grasp input shaft and slide input shaft and rear clutch assembly out of the case C
3. COMPONENT SERVICE AUTOMATIC TRANSMISSION 2 x of the two clutches ang two bands 4a v 21 62 COMPONENT SERVICE AUTOMATIC TRANSMISSION HYDRAULIC CONTROL SYSTEM The hydraulic control circuits show the position of various valves with color coded passages to indicate those under hydraulic pressure for all operations of the trans mission The hydraulic control system makes the transmission fully automatic and has four important functions to perform In a general way the components of any automatic control system may be grouped into the following four basic groups 1 the pressure supply system 2 the pressure regulating valves 3 the flow control valves and 4 the clutches and band servos Taking each of these basic groups of systems in turn the control system may be described as follows 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 pressure regulating valves consist of a regulator valve which controls line pressure at a value dependent on throttle opening The switch valve maintains torque converter operating pres sure and transmission lubricating pressure The governor valve transmits regulated pressure to the transmission in conjunction with vehicle speed to control upsh
4. Tightening torque 4 9 Nm 3 6 6 165 3 Back off adjusting screw 7 turns from 4 9 Nm 3 6 ft lbs 4 Mount and tighten lock nut to specified torque Tightening torque 34 47 Nm 25 35 ft lbs 5 Clean oil pan replace gasket and reinstall Tighten oil MUST pan bolts to specified toruge Tightening torque 15 20 Nm 11 14 ft Ibs 6 Fill transmission with specified ATF For how to pour in ATF refer to Lubrication in this section 21 26 SERVICE ADJUSTMENT PROCEDURES HYDRAULIC CONTROL PRESSURE ADJUSTMENTS Line Pressure An incorrect throttle pressure setting will cause incorrect line pressure readings even though line pressure adjustment is correct Always inspect and correct throttle pressure adjustment before adjusting the line pressure The approximate adjustment is 33 3 mm 1 3 in measured from valve body to inner edge of adjusting nut 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 One complete turn of adjusting screw changes closed throttle line pressure approximately 9 8 kPa 1 4 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 malfunction is evident
5. 5 6 Mount shift valve cover to valve body Tighten screw to specified torque 1 2 shift valve spring Tightening Cover screw 2 9 4 9 Nm 2 2 3 6 11 105 Limit valve body assembly Throttle plug Shift valve cover 21 100 COMPONENT SERVICE VALVE BODY 7 Install springs throttle pressure plug line pressure plug and sleeve and secure regulator valve cover to valve body 8 Place 1 2 and 2 3 shift valve plugs in their respective bores 904038 9 Install shuttle valve primary spring and shuttle valve throttle plug 904038 mE 10 Install sleeve and secondary spring to shuttle valve end and secure with E clip 904038 11 Install shift valve plug cover and tighten five screws 12 Install shuttle valve cover and tighten six screws 13 Install throttle valve throttle valve spring kickdown valve and kickdown detent plug 904120 14 Slide manual valve into its bore Throttle pressure plug Sleeve 1 2 shift valve plug Primary spring Shuttle valve plug 5 M23 shift valve plug Sleeve Shuttle valve Secondary spring Shuttle valve cover 904037 Manual valve Throttle valve Throttle valve spring Xs Kickdown valve Kickdown detent 21 101 15 Install throttle lever on valve body Insert detent spring and ball in its bore in valve body Depress ball and spring and slide manual lever over throttle shaft so tha
6. Clearance C B 0 3 mm 012 A Install the snap ring large to the main drive gear bearing Select and install a main drive gear snap ring of the COMPONENT SERVICE MANUAL TRANSMISSION the mainshaft Install the synchronizer ring to 3 4 synchronizer as sembly Install the main drive gear to the mainshaft Insert the 1 2 and 3 4 shift forks to the synchronizer sleeve groove 5 Insert the countershaft gear into the transmission case With the snap ring fitted to the countershaft front bearing needle drive the bearing into the case by pushing on the outer race 130017 Install the snap ring to the countershaft rear bearing ball then install it into place with special tool 130018 Drive in the main drive gear bearing using special tool MD998029 Drive in the mainshaft bearing using special tool 130019 While driving the bearing in make sure that the synchronizer ring is properly positioned between the main drive gear and the 3 4 synchronizer MD998199 proper thickness to minimize clearance between the snap ring and bearing In other words install the thickest snap ring that will fit into the snap ring groove Thickness of snap ring mm Identification color 2 3 091 White 2 35 092 None 2 4 094 Red 2 45 096 Blue 2 5 098 Yellow Install the front bearing retainer When installing the retainer install a spacer of prop
7. 1 Insert Special Tool Throttle Pressure Adjust Tool MD998563 between the throttle lever cam and kickdown valve 2 By pushing in on tool compress kickdown valve against its spring so that 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 Wrench 33 3 mm 1 3 in Wrench V 904021 21 27 COMPONENT SERVICE TRANSMISSION AND TRANSFER CASE COMPONENTS Transfer gearshift lever Transmission gearshift lever Dust cover retaining plate Gearshift lever cover Bell housing cover Vehicles with a manual transmission Vehicles with an automatic transmission Nm A 42 54 42 54 22 31 D 20 29 21 28 Manual transmission and transfer assembly Automatic transmission and transfer assembly ft ibs 31 40 31 40 16 23 15 22 t 09W526 O D x Length mm in 7 10x 40 4 x 1 6 7 10x65 4x26 7 10x60 4x 24 7 10x65 4 2 6 145003 146001 Bolt identification AxB YI B Y09512 COMPONENT SERVICE TRANSMISSION AND TRANSFER CASE Ics REMOVAL l Disconnec
8. pues gt L3 d f 2 LI 8 4 A P 3 E x c vs ES Wenger cmm EU s gt H i ie i amp Hi DO E P 5 DN 24 aus a PE ENS COOLER LUBRICATION M Rc PS SRR GR AE i BS mm mw 4 ki 25 CLUTCH LUBRICATION t Mateos ci HYDRAULIC PRESSURE whe ZA REGU OO 0 Eas GOVERNOR tie LINE SCREEN T PUMPSUCTION LUBRICATION TORQUE CONVERTER OIL FILTER Js dn X501 NOISSINSNVHI 5 LN3NOdWOO 010706 GOVERNOR VALVE MEM FRONT SERVO REAR CLUTCH FRONT CLUTCH ACCUMU LATOR Tm p E 4 COOLER TO LUBRICATION TO FRONT CLUTCH LUBRICATION HYDRAULIC PRESSURE 7 LUBRICATION _____ SCREEN TORQUE CONVERTER OIL FILTER NOISSINSNVUL OU YWO1nv 32IAH3S 1N3NOdWOO COMPONENT SERVICE AUTOMATIC TRANSMISSION DISASSEMBLY Caution Prior to removing any transmission sub assemblies plug all openings and thorouglily clean exterior of the unit prefe rably by steam Cleanliness through entire disassembly and assembly cannot be overemphasized When disassembling each part shou
9. to each position VP to L ending in the neutral position 8 Add ATF until fluid level reaches lower notch of dipstick After transmission has reached average operating temper ature recheck fluid level Fluid level should be between notches of dipstick Caution Check fluid level with vehicle on flat surface Use care to prevent entry of dust and foreign matter through filler tube After inspection reinsert dipstick all the way into filler tube 21 24 SERVICE ADJUSTMENT PROCEDURES ADJUSTMENT OF THROTTLE LINKAGE Caution When engine idling adjustment is made make sure that throttle linkage is readjusted 1 Install each linkage Loosen the bolts so that rods B and C slide properly 2 Allow engine to warm up until engine coolant tempera ture reaches average operating temperature about 80 170 F Confirm complete release of fast idle This confirmation can be made by checking to see if cam surface of choke lever of carburetor is completely off cam follower of throttle lever 3 Lightly push rod or the transmission throttle lever toward the idle stopper to the right in illustration 904017 and set the rods to the idle position Tighten the bolt securely to connect rods B and C 4 Make sure that when the carburetor throttle valve is wide open the transmission throttle lever moves as shown in illustration 904017 operating angle 47 5 54 and that there is some range i
10. range first gear only the transmission should never be disassembled until hydraulic pressure tests have been performed 21 17 SERVICE ADJUSTMENT PROCEDURES Automatic Shift Speed Pattern Pa EN mW a Output shaft speed rpm 0 20 40 60 80 100 120 Vehicle speed mph Elements in Use at Each Position of the Selector Lever Selector Clutches Bands Lever Gear Start Parking Over Kickdown Low Rev Position Ratio Safety Sprag Rear running Front Rear E N NEUTRAL X D DRIVE First 2 45 X X Second 1 45 X X Direct 1 00 X 2 SECOND First 2 45 X X Second 1 45 X X L LOCK UP First 2 45 X X 21 18 SERVICE ADJUSTMENT PROCEDURES HYDRAULIC PRESSURE TESTS Pressure testing is a very important 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 ATF condition control rod adjustments and throttle linkage adjustments have been checked and approved Fluid must be at operating temperature approx 80 C 170 F Install an engine tachometer raise vehicle on hoist which allows rear wheels to turn and position tachometer so it can be read under the vehicle Disconnect throttle rod and shift rod A from transmis sion levers so they can be controlled under the vehicle Attach 3MPa 300 psi gauge MD998300 and adaptor MD998
11. 096 Blue 2 50 098 Green 5 Press two ball bearings over the front output shaft pushing down on the inner race After fitting check to see that they rotate smoothly 6 Install the ball bearing over the rear output shaft from the rear and press into place To install push on the inner race Refer to p 21 43 After installation oheck to see that the ball bearing rotates smoothly 7 Mount the stop plate and install the REAR WHEEL DRIVE 4 WHEEL DRIVE clutch hub and sleeve Refer to p 21 43 When mounting the hub and sleeve be sure the direction of installation is correct 144022 8 Mount the steel ball for sprocket sleeve positioning on the rear output shaft and mount the sprocket sleeve Refer to p 21 43 9 Mount the two needle bearings on the outer circumference of the sprocket sleeve and then mount the drive sprocket Refer to p 21 43 10 After mounting the steel balls and the sprocket spacer press the ball bearing Refer to p 21 43 by pushing on the inner race Check that the bearing rotates smoothly after it is fully installed 11 Tighten the mainshaft lock nut and drive in the detent section with a punch After the lock nut is tightened check that the drive sprocket rotates smoothly 12 Mount the needle bearing the thrust washer and the low J speed gear on the rear output shaft from the front end 13 Mount the H L clutch hub making sure that the direction of installation is correct 14
12. TRANSMISSION UTOMATIC CONTENTS SPECIFICATIONS erret 2 COMPONENT SERVICE 28 GENERAL SPECIFICATIONS 2 TRANSMISSION AND TRANSFER CASE 28 SERVICE SPECIFICATIONS 3 AUTOMATIC TRANSMISSION CONTROL 33 TORQUE SPECIFICATIONS 6 TRANSFER dote Noa RIDERE et 39 LUBRICANTS 7 MANUAL TRANSMISSION 50 SEALANT aioe 7 MAINSHAFT 0 2 2 4 0005 58 SPECIAL TOOLS CETEROS 8 AUTOMATIC TRANSMISSION di OIL PUMP AND REACTION SHAFT TROUBLESHOOTING 11 SUPPORT 86 FRONT CLUTCH 90 SERVICE ADJUSTMENT PROCEDURES 14 REAR CLUTCH 93 DIAGNOSIS CHART GENERAL PLANETARY 96 ES VALVE BODY 2 5 9 2 20 00 99 GENERAL SPECIFICATIONS Manual transmission and transfer case model Transmission Type Gearratio 18 2nd 3rd 4th 5th Reverse Final gear ratio Speedometer gear ratio Transfer case Type Gear ratio High Low Drive system Front wheel Rear wheel Automatic transmission and transfer case model Automatic transmission Type Torque converter diameter Oil capacity transmission and torque converter Cooling method pump Gear ratio lst 2nd 3rd Reverse Speedometer gear ratio Transfer case Typ
13. is selector R position Rear servo pressure should read 1 570 to 1 790 kPa 230 to 260 psi This tests pump output pressure regulation and condi tion of front clutch and rear servo hydraulic circuits Move selector lever on transmission to position to check that rear servo pressure drops to zero This tests for leakage into rear servo due to case porosity which can cause low reverse band burn out 21 20 SERVICE ADJUSTMENT PROCEDURES SERVICE ADJUSTMENT PROCEDURES Test result 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 L and 2 but correct pressure in R indicates rear clutch circuit leakage 3 Low pressure in D and R but correct pressure in L indicates front clutch circuit leakage 4 Low pressure in and L but correct pressure in 2 indicates rear servo circuit leakage 5 Low line pressure in all positions indicates a defective pump a clogged filter or a stuck pressure regulator valve or throttle valve GOVERNOR PRESSURE TEST Test only if transmission shifts at wrong vehicle speeds when throttle rod is correctly adjusted 1 Connect a pressure gauge to governor pressure take off point located at lower left side of extension near the mounting flange 2 Operate transmission in third gear to read pressures and compare speeds shown i
14. Thrust washer 1 cannot be removed unless two seal rings of reaction shaft support are removed INSPECTION 1 Check seal ring of reaction shaft support for wear and damage Check to ensure that it turns freely in groove 2 Check thrust washer 1 inserted between reaction shaft support and front clutch retainer for wear and replace if necessary 3 Check finished surfaces of oil pump housing and reaction shaft support for damage and burr Check bushing for wear and damage 4 Check pump rotor for scratches and pitching Clean pump rotor reinstall to pump housing and measure all clearances with thickness gauge Hold straight edge to rotor end and pump housing surface to measure clearance between rotor end and straight edge side clearance Measure rotor tip clearance between inside and outside teeth of rotor Measure clearance between bore I D of oil pump housing and outer rotor O D body clear ance 21 86 COMPONENT SERVICE OIL PUMP AND REACTION SHAFT SUPPORT OIL PUMP SEAL REPLACEMENT Oil pump seal can be replaced without removing oil pump housing assembly from transmission case 2 Use screwdriver as lever to remove oil seal To install a new seal place seal in opening of pump housing lip side facing inward Using Special Tool drive seal into housing until tool bottoms PUMP HOUSING BUSHING REPLACEMENT 1 2 3 aS Place pump housing seal face down on a smooth firm surfac
15. detach the clutch release cylinder from the transmission 12 Remove the bell housing cover 13 Detach the starting motor from the On vehicles with an air remove the front propeller shaft and then lower the starting motor down ward from under the vehicle to remove it 21 30 COMPONENT SERVICE TRANSMISSION AND TRANSFER CASE 14 Detach the engine support rear insulator from the No 2 crossmember 15 Remove the No 2 crossmember 00W530 16 Support the transmission and transfer assembly with a transmission jack 17 Detach the transfer from the transfer mounting bracket 18 Remove the transmission mounting bolts from the engine 21 31 COMPONENT SERVICE TRANSMISSION AND TRANSFER CASE 19 Disconnect the transmission and transfer assembly the engine by pulling it slowly toward the rear of the vehicle 09W51 1 20 When lowering the transmission and transfer assembly tilt the front of the transmission downward and slowly lower forward while using care to make sure that the rear _ of the transmission does not hit the No 4 crossmember 09W511 m 21 32 COMPONENT SERVICE AUTOMATIC TRANSMISSION CONTROL COMPONENTS Position indicator cover Control arm 2s Lever bracket assembly Detent plate Selector lever Selector lever rod assembly Rod adjusting cam Selector handie Pushbutton 10 Se
16. 2 2 2 39 812 6 Z gt e lt 2 los i5 o a5 se ge 25 25 2 2 212 2 222 21 14 SERVICE ADJUSTMENT PROCEDURES DIAGNOSIS Automatic transmission malfunctions may be caused by four general conditions poor engine performance improper adjustments hydraulic malfunctions and mechanical mal functions Diagnosis of these problems should always begin by checking the easily accessible variables fluid level and ATF condition control rod adjustment and throttle linkage adjustment 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 1 Drive to a flat surface 2 Before the dipstick is removed clean the protective cap and the top of the filler tube 3 Run the engine at idle 4 Move the selector lever through a round of all positions P L before placing it in position Pull the parking brake lever beforehand 5 Make sure that the ATF is heated to normal operating temperature approx 80 C 170 F 6 The fluid level should be between the notches above ADD I PINT and below FULL inscribed on the dipstick 904011 Low fluid level can cause a variety of conditions because it allows the pump
17. 98 0 50 72 19 6 58 8 15 43 29 4 22 58 8 43 29 4 34 3 22 25 2 0 1 4 or more 13 9 10 13 7 9 18 24 13 17 11 14 8 10 9 6 7 1 42 54 31 40 20 29 15 22 112 7 121 5 83 90 46 51 34 38 10 12 8 9 41 54 30 40 15 19 11 14 15 19 11 14 17 23 12 17 15 19 11 14 11 14 8 10 16 21 12 15 35 47 26 34 38 2 28 2 9 4 9 2 2 3 6 10 13 7 9 SPECIFICATIONS Nm ft lbs Transfer case Adapter to transfer case mounting bolts and nuts 30 41 22 30 Chain cover bolt Side cover bolt Rear cover bolt Cover bolt Control housing bolt Oil filler plug Drain plug Select plug Rocking plate bolt Rear output shaft lock nut Speedometer sleeve clamp bolt 30 41 22 30 30 41 22 30 8 9 5 6 7 15 21 11 15 10 12 7 5 9 30 34 22 25 30 34 22 25 30 34 22 25 15 21 11 15 98 127 73 94 15 21 11 15 Seal plug 30 41 22 30 4WD switch 30 22 LUBRICANTS lit U S qts Imp qts Specified lubricant Quantity Manual transmission Hy poid gear oil 2 2 2 3 1 9 SAE80W 75W 85W conforming to API GL 4 Automatic transmission ATF DEXRON or 6 8 7 2 6 0 DEXRON type Transfer case Hypoid gear oil 2 2 23 1 9 SAE80W 75W 85W conforming to GL 4 Sliding parts of the selector lever Multipurpose grease As required SAE J310a NLGI grade 3 Sliding parts of the selector handle Multipurpose grease As required SAE
18. J310a NLGI grade 3 Sliding parts of the control rods Multipurpose grease required SAE J310a NLGI grade 3 SEALANT Both sides of the extension housing gasket Threads of extension housing attaching bolts Specified sealant 3M Super silicone 8662 or equivalent Super silicone 8662 or equivalent Quantity s required As required 21 7 Tool Number and name MD998020 Bearing puller MD998067 Mainshaft bearing installer MD998192 Counter gear bearing puller MD998200 Front bearing retainer oil seal installer MD998330 C 3292 for 100 psi and C 3293 for 300 psi Oil pressure gauge MD998352 D Dial gauge support eem see page 2 for instructions 21 8 SPECIAL TOOLS Use Removal of the main drive gear bearing Measurement of the oil pressure Measurement of the input shaft end play C 3422 B Tool Number and name Use MD998028 Use with MD998020 Bearing puller adapter MD998029 4 Main ring gear bearing installer MD998199 Countershaft bearing installer MD998303 Common to engine and automatic transmission Removal and installation of the kickdown servo and low reverse servo Valve spring compressor MD998335 Assembling the oil pump Oil pump band DL MD998353 Tightening the valve Torque driver
19. and tighten bolts finger tight Make sure oil passage of gover nor body aligns with passage in the support 2 Assemble inner weight and spring to outer weight and secure with snap ring Place weight assembly in governor body and install snap ring INSPECTION Inspect clutch rollers for smooth round surfaces they must be free of flat spots and chipped edges Inspect roller contact ing surfaces in cam and race for brinelling Inspect roller springs for distortion wear or other damage EOS COMPONENT SERVICE VALVE BODY OVERRUNNING CLUTCH CAM REPLACEMENT If overrunning clutch cam or spring retainer is found dam aged it can be replaced with a service replacement cam spring retainer and retaining bolts The service parts are retained in the case with bolts instead of rivets To install proceed as follows mE 1 Remove four bolts securing output shaft support to rear of transmission case Tap support rearward out of 0 J a Serm the case with a soft faced hammer 904061 2 Center punch rivets exactly in center of each rivet head 904062 3 Drill through each rivet head with a 9 5 mm 4 in drill Be careful not to drill into transmission case Chip off rivet heads with a small chisel and drive rivets and cam from the case with a blunt punch of proper size 904062 4 Carefully enlarge rivet holes in the case with a 6 7 mm 17 64 in drill Remove all chips and foreign matter from the cas
20. synchronizer positioning hub toward correct direction 110009 3 As for mainshaft front end snap ring select and install one of such thickness that will minimize clearance be tween snap ring and hub In other words install the thickest snap ring that fits in snap ring groove 4 Make sure that 3rd speed gear turns smoothly 5 Check synchronizer ring for worn and damaged threads and teeth 6 With synchronizer assembled to cone of each gear check dimension A 110009 If is less than 0 5 mm 02 in replace synclironizer ring and or gear 7 After installation of 2nd speed gear 1st 2nd synchronizer and Ist speed gear push bearing spacer firmly toward 1st speed gear and make sure that Ist and 2nd speed gears turn smoothly 21 60 COMPONENT SERVICE MAINSHAFT Mainshaft 3 4 speed synchronizer hub 134024 Synchronizer ring 119060 COMPONENT SERVICE AUTOMATIC TRANSMISSION COMPONENTS 1 Torque converter 2 Screw 14 pan 4 Oil pan gasket 5 Bolt 6 Plain washer 7 Square nut 8 Transmission throttle lever 9 Bolt 10 Plain washer 11 Square nut 12 Manual control lever 13 Flange bolt 10 14 Valve body assembly 15 Accumulator spring 16 Accumulator piston 17 Seal ring 18 Seal ring 19 Output shaft bearing 20 Governor body snap ring 21 Governor valve shaft snap ring 22 Governor valve shaft 23 Governor valve 24 Governor and support 25 Scr
21. the shuttle valve is to regulate kick band application and timing when making direct to second kickdowns Clutches Band Servos and Accumulator The front and rear clutch pistons and both servo 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 kick down servo piston is released by spring tension and hydraulic pressure The accumulator controls the hydraulic pressure on the apply side of the kickdown servo during the 1 2 shift thereby cushioning the kickdown band application at any throttle position 21 64 COMPONENT SERVICE AUTOMATIC TRANSMISSION OPERATING INSTRUCTIONS The transmission will automatically upshift and downshift at approximately the speeds shown in the Automatic Shift Speed Chart described under SERVICE DIAGNOSIS AND TESTS shift speeds given in the Chart may vary somewhat due to production tolerances and rear axle ratios The quality of the shifts is very important shifts should be smooth and positive with no noticeable engine runaway Selector Lever and Parking Lock Controls The transmission is controlled by a type selector lever incorporated within the console box The control has six selector lever positions park reverse neutral and D drive 2 second and L lock up The parking lo
22. the six bolts securing the control lever assembly and remove the control lever assembly and the gasket Remove the plugs from the top of the adapter and remove the resistance spring steel ball neutral return springs and plungers Remove the lock pin from the change shifter using a 4 8 mm 3 16 in punch 145009 Remove the four bolts and two nuts securing the transfer case to the adapter Remove the transfer case assembly from the adapter and remove the change shifter from the control shaft Automatic Transmission 1 2 Remove the transfer case from the 3 Remove the four bolts and two nuts securing the transfer case to the adapter 4 Remove the adapter from the transfer case DISASSEMBLY 1 Remove two 4WD indicator light switches R emove two Steel balls 144007 2 Remove the speedometer sleeve clamp and remove the speedometer sleeve assembly 3 Remove the bolts securing the rear cover and remove the rear cover the gasket and the wave spring 4 Remove the cover and gasket and then remove the wave Remove the bolts securing the transfer case and mission case spring and spacer 21 40 COMPONENT SERVICE TRANSFER _ light switch Change shifter 145009 COMPONENT SERVICE TRANSFER 3 Remove the spring pin from the H L shift fork using a 4 8 mm 3 16 in punch 6 Remove the two seal plugs and remove the two poppet springs
23. 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 Improper filling 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 overheating fluid oxidation and varnish which can interfere with normal valve clutch and servo operation Foaming can also result in fluid escaping from the transmission vent and oil filler tube 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 contami nated with metal or friction material particles a complete transmission overhaul is needed 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 7 Insert the dipstick all the way in Proper fluid level 904011 21 15 SERVICE ADJUSTMENT PROCEDURES Adjustment of control rod 1 Check to ensure that when the manual control of the transmission is placed in the position the position indicator correctly shows 2 Check to ensure that the selector lever can be operated smoothly and clicks into each position and that the position indicator correctly indicates the posi
24. work front planetary and annulus ge r assembly on output shaft meshing planetary pinions with sun gear teeth With all components properly positioned install selective snap ring on front end of output shaft Check end play of planetary gear train End play can be adjusted by the use of various thickness snap rings 21 98 COMPONENT SERVICE PLANETARY GEAR Output shaft Feeler gauge Rear annulus gear Driving shell 904059 COMPONENT SERVICE VALVE BODY COMPONENTS 1 Screw 3 56 1 2shift control valve spring 2 Fluid filter 57 1 2shift control valve 3 Screw 58 1 2shift valve spring 4 Screw 59 1 2 shift valve spring 5 Screw 60 2 3shift valve spring 6 Adjusting screw bracket 61 2 3shift valve 7 Line pressure adjusting screw 62 Retainer 8 Switch valve spring 63 Limit valve spring 9 Switch valve 64 Limit valve 10 Regulator valve spring 11 Regulator valve 12 Screw 13 13 Check ball small 6 14 Check ball large 1 15 Screw 4 16 Transfer plate support 17 Valve body plate 18 Screen 19 Steel ball 20 Steel ball 21 Transfer plate 22 Snapring 23 Washer 24 Seal 25 Manual valve lever 26 Detent ball 27 Detent spring 28 Throttle valve lever 29 Kickdown detent 30 Kickdown valve 31 Throttle valve spring 32 Throttle valve 33 Manual valve 34 Screw 6 35 Shuttle valve cover 36 Screw 5 37 Shift valve plug cover 38 S
25. 0 Output shaft forward end Thickness mm in color 1 02 1 12 040 044 Red 1 57 1 68 062 066 Green 2 08 2 18 082 086 White Thrust washers Reaction shaft support to front clutch retainer 1 1 55 1 60 061 063 Front clutch to rear clutch 2 1 55 1 60 061 063 Input shaft to output shaft 33 selective 1 32 1 37 052 054 1 73 1 78 068 070 Red 2 11 2 16 083 085 Green Front annulus gear support to snap ring 4 3 07 3 18 120 125 Front annulus support to front carrier 5 1 22 1 27 048 050 Front carrier to driving shell thrust plate 6 1 22 1 27 048 050 Driving shell thrust plate 7 8 1 27 1 32 050 052 Driving shell thrust plate to rear carrier 9 1 22 1 27 048 050 Rear carrier to rear annulus support 10 1 22 1 27 048 050 21 4 SPECIFICATIONS Transfer case Snap ring for input gear assemby Thickness mm in color 2 70 106 Purple 2 75 108 Pink 2 80 110 Yellow 2 85 112 White 2 90 114 Blue Snap ring for H L clutch hub Thickness mm in color 2 14 084 None 2 21 087 Yellow 2 28 090 White 2 35 093 Blue 2 42 095 Red Snap ring for input gear bearing Thickness mm in color 2 30 091 None 2 35 093 Red 2 40 094 White 2 45 096 Blue 2 50 098 Green Spacer for rear output shaft bearing Thickness mm in color 0 84
26. 033 Black 0 93 037 None 1 02 040 Red 1 11 044 White 1 20 047 Yellow 1 29 051 Blue 1 38 054 Green 21 5 TORQUE SPECIFICATIONS Manual transmission Transmission mounting bolts Starting motor mounting bolts Clutch cable bracket attaching bolts Mainshaft lock nut Idler shaft lock nut Under cover attaching bolt Control lever housing attaching bolts Countershaft gear lock nut Reverse shaft nut Backup light switch Drain plug filler plug Automatic transmission Selector handle set screw Control arm to control rod B Cross shaft bracket mounting bolt Control arm to selector lever lock nut Cooler line fitting Cooler line nut Transmission mounting bolts Starting motor mounting bolts Converter drive plate to crankshaft bolt Converter drive plate to torque converter bolt Governor body to support bolt Kickdown band adjusting screw lock nut Kickdown lever shaft plug Oil pan bolt E Oil pump housing to transmission case bolt Output shaft support bolt Pressure test take off plug Reaction shaft support to oil pump bolt Reverse band adjusting screw lock nut Transmission to engine bolt Valve body screw Valve body to transmission case bolt SPECIFICATIONS Nm ft bs 42 54 31 40 22 31 16 23 9 8 12 7 7 2 9 4 98 127 72 94 19 6 58 8 14 5 43 7 8 9 8 6 7 4 9 6 9 4 5 68 6
27. 18 Assemble the overdrive synchronizer The front and 19 20 21 rear directions of the synchronizer hub and sleeve can identified as illustrated 134027 The spring can be in stalled in a manner similar to the installation of the 3 4 and 1 2 synchronizer springs Install the spacer the stop plate the overdrive synchronizer assembly the overdrive gear bearing sleeve the needle bearing the synchronizer ring and the overdrive gear in that order onto the mainshaft from the rear end Tighten the lock nut and stake it at the mainshaft notch and then check the overdrive gear end play 134039 Overdrive gear end play PM 0 1 0 25 mm 004 010 in Install the spacer the counter reverse gear the spacer the counter overdrive gear and the ball bearing onto the countershaft gear from the rear end After tightening the nut stake the nut at the notch at the rear end of the counter shaft gear Insert the 3 4 and 1 2 shift forks into their respective synchronizer sleeves Insert each shift rail from the rear of the case Lock the shift forks and rails with spring pins and then install the interlock plunger between shift rails The spring pin should be installed with the slot in the axial direction of the shift rail 21 56 COMPONENT SERVICE MANUAL TRANSMISSION Synchronizer hub Synchronizer sleeve Ae x 134027 22 23 24 25 26 21 2
28. 356 to ports required for test being conducted Test port locations are shown in illustration 904012 904013 Test 1 Selector L l 2 3 4 Attach gauges to and rear servo ports Operate engine at 1 600 rpm for test Move selector lever on transmission all the way forward L position Read pressures on both gauges as throttle lever on trans mission is moved from full rearward position to full forward position Line pressure should read 372 to 414 kPa 54 to 60 psi with throttle lever rearward and gradually increase as lever is moved forward to 621 to 662 kPa 90 to 95 psi Rear servo pressure should read the same as line pressure within 21 kPa 3 psi This tests oil pump oil pressure regulating valves regu lator valve and throttle valve and hydraulic circuit conditions Kickdown servo release 904012 Governor pressure N Rear servo NC apply pressure NON om Lubrication AN pressure We 21 19 Test 2 Selector in 2 l 2 3 Attach gauge to line pressure port and tee into rear cooler line fitting to read lubrication pressure Operate engine at 1 600 rpm for test Move selector lever on transmission one detent rear ward from full forward position This is selector 2 position Read pressures on both gauges as throttle lever on trans mission is moved from full rearward position to full f
29. 4 10 0 0 06 0 002 Adjusting with snap ring 0 0 08 0 003 Adjusting with snap ring 28 1 10 42 1 65 2 5 1 WW 559 0 61 1 78 024 070 0 64 1 22 025 048 Adjusting snap ring 0 56 2 3 022 091 0 16 0 83 006 033 0 025 0 064 001 0025 0 13 0 25 005 010 0 09 0 19 0035 0075 Backed off 3 1 2 turns from 5 9 Nm 4 3 ft Ibs Backed off 7 turns from 4 9 Nm 3 6 ft lbs 0 0 1 0 004 Adjusting with snap ring a 21 3 SPECIFICATIONS Adjustment Spacer and Snap Ring Manual transmission Snap ring for main drive gear Thickness mm in Ident color Part No 2 30 091 White MD701729 2 35 093 None MD701730 2 40 094 Red MD701731 2 45 096 Blue MD701732 2 50 098 Yellow MD701733 Spacer for main drive gear bearing to front retainer Thickness mm in Ident color Part No 0 84 033 Black MD701845 0 93 037 None MD701839 1 02 040 Red MD701840 1 11 044 White MD701841 1 20 047 Yellow MD701842 1 29 051 Blue MD701843 1 38 054 Green MD701844 Snap ring for mainshaft front end Thickness mm in Ident color Part No 2 15 085 Blue MD701761 2 22 087 None MD701762 2 29 090 Brown MD701 763 2 36 093 White MD701 764 Automatic transmission Snap rings Rear clutch snap ring Thickness mm in 1 52 1 57 060 062 1 93 1 98 076 078 2 49 2 54 098 10
30. 4023 21 45 14 Mount the H L clutch hub snap ring on the front end of the rear output shaft Snap rings are available in five Snap ring different thicknesses Use the thickest one that will fit into the groove 144024 COMPONENT SERVICE TRANSFER Snap ring thickness mm in Identification color 2 14 084 None Sis j 2 21 087 Yellow vm 2 28 090 White AUT j J 2 35 093 Blue NC NC 144024 2 42 095 Red 15 Insert the input gear assembly into the transfer case and mount the snap ring Refer to p 21 42 Snap rings are available in five different thicknesses Use the thickest one that will fit into the groove LE Snap ring thickness mm in Identification color 2 70 106 Purple 2 75 108 Pink 2 80 110 Yellow 2 85 112 White 2 90 114 Blue 16 Insert the needle bearing into the input gear 17 Mount the H L clutch sleeve and shift fork making sure that the direction of the clutch sleeve is correct The direction of installation is the same as for the clutch sleeve for REAR WHEEL DRIVE 4 WHEEL DRIVE 144025 18 Install the REAR WHEEL DRIVE 4 WHEEL DRIVE shift rail Refer to p 21 42 19 Securely engage the chain with the front and rear shaft sprockets Assemble the REAR WHEEL DRIVE 4 WHEEL DRIVE clutch sleeve with the REAR WHEEL DRIVE 4 WHEEL DRIVE shift fork and install the assembly over the REAR WHEEL DR
31. 4051 4 Invert pump housing and reaction shaft support assembly Pump rotors with oil pump band intact Install support to pump 904051 housing bolts and tighten to specified torque Remove oil pump band pilot studs B and rotor alignment tool Tightening torque 16 21 Nm 12 15 16 S Place a new oil seal in opening of pump housing lip of seal facing inward Using Special Tool drive seal into housing until tool bottoms 904110 lt Oil seal 21 89 SERVICE FRONT CLUTCH COMPONENTS Wave snap ring Pressure plate Clutch disc 3 Clutch plate 3 Snap ring Piston spring retainer Piston spring Front clutch piston Seal outer Seal inner Front clutch retainer gt gt b Numbers show order of disassembly For reassembly reverse order of disassembly _ 904134 DISASSEMBLY 1 Install Special Tool over piston spring retainer Compress MD998572 spring and remove snap ring then slowly release tool until spring retainer is free of hub Remove tool retainer and spring 904053 2 Invert clutch retainer assembly and bump it on a wood block to remove piston Remove seals from V piston and clutch retainer hub aug 0 Spring retainer Snap ring 21 90 _ COMPONENT SERVICE FRONT CLUTCH INSPECTION l Inspect plates and discs for flatness They must
32. 8 29 COMPONENT SERVICE MANUAL TRANSMISSION Insert the ball and poppet spring small end facing the ball into each shift rail Tighten the plug to the specified position After installation seal the plug head with sealant 13404 1 Install the ball bearing on to the rear end of the main shaft Install the speedometer drive gear Apply recommended sealant to both sides of the exten sion housing gasket and install the gasket on the housing Next install the extension housing to the transmission case When installing the housing turn the change shifter fully down to the left Make sure the forward end of the control finger fits snugly in the slot of the shift lug Apply recommended sealant to the threads of extension housing attaching bolts before installation Recommended sealant 3M Super Silicone 8662 or equivalent Install the neutral return plungers A and B the springs and resistance spring and ball Tighten each plug till the top is flush with the boss top surface Apply sealant to the plug heads 134044 Apply sealant to the outside surface of the speedometer driven gear sleeve install the sleeve into the extension housing and mesh it with the drive gear After installing into the locking plate groove lock the sleeve with the locking plate Install the backup light switch after applying sealant to the threads Remember to install the steel ball Install the under cover a
33. 8 Radial ball bearing 2 Bearing 13 Rear cover assembly 9 Sprocket spacer 3 Input gear 1 Dustseal 10 Steel ball 56 Oil seal 2 Dust seal guard 11 Drive sprocket 57 Baffle plate Rear cover 12 Needle bearing 2 58 Dust seal guard 14 Rear cover gasket 13 Sprocket sleeve 59 Oil seal 15 Wave spring 14 Steel ball 60 Transfer case 16 Spring pin 15 Clutch sleeve 17 Seal plug 2 16 Clutch hub 18 Poppet spring 2 Stopper plate 19 Steel ball 2 Bearing 20 Interlock plunger 21 H L shift rail 22 Snap ring 23 Bolt 5 24 Cover 25 Cover gasket 26 Spacer AR 27 Wave spring 28 Bolt 10 29 Cord fastener 4 30 Chain cover 31 Chain cover gasket 32 Oil guide 33 Bolt 8 34 Side cover 35 Side cover gasket 36 Bolt 37 Lock plate 38 Counter gear shaft 39 O ring 40 Counter shaft gear 41 Thrust washer 2 42 Needle bearing 2 43 Bearing spacer 44 Snapring Nm ft lbs A 30 34 22 25 B 15 21 11 15 30 22 15 21 11 15 30 41 22 30 15 21 11 15 30 41 22 30 H 8095 6 7 1521 11 15 NOTE Numbers show order of disassembly For reassembly reverse order of disassembly 145026 21 39 Manual Transmission l 2 Remove the backup light switch from the lower right of the adapter Remove the steel ball 144005 Remove the plug from the right side of the transfer case and then remove the select spring and the select plunger 144005 Remove
34. 904054 2 Drive bushing straight down and out of clutch retainer A 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 Special Tool and start them in clutch retainer bore 904054 4 Install handle in installing head Drive bushing into clutch retainer until tool bottoms 5 Thoroughly clean clutch retainer before assembly and installation MD998506 Front clutch retainer Installation MD998581 MD998507 Bushing Front clutch retainer 904054 21 91 _ COMPONENT SERVICE FRONT CLUTCH REASSEMBLY 1 Lubricate inner seal with ATF and install on hub of clutch retainer Make sure lip of seal faces down and is properly seated in groove Seal 3515176 5989890808098 RnS NS N 2 Install outer seal on clutch piston with lip of seal toward bottom of clutch retainer Apply vaseline to outer edge of seals and press seal to bottom of its groove around piston diameter for easier installation of piston assembly Place piston assembly in retainer and carefully seat piston in bottom of retainer Piston _ 3743090 3 Place spring on piston hub and position spring retainer and snap ring on spring Compress spring with Special _ Tool and seat snap ring in hub groove Remove com pressor tool 904053 4 Immerse all clutch plates and discs ATF and install two clutch plat
35. IVE 4 WHEEL DRIVE shift rail At the same time mount the front and rear output shafts and chain etc as a unit 21 42 20 Mount the two spring retainers and the spring Refer to p 21 42 21 46 COMPONENT SERVICE TRANSFER 21 Insert the two needle bearings and the spacer into the counter gear and install the assembly into the transfer case Mount one thrust washer at the front of the counter gear and the other at the rear Refer to p 21 41 22 Insert the counter shaft and install the locking plate Refer to p 21 41 23 Install the side cover and gasket 24 Install the oil guide 144026 25 Install the chain cover and gasket making sure that the oil guide end fits into the chain cover opening 144026 26 Fit the snap ring into the groove of the rear output shaft rear bearing 27 Insert the interlock plunger 28 Insert the H L shift rail and pass it through the H L shift fork ZEE Caution Unless the REAR WHEEL DRIVE 4 WHEEL DRIVE shif fork is shifted to the 4 WHEEL DRIVE side the H L shift rail can not be inserted 29 Mount the two poppet balls and springs and mount the seal plugs Refer to p 21 41 When mounting the poppet springs the smaller end should face toward the ball 30 With the H L shift fork and shift rail spring pin holes 31 aligned drive in the spring pin using punch When driving in the spring pin position it so that its slot is placed on
36. OOLER gt TO LUBRICATION TO FRONT aQ CLUTCH SWITCH LUBRICATION VALVE HYDRAULIC PRESSURE apni A qp LINE ER GOVERNOR 07708 SCREEN PUMP SUCTION LUBRICATION THROTTLE TORQUE CONVERTER OIL FILTER NOISSIASNVH L 2LLVWOLRV 32IAH3S LN3NOdWOO 69 12 S00v06 a FRONT SERVO GOVERNOR VALVE REAR SERVO REAR CLUTCH FRONT CLUTCH ACCUMULATOR THROTTLE PLUG OL V ioe ALVE E TO LUBRICATION TO FRONT CLUTCH LUBRICATION LINE pumpsuction LUBRICATION THROTTLE TORQUE CONVERTER OIL FILTER NOISSIASNVH L 2LLVWOLRnV 32IAH3S 1N3NOdWOO 904006 347114 n 4 NOI1vOIugn wNouonsawna Jm oo o o GL wm MONH3AOD e 3NH 2 ga 57 boooog i Ai N33H2S 3unss3ud L T u H3LH3ANOO 3n0HOL 1 311101 NOILV2IHS81 LNOYS OL NOILVOIH8Snl 5 OL 431000 s NH3AOO9 E AUTOMATIC TRANSMISSION M de LLI on e 4 23i1108H1 gt Wer m x js
37. With transmission case in an upright position insert overrunning clutch race inside the cam 15 Install overrunning clutch rollers and springs exactly as shown in illustration 904065 16 Position low reverse band in the case install short strut then connect long link to band Screw in band adjusting screw just enough to hold strut in place 904068 17 Install low reverse drum Be sure long link assembly is installed to provide running clearance for the low and _ reverse drum 18 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 Caution Be very careful not to damage ground surfaces on output shaft during installation 19 Front and rear clutches kickdown band and oil pump assembly are more easily installed with transmission in an upright position One method to support transmission is outlined as fol lows 1 Cut 90 mm 3 5 in 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 90 mm 3 5 in hole so that output shaft support will fit and lay flat in the hole 2 Carefully insert output shaft into hole to support trans mission upright with its weight resting on flange of output shaft support Snap ring 43 3 MD998303 904103 Adjusting screw Lever O
38. aft m Ce T 22 Using special tool remove the main drive gear bearing 23 Remove the mainshaft bearing outer race snap ring 24 Using special tools remove the double row ball bearing The inner race of the front bearing will remain on the mainshaft 130013 b MD998020 mT i IS VS A SS SL 130013 21 52 COMPONENT SERVICE MANUAL TRANSMISSION 25 Remove the rear bearing snap ring Then remove the counter rear bearing using special tool 26 Remove the snap ring from the counter front bearing and then remove the bearing with the special tool MD998192 Ip y Qu 27 Remove the countershaft gear from the transmission case 28 Remove the main drive gear from case 29 Lift the mainshaft assembly from the case 134015 30 Disassemble the mainshaft assembly in the following order 1 Install suitable puller to the Ist speed gear and remove it along with the inner race of the double row bearing 2 Remove the 1 2 synchronizer and the 2nd speed gear by moving them toward the rear of the main shaft 3 Remove the snap ring from the front end of the mainshaft and then remove the 3 4 synchronizer and the 3rd speed gear 21 53 REASSEMBLY 1 Insert the mainshaft assembly in the transmission case 2 Install the pilot bearing needle bearing on front end of 10 13 Front bearing retainer to bearing clearance C
39. and two balls 144009 Pull the H L shift rail out toward the rear Remove the interlock plunger _ Remove the snap ring from the rear bearing of the rear output shaft 10 Remove the chain cover 11 Remove the oil guide 12 Remove the side cover N 13 Remove the counter shaft locking plate and remove the counter shaft 14 Remove the counter gear two thrust washers two needle bearings and the spacer through the side cover opening Counter shaft PM plate Thrust washer m Counter gear 21 41 Eod COMPONENT SERVICE TRANSFER 15 Remove the snap ring from the REAR WHEEL DRIVE 4 WHEEL DRIVE shift rail and remove the two spring retainers and the spring from the shift rail 16 Remove the front output shaft the rear output shaft and the chain from the transfer case as a unit 17 Remove the REAR WHEEL DRIVE 4 WHEEL DRIVE shift rail 144014 18 Remove the H L shift fork and the clutch sleeve 19 Remove the needle bearing from the input gear REAR WHEEL DRIVE 4 WHEEL DRIVE shift rail 20 Remove the snap ring and the input gear assembly 144015 2 Remove the snap ring from the front end of the rear output shaft and remove the H L clutch hub the low speed gear the thrust washer and the needle bearing 21 42 COMPONENT SERVICE TRANSFER 1 Snapring 12 Rear output shaft 2 L clutch hub 13 Thrust washer 3 Low speed gear 14 Needle be
40. aring 4 Ball bearing 15 Steel ball 5 Stop plate 16 Sprocket sleeve 1 6 REAR WHEEL 17 Needle bearings DRIVE 4 WHEEL 18 Steel ball DRIVE clutch sleeve 7 REAR WHEEL DRIVE A WHEEL DRIVE clutch hub 8 Drive sprocket 9 Sprocket spacer 10 Ball bearing 11 Lock nut 22 Loosen the staking on the rear output shaft lock nut and remove the lock nut 23 Remove the ball bearing from the rear end using a universal bearing puller or a press 24 Remove the sprocket spacer and the steel balls 25 Remove the drive sprocket the two needle bearings the sprocket sleeve and the steel ball 26 Remove the REAR WHEEL DRIVE 4 WHEEL DRIVE clutch sleeve the hub and the stop plate and remove the ball bearing using a puller or press 27 Remove the snap ring from the input gear With the bearing supported by the press base push on the front end of the input gear to remove the bearing 28 Remove two bearings from the front output shaft using a universal bearing puller or a press base 29 Remove the control shaft oil seal input gear oil seal and front output shaft oil seal from the transfer case 144016 21 43 REASSEMBLY Cautions 1 Replace gaskets oil seals etc with new ones 2 Coat the gaskets and threads with sealant 3 Apply transmission oil to sliding and parts before assembling 4 Do not reuse spring pin Press the control shaft oil seal the input gear oil seal and the front
41. aution Be careful not to lose thrust washer located between rear end of input shaft and forward end of output shaft 20 While supporting output shaft and driving shell carefully slide assembly forward and out through the case Caution very careful not to damage ground surfaces on output shaft during removal 21 77 Eom COMPONENT SERVICE AUTOMATIC TRANSMISSION 21 Remove low reverse drum then loosen low reverse band adjusting screw remove band strut and link then remove band from the case E 22 Note position of overrunning clutch rollers and springs before disassembly to assist in reassembly 23 Carefully slide out clutch race and remove rollers and springs If overrunning clutch cam and or roller spring retainer are found damaged or worn replace 904065 Spring Roller 24 Compress kickdown servo spring by using Special Tool then remove snap ring 904095 25 Remove servo guide spring rod and servo piston from the case Be careful not to damage piston rod or guide during removal 26 Compress low reverse servo piston spring by using Engine Valve Spring Compressor then remove snap ting 904096 T 27 Remove spring retainer spring and servo piston from the m case VE RE 21 78 COMPONENT SERVICE AUTOMATIC TRANSMISSION 28 Remove four output shaft support to case bolts and then remove ou
42. bracket Regulator valve spring 23 Install oil filter and tighten pressie 24 After valve body has been serviced and completely adjusting screw assembled measure throttle and line pressure adjust ments However if pressures were satisfactory prior to disassembly use original settings 904034 Regulator valve spring Adjusting screw bracket 904034 21 103 COMPONENT SERVICE VALVE BODY DISASSEMBLY See 1 Remove four bolts and separate governor and support Midi d M parking gear MEE B Governor 2 Take out governor screen from governor body 3 Remove two snap rings 4 Take out governor weight and spring Inner weight 904031 21 104 COMPONENT SERVICE VALVE BODY INSPECTION 1 Check all parts for burrs and wear 2 Check inner weight for free movement in outer weight and outer weight for free movement in governor body Check valve for free movement in governor body Weights and valve should fall freely in bores when clean dry Rough surfaces may be removed with crocus cloth Wash governor screen Check governor weight spring for distortion Thoroughly clean all governor parts in clean solvent dry with compressed air and test for free movement before assembly 9 Check lugs on parking gear for broken edges or other damage 2222 poe REASSEMBLY l Assemble governor body and filter to the support
43. ck is applied by moving the selector lever to the P position Caution 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 or positions safety precaution when starting in the N position apply the parking or foot brake The automatic transmission will not permit starting the engine by pushing or towing Mountain Driving When driving in the mountains with heavy loads or when pulling a trailer the 2 or L position should be selected on upgrades which require heavy throttle for 0 8 km 1 2 mile or more This reduces the possibility of overheating the transmission and converter under these conditions Towing Vehicle Transmission Inoperative Tow the vehicle with a rear end pickup and place the free wheel hub lever to free position or remove the propeller shaft Transmission Operating Properly The vehicle may be towed safety neutral with re r wheels on the ground at a speed not to exceed 50 km h 30 mph If the vehicle is to be towed for extended distance it should be done with a rear end pickup and place the free wheel hub lever to free posi tion or the propeller shaft removed Because the transmission receives lubrication only when the engine is running it is good practice to always tow a disabled vehicle with a rear end pickup or rem
44. clutch piston spring on top of piston in clutch retainer Start one end of wave spring in retainer groove then progressively push or tap spring into place making sure it is fully seated in groove 904057 Install inner pressure plate in clutch retainer with raised portion of plate resting on spring Lubricate all clutch plates and discs with ATF install one clutch disc facing material followed by a steel clutch plate until all plates are installed Install outer pressure plate and selective snap ring Measure rear clutch plate clearance by having an assistant press down firmly on outer pressure plate then insert a feeler gauge between plate and snap ring If necessary install a new snap ring of proper thickness to obtain specified clearance Low limit clearance is desir able Rear clutch plate clearance is very important in ob taining proper clutch operation Clearance can be adjust ed by use of various thickness snap rings Sea inner Piston spring Snap ring Wave snap ring Selective snap ring 21 95 COMPONENTS Snap ring selective Front planetary gear assembly Snap ring Thrust washer 5 Front planetary gear Thrust washer 6 Snap ring Front annulus gear support Annulus gear Thrust washer 7 Sun gear and driving shell assembly Lock ring Thrust plate 8 Lock ring Thrust plate 49 Sun gear driving shell Sun gear Thrust wash
45. e Place Special Tool in bushing and install Special Tool in the removing head 904048 Drive bushing straight down and out of pump housing bore Be careful not to cock tool in the bore Position new bushing on Special Tool 904048 With pump housing on a smooth clean surface start bushing and installer in bushing bore Install Handle MD998581 in installer Drive bushing into housing until tool bottoms in the pump rotor housing Be careful not to cock tool during installation Stake bushing in place by using a blunt punch or simi lar tool A gentle tap at each stake slot location will suffice 904049 Using a narrow bladed knife or similar tool remove high points or burrs around staked area Do not use a file or similar tool that will remove more metal than is neces sary MD998581 Removal Front pump housing MD998500 Bushing MD998501 904048 Narrow blade Two stakes C zi REACTION SHAFT BUSHING REPLACEMENT In case of a reaction shaft bushing failure always inspect the support for wear from input shaft seal ring lands If worn or grooved replace reaction shaft support assembly 1 Assemble Special Tools Caution Do not clamp any part of reaction shaft or support in a vise 2 With cup held firmly against reaction shaft screw bushing remover into bushing as far as possible by hand 3 Using a wrench screw bushing remover into bushing 3 A to 4 additional turns to f
46. e Gear ratio High Low Drive system Front wheel Rear wheel 21 2 SPECIFIC ATIONS 145 Forward full synchromeshed 3 740 2 136 1 360 1 000 0 856 3 578 4 625 4 875 Option 26 8 Final gear ratio 4 625 27 8 Final gear ratio 4 875 Option Constant mesh type 1 000 1 944 Chain drive Direct drive KM146 Full automatic three speed with torque converter 241 mm 9 5 in 6 8 liters 7 2 U S pts 6 0 Imp pts Water cooling Rotor type 2 745 1 545 1 000 2 214 24 8 Final gear ratio 4 222 26 8 Final gear ratio 4 625 Option Constant mesh type 1 000 1 944 Chain drive Direct drive SPECIFICATIONS SERVICE SPECIFICATIONS mm in Manual transmission Retainer to bearing clearance Reverse idler gear end play Over drive gear end play Main drive gear end play 3rd 4th synchronizer hub end play Resistance springs free length Plunger springs free length Automatic transmission Inhibitor switch to selector lever clearance Clutches Number of front clutch plates Number of front clutch discs Number of rear clutch plates Number of rear clutch discs Clutch plate clearance Front clutch Rear clutch Input shaft end play Gear train end play Pump clearance Side clearance Tip clearance Body clearance Band adjustments Kickdown Low reverse band Transfer case Rear bearing end play 0 0 1 0 004 Adjusting with spacer 0 12 0 28 005 011 0 1 0 25 00
47. e and make sure cam area is free of chips and burrs 904062 7 rivet heads 904062 5 To install position cam and roller spring retainer in the case Align cam bolt holes with holes in the case then thread all seven retaining bolts and washer assemblies into cam a few turns 904063 6 Tap cam firmly into the case if necessary Draw retaining bolts down evenly then tighten to specified torque Tightening torque 12 Nm 9ft lbs Cam retaining bolts 7 904063 21 106 COMPONENT SERVICE VALVE BODY DISASSEMBLY l Slide shaft out of adapter to remove parking sprag and spring 904032 2 Remove snap ring and slide reaction plug assembly out of the housing 904032 INSPECTION 1 Check sprag shaft for scores and free movement in adapter and sprag 2 Check sprag and sprag rod springs for distortion and tension 3 Check square lug on sprag for broken edges also lugs on parking gear for damage 4 Check cam on end of sprag rod for nicks burrs and free turning REASSEMBLY 1 Install reaction plug assembly in adapter and secure with snap ring 2 Position sprag and spring in adapter and insert shaft Make sure square lug on sprag is toward parking gear and spring is positioned so it moves sprag away from gear Adapter 904032 21 107
48. er 10 Rear planetary gear Thrust washer 11 Rear annulus gear assembly Snap ring Annulus gear support Annulus gear Output shaft NOTE Numbers show order of disassembly For reassembly reverse order of disassembly DISASSEMBLY Measure end play of planetary gear assemblies sun gear und driving shell before removing these parts from output shaft Stand assembly upright with forward end of output shaft on a wood block so that all parts will move forward against selective snap ring at front of shaft Insert a feeler gauge bet ween rear annulus gear support hub and shoulder on output shaft The clearance should satisfy specifications If clearance exceeds specifications replace thrust washers and or neces sary parts 21 96 p COMPONENT SERVICE PLANETARY GEAR Driving shell 904060 Output shaft annulus gear 904059 eee _ 2 _ COMPONENT SERVICE PLANETARY GEAR INSPECTION 1 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 2 Inspect bushings in sun gear for wear or scores Replace sun gear assembly if bushings are damaged 3 Inspect all thrust washers f
49. er size so that the clearance C shown in illustration will be within the specified tolerance 134036 and 110022 VOX DP 52 0 0 1 mm 0 004 in 21 54 COMPONENT SERVICE MANUAL TRANSMISSION Thickness of spa er mm in Identification color 0 84 033X Black A lc 0 93 037 None Front mission 1 02 040 Red pearing case 1 11 044 White 1 2 047 Yellow 1 29 051 Blue 1 38 054 Green Front bearing retainer 14 Apply recommended sealant to both sides of the front bearing retainer gasket and fill with gear oil to the oil seal lip then instal the gasket and oil seal When install ing the new oil seal use special tool 134032 Recommended sealant _ 3M Super Silicone 8662 or equivalent 15 Install the rear b aring retainer 16 Install the reverse idler gear shaft When installing the shaft install the bolts as guides as illustrated Reverse idler gear shaft 0 269 m Ne T 134037 17 Install the needle bearing the reverse idler gear the thrust washer and the nut Install the cotter pin to lock the nut and prevent it from turning and check the reverse idler gear end play 134038 Install the thrust washer with the ground side directed toward the gear Reverse idler gear end play 0 12 0 28 mm 005 01 1 in CR 3 Wy lt gt PY OS
50. es made of steel and clutch discs with facing each alternately in retainer Install pressure plate and snap ring Check to ensure that snap ring is correctly positioned in groove Spring retainer Snap ring 904053 5 Insert a feeler gauge between pressure plate and wave snap ring to measure maximum clearance where snap eS Feeler gauge ring is waved away from pressure plate 904055 21 92 ee a m COMPONENT SERVICE REAR CLUTCH COMPONENTS Snap ring selective Pressure plate Clutch disc 4 Clutch plate 3 Pressure plate Wave snap ring Piston spring Rear clutch piston Seal outer 10 Seal inner 11 Input shaft snap ring 12 Input shaft 13 Seal ring 14 Seal ring 15 Rear clutch retainer 16 Sealring Numbers show order of disassembly For reassembly reverse order of disassembly 904060 Disassembly 1 Carefully pry one end of wave snap ring out of its groove in clutch retainer then remove wave spring and clutch piston spring 904140 2 Invert clutch retainer assembly and bump it on a wood block to remove piston Remove seals from piston Piston spring Snap ring Wave snap ring 904140 3 If necessary remove snap ring and press input shaft from clutch retainer Retainer 4202046 Input shaft 4130788 21 93 INSPECTION l Inspect plates and discs
51. ew 6 26 Oil pump and reaction shaft support assembly 27 Reaction shaft support gasket 28 Kickdown band 29 Kickdown band strut 30 Thrust washer 1 31 Front clutch assembly 32 Front clutch thrust washer 32 33 Rear clutch assembly 34 Input shaft thrust plate 3 35 Output shaft thrust washer 4 36 Planet and output shaft assembly 37 Low reverse drum 38 Reverse band link 39 Reverse band 40 Reverse band strut 41 Overrunning clutch roller 10 42 Overrunning clutch roller spring 10 43 Kickdown servo snap ring 44 Kickdown servo guide 45 Kickdown servo guide ring 46 Kickdown servo spring 47 Snapring 48 Kickdown servo piston rod 49 O ring 50 Kickdown servo piston 51 Sealring 52 Seal ring 53 Spring retainer snap ring 54 Reverse servo spring retainer 55 Reverse servo spring 56 Reverse servo plug ring 57 Reverse servo piston plug 58 Reverse servo cushion spring 59 Reverse servo piston 60 Reverse servo piston seal NOTE Numbers show order of disassembly For reassembly reverse order of disassembly 61 62 63 64 65 66 67 68 69 70 71 72 73 74 Kickdown band locking nut Kickdown band adjusting screw Output shaft support bolt 4 Output shaft support Kickdown lever shaft plug Kickdown band lever shaft Kickdown band lever Reverse band lever shaft Seal Reverse band lever Reverse band adjusting screw Locking nut Manual valve shaft seal Transmissi
52. for flatness They must not be warped or cone shaped Inspect facing material on all clutch 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 clutch disc splines for wear or other damage Inspect clutch plate and pressure plate surface for burning scoring or damaged driving lugs Replace if necessary Inspect clutch plate lug grooves in clutch retainer for smooth surfaces plates must travel freely in grooves Inspect piston seal surfaces in clutch retainer for nicks or deep scratches Light scratches will not interfere with sealing of seal rings Check to ensure that check ball of piston can move freely Inspect piston spring and wave spring for distortion or breakage Inspect teflon seal rings on input shaft for wear Do not remove rings unless conditions warrant Inspect rear clutch to front clutch thrust washer for wear 21 94 COMPONENT SERVICE REAR CLUTCH COMPONENT SERVICE REAR CLUTCH REASSEMBLY 1 2 If removed press input shaft into clutch retainer and install snap ring Install inner and outer seals on clutch piston and lubri cate with ATF Make sure lip of seals face toward head of clutch retainer and are properly seated in piston grooves 904114 Place piston assembly in retainer and with a twisting motion seat piston in bottom of retainer Place
53. h governor weights Install valve shaft retaining snap ring 904030 Install bearing on shaft with its outer race ring groove toward front Press or tap bearing tightly against front shoulder on output shaft then install rear snap ring 2 SCA nee 4 Reaction 5 shaft C D Sa MD998584 904070 Governor support and parking gear Snap ring D md snap ring i A Governor body 904030 21 83 COMPONENT SERVICE AUTOMATIC TRANSMISSION 36 Install seal rings to accumulator piston 904108 37 Install accumulator piston in transmission case 38 Position accumulator spring between piston and valve body 39 Place valve body in position working parking sprag rod through opening install ten hex head valve body to transmission case bolts finger tight 904088 40 Snug bolts down evenly then tighten to specified torque Tightening torque 10 13 Nm 7 9 ft Ibs 41 Drive a new seal into the case with a 24 mm 9 in socket and hammer 904033 NOTE This seal can be replaced without removing valve body from transmission by using a small screwdriver to pry seal out of its bore Be careful not to scratch manual lever shaft or the seal bore in transmission 42 Install gearshift lever and tighten clamp bolt Check lever shaft for binding in the case by moving lever through all detent positions If bi
54. han 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 idle in neutral for 20 seconds to cool the ATF between runs If engine speed exceeds the maximum limits shown release the accelerator immediately since transmission clutch slippage is indicated Engine stall speed 2 300 2 800 rpm Stall Speed Above Specification in D If stall speed exceeds specification transmission overrunning clutch or rear clutch slippage is indicated Follow the trans mission oil pressure checks outlined in this section to deter mine the cause of slippage Stall Speed Below Specification Low stall speeds with a properly tuned engine indicate torque converter problems If stall speeds are below specification and the vehicle operates properly at highway speeds but has poor through gear acceleration the stator overrunning clutch is slipping If stall speed and acceleration are normal but abnormally high throttle opening is required to maintain highway speeds the stator clutch has seized Both of these stator defects require replacement of the torque converter Noise A whining or siren like noise due to fluid flow is normal during stall operation with some converters however loud metallic noises from loose parts or interference within the assembly indicate a defective torque converter To confirm that the noise origi
55. huttle valve plug 39 Primary spring 40 1 2shift valve plug 41 2 3 shift valve plug 42 Snap ring 43 Shuttle valve 44 Sleeve 2 45 Secondary spring 46 Screw 2 47 Regulator valve cover 48 Line pressure plug 49 Sleeve 50 Throttle pressure plug 51 Spring 52 Screw 3 53 Shift valve cover 54 Throttle plug 55 Limit valve body NOTE Numbers show order of disassembly For reassembly reverse order of disassembl y 904116 21 99 Ec3 COMPONENT SERVICE VALVE BODY EM NN UNUM lnc C CN DISASSEMBLY Caution Never clamp any portion of valve body or transfer plate in a vise Any slight distortion of valve body or transfer plate will result in sticking valves excessive leakage or both When removing or installing valves or plugs slide them in or out carefully Do not use force Tag all springs and valves as they are removed for reassembly identification REASSEMBLY Caution 5 Tighten all valve body screws to 2 9 to 4 9 Nm 2 2 to 3 6 ft lbs Using torque set driver etc torque all screws evenly 1 Insert limit valve and spring into limit valve body 904117 2 Fit spring retainer in groove of limit valve body 904117 3 Put throttle plug in limit valve body Retainer A Limit valve body Limit valve Spring 4 Insert 1 2 and 2 3 shift valves and springs into hole of valve body 904118 Set limit valve body assembly against shift valve spring
56. ift and downshift speeds The throttle valve transmits regulated pressure to the trans mission in conjunction with throttle position to control upshift and downshift speeds Flow Control Valves The manual valve provides the different transmission drive ranges as selected by the vehicle operator The 1 2 shift valve and governor pressure plug automatically shifts the transmission from low to second or vice versa depending on vehicle operation When a shift is made from direct to second the 1 2 shift control valve controls the orifice of the hydraulic pressure feed circuit to the kickdown servo to assure smooth shifting 21 63 COMPONENT SERVICE AUTOMATIC TRANSMISSION The 2 3 shift valve governor pressure plug and throttle pres sure plug automatically shift the transmission from second to direct or vice versa depending on vehicle operation The kickdown valve makes possible a forced downshift from direct to second or from second to low or from direct to low depending on vehicle speed by depressing the pedal past the detent near wide open throttle The limit valve determines the maximum speed at which a 3 2 part downshift can be made The shuttle valve has two separate functions and ee 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 takes a lift foot upshift from second to direct The second function of
57. ing cam so that surface A faces the direction of the driver s seat 99 09 514 21 36 COMPONENT SERVICE AUTOMATIC TRANSMISSION CONTROL Ec 4 Set the selector lever to the position and then mount the indicator panel so that the N indication is properly aligned 09K 504 Selector Handle 1 Apply multipurpose grease to each sliding part Recommended grease TUE Multipurpose grease SAE J310a NLGI grade 3 2 Tighten the selector handle to the specified torque Selector handle set screw tightening torque 2 0 Nm 1 4 ft lbs or more Inhibitor Switch 1 Install the inhibitor switch temporarily 2 Connect an ohmmeter to the terminals BY BY of the inhibitor switch connector and prepare for continuity check 3 Set the selector lever so that the selector lever pin comes to the position shown in the illustration 098565 4 Slide the inhibitor switch from the rear to the front secure it at the point at which continuity begins and then make a mark on the lever bracket assembly 09W524 5 Tighten the inhibitor switch mounting screws at the position where the clearance between the inhibitor switch and the selector lever is the specified distance Clearance between the side of the inhibitor switch and the selectorlever 2 5 mm 1 in 09K504 25 mm 1 0 in Set position Continuity range of Selector leve
58. irmly engage threads in 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 remover out of bushing Be careful not to damage threads on bushing remover 6 Slide a new bushing on Special Tool and start them in the bore of reaction shaft 904050 7 Support reaction shaft upright on a clean smooth surface and install Special Tool in installing head Drive bushing into shaft until tool bottoms 8 Thoroughly clean reaction shaft support assembly before installation 21 88 COMPONENT SERVICE OIL PUMP AND REACTION SHAFT SUPPORT Removal MD998502 Reaction shaft support installation MD998581 pra 998505 COMPONENT SERVICE OIL PUMP AND REACTION SHAFT SUPPORT EOS REASSEMBLY 1 Place reaction shaft support in Special Tool with hub of support and tool resting on a smooth flat surface bench Screw two Special Tools into threaded holes of reaction shaft support flange 904051 2 Assemble and place rotors in center of the support Pump housing 3 Lower pump body over pilot studs insert Special Tool through pump body and engage pump inner rotor Rotate rotors with tool to center rotors in pump body MD998335 MD998573 MD998585 then with pump body firm against reaction shaft support tighten clamping tool securely 90
59. ission Perform reinstallation in reverse procedure of removal pay attention to the following items 1 Mount the neutral return plungers and the springs in the hole on top of the adapter and tighten the plug until it is flush with the adapter surface 2 Install steel ball resistance spring and plug Automatic Transmission Perform reinstallation in reverse procedure of removal Neutral return plunger A Neutral return plunger B Plug Spring Spring Plug Neutral return plunger A 21 49 COMPONENTS gt 21 50 Bolt w washer 12 Under cover Under cover gasket Plug 3 Poppet spring 3 Steel ball 3 Spring pin for 3 4 shift fork Spring pin for 1 2 shift fork Spring pin for OD R shift fork OD R shift OD R shift fork Mainshaft lock nut Counter gear lock nut Ball bearing Counter overdrive gear Spacer Counter reverse gear Spacer 3 4 shift rail 1 2 shift rail Interlock plunger Spacer Steel ball Overdrive gear Needle bearing Overdrive gear sleeve Bearing spacer Synchronizer ring Overdrive synchronizer assembly Synchronizer sleeve Synchronizer key 3 Synchronizer spring 2 Synchronizer hub Stop plate Spacer Split pin Nut Thrust washer Reverse idler gear Needle bearing Bolt w washer 4 Reverse idler shaft B
60. it in the case it may be neces sary to expand the case with heat during pump installation Using a suitable heat light heat the case in area of pump for a few minutes prior to installing pump assembly 28 29 30 Screw two Special Tools in pump opening in the case Install a new gasket over the pilot studs 904070 Place a new rubber seal ring in groove on outer flange of pump housing Make sure seal ring is not twisted Coat seal ring with grease for easy installation Install pump assembly in the case tap it lightly with a Soft mallet if necessary 3l 32 33 34 35 Make sure 1 thrust washer is installed on reaction shaft support hub Remove pilot studs install bolts and snug down evenly Rotate input and output shafts to see if any binding exists then tighten bolts to specified torque Check shafts again for free rotation Tightening torque Ra Acba x E Oil pump tightening bolts 17 23 Nm 20 17ft Ibs Adjust both bands as described in Maintenance and adjustment Position support and governor body assembly on output shaft Align assembly so governor valve shaft hole in governor body aligns with hole in output shaft Install snap ring behind governor body Tighten body to support bolts to specified torque MEE Tightening torque Governor tightening bolt 10 12 Nm 8 9 ft lbs Place governor valve on valve shaft insert assembly into body and throug
61. ld be washed in a suitable solvent then dried by compressed air Do not wipe parts with shop towels mating surfaces in the transmission are accurately ma chined therefore careful handling of parts must be exercised to avoid nicks or burrs Remove torque converter Remove the transfer case assembly See Component Case for detailed procedure 3 Place transmission on Work bench with oil pan upward Use block such as the one shown in illust ration 904132 under rear of case to hold assembly in position 4 Measuring input shaft end play before disassembly will usually indicate when a thrust washer change is required except when major parts are replaced Thrust washer is located between input and output shafts Dial indicator Attach a dial indicator to transmission bell housing with its plunger seated against end of input shaft Move input shaft in and out to obtain end play reading SM LYR 5 MD998352 Record indicator reference when reassembling RX the transmission S 904044 5 Unscrew oil pan screws and remove oil pan and gasket 904087 6 Loosen clamp bolts and remove throttle and manual control levers from transmission COMPONENT SERVICE AUTOMATIC TRANSMISSION 27 Remove ten hex head valve body to transmission case bolts 904088 8 Remove valve body assembly while lifting the valve body assembly upward out of transmission case
62. n When ATF temperature is about 80 170 F average operating temperature fluid level should be between upper and lower notches of dipstick 90401 1 Proper fluid level Changing Fluid Recommended fluid ATF DEXRON DEXRON Be type NOTES 1 When factory fill fluid is changed as recommended incre only fluids of type labeled ATF DEXRON or DEX RON type should be used 2 If the transmission is disassembled for any reason the fluid and filter should be changed Fluid Changing Procedure 1 Raise vehicle on a hoist Place a drain container with a large opening under transmission fluid 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 low reverse band 4 Install a new filter on bottom of the valve body and tighten retaining screws to specified torque Tightening torque 3 5 Nm 2 2 3 6 ft Ibs 5 Clean the oil pan and reinstall using a new gasket Tighten oil pan bolts to specified torque Tightening torque 15 20 Nm 1 1 14 ft Ibs 6 Pour 3 8 liter 4 0 U S qts 3 4 Imp ats of recom mended fluid through the filler tube Recommended ATF DEXRON or DEXRON Ir type 7 Start engine and allow it to idle for at least bud minutes Then with parking brake on move selector lever momen
63. n chart If governor pressures are incorrect at the given vehicle speeds the governor valve and or weights are probably sticking The governor pressure should respond smoothly to changes in km h mph and should return to 0 to 10 kPa 0 to 1 5 psi when vehicle is stopped High pressure at stand still above 14 kPa 2 psi will prevent the transmission from down shifting THROTTLE PRESSURE TEST No gauge port is provided for the throttle pressure Incorrect throttle pressure should only be suspected if part throttle up shift speeds are either delayed or occur too early in relation to vehicle speeds Engine runaway on either up shifts or down shifts can also be an indicator of incorrect low throttle pressure setting Caution In no case should throttle pressure be adjusted until the transmission throttle linkage adjustment has been verified to be correct 21 21 CONVERTER STALL TEST Warning During test let no one stand in front of vehicle The stall test consists of determining the engine speed ob tained at full throttle in D position This test checks the torque converter stator clutch operation and the holding ability of the transmission clutches The transmission fluid level should be checked and the engine brought to normal operating temperature 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 t
64. n the lever stroke Also make sure that when the throttle linkage alone is slowly returned from the fully opened position the transmission throttle lever completely returns to IDLE by return spring force Throttle rod C in rod B Throttle lever Cam follower Cam surface Throttle lever 21 25 BAND ADJUSTMENTS Kickdown Band The kickdown band adjusting screw is located on left side of the transmission case B09510 1 Loosen lock nut and back off approximately five turns Test adjusting screw for free turning in the transmission case 2 Using torque wrench with kickdown band adjusting wrench MD998357 tighten band adjusting screw to specified torque SERVICE ADJUSTMENT PROCEDURES Kickdown band adjusting screw Gearshift control lever Tightening When adjuster MD998357 is used 5 9 Nm 4 3 ft bs When adjuster MD998357 is 27 not used 7 8 Nm 5 8 ft lbs 3 Back off adjusting screw three and a half turns from 5 9 Nm 4 3 ft lbs Hold adjusting screw in this position and tighten lock nut to specified torque Tightening torque 40 55 Nm 30 41 ft Ibs n Low and Reverse Band m Low reverse band adjusting screw 1 Raise vehicle drain ATF from loosened oil pan and remove the oil pan 2 After lock nut has been removed tighten adjusting screw to specified torque using special tool 904133
65. nates within the converter operate vehicle at light throttle in and ona hoist and listen under the transmission bell housing 21 22 SERVICE ADJUSTMENT PROCEDURES SERVICE ADJUSTMENT PROCEDURES FLUID LEAKAGE TRANSMISSION CONVERTER HOUSING AREA Check for Source of Leakage Since fluid leakage at or around the converter area may originate from an engine oil leak the area should be examined closely Factory fill ATF is dyed red and therefore can be distinguished from engine oil Prior to removing the transmission perform the following checks When leakage is determined to originate from the trans mission check fluid level prior to removal of the trans mission and torque converter High fluid level can result in fluid leakage out of the vent located at the top of the front pump housing If the fluid level is high adjust to proper level After performing these operations re check for leakage If a leakage persists carefully check to determine whether it is the converter or the transmission the oil seal of the oil pump housing or the fitting portions of the oil pump housing and case that 1 leaking 21 23 SERVICE ADJUSTMENT PROCEDURES LUBRICATION Checking Fluid Level and Replenishing Fluid Check and replenish interval Every 48 000 km 30 000 miles Inspect fluid level of dipstick with engine idling and trans mission in neutral positio
66. nd then tighten attaching bolts to the specified torque Be careful not to overtighten the bolts otherwise the gasket will be damaged resulting in oil leakage Under cover attaching bolts torque specification 7 8 9 8 Nm 6 7 ft lbs a K gt N Uhhh gt TE NS 7 222222222 y ws S LIIAN Neutral return plunger A Neutral return plunger B Spring A Spring B 00001 8 6 1 24 Apply sealant 6 1 mm 24 in 6 1 mm 24 in 6 Lx gt Plug Resistance spring Ball Neutral return finger a 134041 21 57 COMPONENT SERVICE MAINSHAFT COMPONENTS 1 First speed gear 2 Needle bearing 3 Bearing sleeve 4 Synchronizer ring 5 1 2synchronizer assembly 1 1 2 synchronizer sleeve 2 Synchronizer spring 2 3 Synchronizer key 3 4 1 2 synchronizer hub 6 Synchronizer ring 7 Second speed gear 8 Needle bearing 9 Snap ring 3 4 synchronizer assembly 1 3 4 synchronizer sleeve 2 Synchronizer spring 2 3 Synchronizer key 3 4 3 4synchronizer hub 11 Synchronizer ring 12 Third speed gear 13 Needle bearing 14 Mainshaft NOTE Numbers show order of disassembly For reassembly reverse order of disassembly 145024 DISASSEMBLY 1 Disassemble in
67. nding exists loosen valve body bolts and realign 43 Install throttle lever and tighten clamp bolt 44 Install oil pan and a new gasket 45 Insert Special Tool into oil pump rotor and turn tool until two small holes of handle are vertical Remove tool while using care not to turn tool By so doing projection of pump inner rotor can be set in vertical position 21 84 we Alignment holes COMPONENT SERVICE AUTOMATIC TRANSMISSION EOS 46 Apply thin coat of vaseline to outside periphery of con verter Turn converter hub until slots are vertical care fully install converter assembly onto input shaft and reaction shaft until it securely fits projection of pump inner rotor To confirm that they are in complete engagement meas ure distance from transmission case bell housing front surface to ends of three drive plate attaching bosses of torque converter Distance should be at least 15 mm 6 in when torque converter is pushed all the way into transmission 21 85 EOS COMPONENT SERVICE OIL PUMP AND REACTION SHAFT SUPPORT COMPONENTS Bolt 6 Reaction shaft support Inner rotor Outer rotor Oil pump housing seal Oil pump housing Oil seal Reaction shaft support seal ring 2 Front clutch thrust washer 1 Numbers show order of disassembly For reassembly reverse order of disassembly i 904047 DISASSEMBLY
68. not be warped or cone shaped Inspect facing material on all clutch discs Replace discs that are charred glazed or heavily pitted Discs should also be replaced if they shown evidence of mateiral flaking off or if facing material can be scraped off easily Inspect clutch disc splines for wear or other damage Inspect clutch plate and pressure plate surfaces for burning scoring or damaged driving lugs 2 Inspect clutch 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 seal rings Inspect clutch retainer inner bore surface for wear from reaction shaft support 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 seal rings for deterioration wear and hardness Inspect piston spring retainer and snap ring for distortion FRONT CLUTCH RETAINER BUSHING REPLACEMENT 1 Lay clutch retainer open end down on a clean smooth MD998581 surface and place Special Tool in bushing Install Special Tool in removing head
69. nstructions 21 10 Pilot stud SPECIAL TOOLS Tool Number and name Use MD998573 D C 3756 Converter alignment tool gt MD99858 Alignment of holes of the oil pump rotor Removal and installation C 4171 of pump housing bushing Driver bandle Use with MD998500 or MD998501 XR MD998584 C 3238 B Installation of output shaft support d TROUBLESHOOTING MANUAL TRANSMISSION Hard shifting Malfunction of gear shift lever and control shaft Improper contact of synchronizer ring and cone section or gear excessive wear Synchronizer spring deteriorated AUTOMATIC TRANSMISSION Selector lever maladjusted Control rod and control arm connected in improper position Gear shift fork worn or poppet spring broken Main drive gear and main shaft bearing worn broken Clearance of clutch hub and hub sleeve splines excessive Second gear and bushing worn Selector lever operates unsmoothly or is hard to operate Detent plate worn Selector lever rod end pin worn Jumping out of gear First gear and bushing worn Reverse idler gear and bushing worn Counter gear worn Control arm shaft excessively tightened Transmission noise Lubricating oil insufficient or inadequate Gears or bearing worn or broken Mainshaft spline worn Starter won
70. olt w washer 3 Baffle plate Rear bearing retainer Nut 6 Spring washer 6 Front bearing retainer Front bearing retainer gasket Nm ft Ibs 8 0 9 5 6 7 99 127 73 94 6998 51 72 20 58 15 437 x 15 21 11 15 15 21 11 15 10 12 7 59 0 30 34 22 25 46 47 48 Ball bearing Spacer 51 52 Counter gear 54 55 56 97 58 59 60 1 2 3 EE 6 7 COMPONENT SERVICE MANUAL TRANSMISSION Spacer Snap ring Ball bearing Counter rear bearing Counter front bearing 3 4 shift fork 1 2 shift fork Main drive gear Needle bearing Synchronizer ring Mainshaft assembly Transmission case assembly Oil filler plug Gasket Oil seal Cap Clutch shaft bushing Bush knock Transmission case 145013 COMPONENT SERVICE MANUAL TRANSMISSION DISASSEMBLY 1 Remove the under cover 2 Remove the snap ring and ball bearing from the rear end the mainshaft 3 Loosen the three poppet spring plugs then remove three poppet springs and three steel balls 4 Using a 3 16 in punch remove 3 4 and 1 2 shift fork spring pins 134006 5 Using 3 16 in punch drive the overdrive reverse shift forks spring pins out then remove the shift rails and forks 1132026 6 Bend back the locking washer and loosen the lock nuts mainshaft and countershaft The nuts can be loosened _ by double engaging reverse and 2nd gears 132027 7 Move the 1 2 shif
71. on case 904131 21 61 GENERAL INFORMATION The MA904A automatic transmission combines a torque converter and a fully automatic 3 speed gear system The converter housing and transmission case are an integral aluminum alloy die casting The transmission consists of two multiple disc clutches an overruning clutch two servos and bands and two planetary gear sets to provide three forward ratios and a reverse ratio The common sun gear of the planetary gear sets is connected to the front clutch by a driving shell which is splined to the sun gear and to the front clutch retainer The hydraulic system consists of an oil pump and a single valve body which contains all of the valves except the governor valve Venting of the transmission 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 plate Cooling of the ATF automatic transmission fluid heated in the converter is accomplished by circulating the ATF through the water cooled type cooler in the radiator lower tank The torque converter assembly is a sealed unit wh ich cannot be disassembled The ATF 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 converter and then through the input shaft to the multiple disc clutches in the transmission The power flow oe on the
72. or wear and scores and re place if damaged or worn below specifications 4 Inspect thrust faces of planetary gear carriers for wear scores or other damage and replace as required Inspect planetary gear carrier for cracks and pinions for broken or worn gear teeth and for broken pinion shaft lock pins Inspect annulus gear and support teeth for damage Replace distorted snap rings REASSEMBLY Place rear annulus gear support in annulus gear and install snap ring 2 Position rear planetary gear assembly in rear annulus gear and place 10 and 11 thrust washers on front and rear sides of planetary gear assembly 3 Carefully work output shaft through annulus gear sup port Make sure shaft splines are fully engaged in splines of annulus gear support 4 Install thrust plate and snap ring on one end of sun gear Insert sun gear through front side of driving shell and install rear thrust plate and snap ring 904115 5 Carefully slide driving shell and sun gear assembly on output shaft engaging sun gear teeth with rear planetary pinion teeth 6 Place front annulus gear support in annulus gear and install snap ring Driving shell 9 thrust plate Snap ring 21 97 7 Position front planetary gear assembly in front annulus gear place 5 thrust washer over planetary gear assembly hub and install snap ring Position 6 and 7 thrust washers on front and rear sides of planetary gear as sembly 1 Carefully
73. orjoeer uexo1q 10 IO Uo o1q 8 1 eos 3J0ddns 10u19407 poSeurep Surjsnq 10 pue Sui1eoq 3jeus urpjou jou SuruuniroAQ jueunsn pe jo jno umopyory odeur 11014 12911094 00 poeds o pr pejerov 80 eos 3jeus 114 uoxoiq 10 8 1 jueunsn pe eSexur 03002 1451898 OaIIONU 10 pueq 195 9SI19A91 MO T X X X X X X X XIX X X X XIX X X ox xx x ___ xx x x E qe DAT X XXX x x XXX X 1234 5 6 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 x Jo uorjounj eur Apod x jueunsn p jo pueq 003 9115 914 x x x 2 X TISISSOd ile m m 2 a 2 5 5 g E 2 3 E mu AS 9 Sali 2 n B c 15 E TB gt Al gt Sla Sz 4 amp 2 22 m lt On c Zu 2 zt Zoe ic ui 122 Kg uu Of W 5 2 Z gt je O g PA gt gt 5 9 E 49 8 oO 8 Em lt 5 5 ly 56 2 gt 2
74. orward position Line pressure should read 372 to 657 kPa 54 to 95 psi with throttle lever rearward and gradually increase as lever is moved forward to 621 to 662 kPa 90 to 96 psi Lubrication pressure should be 39 to 108 kPa 6 to 16 psi with lever rearward and 69 to 207 kPa 10 to 30 psi with lever forward This tests pump output pressure regulation and condi tion of rear clutch and lubrication hydraulic circuits Test 3 Selector in D 1 2 3 Attach gauges to line kickdown servo release ports Operate engine at 1 600 rpm for test Move selector lever on transmission two detents rearward from full forward position This is selector D position Read pressures on both gauges as throttle lever on trans mission is moved from full rearward position to full forward position Line pressure should read 372 to 414 kPa 54 to 60 psi with throttle lever rearward and gradually increase as lever is moved forward Kickdown servo release is pressurized only in 3rd gear direct drive and should be same as line pressure within 21 kPa 3 psi up to downshift point This tests pump output pressure regulation and condi tion of rear clutch and front clutch hydraulic circuits Test 4 Selector in Reverse 1 2 3 Attach gauge to rear servo apply port Operate engine at 1 600 rpm for test Move selector lever on transmission four detents rearward from full forward position
75. output shaft oil seal into the transfer case When press fitting the oil seals push down on the outer circumference uniformly After press fitting pack grease _ between lips 144018 144019 144020 2 Assemble the adapter and the transfer case with a new gasket placed between them Tighten the bolts and nuts Be sure to install the change shifter over the control shaft before tightening the bolts and nuts Caution If this sequence is reversed the change shifter cannot be installed Transfer case mounting bolts and nuts tightening torque 30 41 Nm 22 30 ft Ibs Caution When inserting the transmission control shaft through the oil seal take care not to damage the oil seal lip If the change shifter lock pin hole in the shaft has burrs remove them before inserting the shaft through the oil seal 3 Press the bearing onto the input gear being sure to push on the inner race After fitting check to see that the bearing rotates smoothly 4 Fit a snap ring over the front end of the input gear Snap rings are available in five different thicknesses Use the thickest one that will fit into the groove 144021 21 44 ECS COMPONENT SERVICE TRANSFER Control shaft oi sea Input gear oil seal Baffle plate 144019 Front output shaft oil seal 44021 COMPONENT SERVICE TRANSFER EC Snap ring thickness mm in Identification color 2 30 091 None 2 35 093 Red 2 40 094 White 2 45
76. ove the propeller shaft 21 65 99 17 Test TL vave EE SCREEN EXE T NEUTRAL OIL FILTER _ SCREEN OIL FILTER COOLER Ej s soo b o seq fl eS VALVE KICKDOWN vAtve p A TO FRONT aoe CLUTCH LUBRICATION VALVE HYDRAULIC PRESSURE Line ANN om YE PUMP LUBRICATION ___ gt TORQUE CONVERTER HYDRAULIC PRESSURE LINE REN TO LUBRICATION SUD Jed pue x m 2 U m J lt C NOISSINSNVH L SILVWOLNY L9 ic 500706 GOVERNOR VALVE A REAR CLUTCH HEAR SERVO FRONT CLUTCH ACCUMULATOR GOVERNOR 3 PLUG COOLER TO LUBRICATION TO FRONT CLUTCH LUBRICATION HYDRAULIC PRESSURE LINE MEME 7 ___ 7 THROTTLE TORQUE CONVERTER OIL FILTER 15 9 m 2 QU m 2 lt gt c gt 2 gt o o 89 1 70006 FRONT SERVO GOVERNOR VALVE REAR SERVO REAR CLUTCH FRONT CLUTCH ACCUMULATOR THROTTLE PLUG GOVERNOR 2 3 SHIFT 1 2SHIFTCONTROLVALVE com Ls C
77. peration 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 analysis By observing that the rear clutch and the overrunning clutch are applied in the D first gear and that the rear clutch and low reverse band are applied in 1 first if the transmission slips in D range first gear but does not slip in L 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 front clutch are applied in D third gear If the transmission slips in third gear either the front clutch or the rear clutch is slip ping By selecting another gear which does not use one of those units the unit which is slipping can be determined If the transmission also slips in reverse the front clutch is slipping If the transmission does not slip in reverse the rear clutch is slipping This process of elimination can be used to detect any unit which slips and to confirm proper operation of good units However although road test analysis can usually diagnose slipping units the actual cause of the malfunction usually cannot be decided Practically any condition can be caused by leaking hydraulic circuits or sticking valves Therefore unless the condition is obvious like no drive in D
78. r pin 21 37 COMPONENT SERVICE AUTOMATIC TRANSMISSION CONTROL Control Rods 1 Apply multipurpose grease to each sliding part Recommended grease PE Multipurpose grease SAE J310a NLGI grade 3 2 To connect the control rod B to the control arm set the selector lever to the position move the control rod to place the transmission in the Neutral position and then tighten the rod to the lever lock nut 095567 3 Torque all parts to specifications during assembly 4 After installing each part make certain that the selector lever moves smoothly and that the lever on the trans mission side moves properly to each selector position 098567 21 38 COMPONENT SERVICE TRANSFER COMPONENTS 1 Filler plug 45 Spring retainer 19 Rear output shaft 2 Gasket 46 Spring 20 Bearing 2 3 Bolt 47 Spring retainer 21 Front output shaft 4 Sleeve clamp 48 Output shaft assembly 49 Rear wheel drive 4 wheel drive shift fork 5 Speedometer sleeve assembly 1 chain 50 Rear wheel drive 4 wheel drive shift rail 6 4WD indicator lamp switch 2 Snapring 51 H L shift fork 7 Gasket 3 Clutch hub High and Low 52 Needle bearing 8 Steel ball 4 Bearing spacer 53 Clutch sleeve 4WD indicator lamp switch 5 speed gear 54 Snap ring 10 Gasket 6 Needle bearing 55 Input gear assembly 11 Steel ball 7 Locking nut 1 Snap ring 12 Bolt 6
79. rol rod A from the transmission 14 Remove the cover of selector handle 15 Remove the spring pin in order to disassemble the selec tor handle 09W 525 09W525 INSPECTION Check detent plate for wear 2 Check pin at the end of selector lever for wear 3 Check the pushbutton and the rod adjusting cam for worn contact surface 4 Check control rods for damage cracking or deformation 5 Check each bushing for cracking deterioration or wear 6 Check the cross select shaft for damage cracking or deformation 21 35 COMPONENT SERVICE AUTOMATIC TRANSMISSION CONTROL Operating Condition of the Inhibitor Switch Shift the selector lever to each position and check for continuity as shown in the table T Position e Q 09W513 Continuity INSTALLATION Selector Lever 1 Apply multipurpose grease to each sliding part 09 515 Recommended Oe detur TT grease SAE 3 10 NLGI 3 2 Mount the selector lever and the control arm ante the lever bracket assembly and then tighten the lock nut to the specified torque Lock nut tightening torque S LT 18 24 Nm 13 17 ft Ibs Set the selector lever to the position and then turn the rod adjusting cam to adjust it so that its bottom surface is flush with the end of the selector lever as shown in the illustration At this time position the rod adjust
80. s sion and converter as an assembly Disassemble clean and inspect all parts Clean valve body install all new seals rings and gaskets replace worn or defective parts Debris is present remove transmission and converter as an assembly disassemble clean and inspect all parts Clean valve body install all new seals rings and gaskets replace worn or defective parts 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 to case seal or torque converter weld Cracked or porous transmission case 21 13 SERVICE ADJUSTMENT PROCEDURES pE DIAGNOSIS CHART GENERAL AUTOMATIC TRANSMISSION Diagnosis Chart General pedeurep ooe1 423 SuruuniioAQ E x x x x x x x x x x 7 10 uexo1q SuruunileA pezres 10 uoxo1q 51295 1898 Suidde1p 1e o3 21 2 10 eougIeo 9 o1e d 1uororgrnsu urojs s guti ooo 4 14811 00 1ueurjsn pe uMopsory 8 001 o1nsse1d or ne1p H 1 3 prp usrH 1001 10 JO pueq 1 58011 eos 310ddns 1 2 5 u
81. set body bolts SPECIAL TOOLS ES Tool Number and name MD998356 Oil pressure gauge adapter 67 MD998358 D Low reverse band adjusting wrench D MD998501 D SP 5117 Pump housing bushing installer MD998503 D SP 3633 Cup MD998505 D SP 5325 Reaction shaft bushing installer MD998507 D SP 3626 Front clutch retainer bushing Use Tool Number and name Use MD998357 D Adjustment of the Kickdown band adjustin kickdown band wrench Connecting the oil pressure gauge MD998500 D SP 3551 Pump housing bushing remover MD998502 D SP 3524 Reaction shaft bushing remover Adjustment of the low reverse band Use with MD998502 MD998504 D SP 1911 Nut Use with MD998502 e MD998506 D SP 3627 Front clutch retainer bushing MD998563 C 3763 Throttle pressure adjust tool Adjustment of the throttle pressure D see page 2 for instructions 21 9 Tool Number and name Use Removal and installation of the front clutch bearing MD998572 C 3575 A Spring compressor MD998580 4193 Oil pump oil seal installer MD998583 Removing oil pump C 3752 housing Oil pump remover MD998585 Assembly of oil pump C 3283 A Pilot stud d cene see page 2 for i
82. sure 21 12 TROUBLESHOOTING 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 L mark before Starting the engine Then start the engine with the transmission in neutral and listen for noise No abnormal noise move the selector to a forward drive range and observe the propeller shaft for turning Propeller shaft turns but rear wheels do not turn inspect for broken rear axle parts No debris remove valve body disassermble clean and inspect all parts Reassemble install and check pressures and operation The following leaks may be corrected without removing the transmission manual lever shaft oil seal filler tube O ring pressure gauge plug 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 Propeller shaft does not turn remove the trans mission oil pan Inspect for debris 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 Abnormal noise stop engine immediately remove the transmi
83. t start with selector lever in and positions Inhibitor switch installed in improper position Inhibitor switch defectively operating 21 11 TROUBLESHOOTING Diagnosis guide abnormal noise Inspect and 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 Knock click or scrape Whine or buzz noise imr Remove torque and inspect for loose or Listen to transmission cracked converter drive and converter for plate inspect for source of noise contact of the starter drive with the starter ring gear Gear noise or grinding Remove the transmis sion and converter assembly disassemble clean and inspect all parts clean the valve body install all new seals rings and gaskets replace worn or defective parts Transmission has buzz Converter has loud or whine buzz or whine Remove the transmis sion pan inspect for debris indicating worn converter or failed parts Replace torque Debris present remove transmission and converter as an assembly disassemble clean and inspect all parts clean the valve new seals rings and gaskets replace worn or defective parts No debris present remove valve body disassemble clean and inspect parts reassemble install check operation and pres
84. t it en gages manual valve and detent ball Install seal retaining washer and E clip on throttle shaft E COMPONENT SERVICE VALVE BODY Throttle valve lever shaft 16 Install rear clutch check ball and rear servo check ball to transfer plate and install regulator valve screen to valve body plate 904035 D 17 Install transfer plate support and valve body plate to transfer plate with four screws 904035 support 18 Install the seven check balls in valve body 19 Place transfer plate assembly on valve body and tem porarily tighten 13 screws 904122 20 Torque screws to specified torque in correct sequence working from center screw to outward ones Tightening torque ee Valve body screw 2 9 4 9 Nm 2 2 3 6 ft Ibs 21 102 Transfer plate Snap ring Manual valve lever Paring sprag rod Rear clutch check bal Rear servo check ball Transfer plate 904035 6 4 mm 1 4 in diameter balls 8 7 mm 11 32 in diameter ball 904036 904122 COMPONENT SERVICE VALVE BODY 21 Put switch valve regulator valve and spring in respective bores 5 Switeh valve E Hos ueni 904123 22 Set adjustment screw bracket on spring and temporarily tighten one screw one for mounting to side of valve body After top and bottom screws have been tightened x tighten side screw ucc ud Switch valve spring Adjusting screw
85. t rail toward the 1st speed side 8 Remove the counter overdrive gear and ball bearing with a suitable puller 132028 Be sure to remove the ball bearing and the overdrive gear as a unit by installing the puller onto the gear 9 Remove distance spacers and counter reverse gear from countergear shaft 10 Remove the shift rails toward the rear of the transmission case Remove the shift forks 11 Remove the spacer and steel ball from the mainshaft 12 Remove the overdrive gear needle bearing and synchro nizer ring from the mainshaft 13 Remove the overdrive synchronizer sleeve from the hub lt Mi Ld COMPONENT SERVICE MANUAL TRANSMISSION 14 Using special tool MD998056 remove synchronizer hub and overdrive gear bearing sleeve 15 Remove the synchronizer key stop plate and the distance eS gear shaft _ S ss spacer from the mainshaft 16 Remove the cotter pin from the reverse idler gear shaft and loosen the nut and then remove the thrust washer reverse idler gear and needle bearing 17 Remove the idler gear shaft locking bolts 18 Loosen the reverse idler gear shaft by driving from inside the case 134011 19 Remove the rear bearing retainer 134010 20 Remove the front bearing retainer 21 Remove snap rings from main drive gear and main drive Rear everse gear bearing i idler gear sh
86. t screw 11 Inhibitor switch 12 Lever bracket cover 13 Heat protector 14 Control rod B 15 Cross select shaft 16 Protector 17 Control rod A 18 Cross shaft bracket WN ft Ibs A 2 more 1 4 18 24 13 17 13 9 10 13 7 9 09 001 REMOVAL 1 Remove the selector handle from the selector lever 09K 505 2 Remove the console box Refer to GROUP 23 3 Remove the indicator panel 09W 522 4 Disconnect the connector of the position indicator light 58 09 522 21 33 COMPONENT SERVICE AUTOMATIC TRANSMISSION CONTROL 5 Disconnect the control rod B from the control arm by lossening the nut from under the floor 6 Disconnect the connector of the inhibitor switch NOTE Do not remove the inhibitor switch from the lever bracket assembly unless it is necessary to do so 7 Remove the lever bracket assembly by loosening the attaching screws 09W516 8 Disconnect the cross select shaft from the heat protector 9 Disconnect the cross select shaft from control rod B 09W518 10 Disconnect the cross select shaft from control rod A 21 34 COMPONENT SERVICE AUTOMATIC TRANSMISSION CONTROL 11 Remove the cross shaft bracket mounting bolts from the transfer assembly 09W519 12 Detach the cross shaft bracket from the bracket on the No 1 crossmember side uL 13 Remove cont
87. t the negative cable from the battery 2 Vehicles with an automatic transmission disconnect the down shift link 09Y 536 3 Remove the transmission gearshift lever vehicles with a manual transmission or transmission selecter lever vehicles with an automatic transmission refer to P 21 33 and transfer shift lever 098549 809022 Caution When removing the gearshift lever assembly keep the trans mission gearshift lever and the transfer gearshift lever in the following positions Transmission gearshift lever vehicles with a manual transmission only Neutral position Transfer gearshift lever 4H 4 wheel drive high range position After the gearshift lever assembly has been removed cover it with a shop towel to prevent entry of foreign substances into the extension housing 4 Raise the vehicle Remove the transfer case protector 09 512 6 Vehicles with an automatic transmission remove the control arm control rod cross select shaft Refer to P 21 34 Drain the transmission and transfer case oil Vehicles with an automatic transmission remove the oil cooler hoses and tubes Refer to GROUP 7 9 Remove the front and rear propeller shafts Refer to GROUP 16 Un 2955 COMPONENT SERVICE TRANSMISSION AND TRANSFER CASE 10 Disconnect speedometer cable back up light switch harness and the 4 wheel drive indicator light harness 11 Vehicles with a manual transmission
88. the center line of the shift rail 144027 Mount the spacer onto the rear end of the rear output shaft bearing and install the rear cover and gasket Be sure to select and mount a spacer which is thick enough to keep the end play of the rear bearing outer race in the range of 0 to 0 1 mm 0 to 04 in Thickness of spacer mm Identification color 0 84 033 Black 0 93 037 None 1 02 040 Red 1 11 044 White 1 2 047 Yellow 1 29 051 Blue 1 38 054 Green SZ AV M DE Oil guide Spring pin 21 47 ESS COMPONENT SERVICE TRANSFER 32 Mount the wave spring on the rear end of the front output shaft rear bearing and install the cover and the gasket 144028 If the bearing rear end to cover clearance C exceeds 2 mm 079 in use an appropriate spacer to reduce the clearance to 2 mm 079 in or less 144029 Cover Bearing 33 Insert the speedometer sleeve assembly into the rear cover Align the mating mark on the sleeve with that on the case according to the number of teeth of the speedo meter driven gear 134045 34 Mount the sleeve clamp and tighten the bolt Clamp bolt tightening torque 10 12 Nm 7 5 ft lbs 35 Install two 4WD indicator light switches along with their steel balls Mating marks COMPONENT SERVICE TRANSFER INSTALLATION Manual Transm
89. the numerical order indicated in the component illustration 145024 2 Before synchronizer assembly is disassembled put an alignment mark on synchronizer hub and sleeve at ap propriate location in aid of reassembly 3 Since synchronizer key is common to both 1 2 and 3 4 synchronizers do not change the combination 21 58 COMPONENT SERVICE MAINSHAFT REASSEMBLY 1 2 and 3 4 synchronizer T Teeth missing here 1 Mate synchronizer hub with sleeve using mark made at disassembly Make sure that hub and sleeve slide smooth ly If they slide unsmoothly replace hub and sleeve assembly 2 3 4 synchronizer sleeve has teeth missing at six portions Assemble hub to sleeve in such a way that center tooth T between two missing teeth will touch synchronizer key 110012 Synchronizer key 110012 3 Use care when installing 3 4 synchronizer hub since only 3 4 synchronizer is directional Smaller diameter side A of center boss is front of 3 4 synchronizer hub ice z 145025 Insert three keys into groove of synchronizer hub Install two synchronizer springs to synchronizer When synchronizer springs are installed make sure that front and rear ones are not faced in same direction 110013 2 ES 110013 21 59 Mainshaft 1 Assemble the mainshaft assembly in the reverse of the order indicated in the component illustration 145024 2 Assemble 3 4
90. tion 3 For adjustment refer to Maintenance and Adjustment Throttle linkage The throttle linkage adjustment is very transmission operation This adjustment positions a valve which controls shift speed shift quality and part throttle down shift 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 down shifts may be very sensitive For adjustment refer to Maintenance and Adjustment 21 16 SERVICE ADJUSTMENT PROCEDURES Road test Prior to performing a road test be certain that the fluid level and ATF condition control rod adjustments and throttle linkage adjustments 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 speeds for the various modes of operation are shown in the Automatic Shift Speed Pattern 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 ad vanced 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 o
91. tput shaft support z 904097 REASSEMBLY l Screw two Special Tools into the case Position output shaft support over pilot studs and tap it firmly into the case with a soft faced hammer 904064 2 Remove pilot studs 3 Install four bolts and tighten to specified torque Output shaft support 904064 4 Install new seal to reverse servo piston 8 TIUS Reverse servo piston 2 1 ia 5 Install cushion spring and piston plug to reverse servo piston and secure with snap ring Piston spring Piston plug ka A spring Spring retainer Snap ring Reverse servo piston Ae 21 79 6 Carefully work servo piston assembly into the case with a twisting motion Place spring retainer and snap ring overpiston 7 Compress low and reverse servo piston spring by using Special Tool and then install snap ring 904099 8 Install new seal rings to kickdown servo piston 9 Install new O ring to kickdown servo piston rod 10 Install new seal ring to kickdown guide 21 80 COMPONENT SERVICE AUTOMATIC TRANSMISSION 904099 Kickdown servo position Kickdown guide 904100 Kickdown servo piston rod COMPONENT SERVICE AUTOMATIC TRANSMISSION EOS 11 Carefully push kickdown servo piston into case bore 12 Install piston rod spring and guide 13 Compress kickdown servo springs by using Special Tool then install snap ring 904103 14
92. utput shaft Drum or box 90 3 5 in diameter 21 81 Eom COMPONENT SERVICE AUTOMATIC TRANSMISSION 20 Apply a coat of grease to 4 selective thrust washer and install washer on front end of output shaft If input shaft end play was not within specifications when tested before disassembly replace thrust washer with one of proper thickness 904105 21 Apply a coat of grease to 3 thrust plate and install plate on thrust washer 904105 22 Apply a coat of grease to 2 thrust washer and install washer on rear clutch retainer 904106 23 Align front clutch disc inner splines and place front clutch in position on rear clutch Make sure front clutch disc splines are fully engaged on rear clutch splines 2 thrust washer 904106 24 Align rear clutch disc inner splines grasp input shaft and lower the front and rear clutch assemblies into trans mission case 904107 25 Engage rear clutch splines over splines of front annulus gear Make sure front clutch retainer lugs are fully engaged in slots in the driving shell 26 Slide kickdown band over front clutch assembly 27 Install band strut screw in adjusting screw just enough to hold strut in place 904069 E Adjusting screw 21 82 COMPONENT SERVICE AUTOMATIC TRANSMISSION Caution If difficulty was encountered in removing pump assembly due to an exceptionally tight f

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