Home

TRANSMISSIONS

1. Wide Open Throttle 1 2 Upshift Wide Open Throttle 2 3 Upshift 3 2 Kickdown Limit 3 1 Kickdown Limit pistons are moved hydraulically to engage the clutches and apply the bands The pistons are re leased by spring tension when hydraulic pressure is released On the 2 3 upshift the kickdown servo pis ton is released by spring tension and hydraulic pres sure The accumulator controls the hydraulic pressure on the apply side of the kickdown servo during the 1 2 shift thereby cushioning the kickdown band applica tion at any throttle position OPERATING INSTRUCTIONS The transmission will automatically upshift and downshift at approximately the miles per hour given in the Shift Pattern Summary Chart All shift speeds given in the Chart may vary somewhat due to pro duction tolerances and rear axle ratios The quality of the shifts is very important All shifts should be smooth responsive and with no noticeable engine runaway Gearshift and Parking Lock Controls The transmission is controlled by a lever type gearshift incorporated within the steering column The control has six selector lever positions P park R reverse N neutral D drive 2 second and 1 low Some vehicles are equipped with a lever type console gearshift which has the same selector lever positions The parking
2. 46 Hydraulic Control Pressure Tests Parking Lock Sprag 3B Hydraulic Control Pressure Adjustments 24 Planetary Gear Train 45 L bricatioli ua mer wate emu 19 Rear eden aw ape win elt dn 43 Neutral Starting Switch 21 Valve Body Assembly 35 Parking Lock Components 28 Removal Transmission and Converter 29 Speedometer Pinion 26 Pump Oil Seal 32 Throttle Rod Adjustment 22 Starter Ring Gear 30 Valve Body and Accumulator Piston 29 Torque Converter Flushing 31 Service Out of Vehicle 29 Specifications cane ster RW ear 69 Assembly Sub Assembly Installation 48 Tightening Reference 70 GENERAL INFORMATION The TorqueFlite Transmission model identification markings are cast in raised letters about 3 8 inch high on the lower left side of the transmission bell housing The A 727 B TorqueFlite Transmission servicing procedures are in general the same for all models CAUTION Transmission operation requirements are different for each vehicle and engine combination and some internal parts will be different to provide for this Therefore when replacing parts refer to the seven digit part numb
3. Oil return hole in front pump housing plugged or omitted d Seal worn out high mileage cars 2 Fluid leakage at the outside diameter from pump housing ring seal 3 Fluid leakage at the front pump to case bolts 4 Fluid leakage due to case or front pump housing porosity 5 Oil leakage out the vent 6 Kickdown lever shaft access plug Possible sources of converter leakage shown in Fig 3 are 1 Torque converter weld leaks at the outside diam eter peripheral weld 2 Front pump hub weld 3 Crankshaft pilot weld 4 Fluid leakage from the converter drain plug These leaks appear at the outside diameter of the con verter on the engine side AIR PRESSURE TEST OF TRANSMISSION The transmission should be prepared for pressure OUTSIDE DIAMETER WELD TORQUE CONVERTER HUB WELD CRANKSHAFT PILOT WELD RING GEAR PLUG PY16 Fig 3 Torque Converter Cross Section TORQUEFLITE TRANSMISSION 21 53 VENT PLUG RETAINER RETAINER SLIDING YOKE WIRED IN PLACE HUB SEAL CUP PLUG MADE FROM OLD FILLER TUBE PY302 Fig 4 Transmission Prepared for Test test as follows after removal of the torque converter 1 Install filler tube bore plug propeller shaft yoke tie in with cord or wire flared tube fitting cap on FLARE CAP 1 8 PIPE NIPPLE HOSE CLAMP PY303 Fig 5 Pressurizing Transmission WELD OR BREAK EDGE 1 16 BRAZE MIN 1 8
4. ADJUSTMENT PRAET Sgt MANUAL THROTTLE LEVER Mio omg LEVER ASSY STOP SCREW REPAIR STAND NN80A Fig 41 Valve Body and Control Assembly inch deep Fig 40 The stand can then be used with either the old or new type valve bodies Disassembly 1 Place valve body assembly on repair stand Tool C 3749 Fig 41 Remove three screws from fluid filter and lift off the filter 2 While holding spring retainer firmly against the spring force remove the three bracket retaining screws Fig 41 3 Remove the spring retainer torque converter control valve spring and regulator valve spring with line pressure adjusting screw assembly Do not alter setting of line pressure adjusting screw and nut The nut has an interference thread and does not turn easi ly on the screw 4 Slide regulator valve out of valve body Slide torque converter control valve out of valve body STIFFENER PLATE SEPARATOR PLATE NU461A Fig 42 Transfer and Separator Plate 21 36 TRANSMISSION TORQUEFLITE 5 Remove 17 transfer plate retaining screws Carefully lift transfer plate and steel separator plate assembly off the valve body 6 Invert transfer plate assembly and remove the stiffener plate Remove remaining screws securing separator plate to the transfer plate and carefully lift off the separator plate Fig 42 7 Remove and note location of 7 steel balls and 1 spring in valve body Fig 43 CAUTION Do Not mix u
5. eere ep NE 55 Converter Drive Plate to Torque Converter Bolt 270 Extension Housing to Transmission Case Bolt 2 lema 24 Extension Housing to Insulator Mounting Bolt 40 Extension Housing Crossmember to Frame Bolt 75 Governor Body to Support Bolt 100 Kickdown Band Adjusting Screw Lock M t woe ee RE 29 Kickdown Lever Shaft Plug 150 REFERENCE Foot Pounds Gearshift Operating Lever Nuts 18 Transmission to Clutch Housing Bolts 50 Transmission Cover Retaining Bolts 12 Transmission Drain Plug 25 Pounds Foot Inch Neutral Starter Switch 24 Oil Bolt ooo er taxa 150 Oil Pump Housing to Transmission Case Bolt rece e eR 175 Output Shaft Support Bolt 150 Overrunning Clutch Cam Set Screw 40 Pressure Test Take off Plug 75 Reaction Shaft Support to PUMP Bolt erm meten 160 Reverse Band Adjusting Screw Lock asua tm nena 35 Speedometer Drive Clamp Screw 100 Transmission to Engine Bolt 28 Valve Body Screw 35 Valve Body to Transmission Case Bolt CE RICE 100
6. Low fluid level b Hydraulic pressures too low c Valve body malfunction or leakage d Faulty oil pump e Clutches or servos sticking or not operating f Worn or broken input shaft and or reaction shaft support seal rings TORQUEFLITE TRANSMISSION 21 15 Correction k Inspect and replace seal rings as re quired also inspect respective bores for wear Replace parts as required Refill to correct level with Automatic Transmission Fluid AQ ATF Suffix A or Dexron b Inspect for air leakage into pump suction passages c Adjust throttle linkage d Adjust control linkage e Perform hydraulic pressure tests and adjust to specifications f Perform pressure tests to determine cause and correct as required g Inspect accumulator for sticking broken rings or spring Repair as re quired h Remove valve body assembly and per form air pressure tests Repair as re quired i Disassemble and inspect clutch Re pair or replace as required D Disassemble transmission and repair overrunning clutch as required k Inspect and replace seal rings as re quired also inspect respective bores for wear Replace parts as required a Refill to correct level with Automatic Transmission Fluid AQ ATF Suffix A or Dexron b inspect for air leakage into pump suction passages c Adjust control linkage d Perform hydraulic pressure tests and adjust to s
7. SEAL THIS END AIR TIGHT 3 4 1 873 le 1 3 4 5 1 4 POLISH 1 876 OUTSIDE OF OPEN MATERIAL 1 7 8 INCH THIN WALLED STEEL TUBING AND 1 8 INCH STEEL DISC PY304 Fig 6 A 727 Converter Hub Seal Cup 21 54 TRANSMISSION 3 SPEED MANUAL 15 32 DRILL 4 HOLES 1 13 64 14 3 16 16 1 2 17 19 32 20 MATERIAL 1 4 STEEL STOCK 1 1 4 WIDE PY306 Fig 7 Hub Seal Cup Retaining Strap front cooler line fitting and pipe nipple in case at rear cooler line fitting Fig 4 and 5 2 Remove necessary front pump housing bolts and vent shield in A 727 transmission Install vent plug rubber stopper and vent plug retainer Fig 4 preferably using longer bolts than those removed 3 With rotary motion install converter hub seal cup Fig 4 over input shaft and through the con verter hub seal until the cup bottoms against the pump rotor lugs Secure with cup retainer strap Fig 4 using converter housing to engine block retaining bolts 4 Attach and clamp hose from nozzle of Tool C 3499 to pipe nipple which is in rear cooler line fitting position in case Fig 5 5 Pressurize the transmission using Tool C 3499 until the pressure gage reads 8 psi Position transmis sion so that pump housing and case front may be covered with soapy solution or water Leaks are some times caused by porosity in the case or pump housing CAUTION Do not under any circumstances pressur ize a tr
8. 8 Tap with plastic hammer to break gasket seal and carefully guide housing off rear of mainshaft Idler Gear and Mainshaft Fig 7 1 Insert arbor tool C 464 in case to push reverse DRIVE PINION ASSEMBLY PY63 Fig 5 Tap Drive Pinion Forward for Mainshaft Pilot Clearance __ SYNCHRONIZER SLEEVES MOVED FORWARD POSITION CUT AWAY AREA ON 2ND GEAR NEXT TO CLUSTER GEAR FOR CLEARANCE x 5 il COUNTERSHAFT PY632 Fig 6 Position 2nd Gear and Shift Sleeves for Clearance idler shaft and key out of case Fig 7 2 Remove idler gear with arbor in place to retain rollers 3 Remove both thrust washers Fig 8 4 Grasp mainshaft assembly and remove through rear of case Fig 8 Countershaft Gear and Drive Pinion 1 Using a mallet and arbor Tool C 4112 tap coun tershaft rearward and remove key Continue to drive countershaft out of case maintaining contact between shaft and arbor so that washers will not drop between them Fig 9 2 Lower countershaft gear to bottom of case to permit removal of main drive pinion 3 Remove snap ring from pinion bearing outer race Fig 10 4 Using a plastic hammer drive the pinion into MAINSHAFT BEARING RETAINER MIDLER SHAFT MAINSHAFT ASSEMBLY AND KEY ARBOR FOR ROLLERS PY633 Fig 7 Reverse Idler Gear Removal or Installation GEAR REVERSE IDLER GEAR THRUST WASHERS C PY634 Fig 8 Mainshaf
9. Fig 71 2 Compress low and reverse servo piston spring by using engine valve spring compressor Tool 3422 then install snap ring 3 Position rear band in the case install short strut then connect long link and anchor to the band Fig 73 Screw in band adjuster just enough to hold strut in place Be sure long link and anchor assembly is installed as shown in Figure 72 to provide a run ning clearance for the low and reverse drum Install the low reverse drum Kickdown Servo 1 Carefully push servo piston into the case bore Install piston rod two springs and the guide Fig 70 The transmission used with Hi Performance en LOW AND REVERSE LINK ND14 Fig 72 Overrunning Clutch Low and Reverse Band Link gines use only one small inner spring in the kick down servo 2 Compress kickdown servo springs by using en gine valve spring compressor Tool 3422 then install snap ring Planetary Gear Assemblies Sun Gear and Driving Shell 1 While supporting assembly in the case insert output shaft through the rear support Carefully work assembly rearward engaging rear planetary carrier ADJUSTING SCREW AND LOCKNUT LINK AND ANCHOR Fig 73 Low Reverse Band and Linkage A lugs into the low reverse drum slots CAUTION Be very careful not to damage ground sur faces on output shaft during installation Front and Rear Clutch Assemblies The front and rear clutches
10. Fig 8 tilting it as required to clear cluster gears and finally entering the pilot rollers in the drive pinion gear If everything is in proper position the bearing re tainer will bottom to the case without force If not check to see if a strut pinion roller or stop ring is out of position Reverse Idler Gear 27 Place assembly arbor Tool C 464 into idler gear along with 22 greased rollers Fig 32 28 Position reverse idler thrust washers in case with grease to retain them 29 Now position reverse idler gear with arbor and CLUTCH GEAR SLEEVE STOP STRUT SPRINGS 2 N E n 2 2 CLUTCH GEAR amp POSITION LONG FQ FORWARD eae LUG STOP RING SNAP RING CLUTCH GEAR Fig 29 2nd 3rd Synchronizer Disassembled PY202 21 64 TRANSMISSION 3 SPEED MANUAL 1ST GEAR SYNCHRONIZER CLUTCH GEAR SLEEVE PRESS BED REVERSE GEAR PLATES mr lt STEP T PLACE CLUTCH GEAR AND CLUTCH SLEEVE ON STOP RING STRUTS Fig 31 Using Press to Install Mainshaft Bearing rollers in the case Fig 7 while installing idler shaft and key 30 Install extension housing and gasket now to hold mainshaft and bearing retainer in place Fig 33 First replace bushing and seal if necessary Extension Housing Bushing Replacement a Remove extension housing yoke seal Fig 34 with Tool C 3985 MARNE b Drive the bushing out of ho
11. Remove burrs from shafts before removal from housing to avoid scoring the bores which would cause leakage after reassembly 6 Push gearshift lever shafts through housing bores and remove Drive Pinion Retainer and Extension Housing 1 Remove bolts holding drive pinion bearing re tainer to front of transmission case 2 Slide retainer and gasket forward off the drive pinion Pry pinion oil seal from bearing retainer To avoid leakage around the new seal do not nick or scratch the bore in which the seal is pressed or the surface on which seal bottoms 3 Tap drive pinion forward carefully with a brass 21 58 TRANSMISSION 3 SPEED MANUAL SLEEVE IN SLEEVE IN 2 E NEUTRAL 2ND GEAR DRIVE PINION INSTALLED HERE THE LONG SHOULDER BOLT ACTS AS A COVER LOCATING DOWEL PY630 SHIFT FORKS Fig 4 A 230 With Shift Mechanism Assy Pinion Bearing Retainer and Extension Housing Removed drift as far as possible to provide maximum disas sembly clearance for mainshaft removal Fig 5 4 Rotate cut away part of second gear next to countershaft gear for mainshaft removal clearance Fig 6 5 Also shift 2nd 3rd synchronizer sleeve forward for the same reason 6 Remove bolt and retainer securing speedometer pinion adapter in extension housing Fig 2 Carefully work adapter and pinion out of extension housing 7 Remove bolts that attach extension housing to rear of transmission case
12. edge of the slot is against the carburetor lever pin Tighten transmission rod adjustment locking screw Note The slotted link and transmission lever must be held forward while the locking screw is being tight ened 6 To check transmission linkage freedom of oper ation move slotted link to the full rearward position then allow it to return slowly making sure it returns to the full forward position 7 Loosen carburetor cable clamp nut Adjust posi tion of cable housing ferrule in the clamp so that all slack is removed from cable with carburetor at curb idle To remove slack from cable move ferrule in the clamp in direction away from carburetor lever 8 Back off ferrule 1 4 This provides 1 4 free play Tighten cable clamp nut to 45 inch pounds 9 Connect choke rod or remove blocking fixture HYDRAULIC CONTROL PRESSURE TESTS Line Pressure and Front Servo Release Pressure Line pressure and front servo release pressure tests must be made in D drive position with rear wheels free to turn The transmission fluid must be at operat ing temperature 150 F to 200 F TRANSMISSION THROTTLE LOCK SCREW TORQUEFLITE TRANSMISSION 21 23 ROD ADJUSTMENT aS e CARBURETOR CABLE CLAMP NUT TRANSMISSION THROTTLE LEVER PY369 Fig 11 Throttle Rod Adjustment 1 Install an engine tachometer raise vehicle on a hoist and position tachometer so it can be read under the vehicle 2 Connect
13. extension housing and on the output shaft splines Align marks made at removal and connect propeller shaft to rear axle pinion shaft yoke EXTENSION HOUSING AND OUTPUT SHAFT BEARING Removal 1 Mark parts for reassembly then disconnect pro peller shaft at rear universal joint Carefully pull shaft assembly out of the extension housing 2 Remove speedometer pinion and adapter as ADAPTER LOCK RING MIE WV RR _ SEAL NP2 Fig 20 Installing Speedometer Pinion Seal TOOL NN361 Fig 21 Removing Extension Housing Yoke Seal ie gt NN125 Fig 22 Installing Extension Housing Yoke Seal sembly Fig 18 Drain approximately two quarts of fluid from the transmission 3 Remove bolts securing extension housing to the crossmember Raise transmission slightly with service jack Tool C 3203A then remove center crossmember and support assembly 4 Remove the extension housing to transmission bolts Console Shift Remove two bolts securing gearshift torque shaft lower bracket to the extension housing Swing bracket out of way for extension housing re moval IMPORTANT In removing or installing the extension housing step 5 the gearshift lever must in in 1 low position This positions the parking lock control rod rearward so it can be disengaged or engaged with the parking lock sprag 5 Remove two screws plate and gasket from bot tom of extens
14. rod to the valve body manual lever 5 Remove Back Up Light and Neutral Start Switch 6 Place a drain pan under transmission then re move the ten hex head valve body to transmission case bolts Hold valve body in position while removing the bolts 7 While lowering valve body out of transmission case disconnect parking lock rod from the lever To remove parking lock rod pull it forward out of the case If necessary rotate propeller shaft to align parking gear and sprag to permit knob on end of control rod to pass the sprag 8 Withdraw accumulator piston from transmis sion case Inspect piston for scoring and rings for wear or breakage Replace as required 9 If valve body manual lever shaft seal requires replacement drive it out of the case with a punch 10 Drive a new seal into the case with a 15 16 inch socket and hammer Fig 29 Servicing the valve body assembly is outlined under Recondition Sub Assemblies Installation 1 Make sure Back Up Light and Neutral Start Switch has been removed If parking lock rod was re 2 Iz m PARKING LOCK CONTROL ROD SNEUTRAL STARTING SWITCH NU452 Fig 28 Parking Lock Control Rod Retainer E Clip TORQUEFLITE TRANSMISSION 21 29 C NS 15 16 SOCKET Fig 29 Installing Valve Body Manual Lever Shaft Oil Seal moved insert it through the opening in rear of case with
15. 3 4 DRILL 7 16 HOLES 5 PLACES 5 8 LEFT SIDE BRACKET 2 1 4 5 8 IS MATERIAL STEEL 5 8 3 16 THICK 1 1 2 WIDE 12 NK 162 Fig 36 Repair Stand Bracket Dimensions TORQUEFLITE TRANSMISSION 21 33 d Fig 37 Transmission Installed in Repair Stand lock rod forward out of the case Rotate output Shaft if necessary to align parking gear and sprag to permit knob on end of control rod to pass the Sprag 1 Remove speedometer pinion and adapter as sembly 2 Remove extension housing to transmission bolts 3 Remove two screws plate and gasket from bot tom of extension housing mounting pad Spread large snap ring from output shaft bearing with Tool C 3301A Fig 23 With snap ring spread as far as pos sible carefully tap extension housing off the output shaft and bearing 4 Using heavy duty snap ring pliers C 4020 remove output shaft bearing rear snap ring Remove bearing from shaft then remove front snap ring Governor and Support 1 Carefully pry snap ring from weight end of governor valve shaft Fig 27 Slide valve and shaft assembly out of the governor body 2 Remove snap ring from behind governor body then slide governor body and support assembly off the output shaft Oil Pump and Reaction Shaft Support 1 Tighten front band adjusting screw until band is tight on the front clutch retainer This prevents clutch retainer from coming out with pump which m
16. 30 psi TO LUB 009 HIGH PRESS CONTROL SYSTEM IN 9C VALVE PUMP DRIVE DIRECT OIL FILTER Drive Direct Hydraulic Circuits A TORQUEFLITE TRANSMISSION 21 7 TORQUE CONVERTER OIL PRESSURES UNE 90 psi PUMP SUCTION 90 psi GOVERNOR 60 65 psi CONVERTER 30 75 psi Ez LUBRICATION 5 30 psi L l E CONTROL SYSTEM IN FO HIGH PRESS 1 Z DRIVE KICKDOWN 50 NR736A RELIEF VALVE Drive Kickdown Hydraulic Circuits 21 8 TRANSMISSION TORQUEFLITE LOW amp REV SERVO i RE IE Ta EN d 1 2 SHIFT a TELO OO COG mg TORQUE CONVERTER OIL PRESSURES LINE 55 psi PUMP SUCTION GOVERNOR 6 55 psi CONVERTER 30 75 psi LUBRICATION 5 30 psi CONTROL SYSTEM IN MANUAL SECOND CLOSED THROTTLE TO UB P 009 HIGH PRESS RELIEF VALVE PUMP NR737A Selector Lever Second Hydravlic Circuits TORQUEFLITE TRANSMISSION 21 9 KD 9 servo ss STRATES 22 H E i i oll H i 1 1 ACCUMULATOR gt 0000 ws NM ERI TORQUE CONVERTER FRONT CLUTCH LUB R 1 OIL PRESSURES r COOLER P H A UNE_ 55 8 ENSEM PUMP SUCTION T
17. 69 Washer 44 Bearing 57 Bolt 70 Shaft 45 Pinion Drive 58 Gasket 71 Key 46 Roller 59 Lever Interlock 72 Washer 47 Snap Ring 60 Lever 73 Plug Filler 48 Case 61 Fork 74 Gear Clutch 49 Plug Drain 62 Spring 75 Gear Clutch 50 Fork 63 Snap Ring 76 Key 51 Lever 64 77 Gasket Housing Washer Gear Countershaft LEGEND FOR FIGURE 3 Correction a Inspect and remove all linkage inter ferences b Adjust gearshift rods as outlined in Gearshift Linkage Adjustments Disassemble transmission and place parts as necessary re d Clutch housing bore or face out of d Refer to Clutch Group for correction Condition Possible Cause TRANSMISSION SLIPS a Linkage interference OUT OF GEAR I b Gearshift rods out of adjustment c Synchronizer clutch teeth worn alignment TRANSMISSION NOISES mainshaft procedure a Excessive end play in countershaft a Replace thrust washers gear b Loose synchronizer hub spline fit b Inspect mainshaft and synchronizer hub and replace parts as necessary Damaged broken or excessively worn Replace worn gears gear teeth d Rough or pitted bearing races or balls d Replace worn bearing SERVICE PROCEDURES TRANSMISSION REMOVAL 1 Remove shift rods from transmission levers 2 Drain fluid from transmission 3 Disconnect propeller shaft at rear universal joint Mark both parts to reassem
18. Adjust kickdown band d Perform hydraulic pressure tests and adjust to specifications e Remove and clean governor Replace parts if necessary f Perform pressure tests to determine cause and correct as required g Remove valve body assembly and per form air pressure tests Repair as re quired h Perform hydraulic pressure tests ad just or repair as required i Inspect servo for sticking broken seal rings binding linkage or faulty band lining Repair as required j Disassemble and inspect clutch Re pair or replace as required Inspect and replace seal rings as re quired also inspect respective bores for wear Replace parts as required Adjust throttle linkage b Adjust contro linkage c Adjust kickdown band d Perform hydraulic pressure tests and adjust to specifications Remove and clean governor Replace parts if necessary f Perform pressure tests to determine cause and correct as required g Remove valve body assembly and perform air pressure tests Repair as required h Inspect servo for sticking broken sea rings binding linkage or faulty band lining Repair as required i Disassemble transmission and repair overrunning clutch as required a Refill to correct level with Automatic Transmission Fluid AQ ATF Suffix A or Dexron b Inspect for air leakage into pump suction passages c Adjust throttle linkage d Adjust control lin
19. H Era r3 GOVERNOR 0 30 psi 6 00000 7 4 ys REGULATOR CONVERTER 30 75 psi 0000 iB ANON LUBRICATION 5 30 psi E d CONTROL SYSTEM IN MANUAL LOW z xg amy p He CLOSED THROTTLE PUMP iE gt BH Ol FILTER z aE GE dS XE Hi NR738A Selector Lever Low Hydraulic Circuits 21 10 TRANSMISSION TORQUEFLITE SS T RS KICKDOWN TORQUE CONVERTER OIL PRESSURES LINE 230 260 psi PUMP SUCTION CONVERTER 30 75 psi 555 LUBRICATION 5 30 psi 4 CONTROL SYSTEM IN TO LUB g 79 HIGH PRESS REVERSE od RELIEF VALVE PUMP SU E FILTER a NR739A Reverse Hydraulic Circuits A HYDRAULIC CONTROL SYSTEM The hydraulic control circuits on pages 3 through 10 show the position of the various valves with color coded passages to indicate those under hydraulic pressure for all operations of the transmission The hydraulic control system makes the transmis sion fully automatic and has four important functions to perform In a general way the components of any automatic control system may be grouped into the following basic groups The pressure supply system the pressure regulat ing valves the flow control valves and the clutches and band servos Taking each of these basic groups or systems in
20. free of the hub Remove tool retainer and springs 3 Invert clutch retainer assembly and bump on a wood block to remove piston Remove seals from pis ton and clutch retainer hub Inspection Inspect facing material on all driving discs Replace dises that are charred glazed or heavily pitted Discs should also be replaced if they show evidence of ma terial fiaking off or if the facing material can be scraped off easily Inspect driving disc splines for wear or other damage Inspect steel plate and pres sure plate surfaces for burning scoring or damaged driving lugs Replace if necessary Inspect steel plate lug grooves in clutch retainer for smooth surfaces plates must travel freely in the grooves Inspect band contacting surface on clutch retainer for scores Note ball check in clutch retainer make sure ball moves freely Inspect seal surfaces in clutch retainer for nicks or deep scratches light scratches will not interfere with sealing of neoprene rings Inspect clutch retainer bushing for wear or scores Fig 54 Removing or Installing Front Clutch Retainer Snap Ring A 727 21 42 TRANSMISSION TORQUEFLITE Inspect inside bore of piston for score marks if light remove with crocus cloth Inspect seal grooves for nicks and burrs Inspect neoprene seals for deteri oration wear and hardness and the piston springs retainer and snap ring for distortion Front Clutch Retainer Bushing Replacement 1 Lay clutch re
21. front band pump and reaction shaft support are more easily installed with transmission in an upright position If transmission repair stand DD 1014 was not avail able to support transmission an alternate method is outlined in Steps 1 and 2 1 Cut a 3 1 2 inch 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 the edge of the 3 1 2 inch hole so output shaft support will fit and lay flat in the hole 2 Carefully insert output shaft into the hole to support the transmission upright with its weight rest ing on flange of the output shaft support 3 Apply a coat of grease on the input to output shaft thrust washer Fig 65 and install the washer on front end of the output shaft 4 Align front clutch plate inner splines and place assembly in position on the rear clutch Make sure front clutch plate splines are fully engaged on the rear clutch splines 5 Align rear clutch plate inner splines grasp in put shaft and lower the two clutch assemblies into the transmission case 6 Carefully work clutch assemblies in a circular motion to engage rear clutch splines over splines of the front annulus gear Make sure front clutch drive lugs are fully engaged in slots in the driving shell Front Band Figure 74 shows disassembled view of the kick down band assembly 1 Slide the band over front clutch assembly 2 Install the band strut
22. gauge measure clearance between straight edge and face of the rotors Clearance limits are from 0015 to 003 inch Also with a feeler gauge measure rotor tip clearance between inner and outer rotor teeth Clearance limits are from 005 to 010 inch Clearance between outer rotor and its bore in oil pump body should be 004 to 008 inch Pump Bushing Replacement 1 Place pump housing on a clean smooth surface VENT BAFFLE SEAL RINGS U SHAFT SUPPORT INNER ROTOR THRUST WASHER SELECTIVE BOLTS 6 Fig 49 Oil Pump and Reaction Shaft Support A 727 21 40 TRANSMISSION TORQUEFLITE TOOL HANDLE SP 3549 REMOVAL REMOVING HEAD SP 3550 FRONT PUMP HOUSING BUSHING 2 et TOOL HANDLE SP 3549 INSTALLING HEAD SP 5118 INSTALLATION ND347B Fig 50 Replacing Pump Bushing A 727 with the rotor cavity down 2 Place removing head Tool SP 3550 in the bush ing and install handle Tool SP 3549 in the removing head Fig 50 3 Drive bushing straight down and out of the bore Be careful not to cock tool in the bore 4 Position a new bushing on the installing head Tool SP 5118 5 With pump housing on a smooth clean surface hub end down start bushing and installing head in the bushing bore Install handle Tool SP 3549 in the installing head Fig 50 6 Drive bushing into housing until tool bottoms in the pump cav
23. ing pump and reaction shaft support assembly from the transmission case 1 Screw seal remover Tool C 3861 into the seal Fig 32 Tighten screw portion of tool to withdraw the seal 2 To install a new seal place the seal in opening of the pump housing lip side facing inward Using Tool C 3860 drive the seal into housing until tool bottoms Fig 33 DISASSEMBLY SUB ASSEMBLY REMOVAL Prior to removing transmission sub assemblies plug all openings and thoroughly clean exterior of the unit preferably by steam Cleanliness through entire disas sembly and assembly cannot be over emphasized When disassembling each part should be washed in a suitable solvent then dried by compressed air De not wipe parts with shop towels All mating surfaces in the transmission are accurately machined therefore careful handling of parts must be exercised to avoid nicks or burrs Drive Train End Play Measuring drive train end play before disassembly will usually indicate when a thrust washer change between the reaction shaft support and front clutch retainer is required to properly adjust end play dur ing assembly except when major parts are replaced 1 Attach a dial indicator to transmission bell housing with its plunger seated against end of input shaft Fig 34 af cg ND183A Fig 32 Removing Pump Oil Seal Fig 33 Installing Pump Oil Seal 2 Move input shaft in and out to obtain end play rea
24. lock is applied by moving the selector lever past a gate to the P position CAUTION Never apply the parking lock until the vehicle has stopped otherwise a severe ratcheting noise will occur Car Speed To Axle Ratios Chrysler imperial 2 76 1 3 23 1 2 94 1 8 14 7 13 7 12 14 19 13 18 12 16 33 52 31 49 28 44 77 90 72 85 66 77 66 31 62 76 56 69 30 34 28 32 25 29 6 13 6 12 5 11 Starting Engine The engine will start with the selector lever in either the P park or N neutral positions 1 As a safety precaution when starting in the N neutral position apply the parking or foot brake 2 Depress the accelerator pedal one third of travel to insure proper choke operation 3 Turn the ignition key all the way to the right to START position When the engine starts release the key and it will return to the ON position The TorqueFlite transmission will not permit start ing the engine by pushing or towing Mountain Driving When driving in the mountains with either heavy loads or when pulling trailers the 2 second or 1 low position should be selected on upgrades which requires heavy throttle for 1 2 mile or more This reduces the possibility of overheating the transmis sion and converter under these conditions Towing Vehicle Transmission Inoperative Tow the vehicle with a rear end pickup or remove the propeller shaft Transmission Operating Properly The vehicle may be towed safely in N neutral with rear whe
25. mating area on extension housing are perfectly clean Dirt or sand will cause mis alignment resulting in speedometer pinion gear noise 4 Note number of gear teeth and install speed ometer pinion gear into adapter Fig 19 5 Rotate the speedometer pinion gear and adapter assembly so that the number on the adapter corres ponding to the number of teeth on the gear is in the 6 o clock position as the assembly is installed Fig 18 6 Install retainer and bolt with retainer tangs in adapter positioning slots Tap adapter firmly into the extension housing and tighten retainer bolt to 100 inch pounds EXTENSION HOUSING YOKE SEAL Replacement 1 Mark parts for reassembly then disconnect pro peller shaft at rear universal joint Carefully pull shaft ADAPTER 6 O CLOCK POSITION NN74A Fig 18 Speedometer Pinion and Adapter installed Retainer Removed for View pean RETAINER BOLT AND WASHER ADAPTER RING PINION SEAL RETAINER Fig 19 Speedometer Drive yoke out of transmission extension housing CAUTION Be careful not to scratch or nick ground surface on sliding spline yoke during removal and installation of the shaft assembly 2 Remove the extension housing yoke seal Fig 21 with Tool C 3985 3 To install a new seal position seal in opening of extension housing and drive it into housing with Tool C 3972 Fig 22 4 Carefully guide front universal joint yoke into
26. output shaft meshing planetary pinions with the sun gear teeth 7 With all components properly positioned install selective snap ring on front end of the output shaft Re measure end play of the assembly The clearance can be adjusted by the use of various thickness snap rings Snap rings are available in 048 052 055 059 and 062 066 inch thickness OVERRUNNING CLUTCH Inspection Inspect clutch roliers for smooth round surfaces they must be free of flat spots and chipped edges Inspect roller contacting surfaces in the cam and race for brinelling Inspect roller springs for distortion wear or other damage Inspect cam set screw for tightness If loose tighten and restake case around the screw Overrunning Clutch Cam Replacement If overrunning clutch cam and or roller spring re tainer are found damaged replace cam and spring FRONT ANNULUS GEAR ASSEMBLY SNAP RING SELECTIVE DRIVING THRUST WASHER FRONT PLANETARY GEAR SNAP RING ASSEMBLY THRUST WASHER THRUST WASHER NK144B s A OUTPUT SHAFT OUTPUT SHAFT SUPPORT NN129 Fig 66 Removing Overrunning Clutch Cam A 727 retainer in the following manner 1 Remove set screw from case below the clutch cam 2 Remove four bolts securing output shaft sup port to rear of the transmission case Insert a punch through the bolt holes and drive cam from the case Fig 66 Alternate the punch from one bolt hole to another
27. pilot bushing in fly wheel and on pinion bearing retainer pilot for clutch DRIVE PINION BEARING RETAINER an ee SEAL INSTALLING TOOL NU44 Fig 37 Installing Seal in Drive Pinion Bearing Retainer 21 66 TRANSMISSION 3 SPEED MANUAL SHIFT LEVER TYPICAL INTERLOCK LEVERS 1ST REVERSE SHIFT SHAFT SHIFT FORKS PIVOT PIN E CLIP INTERLOCK PIVOT INTERLOCK LEVER SPRING RING OIL SEAL 2ND 3RD SHIFT SHAFT PY648 Fig 38 Gearshift Mechanism and Housing Disassembled release sleeve Do not lubricate end of pinion shaft clutch disc splines or clutch release levers 1 With transmission on a suitable jack slide as sembly under vehicle 2 Raise transmission until drive pinion is centered in clutch housing 3 Roll transmission slowly forward until pinion shaft enters clutch disc Turn pinion shaft until splines are aligned then work transmission forward until seated against clutch housing Do not allow trans X LC TRANSMISSION EXT HOUSING ADAPTER 6 O CLOCK POSITION Fig 40 Speedometer Pinion and Adapter Installed in Extension Housing mission to hang after pinion shaft has entered the clutch disc 4 Install transmission to clutch housing bolts and tighten to 50 foot pounds 5 Using a pointed drift align crossmember bolt holes then install attaching bolts Tighten to 75 foot pounds Fig 39 6 Remove eng
28. ring from forward end of output shaft then slide front planetary assembly off the shaft 3 Slide front annulus gear off the planetary gear set Fig 65 Remove thrust washer from rear side of the planetary gear set 4 Slide sun gear driving shell and rear plane tary assembly off the output shaft SELECTIVE SNAP RING FEELER GAUGE ND3 Fig 63 Measuring Rear Clutch Plate Clearance 21 45 TORQUEFLITE TRANSMISSION 5 MWB SHAFT a FEELER GAUGE REAR ANNULUS GEAR REAR PLANETARY GEAR ASSEMBLY NK292 Fig 64 Measuring End Play of Planetary Gear Assemblies 5 Lift sun gear and driving shell off rear plane tary gear assembly Remove thrust washer from in side the driving shell Remove snap ring and steel washer from sun gear rear side of driving shell and slide sun gear out of the shell Remove front snap ring from the sun gear if necessary Note that front end of sun gear is longer than the rear 6 Remove thrust washer from forward side of rear planetary gear assembly remove planetary gear set and thrust plate from the rear annulus gear Inspection Inspect bearing surfaces on output shaft for nicks burrs scores or other damage Light scratches small nicks or burrs can be removed with crocus cloth or a fine stone Inspect speedometer drive gear for any nicks or burrs and remove with a sharp edge stone Make sure all oil passages in the shaft are open and c
29. should respond smoothly to changes in m p h and should return to 0 to 1 1 2 psi when the vehicle is stopped High pressure at stand still above 2 psi will prevent the transmission from downshifting PRESSURE oo COOLER RETURN TT GOVERNOR FITTING PRESSURE PRESSURE Fig 13 Pressure Test Locations Rear End of Case REAR SERVO APPLY Throttle Pressure No provisions are made to test the throttle pressure Incorrect throttle pressure should only be suspected if part throttle shift speeds are either very delayed or occur too early in relation to vehicle speeds In which case the throttle linkage should be adjusted before throttle pressure setting is adjusted HYDRAULIC CONTROL PRESSURE ADJUSTMENTS Line Pressure An incorrect throttle pressure setting will cause in correct line pressure readings even though line pres sure adjustment is correct Always inspect and cor rect throttle pressure adjustment before adjusting the line pressure Before adjusting line pressure measure distance between the manual valve valve in position and line pressure adjusting screw Fig 14 This measurement must be 1 7 8 inches correct by loosening spring retainer screws and repositioning the spring retainer The regulator valve may cock and hang up in its bore if spring retainer is out of posi tion If line pressure is not correct it will be necessary to remove valve body assembly to perfo
30. so cam will be driven evenly from the case IMPORTANT The output shaft support must be in the case to install the overrunning clutch cam If the support requires replacement drive it rear ward out of the case with a wood block and hammer To install screw two C 3288 pilot studs into the case Fig 67 Chill the support with ice preferably dry ice Quickly position support over the pilot studs and drive it firmly into the case with a wood block and hammer 3 Clean all burrs and chips from cam area in the case SHELL REAR PLANETARY GEAR THRUST WASHER ASSEMBLY STEEL REAR ANNULUS THRUST GEAR ASSEMBLY SNAP RING LOW AND REVERSE DRUM Fig 65 Planetary Gear Train and Output Shaft Disassembled A 727 OUTPUT SHAFT SUPPORT NN130 Fig 67 Installing Output Shaft Support A 727 4 Place spring retainer on the cam making sure retainer lugs snap firmly into notches on the cam 5 Position cam in the case with cam serrations aligned with those in the case Tap cam evenly into the case as far as possible with a soft mallet 6 Install Tool C 3863 and Adapter SP 5124 as shown in Figure 68 tighten nut on tool to seat cam into the case Make sure cam is firmly bottomed then install cam retaining set screw Stake case around set screw to prevent it coming loose 7 Remove cam installing tool Install and tighten support retaining screws to 150 inch pounds Stake case around the cam in twelve places
31. then remove wave spring spacer ring and clutch piston spring PISTON RETAINER INNER CLUTCH RETAINER INPUT SHAFT SEAL RINGS 2 PISTON SEAL SNAP RING OUTER THRUST WASHER PISTON SEAL TORQUEFLITE TRANSMISSION 21 43 FEELER GAUGE SELECTIVE SNAP RING ND2 Fig 59 Measuring Front Clutch Plate Clearance 3 Invert clutch piston retainer assembly and bump on a wood block to remove the piston Remove seals from the piston 4 If necessary remove snap ring and press input shaft from the clutch piston retainer Inspection Inspect facing material on all driving discs Replace discs that are charred glazed or heavily pitted Discs SNAP RING DRVNE UTR PRESSURE DISCS PISTON SPRING PLATE lt PRESSURE PLATE CLUTCH PLATES WAVE SPRING SPACER RING PISTON ND165A Fig 60 Rear Clutch Disassembled A 727 21 44 TRANSMISSION TORQUEFLITE should also be replaced if they show evidence of ma terial fiaking off or if facing material can be scraped off easily Inspect driving disc splines for wear or other damage Inspect steel plate and pressure plate surfaces for burning scoring or damaged driving lugs Replace if necessary Inspect steel plate lug grooves in clutch retainer for smooth surfaces plates must travel freely in grooves Note ball check in the piston make sure ball moves freely Inspect seal surfaces in clutch retainer for nicks o
32. to 35 inch pounds After valve body has been serviced and completely assembled adjust the throttle and line pressures See Hydraulic Control Pressure Adjustments However if pressures were satisfactory prior to disassembly use original settings ACCUMULATOR PISTON AND SPRING Inspection Inspect the two seal rings for wear and make sure they turn freely in piston grooves It is not necessary to remove rings unless condition warrants Inspect piston for nicks burrs scores and wear Inspect pis ton bore in the case for scores or other damage and piston spring for distortion Replace parts as required EXTENSION HOUSING BUSHING REPLACEMENT 1 Remove the extension housing yoke seal Fig 21 with Tool C 3985 2 Press or drive out bushing with Tool C 3974 Fig 48 3 Slide a new bushing on installing end of Tool C 3974 Align oil hole in bushing with oil slot in the housing then press or drive bushing into place Fig 48 4 Position a new seal in opening of extension housing and drive it into the housing with Tool C 3972 Fig 22 PARKING LOCK SPRAG Disassembly 1 Slide shaft out of extension housing to remove parking sprag and spring Fig 27 Remove snap ring and slide reaction plug and pin assembly out of the housing Inspection Inspect sprag shaft for scores and free movement in the housing and sprag Inspect sprag and control rod springs for distortion and tension Inspect square lug on the sp
33. two 0 100 psi pressure gauges Tool C 3292 to pressure take off points at side of accumu lator and at front servo release Fig 12 3 With control in D drive position speed up engine slightly until transmission shifts into direct Front servo release will be pressurized in direct Re duce engine speed slowly to 1 000 rpm Line pressure at this time 1 000 rpm must be 54 60 psi and front servo release pressure must not be more than 3 psi below line pressure 4 Disconnect throttle linkage from transmission throttle lever and move throttle lever gradually to full throttle position Line pressure must rise to a maximum of 90 96 psi just before or at kickdown into low gear Front servo release pressure must fol low line pressure up to the kickdown point and should not be more than 3 psi below line pressure If line pressure is not 54 60 psi at 1 000 rpm see Hydraulic Control Pressure Adjustments If front servo release pressures are less than pres sure specified and line pressures are within limits there is excessive leakage in front clutch and or front servo circuits Always inspect the external transmis sion throttle lever for looseness on the valve body shaft when making pressure tests Lubrication Pressures The lubrication pressure test should be made at same time that line pressure and front servo release pressures are tested 1 Install a tee fitting between cooler return line fitting and fitting hole in
34. with a blunt chisel Fig 69 KICKDOWN SERVO AND BAND Inspection Figure 70 shows disassembled view of the kick down servo assembly The large outer spring shown in Figure 70 is not used in transmissions with Hi Performance engines ADAPTER Fig 68 Installing Overrunning Clutch Cam A 727 21 47 tur TORQUEFLITE TRANSMISSION LEES Ames Fig 69 Overrunning Clutch Cam Staked A 727 Inspect piston and guide seal rings for wear and make sure they turn freely in the grooves It is not necessary to remove seal rings unless conditions war rant Inspect piston for nicks burrs scores and wear and piston bore in the case for scores or other dam age Inspect fit of guide on piston rod and piston spring for distortion Inspect band lining for wear and bond of lining to band and lining for black burn marks glazing non uniform wear pattern and flaking If lining is worn so grooves are not visible at ends or any portion of band replace the band Inspect band for distortion or cracked ends LOW REVERSE SERVO AND BAND Disassembly 1 Remove snap ring from piston plug and remove plug and spring from the piston Fig 71 Inspection Inspect seal for deterioration wear and hardness Inspect piston and piston plug for nicks burrs scores and wear piston plug must operate freely in the pis ton Inspect piston bore in the case for scores or other damage and springs for distortion Inspe
35. 33 9 15 x 15 T 25 26 27 30 33 H78 x 15 25 26 27 30 33 J78 x 15 25 26 27 30 33 _ G70 x 15 26 27 29 31 35 E60 x 15 29 34 37 37 41 43 F60 x 15 25 28 28 30 33 36 40 42 TORQUEFLITE TRANSMISSION TRANSMISSION MODEL A 121 B ELSE Automatic Three fix A or Dexron Std 19 pts Speed with Imp Meas Torque Converter 16 pts High Perf d arde pts mp Meas TORQUE CONVERTER Diameter Std 113 4 Ime pt High Perf 10 3 4 COOLING METHOD Water Heat OIL CAPACITY TRANSMISSION AND TORQUE CONVERTER LUBRICATION Pump Rotor Type Use Automatic Transmission U S CLUTCHES eos Fluid labeled Type AQ ATF Suf Measure Number of Front Clutch Plates 4 21 70 TIGHTENING REFERENCE BAND ADJUSTMENTS Kickdown Band Front Low Reverse Band Internal THRUST WASHERS Reaction Shaft Support to 2 Turns 2 Turns Number of Front Discs 4 Number of Rear Clutch Plates 3 Number of Rear Discs 4 GEAR RATIOS First 2 45 to 1 2 Second 1 45 to 1 D Third 422 7 DES 1101 R Reverse 2 20 to 1 PUMP CLEARANCES Outer Rotor to Case Bore Outer to Inner Tip 004 to 008 inch 005 to 010 inch End Clearance Rotors 0015 to 003 inch Planetary Assy End Play Drive Train End Play CLUTCH PLATE CLEARANCE
36. ALVE CONTROL SYSTEM IN NEUTRAL OIL FILTER ENGINE RUNNING NN35C Neutral Hydraulic Circuits 21 4 TRANSMISSION TORQUEFLITE 9 TORQUE CONVERTER OIL PRESSURES T SET PUMP SUCTION THROTTLE sess AD psi GOVERNOR 0 75 CONVERTER 030 75 psi 78S LUBRICATION 5 30 psi CONTROL SYSTEM IN DRIVE BREAKAWAY HALF THROTTLE TO LUB o oq HIGH PRESS RELIEF VALVE Olt FILTER S s NR733A Drive Breakaway Hydraulic Circuits A TOR QU EFLITE TRANSMISSION 8 HT em TORQUE CONVERTER TO LUB HIGH PRESS O OQ RELIEF VALVE PUMP MATE CHEN C NN i OIL FILTER 54 vo 6 Uu xd Drive Second Hydraulic Circuits 21 5 OIL PRESSURES 75 PUMP SUCTION THROTTLE 40 psi m GOVERNOR 6 75 psi CONVERTER 30 75 ps LUBRICATION 5 30 psi CONTROL SYSTEM IN DRIVE SECOND HALF THROTTLE NR734A 21 6 TRANSMISSION TORQUEFLITE 4 KD SERVO 5 G Qa Sans rR ee awama ome ees D x ACCUMULATOR CO O MN TORQUE CONVERTER OIL PRESSURES LINE 2s 55 0 psi PUMP SUCTION TRROTILE 890 psi GOVERNOR 6 90 psi CONVERTER 30 75 psi LUBRICATIQN 5
37. Adjust kickdown band b Adjust low reverse band c Remove extension housing and re place bearing and or bushing Condition BUZZING NOISE HARD TO FILL OIL FLOWS OUT FILLER TUBE OIL LEAKAGE TRANSMISSION OVERHEATS Possible Cause d Governor support binding or broken seal rings e Oil pump scored or binding f Front and or rear clutch faulty g Planetary gear sets broken or seized h Overrunning clutch worn broken seized a Low fluid level b Pump sucking air Valve body malfunction d Overrunning clutch inner race dam aged a High fluid level b Breather clogged c Oil filter clogged d Aerated fluid a Speedometer Adaptor b Speedometer Drive Pinion Seal c Oil Pan Gasket d Fluid Filler Tube e Fluid Lines and Fittings D Manual Control Lever g Pipe Plugs h Rear Extension Seal i Rear Bearing Access Plate j Extension Bolts k Extension Gasket D Kickdown Band Adjusting Screw Neutral Switch n Fluid Leakage in Converter Housing Area a Low fluid level b Kickdown band adjustment too tight c Low reverse band adjustment too tight d Faulty cooling system TORQUEFLITE TRANSMISSION 21 17 Correction d Inspect condition of governor sup port and repair as required Inspect condition of pump and re pair as required f Disassemble and inspect clutch Re pair or rep
38. EVER SHAFT AND SEAL 4 E CLIP MANUAL LEVER F ASSY NAT WE DETENT BALL THROTTLE LEVER STOP SCREW MANUAL VALVE SHUTTLE VALVE COVER PLATE Fig 44 Valve Body Controls Assembled View means for identification 15 Remove shift valve end plate Fig 46 and slide out the two springs and valves 16 Remove regulator valve end plate Slide regu lator valve line pressure plug sleeve and regulator valve throttle pressure plug out of valve body Cleaning and Inspection Allow ail parts to soak a few minutes in a suitable clean solvent Wash thoroughly and blow dry with compressed air Make sure all passages are clean and free from obstructions Inspect manual and throttle valve operating levers and shafts for being bent worn or loose If a lever is loose on its shaft it may be silver soldered only or the lever and shaft assembly should be replaced CAUTION Do not attempt to straighten bent levers Inspect all mating surfaces for burrs nicks and scratches Minor blemishes may be removed with cro cus cloth using only a very light pressure Using a straightedge inspect all mating surfaces for warpage or distortion Slight distortion may be corrected using a surface plate Make sure all metering holes in the steel plate are open Using a pen light inspect bores in the valve body for scores scratches pits and ir regularities Inspect all valve springs for
39. Front Clutch 383 amp 440 Cu in Engine 440 High Perf Engine Rear Clutch SNAP RINGS Front and Rear Clutches Rear Snap Ring Selective Output Shaft Forward End 010 to 037 inch 037 to 084 inch 024 to 125 inch 066 to 123 inch 025 to 045 inch 060 to 062 inch 074 to 076 inch 088 to 090 inch 048 to 052 inch 055 to 059 inch Front Clutch Retainer Selective cr Output Shaft to Input Shaft Driving Shell Thrust Plate Steel I Rear Planetary Gear to Driving Shell Front Planetary Gear to Annu lus Gear Support Front Annulus Gear to Driving Shell Front Clutch to Rear Clutch Rear Planetary Gear to Annulus Gear Backed off from 72 inch pounds 061 to 063 inch Green 084 to 086 inch Red 102 to 104 inch Yellow 062 to 064 inch 034 to 036 inch 062 to 064 inch 062 to 064 inch 062 to 064 inch 061 to 063 inch 034 to 036 inch 062 to 066 inch TIGHTENING Foot Pounds Manual A 230 3 Speed Back Up Light Switch 15 Extension Housing Bolts 50 Drive Pinion Bearing Retainer Bolts 30 Pounds Foot Inch Torqueflite A 727 B Cooler Line Fitting 110 Cooler Line Nut 85 Converter Drain Plug 110 Converter Drive Plate to Crankshaft
40. GROUP 21 TRANSMISSIONS CONTENTS Page Page MANUAL TRANSMISSIONS 3 SPEED 54 TIGHTENING REFERENCE SPECIFICATIONS 69 TORQUEFLITE TRANSMISSIONS 1 TORQUEFLITE TRANSMISSION A 727 B INDEX Page Page General Information 1 Disassembly Sub Assembly Removal 32 Hydraulic Control System il Installation Transmission Converter and Operating Instructions 12 Drive Plate irren emere e as 50 Service Diagnosis 12 Fluid Leakage 52 Service in Vehicle 18 Recondition Sub Assemblies 34 Air Pressure Tests 25 Accumulator Piston and Spring 38 Aluminum Thread Repair 18 Extension Housing Bushing Replacement 38 Band Adjustments 22 Front Clutch 41 Console Gearshift 20 Governor and Support 38 Extension Housing and Output Shaft Bearing 26 Kickdown Servo and Band 47 Extension Housing Yoke 5 26 Low Reverse Servo and Band 47 Gearshift Linkage Adjustment 19 Oil Pump and Reaction Shaft Support 39 GoverniOF sean e POR Ree s eb Ea gu 27 Overrunning Clutch
41. L TRANSMISSION m dis ME 21 65 EU NN125 Fig 36 Installing Extension Housing Seal the pivot pin with the spring hangers offset toward each other so the spring will install in a straight line and secure with clip on Pivot pin 34 Grease and install new O ring oil seals on both shift shafts Grease housing bores and push each shaft into its proper bore 35 With pliers install the spring on interlock lever hangers 36 Rotate each shift shaft fork bore to neutral position straight up and install shift forks through bores and under both interlock levers Install Gearshift Mechanism 37 Position the 2nd 3rd Synchronizer sleeve in transmission to rear in 2nd gear Position the ist reverse synchronizer sleeve to middle of travel in neutral Fig 4 Place the shift forks in the gearshift mechanism in the same positions 38 Install gasket and gearshift mechanism on transmission using special shoulder bolts One bolt has an extra long shoulder which enters the transmission case acting as a locating dowel pin This hole is at center rear of case Fig 4 Tighten bolts evenly to 15 foot pounds 39 Install speedometer drive pinion gear and adap ter being sure range number stamped on outside of adapter representing number of teeth on gear is in 6 O clock position Fig 40 TRANSMISSION INSTALLATION Place a small amount of Multi Purpose lubricant around inner end of pinion shaft
42. RING vmm 5 0 KNOB A ea SET SCREW lt CABLE END SHIFT LEVER MOUNTING LEGS 2 NN177B Fig 6 Console Gearshift Unit om ATE Fig 7 Removing or Installing Console BACK UP LIGHT AND NEUTRAL STARTING SWITCH Fig 9 and 10 Replacement and Test The Neutral Starting Switch is the center terminal of the 3 terminal switch It provides ground for the starter solenoid circuit through the selector lever STEERING COLUMN COLUMN LOCK TORQUE SHAFT ASSEMBLY COLUMN FEE Pe COLUMN LOCK REAR ROD ROD v ASSEMBLIES LOWER ROD TORQUEFLITE TRANSMISSION 21 21 CONTACT WIRING CONNECTOR SWITCH Fig 9 Neutral Park Starting Switch and Back Up Light Switch cam in only Park and Neutral positions 1 To test switch remove wiring connector from switch and test for continuity between center pin of switch and transmission case Continuity should exist only when transmission is in Park or Neutral 2 Check gearshift linkage adjustment before re placing a switch which tests bad 3 Unscrew switch from transmission case allowing fluid to drain into a container Move selector lever to Park and then to Neutral positions and inspect to see that the switch operating lever fingers are centered in switch opening in the case 4 Serew switch and new seal into transmission case and tighten to 24 foot pounds Retest switch wi
43. Seal 67 Transmission Installation 65 Gearshift Linkage Adjustment 67 Transmission 57 Speedometer Pinion Gear 67 Specifications 69 Service Out of Vehicle Tightening Reference 70 Assembling Transmission 62 A GENERAL INFORMATION The A 230 three speed transmission Fig 1 has two synchronizer units providing clash free shifting in all forward gears A pad has been provided on the right side of the transmission Fig 2 for identification numbers Sample Number PP 230 3262 2220 The first two letters identify the manufacturing plant The next three numbers are the transmission model number The following four numbers are a date of manufacture code The last four numbers are a sequence number The main drive pinion input shaft is supported by a ball bearing in the transmission case and an olite bushing pressed in the end of the crankshaft The mainshaft output shaft front end is supported by roller bearings in the end of the main drive pinion and a ball bearing retainer in the front of the exten sion housing The output end of the mainshaft is splined to the sliding universal joint yoke which is supported by a bushing in the extension housing The countershaft gear is supported by a double row of needle type roller bearings at each end a
44. Size No Length Size No No No 10 24 1185 3 285 13 64 203 3 CPB 528 3N 1227 6 1 4 20 1185 4 3 8 17 64 265 4 528 4N 1227 6 5 16 18 1185 5 15 32 Q 332 5 CPB 528 5N 1227 6 3 8 16 1185 6 9 16 X 397 6 CPB 528 6N 1227 6 7 16 14 1185 7 21 32 29 32 453 7 CPB 528 7N 1227 16 hole back to its original thread size The chart lists the threaded hole sizes which are used in the aluminum case and valve body and the necessary tools and inserts for the repair of damaged or worn threads Heli Coil tools and inserts are read ily available from most automotive parts jobbers Some thread drag may occur in screwing a bolt into the installed Heli Coil insert Therefore a torque reading should be taken of the thread drag with an inch pound torque wrench and added to the specified bolt torque so that all bolts securing a particular part will be tightened to the same torque LUBRICATION The transmission fluid and filter should provide satisfactory lubrication and protection to the auto matic transmission and no change is recommended in vehicles used in normal service Regularly scheduled fluid and filler changes therefore will not be re quired except when the operation of the vehicle is classified as severe If for any reason the factory fill fluid is replaced with another fluid the fluid must be changed every three years or 36 000 miles in normal service Fluid Level Inspect fluid level every si
45. This can best be determined by slowly turn ing outer race by hand Measure fit of bearings on their respective shafts THRUST FLANGE BETWEEN 157 AND 2ND GEARS CLUTCH GEAR SPLINES AND SNAP RING GROOVES STOP RING 1ST GEAR PY656 Fig 23 1st Gear and Stop Ring Removal Installation 21 62 TRANSMISSION 3 SPEED MANUAL Needle Type Bearing Rollers and Spacers Inspect all bearing rollers for flat spots or brinel ling Inspect all bearing roller spacers for signs of wear or galling Install new parts as required Gears Inspect gear splines on synchronizer clutch gears and stop rings If there is evidence of chipping or ex cessively worn teeth install new parts at reassembly Be sure clutch sleeve slides easily on the clutch gear Inspect countershaft gear and all gear teeth for chipped or broken teeth or showing signs of excessive wear Small nicks or burrs must be stoned off Inspect teeth on main drive pinion If excessively worn broken or chipped a new pinion should be in Stalled If the oil seal contact area on drive pinion shaft is pitted rusted or scratched a new pinion is recommended for best seal life Synchronizer Stop Rings Inspect stop rings for cracks and wear If rings are cracked or show signs of extreme wear on threaded bore install new rings at reassembly Test new rings for good fit on gear cones with minimum wobble Mainshaft Inspect mainshaft gear and bearing mating sur faces If gear
46. actly as shown Make sure all bolt holes are aligned then tighten stiffener plate screws to 28 inch pounds REGULATOR VALVE THROTTLE PRESSURE PLUG SLEEVE rt REGULATOR VALVE LINE PRESSURE REGULATOR PLUG VALVE END PLATE 1 2 SHIFT VALVE SHIFT VALVE END PLATE 2 3 SHIFT VALVE Fig 46 Valve Body Shift Valve Side Disassembled 2 Place 1 2 and 2 3 shift valve governor plugs in their respective bores Fig 45 Install shuttle valve spring and shuttle valve throttle plug Install governor plug end plate and tighten the five retaining screws to 28 inch pounds 3 Install E clip on end of the shuttle valve Fig 44 Install shuttle valve cover plate and tighten the four retaining screws to 28 inch pounds 4 Install 1 2 and 2 3 shift valves and springs Fig 46 Install shift vaive end plate and tighten the three retaining screws to 28 inch pounds 5 Install regulator valve throttle pressure plug sleeve and the line pressure plug Fig 46 Install regulator valve end plate and tighten the two retain ing screws to 28 inch pounds 6 Install throttle valve and spring Fig 45 Slide kickdown detent on the kickdown valve counterbore side of detent toward valve then install assembly in the valve body 7 Install throttie lever stop screw Fig 45 and tighten lock nut finger tight 8 Install manual valve in the valve body Fig 45 9 Install throttle lever and shaft on the va
47. aft for binding in the case by moving lever through all detent positions If binding exists loosen valve body bolts and re align 7 Install flat washer and throttle lever then tighten lever clamp bolt 8 Adjust the kickdown and low reverse bands 9 Install oil pan using a new gasket Tighten pan bolts to 150 inch pounds TRANSMISSION CONVERTER AND DRIVE PLATE INSTALLATION The transmission and converter must be installed as an assembly otherwise the converter drive plate pump bushing and oil seal will be damaged The drive plate will not support a load therefore none of the weight of the transmission should be allowed to rest on the plate during installation 1 Rotate pump rotors with Tool C 3881 until the two small holes in handle of Tool are vertical Fig 77 2 Carefuily slide converter assembly over the in put shaft and reaction shaft Make sure converter im peller shaft slots are also vertical and fully engage the pump inner rotor 1125 Inspect for full engagement by placing a straight edge on face of the case Fig 78 The surface of 9 TOOL HOLES VERTICAL Fig 77 Aligning Pomp Rotors Fig 78 Measuring Converter for Full Engagement in Transmission converter front cover lug should be at least 1 2 inch rear of straightedge when converter is pushed all way into the transmission 3 Attach a small clamp to edge of converter housing to hold converter in place during tra
48. ansmission to more than 10 psi If a leak source is located that part and all associ ated seals and gaskets should be replaced with new parts 3 8 DRILL 2 HOLES WELD OR BRAZE 1 4 ROD 1 4 ROD 4 21 32 RADIUS 5 RADIUS MATERIAL 3 16 STEEL STOCK PY307 Fig 8 A 727 Vent Plug Retainer Fabricate equipment needed for test as shown in Figs 1 6 7 amp 8 TORQUE CONVERTER PRESSURE TEST If fluid leakage has occurred in the bell housing area the torque converter can be leak checked as fol lows after removal from the transmission 1 Drain all oil from the converter If flushing is required flush before checking for leakage 2 Install tool C 4102 and tighten 3 Apply a maximum of 100 psi air pressure to the converter 4 Submerge the converter in a tank of water and observe the hub cup ring gear and seam welds for bubbles Five to ten minutes may be required for bubbles to develop from small leaks If no bubbles are observed it can be assumed that the welds are not leaking If leakage occurs the con verter be replaced MANUAL TRANSMISSION A 230 THREE SPEED INDEX Page Page General Information 55 Cleaning and Inspection 61 Service Diagnosis 55 Disassembling Transmission 57 Service in Vehicle Extension Housing Bushing Replacement 64 Extension Housing Yoke
49. ately five turns Fig 10 Inspect adjust ing screw for free turning in the lever 3 Using wrench Tool C 3380 with adapter C 3705 tighten band adjusting screw to 47 to 50 inch pounds A If adapter C 3705 is not used tighten adjusting screw to 72 inch pounds 4 Back off adjusting screw 2 turns Hold adjust ing screw in this position and tighten lock nut to 35 foot pounds 5 Reinstall oil pan using a new gasket Tighten oil pan bolts to 150 inch pounds 6 Fill transmission with Automatic Transmission Fluid AQ ATF Suffix A Dexron THOTTLE ROD ADJUSTMENT Fig 11 With engine at operating temperature and carbu retor off fast idle cam adjust idle speed of engine using a tachometer Refer to Fuel System Group 14 for idle speed Specifications and carburetor link age adjustment 1 Follow detailed instructions in Lubrication Sec tion for linkage lubrication of all models 2 Disconnect choke at carburetor or block choke valve in full open position Open throttle slightly to release fast idie cam then return carburetor to curb idle 8 Loosen the transmission throttle rod adjustment lock screw 4 Hold the transmission lever forward against its stop while adjusting the transmission linkage On engines with solenoid idle stops the solenoid plunger must also be in its fully extended position 5 Adjust the transmission rod by pulling forward on the slotted link with a slight effort so that the rear
50. ble in same position Carefully pull shaft yoke out of transmission exten sion housing CAUTION careful not to scratch or nick ground surface on sliding spline yoke during removal and installation of the shaft assembly 4 Disconnect speedometer cable and back up light switch leads 5 Some models have exhaust systems which will have to be partially removed for clearance See Ex haust Systems Section 11 6 Install engine support fixture C 3487A engaging the hooks in holes in frame side member Be sure support ends are up against underside of oil pan flange 7 Raise engine slightly with support fixture Dis connect extension housing from removable center crossmember 8 Support transmission with a suitable jack and remove center crossmember 9 Remove transmission to clutch housing bolts Slide transmission toward rear until drive pinion shaft clears clutch disc before lowering transmission 10 Lower transmission and remove from under vehicle Thoroughly clean exterior of unit DISASSEMBLING TRANSMISSION Fig 3 Gearshift Housing and Mechanism 1 Shift transmission to second gear for shift fork clearance 2 Remove housing retaining bolts and lift shift mechanism from case Fig 4 3 If shaft ring seals need replacement ceed as follows Pull shift forks out of shafts 4 Remove nuts attaching operating levers to the shafts Disengage levers from flats on shafts and re move 5
51. careful to place as nearly as possible same amount of weld material in exactly same location as was used in the original weld This is necessary in order to maintain proper balance of the unit Place welds alternately on opposite sides of converter to minimize distortion 3 The following suggestions are offered as an aid in making the weld TORQUEFLITE TRANSMISSION 21 31 a Do not gas weld b Use a D C welder that is set at straight polarity or an A C welder if proper electrode is available c Use a 1 8 inch diameter welding rod and a weld ing current of 80 to 125 amps d Direct the arc at intersection of gear and front cover from an angle of 45 degrees from rear face of the gear 4 Inspect gear teeth and remove all nicks where metal is raised weld metal splatter etc in order to ensure quiet starter operation TORQUE CONVERTER FLUSHING When a transmission failure has contaminated the fluid the torque converter should be flushed to insure that metal particles or sludged oil are not later trans ferred back into the reconditioned transmission HAND FLUSHING 1 Place converter in horizontal position and pour two quarts of new clean solvent or kerosene into con verter through the impeller hub 2 Turn and shake converter so as to swirl solvent through the internal parts Turn the turbine and stator with transmission input and reaction shafts to dis lodge foreign material 3 Position converter in its no
52. cloth is permissible where neces sary providing it is ay carefully When used on Fig 39 Compressing Kickdown Servo Spring 7 8 DIA NN79 Fig 40 Rework Valve Body Repair Stand valves use extreme care to avoid rounding off the sharp edges The sharp edge is vitally important to this type valve Sharp edges prevent dirt and foreign matter from getting between the valve and body thus reducing possibility of sticking When it becomes necessary to recondition the transmission and vehicle has accumulated considerable mileage install new seal rings on parts requiring their usage Coat each part with Automatic Transmission Fluid AQ ATF Suffix A Dexron during assembly VALVE BODY ASSEMBLY CAUTION Never clamp any portion of valve body or transfer plate in a vise Any slight distortion of the aluminum body or transfer plate will result in stick ing valves excessive leakage or both When removing or installing valve or plugs slide them in or out care fully Do not use force Rework valve body repair stand Tool C 3749 by drilling the 5 16 inch diameter hole to 7 8 and 3 4 TRANSFER PLATE TORQUEFLITE TRANSMISSION 21 35 SPRING RETAINER _ a A Na FLUID FILTER 7 I pue SCREWS 3 REGULATOR no VALVE SPRING KICKDOWN VALVE o CONTROL b VALVE SPRING THROTTLE PRESSURE ay ESR 2 LEVER AND
53. contact surfaces show signs of galling or are excessively worn a new mainshaft should be in stalled Inspect snap ring grooves for burred edges If rough or burred remove condition using a fine file or crocus cloth Inspect synchronizer clutch gear splines on shaft for burrs ASSEMBLING TRANSMISSION Countershaft Gear 1 Slide assembly arbor Tool C 4112 into counter shaft gear 2 Slide one roller thrust washer over arbor and into gear followed by 22 Greased Rollers Fig 24 3 Repeat Step 2 adding one roller thrust washer on end 4 Repeat Steps 2 and 3 at other end of counter shaft gear Total of 88 Rollers and 6 thrust washers 5 Place greased front thrust washer on arbor against gear with tangs forward 6 Coat rear thrust washer with heavy grease and Stick it in place in the transmission case with tangs rearward 7 Carefully place countershaft gear assembly in position in bottom of transmission case Fig 13 Do not finish installation with countershaft and key until drive pinion is installed Pinion Gear 8 Press new bearing on pinion with snap ring COUNTERSHAFT GEAR ROLLER E THRUST WASHER M und THRUST WASHER PY649 Fig 24 Countershaft Gear Roller Bearing Assembly groove forward Install snap ring on shaft Fig 12 9 Install 15 rollers and retaining ring in gear Fig 25 10 Install drive pinion and bearing assembly into case Fig 11 11 Now fi
54. ct band lining for wear and bond of lining to the band If SEAL RING SPRING PISTON ROD SEAL RINGS 2 SPRING PISTON ROD GUIDE PISTON ND168A Fig 70 Kickdown Servo 21 48 TRANSMISSION TORQUEFLITE SEAL RING PISTON l PLUG i y D Jan OCU ae SPRING SPRING ON SNAP RING SNAP RING NP 147 Fig 71 Low and Reverse Servo lining is worn so grooves are not visible at ends or any portion of band replace the band Inspect band for distortion or cracked ends Assembly 1 Install piston plug and spring in the piston and secure with snap ring ASSEMBLY SUB ASSEMBLY INSTALLATION The assembly procedures given here include instal lation of sub assemblies in the transmission case and adjusting drive train end play Do not use force to assemble mating parts If parts do not assemble free ly investigate cause and correct the trouble before proceeding with assembly procedures Always use new gaskets during assembly operations IMPORTANT Use only Automatic Transmission Fluid AQ ATF Suffix A Dexron to lubricate transmission paris during assembly Overrunning Clutch 1 With transmission case in an upright position insert clutch hub inside the cam Install overrunning clutch rollers and springs exactly as shown in Figure 72 Low Reverse Servo and Band 1 Carefully work servo piston assembly into the case with a twisting motion Place spring retainer and snap ring over the piston
55. ding 3 Record the indicator reading for reference when reassembling the transmission The end play specifications are 037 to 084 inch Oil Pan 1 Place transmission assembly in repair stand Tool C 3750 with adapter C 3882 Fig 35 If repair stand DD 1014 is available fabricate two attaching brackets Fig 36 and install transmission in the stand Fig 37 file out the 7 16 inch holes if necessary to obtain bracket alignment This stand provides easier disassembly and assembly as trans mission can be rotated as desired 2 Unscrew oil pan bolts and remove the pan and gasket Valve Body Assembly 1 Loosen clamp bolts and remove throttle and gearshift levers from the transmission 2 Remove Back Up Light and Neutral Start Switch amis TRANSMISSION yi VENT SHIELD TOOL Fig 34 Measuring Drive Train End Play ADAPTER TOOL REPAIR STAND ND174 Fig 35 Transmission Installed in Repair Stand 3 Remove the ten hex head valve body to trans mission bolts Remove E clip securing parking lock rod to valve body manual lever Fig 28 4 While lifting valve body out of transmission case disconnect parking lock rod from the lever Accumulator Piston and Spring 1 Lift spring off accumulator piston and withdraw piston from the case Extension Housing and Output Shaft Bearing Before removing extension housing pull parking RIGHT SIDE BRACKET 2
56. distortion and collapsed coils Inspect all valves and plugs for burrs nicks and scores Small nicks and scores may be removed with crocus cloth providing extreme care is taken not to round off sharp edges The sharpness of these edges is vitally important because it prevents foreign matter from lodging between the valve and valve body thus reducing possibility of sticking Inspect all valves and plugs for freedom of operation in valve body bores When bores valves and plugs are clean and dry the SHUTTLE VALVE E CLIP 2 3 SHIFT VALVE GOVERNOR PLUG SHUTTLE VALVE SHUTTLE VALVE THROTTLE PLUG GOVERNOR PLUG END PLATE 1 2 SHIFT VALVE GOVERNOR PLUG TORQUEFLITE TRANSMISSION 21 37 TORQUE CONVERTER CONTROL VALVE THROTTLE VALVE REGULATOR VALVE SPRING RETAINER LINE PRESSURE ADJUSTING SCREW ASSY MANUAL VALVE KICKDOWN VALVE 4 KICKDOWN DETENT THROTTLE LEVER STOP SCREW ASSY Fig 45 Valve Body Lever Side Disassembled valve and plugs should fall freely in the bores The valve bores do not change dimensionally with use Therefore a valve body that was functioning properly when vehicle was new will operate correctly if it is properly and thoroughly cleaned There is no need to replace the valve body unless it is damaged in handling Assembly 1 Place separator plate on the transfer plate Fig 42 Install stiffener plate and retaining screws ex
57. ect the governor weight spring for distortion Inspect the lugs on parking gear for broken edges or other damage Thoroughly clean all governor parts in clean solvent and inspect for free movement before assembly Assembly 1 If the support was separated from governor body assemble and tighten the bolts finger tight 2 Assemble governor weights and spring and secure with snap ring inside of large governor weight Place weight assembly in governor body and install snap ring OIL SEAL OIL PUMP BODY ND22A GASKET OUTER ROTOR TORQUEFLITE TRANSMISSION 21 39 01 PUMP AND REACTION SHAFT SUPPORT Disassembly Figure 49 shows the oil pump and reaction shaft support disassembled 1 Remove bolts from rear side of reaction shaft support remove vent baffle and lift the support off the pump 2 Remove rubber seal ring from pump body flange 3 Drive out the oil seal with a blunt punch Inspection Inspect interlocking seal rings Fig 49 on reaction shaft support for wear or broken locks make sure they turn freely in the grooves Do not remove rings unless conditions warrant Inspect pump body and re action shaft support bushings for wear or scores In spect machined surfaces on pump body and reaction shaft support for nicks and burrs Inspect pump rotors for scoring or pitting With rotors cleaned and installed in the pump body place a straightedge across face of rotors and pump body Using a feeler
58. els on the ground at a speed not to exceed 30 mph If the vehicle is to be towed for extended distances it should be done with a rear end pickup or the propeller shaft removed Because the transmission receives lubrica tion only when the engine is running it is good prac tice to always tow a disabled vehicle with a rear end pickup or remove the propeller shaft SERVICE DIAGNOSIS The transmission should not be removed nor disassembled until a careful diagnosis is made the definite cause determined and all possible external corrections performed In diagnosing any abnormal shift condition always make the hydraulic pressure tests before disassembly or replacement of parts Cendition HARSH ENGAGEMENT IN D 1 2ANDR b Hydraulic pressures too high or low Possible Cause a Engine idle speed too high Correction a Adjust engine idle speed to specifica tions Re adjust throttle linkage b Inspect fluid level then perform hy draulic pressure tests and adjust to specifications Condition DELAYED ENGAGEMENT IN D 1 2 ANDR RUNAWAY OR HARSH UPSHIFT AND 3 2 KICKDOWN Possible Cause c Low reverse band out of adjustment d Valve body malfunction or leakage e Accumulator sticking broken rings or spring f Low reverse servo band or linkage malfunction g Worn or faulty front and or rear clutch a Low fluid level b Incorrect gearshift control linkage adjustment c Hydraulic pr
59. en stop screw lock nut securely AIR PRESSURE TESTS A NO DRIVE condition might exist even with TOOL KICKDOWN VALVE LOCK NUT THROTTLE LEVER STOP SCREW NN73A Fig 16 Throttle Pressure Adjustment TORQUEFLITE TRANSMISSION 21 25 correct fluid pressure because of inoperative clutches or bands The inoperative units clutches bands and servos can be located through a series of tests by substituting air pressure for fluid pressure Fig 17 The front and rear clutches kickdown servo and low reverse servo may be tested by applying air pres sure to their respective passage after valve body as sembly has been removed To make air pressure tests proceed as follows CAUTION Compressed air supply must be free of all dirt or moisture Use a pressure of 30 to 100 psi Front Clutch Apply air pressure to front clutch apply passage and listen for a dull thud which indicates that rear clutch is operating Hold air pressure on for a few seconds and inspect system for excessive oil leaks Rear Clutch Apply air pressure to rear clutch apply passage and listen for a dull thud which indicates that rear clutch is operating Also check for excessive oil leaks If a dull thud cannot be heard in clutches place finger tips on clutch housing and again apply air pressure Movement of piston can be felt as clutch is applied Kickdown Servo Direct air pressure into front servo ap
60. er stamped on left side of the transmission pan flange The A 727 B transmission Fig 1 combines a torque converter and a fully automatic 3 speed gear system The converter housing and transmission case are an integral aluminum casting The transmission consists of two multiple disc clutches an overrun ning clutch two servos and bands and two planetary gear sets to provide three forward ratios and a re verse 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 drilled 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 con verter is accomplished by circulating the transmission fluid through an oil to water type cooler located in the radiator lower tank The torque converter assem bly is a sealed unit which cannot be disassembled The transmission fluid is filtered by an internal Dacron Type filter attached to the lower side of the valve body assembly Engine torque is transmitted to the torque con verter then through the input shaft to the multiple disc clutches in the transmission The power flow de pends on the applica
61. erter housing bolts and tighten to 28 foot pounds 8 Install two lower drive plate to converter bolts and tighten to 270 inch pounds 9 Install starting mtotor and connect battery ground cable 10 Rotate engine with Remote Control Switch and install the other two drive plate to converter bolts Tighten bolts to 270 inch pounds 11 Install crossmember and tighten attaching bolts to 75 foot pounds Imperial Models Position center crossmember in the stub frame Start all retaining bolts including the four rubber isolator bolts then tighten all bolts to 75 foot pounds 12 Lower transmission so extension housing is aligned and rests on rear mount Install bolts and tighten to 40 foot pounds Fig 80 Engine mount to center crossmember bolt and nut loose assembled to this point should now be torqued to 50 foot pounds 13 Install gearshift torque shaft and connect gearshift rod to the transmission lever Console Shift Align gearshift torque shaft lower bracket with the extension housing Install the two retaining bolts and tighten securely Connect gear shift rod to the transmission lever 14 Carefully guide sliding yoke into extension housing and on the output shaft splines Align marks made at removal then connect propeller shaft to the rear axle pinion shaft yoke 15 Connect oil cooler lines to the transmission Install the oil filler tube Connect the speedometer cable 16 Connect throttle rod to bellcrank at
62. essures too high or low d Oil filter clogged e Valve body malfunction or leakage f Accumulator sticking broken rings or spring g Clutches or servos sticking or not operating h Faulty oil pump i Worn or faulty front and or rear clutch Worn or broken input shaft and or reaction shaft support seal rings k Aerated fluid a Low fluid level b incorrect throttle linkage adjustment c Hydraulic pressures too high or low d Kickdown band out of adjustment e Valve body malfunction or leakage f Governor malfunction g Accumulator sticking broken rings or spring h Clutches or servos sticking or not operating band or i Kickdown servo linkage malfunction D Worn or faulty front clutch Worn or broken input shaft and or reaction shaft support seal rings TORQUEFLITE TRANSMISSION 21 13 Correction c Adjust low reverse band d Perform pressure tests to determine cause and correct as required e Inspect accumulator for sticking broken rings or spring Repair as required f Inspect servo for damaged seals bind ing linkage of faulty band lining Re pair as required g Disassemble and inspect clutch Re pair or replace as required a Refill to correct level with Automatic Transmission Fluid AQ ATF Suffix A or Dexron b Adjust control linkage c Perform hydraulic pressure tests and adjust to specifications d Replace o
63. f extension housing mounting pad 5 Install speedometer pinion and adapter as sembly IMPORTANT Measure drive train end play as described under Disassembly Sub Assembly Re moval Correct if necessary Valve Body Assembly and Accumulator Piston 1 Clean mating surfaces and inspect for burrs on both the transmission case and valve body steel plate 2 Install accumulator piston in transmission case and place piston spring on the accumulator piston Fig 76 Make sure Back Up Light and Neutral Start Switch has been removed 3 Insert parking lock rod through opening in rear of case with knob positioned against the reaction plug and sprag Move front end of rod toward cen ter of transmission while exerting rearward pressure on rod to force it past the sprag rotate output shaft if necessary 4 Place valve body manual lever in LOW position Place valve body in its approximate position in the case connect parking lock rod to the manual lever and secure with the E clip Align valve body in the case install retaining bolts finger tight 5 With neutral starting switch installed place manual valve in the neutral position Shift valve body if necessary to center the neutral finger over the neu tral switch plunger Snug bolts down evenly then tighten to 100 inch pounds PISTON tS QUUM SEAL RINGS NR16 Fig 76 Accumulator Piston and Spring 6 Install gearshift lever and tighten clamp bolt Check lever sh
64. ft Bushing A 727 E22 INSTALLATION A with chips Be sure no chips are lodged next to the steel ball 7 Slide a new bushing on installing head Tool SP 3636 and start them in bore of the input shaft 8 Stand input shaft upright on a clean smooth surface and install handle Tool SP 3549 in the install ing head Fig 61 Drive bushing into shaft until tool bottoms 9 Thoroughly clean input shaft and clutch piston retainer before assembly and installation Assembly 1 If removed press input shaft into clutch piston retainer and install snap ring 2 Lubricate and install inner and outer seal rings on the clutch piston Make sure lip of seals face to ward head of clutch retainer and are properly seated in the piston grooves Fig 60 3 Place piston assembly in retainer and with a twisting motion seat piston in bottom of the retainer 4 Position clutch retainer over piston retainer splines and support the assembly so clutch retainer remains in place 5 Place clutch piston spring and spacer ring on top of piston in clutch retainer make sure spring and spacer ring are positioned in retainer recess Start one end of wave spring in the retainer groove Fig 62 then progressively push or tap spring into place making sure it is fully seated in the groove 6 Install inner pressure plate in clutch retainer with raised portion of plate resting on the spring 7 Lubricate all clutch plates install one lined pla
65. gear until it comes off the converter BRASS DRIFT 6 WOOD pe BLOCKS WELDS 4 NY1607 Fig 31 Removing Starter Ring Gear 4 Smooth off weld areas on the cover with a file Installation Any of the following methods may be used to heat and expand starter ring gear for installation on the converter Oven Place ring gear in Oven C 794 and set temperature at 200 degrees F Allow ring gear to re main in oven for 15 to 20 minutes Boiling Water Place ring gear in a shallow con tainer add water and heat for approximately eight minutes after water has come to a boil Steam Place ring gear on a flat surface and direct a steam flow around gear for approximately two minutes Flame Place ring gear squarely on a flat surface Using a medium size tip direct a slow flame evenly around inner rim of the gear Do not apply flame to the gear teeth Place a few drops of water on face of gear at intervals during heating process When gear is hot enough to just boil the water installation of the gear on torque converter can be made 1 After ring gear is expanded by heating place the gear in position on converter front cover Tap gear on cover evenly with a plastic or rawhide mallet until front face of gear is even with scribed line made during removal on the front cover Make sure gear is even with scribed line around full circum ference of the front cover 2 Reweld ring gear to torque converter front cov er being
66. governor body then slide body and support assembly off the output shaft necessary remove four bolts and separate governor from the support Cleaning and Inspection The primary cause of governor operating failure is due to a sticking governor valve or weights Rough surfaces may be removed with crocus cloth Thor oughly clean all parts in clean solvent and inspect for free movement before assembly installation 1 Assemble governor body to the support if dis assembled and tighten the bolts finger tight Make sure oil passage of governor body aligns with passage in the support 247 SPRING BODY SNAP VALVE SHAFT RINGS INNER WEIGHT TUS Lu MZ OUTER WEIGHT N SNAP RING NB 358A Fig 26 Governor Assembly 2 Position support and governor assembly on out put shaft Align assembly so governor valve shaft hole in governor body aligns with hole in the output shaft then slide assembly into place Install snap ring be hind governor body Fig 25 Tighten body to support bolts to 100 inch pounds Bend ends of lock straps over the bolt heads 3 Assemble governor weights and spring and secure with snap ring inside large governor weight Place weight assembly in governor body and install snap ring 4 Place governor valve on valve shaft insert the assembly into body and through governor weights Install valve shaft retaining snap ring Inspect valve and weight assemb
67. haft Fig 20 18 Support inner race of bearing and press shaft through to shoulder Fig 31 Be sure snap ring groove on outer race is forward 19 Install bearing retaining snap ring on main shaft Fig 18 20 Spread snap ring in mainshaft bearing retainer groove and slide it over the bearing Be sure snap ring seats in bearing groove Fig 17 21 Place second gear over front of mainshaft with thrust surface against flange Fig 16 22 Install properly indexed stop ring and 2nd 3rd synchronizer assembly against second gear Fig 15 MAINSHAFT BEARING SNAP RING BEARING RETAINER TO RETAINER FIRST REVERSE GEAR 2ND 3RD SYNCHRONIZER SLEEVE TST REVERSE SYNCHRONIZER SLEEVE SECOND STOP RING GEAR PY642 STOP RING Fig 27 Mainshaft Assembled 3 SPEED MANUAL TRANSMISSION 21 63 CLUTCH GEAR POSITION LONG HUB FORWARD SNAP RING STOP RING CLUTCH SLEEVE C FORWARD STRUT SPRINGS 2 PY203 Fig 28 1st Reverse Synchronizer Disassembled 23 Install 2nd 3rd clutch gear snap ring on shaft Fig 14 24 Move 2nd 8rd synchronizer sleeve forward as far as practical limited by need to retain struts in place and install front stop ring coated with grease to hold it in position inside sleeve with lugs indexed to struts 25 Rotate cut out on second gear so it is toward countershaft gear for clearance Fig 6 26 Now slowly insert mainshaft assembly into case
68. housing mounting pad 4 Install center crossmember and rear mount as sembly tighten retaining bolts to 75 foot pounds Lower transmission install extension housing to sup port bolts and tighten to 40 foot pounds Console Shift Align gearshift torque shaft lower bracket with the extension housing Install the two retaining bolts and tighten securely 5 Install the speedometer pinion and adapter 6 Carefully guide front universal joint yoke into extension housing and on the output shaft splines Align marks made at removal and connect propeller shaft to the rear axle pinion shaft yoke 7 Add fluid to transmission to bring up to proper level GOVERNOR Removal 1 Remove extension housing and output shaft bearing 2 Carefully pry snap ring from weight end of governor valve shaft Fig 25 Slide valve and shaft BEARING SNAP RING GROOVE FRONT SNAP REAR SNAP PARK LOCK NN119A Fig 24 Output Shaft Bearing 21 28 TRANSMISSION TORQUEFLITE GOVERNOR SUPPORT AND PARKING GEAR GOVERNOR BODY BOLTS 4 NN77 Fig 25 Governor Shaft and Weight Snap Rings assembly out of the governor body 3 Remove large snap ring from weight end of governor body lift out governor weight assembly 4 Remove snap ring from inside governor weight remove inner weight and spring from outer weight Figure 26 shows a disassembled view of the governor assembly 5 Remove snap ring from behind
69. ight cause unnecessary damage to the clutches 2 Remove oil pump housing retaining bolts 3 Attach Tool C 3752 to the pump housing flange Fig 38 thread screws of tool into the flange holes at 9 and 3 o clock locations 4 Bump outward evenly on the two knocker weights to withdraw pump and reaction shaft sup port assembly from the case 21 34 TRANSMISSION TORQUEFLITE TRANSMISSION VENT NDI9 Fig 38 Removing Pump and Reaction Shaft Support Assembly Front Band and Front Clutch 1 Loosen front band adjuster remove band strut and slide band out of the case 2 Slide front clutch assembly out of the case Input Shaft and Rear Clutch 1 Grasp input shaft and slide input shaft and rear clutch assembly out of the case CAUTION Be careful not to lose thrust washer locat ed between rear end of input shaft and forward end of output shaft Planetary Gear Assemblies Sun Gear and Driving Shell 1 While supporting output shaft and driving shell carefully slide assembly forward and out through the case CAUTION Be very careful not to damage ground surfaces on output during removal Rear Band and Low Reverse Drum 1 Remove low reverse drum then loosen rear band adjuster remove band strut and then remove band from the case Overrunning Clutch 1 Note position of overrunning clutch rollers and springs before disassembly to assist in reassembly 2 Carefully slide out clutch hub and
70. il filter e Perform pressure tests to determine cause and correct as required f Inspect accumulator for sticking broken rings or spring Repair as required g Remove valve body assembly and perform air pressure tests Repair as required Perform hydraulic pressure tests Ad just and repair as required i Disassemble and inspect clutch Re pair or replace as required j Inspect and replace seal rings as required also inspect respective bores for wear Replace parts as re quired inspect for air leakage into pump suc tion passages a Refill to correct level with Automatic Transmission Fluid AQ ATF Suffix A or Dexron b Adjust throttle linkage c Perform hydraulic pressure tests and adjust to specifications d Adjust kickdown band e Perform pressure tests to determine cause and correct as required f Inspect governor and repair as re quired Inspect accumulator for sticking broken rings or spring Repair as required Remove valve body assembly and per form air pressure tests Repair as required Inspect servo for sticking broken seal rings binding linkage or faulty band lining Repair as required D Disassemble and inspect clutch Re pair or replace as required Inspect and replace seal rings as required also inspect respective bores for wear Replace parts as required g h G 21 14 TRANSMISSION TORQUEFLITE Cond
71. ine support fixture and disengage hooks from holes in the frame side rails Install ex tension housing to rear engine mount bolts and tight en to 40 foot pounds Engine mount to center cross member bolt and nut loose assembled to this point should now be torqued to 50 foot pounds 7 Referring to Gearshift Linkage Adjustment conenct shift control rods to transmission levers and connect speedometer cable IGHTENING TORQUE 50 FT LBS CENTER 75 FT LBS CROSSMEMBER 40 FT LBS 1 NU48A Fig 39 Center Crossmember Reor Engine Mount A gic RETAINER ADAPTER ww O RING s 4 1 W PINION BOLT AND WASHER OIL SEAL RETAINER RING NN362 Fig 41 Speedometer Pinion and Adapter Disassembled 8 Carefully guide front universal joint yoke into extension housing and onto mainshaft splines Con nect propeller shaft to rear axle pinion yoke aligning the marks made at removal 9 Reconnect exhaust pipes if removed Tighten bolts securely 10 Fill transmission See Lubrication Section for detailed recommendations 11 Road test vehicle to make sure transmission shifts smoothly and operates quietly SPEEDOMETER PINION GEAR Removal and Installation Rear axle gear ratio and tire size determines pinion gear size requirements Refer to Speedometer Pinion Gear Chart in Specifications for pinion usage 1 Place drain pan unde
72. ing and bearing housing Install suitable tool to hold this alignment and lock column with ignition key 3 Place console lever in PARK and move shift con trol lever on transmission all the way to the rear in PARK detent 4 Set adjustable rods to proper length with no load applied in either direction on linkage STEERING COLUMN 24 ADJUSTABLE v5 Y REAR ROD TRANSMISSION FRONT ROD ASSEMBLY TORQUE SHAFT ASSEMBLY SIDE RAL ME TES PY228 Fig 4 Gearshift Linkage ME NEUTRAL STARTING SWITCH GEARSHIFT CONTROL LEVER Fig 5 External Controls and Adjustments 5 Check adjustment as follows a Shift effort should be free enough so detents feel crisp b Detent position must be close enough to gate stops in neutral and drive to assure that hand lever will not remain out of detent position when placed against gate and then released c Key start and locking must occur with shift lever held back against the park gate 6 If console removal is required disconnect bat tery ground cable Remove set screw and shift knob or handle Proceed as outlined in Body Section 23 7 After console is in place install shift knob as follows with gearship lever in NEUTRAL thread but ton spring and knob assembly on the cable end until dimension from top of button to top of knob is 13 32 Fig 6 Secure knob with set screw 8 Connect battery ground cable BUTTON c SP
73. ing the accelerator pedal past the detent feel near wide open throttle The shuttle valve has two separate functions and performs each independently The first is that of providing fast release of the kickdown band and smooth front clutch engagement when the driver makes a lift foot upshift from second to direct The second function of the shuttle valve is to regulate the application of the kickdown servo and band when making direct to second kickdowns Clutches Band Servos and Accumulator The front and rear clutch pistons and both servo CLUTCH ENGAGEMENT AND BAND APPLICATION CHART Lever Position Front Rear Front Rear Kickdown Low Rev Overrunning Drive Ratio Clutch Clutch Band Band Clutch N NEUTRAL DISENGAGED DISENGAGED RELEASED RELEASED MOVEMENT D DRIVE Breakaway DISENGAGED ENGAGED RELEASED RELEASED HOLDS 2 45 to 1 Second DISENGAGED ENGAGED APPLIED RELEASED OVER RUNS ao ENGAGED ENGAGED RELEASED RELEASED OVER RUNS KICKDOWN To Second DISENGAGED ENGAGED APPLIED RELEASED OVER RUNS 145 to 1 reat DISENGAGED ENGAGED RELEASED RELEASED HOLDS 2 45 to 1 dar DISENGAGED ENGAGED APPLIED RELEASED OVER RUNS Porn DISENGAGED ENGAGED RELEASED APPLIED PARTIAL HOLD MEE ENGAGED DISENGAGED RELEASED APPLIED MOVEMENT 2 20 to 1 21 12 TRANSMISSION TORQUEFLITE SHIFT PATTERN SUMMARY CHART Condition Closed Throttle 1 2 Upshift Closed Throttle 2 3 Upshift
74. ion housing mounting pad Spread large snap ring from output shaft bearing with Tool C 3301A Fig 23 With snap ring spread as far as pos sible carefully tap extension housing off output shaft bearing Carefully pull extension housing rearward to remove parking lock control rod knob past the parking sprag then remove the housing Bearing Replacement 1 Using heavy duty snap ring pliers C 4020 re SNAP RING PLIERS Fig 23 Removing or Installing Extension Housing TORQUEFLITE TRANSMISSION 21 27 move output shaft bearing rear snap ring and re move bearing from the shaft Fig 24 2 If removed install snap ring in front groove on output shaft Install a new bearing on shaft with outer race ring groove toward front Fig 24 then install rear snap ring NOTE To replace the extension housing bushing refer to INDEX installation 1 Place a new extension housing gasket on the transmission case Position output shaft bearing re taining snap ring in the extension housing Slide ex tension housing on output shaft guiding parking lock control rod knob past the parking sprag While spreading large snap ring in housing with Tool C 3301A Fig 23 carefully tap housing into place then release snap ring Make sure snap ring is fully seated in bearing outer race ring groove 2 Install and tighten extension housing bolts to 24 foot pounds 3 Install gasket plate and two screws on bottom of extension
75. ition NO UPSHIFT NO KICKDOWN OR NORMAL DOWNSHIFT SHIFTS ERRATIC Possible Cause Low fluid level b Incorrect throttle linkage adjustment c Kickdown band out of adjustment d Hydraulic pressures too high or tow e Governor sticking or leaking f Valve body malfunction or leakage g Clutches or servos sticking or not operating h Faulty oil pump i Kickdown servo band malfunction linkage j Worn or faulty front clutch Worn or broken input shaft and or reaction shaft support seal rings a Incorrect throttle linkage adjustment b Incorrect gearshift control linkage adjustment c Kickdown band out of adjustment d Hydraulic pressures too high or low e Governor sticking or leaking f Valve body malfunction or leakage g Clutches or servos sticking or not operating h Kickdown servo band or linkage mal function i Overrunning clutch not holding a Low fluid level b Aerated fluid c Incorrect throttle linkage adjustment d Incorrect gearshift control linkage adjustment e Hydraulic pressures too high or low f Governor sticking or leaking g Oil filter clogged h Valve body malfunction or leakage i Clutches or servos sticking or not operating j Faulty oil pump Correction a Refill to correct level with Automatic Transmission Fluid AQ ATF Suffix A or Dexron b Adjust throttle linkage c
76. itional bolts securing center crossmember then remove crossmember from the stub frame Do not remove rear anchor cross member from the torsion bars 18 Attach a small clamp to edge of converter housing to hold converter in place during removal of the transmission 19 Remove converter housing retaining bolts Carefully work transmission rearward off engine block dowels and disengage converter hub from end of the crankshaft Fig 30 20 Lower transmission jack and remove transmis sion and converter assembly 21 To remove converter assembly remove clamp from edge of the housing then carefully slide assembly out of the transmission STARTER RING GEAR REPLACEMENT The starter ring gear is mounted directly on outer diameter of the torque converter front cover With torque converter removed from vehicle replacement of the gear is as follows Removal 1 Cut through weld material at rear side of ring gear with a hack saw or grinding wheel Fig 31 Be careful not to cut or grind into the front cover stamp ing 2 Scribe a heavy line on front cover next to front face of ring gear to aid in locating the new gear 3 Support converter with the four lug faces rest ing on blocks of wood The converter must not rest on the front cover hub during this operation Using a blunt chisel or drift and hammer tap downward on ring gear near welded areas to break any remaining weld material Fig 31 Tap around ring
77. ity Be careful not to cock tool during installation 7 Stake bushing in place by using a blunt punch or similar tool Fig 51 A gentle tap at each stake slot location will suffice 8 Using a narrow bladed knife or similar tool re move high points or burrs around the staked area Fig 51 Do not use a file or similar tool that will remove more metal than is necessary 9 Thoroughly clean pump housing before installa tion Reaction Shaft Bushing Replacement 1 Assemble remover Tool SP 5301 cup Tool SP 3633 and hex nut Tool SP 1191 CAUTION Do not clamp any part of reaction shaft or support in a vise 2 With cup held firmly against the reaction shaft thread remover into bushing as far as possible by hand Fig 52 3 3 Using a wrench screw remover into bushing 3 to 4 additional turns to firmly engage threads in the e BLUNT PUNCH Ea gt m Fig 51 Staking Pump Bushing A 727 bushing 4 Turn hex nut down against the cup to pull bushing from the reaction shaft Thoroughly clean reaction shaft to remove chips made by the remover threads 5 Lightly grip bushing in a vise or with pliers and back tool out of the bushing Be careful not to damage threads on the bushing remover 6 Slide a new bushing chamfered end first on installing head Tool SP 5302 and start them in bore of the reaction shaft 7 Support reaction shaft upright on a clean smooth surface and install handle Tool SP 3549 i
78. kage e Perform hydraulic pressure tests and adjust to specifications f Remove and clean governor Replace parts if necessary g Replace oil filter h Perform pressure tests to determine cause and correct as required i Remove valve body assembly and per form air pressure tests Repair as re quired Perform hydraulic pressure tests ad just or repair as required Condition SLIPS IN FORWARD DRIVE POSITIONS SLIPS IN REVERSE ONLY SLIPS IN ALL POSITIONS Possible Cause Worn or broken input shaft and or reaction shaft support seal rings a Low fluid level b Aerated fluid Incorrect throttle linkage adjustment d Incorrect gearshift control linkage adjustment e Hydraulic pressures too low f Valve body malfunction or leakage g Accumulator sticking broken rings or spring Clutches or servos sticking or not operating i Worn or faulty front and or rear clutch j Overrunning clutch not holding Worn or broken input shaft and or reaction shaft support seal rings a Low fluid level 5 Aerated fluid c Incorrect gearshift control linkage adjustment d Hydraulic pressures too high or low f g Low reverse band out of adjustment Valve body malfunction or leakage Front clutch or rear servo sticking not operating h Low reverse servo band or linkage malfunction i Faulty oil pump
79. knob positioned against the reaction plug and sprag Move front end of rod toward center of trans mission while exerting rearward pressure on the rod to force it past the sprag Rotate propeller shaft if necessary 2 Install accumulator piston in the transmission case 3 Position accumulator spring on the valve body 4 Place the valve body manual lever in LOW posi tion Lift valve body into its approximate position connect parking lock rod to manual lever and secure with the E clip Position valve body in the case install retaining bolts finger tight 5 With neutral starting switch installed place manual valve in the neutral position Shift valve body if necessary to center neutral finger over the neutral switch plunger Snug bolts down evenly then tighten to 100 inch pounds 6 Install gearshift lever and tighten clamp bolt Check lever shaft for binding in the case by moving lever through all detent positions If binding exists loosen valve body bolts and re align 7 Make sure throttle shaft seal is in place then install flat washer lever and tighten the clamp bolt Connect throttle and gearshift linkage and adjust as required 8 Install oil pan using a new gasket Add trans mission fluid to bring it up to proper level SERVICE OUT OF VEHICLE TRANSMISSION AND CONVERTER REMOVAL The transmission and converter must be removed as an assembly otherwise the converter drive plate pump bushing and oil seal wil
80. l be damaged The drive plate will not support a load therefore none of the weight of the transmission should be allowed to rest on the plate during removal 21 30 TRANSMISSION TORQUEFLITE 1 Connect a Remote Control Starter Switch Tool C 763 to starter solenoid and position switch so engine can be rotated from under the vehicle 2 Disconnect secondary high tension cable from the ignition coil 3 Remove cover plate in front of converter to provide access to converter drain plug and mounting bolts 4 Rotate engine with Remote Control Switch to bring drain plug to 6 o clock position Drain torque converter and transmission 5 Mark converter and drive plate to aid in reas sembly The crankshaft flange bolt circle inner and outer circle of holes in drive plate and four tapped holes in front face of converter all have one hole offset so these parts will be installed in original posi tion This maintains balance of the engine and con verter 6 Rotate engine with Remote Control Switch to locate two converter to drive plate bolts at 5 and 7 o clock positions Remove the two bolts rotate en gine with switch and remove the other two bolts Do not rotate converter or drive plate by prying with a screw driver or similar tool as the drive plate might become distorted Also starter should never be en gaged if drive plate is not attached to converter with af least one bolt or if transmission case to engine block b
81. lace as required g Inspect condition of planetary gear sets and replace as required h Inspect condition of overrunning clutch and replace parts as required Refill to correct level with Automatic Transmission Fluid AQ ATF Suffix A or Dexron b Inspect pump for nicks or burrs on mating surfaces porous casting and or excessive rotor clearance Re place parts as required c Remove and recondition valve body assembly d Inspect and repair clutch as required a Drain fluid to correct level b inspect and clean breather vent opening in oil pump housing c Replace oil filter d Inspect for air leakage into pump suction passage a Replace rubber 0 ring seal Inspect for bore porosity b Replace rubber seal c Can often be stopped by tightening the attaching bolts to proper torque 150 in Ibs If necessary replace gas ket Inspect oil pan gasket mounting face for flatness Caution Do not over torque pan bolts Replace ring seal Inspect for tube damage and bore porosity If leakage cannot be stopped by tight ening a fitting replace the defective part f Replace either or both the manual lever or throttle lever shaft seal Torque to specified torque If leak per sists replace plug Check for O D Bore damage and re place seal i Replace gasket j Replace bolt Replace gasket and check for sealing surface damage on case and extension D Ap
82. lean Inspect bushings in sun gear for wear or scores replace sun gear assembly if bushings are damaged Inspect all thrust washers for wear and scores replace if damaged or worn below specifications Inspect thrust faces of planetary gear carriers for wear scores or other damage replace as required Inspect plane tary gear carrier for cracks and pinions for broken or worn gear teeth and for broken pinion shaft lock pins Inspect annulus gear and driving gear teeth for dam age Replace distorted lock rings Assembly Refer to Figure 65 for parts references 1 Install rear annulus gear on the output shaft Apply a thin coat of grease on thrust plate place it on the shaft and in the annulus gear making sure teeth are over the shaft splines 2 Position rear planetary gear assembly in rear 21 46 TRANSMISSION TORQUEFLITE annulus gear Place thrust washer on front side of the planetary gear assembly 3 Install snap ring in front groove of sun gear long end of gear Insert sun gear through front side of driving shell install rear steel washer and snap ring 4 Carefully slide driving shell and sun gear as sembly on the output shaft engaging sun gear teeth with rear planetary pinion teeth Place thrust washer inside front of the driving shell 5 Place thrust washer on rear hub of front plane tary gear set then slide assembly into front annulus gear 6 Carefully work front planetary and annulus gear assembly on the
83. left side of transmission bell housing 17 Connect wire to the back up light and neutral starting switch 18 Install cover plate in front of the converter assembly 19 Refill transmission with Automatic Transmis sion Fluid AQ ATF Suffix A Dexron 20 Adjust throttle and gearshift linkage FLUID LEAKAGE TRANSMISSION CONVERTER HOUSING AREA 1 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 fluid is dyed red and therefore can be distinguished from engine oil DUST SHIELD MATERIAL 5 1 2 X 1 1 2 X A 2 Prior to removing the transmission perform the following checks When leakage is determined to originate from the transmission check fluid level and torque converter drain plug torque prior to remove of the transmission and torque converter High oil level can result in oil leakage out the vent located at the top of the front pump housing If the fluid level is high adjust to proper level Oil leakage can also occur at the torque converter drain plug Torque the drain plug to 110 inch pounds After performing these two operations re check for leakage If a leak persists perform the following oper ation on the car to determine whether it is the con verter or transmission that is leaking LEAKAGE TEST PROBE 1 Remove converter housing dust shield 2 Position vehicle
84. lock in second position iE SCREWDRIVER Z NP556A Fig 44 Holding Crossover Blade in Neutral Position A SPECIFICATIONS 21 69 3 SPEED TRANSMISSION A 230 ALL SYNCHRONIZED Engine Displacement In 383 Gear Ratio Hit a T EM 2 55 Second cde EE his BEE LS TY 1 49 use I Ie pes olet 1 00 Reverse nC EE DS eeu o ied carere soe puce cura i 3 34 Downshift Speed Limits 3rd tos2ndic uS tenets wie eee MO a dia Dos u aty waya Med tes Pit re 45 to 15 M P H ANG TO USE fans E EET 25 to 0 M P H Lubricant Capacity 2 bone ERN se ME Eh U S Pints IMP Pints 5 4 1 4 TYPO Waa ATI ewes Auto Trans Ftuid AQ ATF Suffix or Dexron Gear YS peu wae aed Helical Tolerances Clutch Housing Face Squareness 006 Max Clutch Housing Bore 008 Max SPEEDOMETER PINION GEAR CHART ALL TRANSMISSIONS NUMBER OF TEETH ON PINION GEAR LISTED UNDER EACH AXLE RATIO Tire Tire Size Size 2 45 1 2 711 2 761 2 93 1 2 94 1 3 23 1 3 54 1 3 55 1 3 91 1 4 10 1 F78 x 15 29 31 35 775x15 __ 24 27 27 29 29 32 35 38 _ 8 25 15 _24 26 27 28 28 31 34 38 G78 x 15 26 26 28 31 34 8 55 15 26 26 28 31 34 8 85 15 _ 25 26 27 30
85. lve body Fig 47 Insert detent spring and ball in its bore in the valve body Depress ball and spring with Tool C 3765 or similar tool and slide manual lever over throttle shaft so that it engages manual valve and detent ball Install seal retaining washer and E clip on the throttle shaft Fig 44 21 38 TRANSMISSION TORQUEFLITE WASHER AND SEAL Fig 47 Installing Detent Ball Spring and Control Levers 10 Position valve body assembly on the repair stand 11 Place the six steel balls in valve body cham bers with large ball in the large chamber Fig 43 In stall spring and high pressure relief valve ball 3 8 dia 12 Position transfer plate assembly on the valve body Install the retaining screws starting at cen ter and working outward tighten screws to 35 inch pounds 13 Install the torque converter valve and regu lator valve Fig 45 14 Position the torque converter valve spring and regulator valve spring over ends of their respective valves Place line pressure adjusting screw assembly on end of regulator valve spring with long dimension of nut at right angles to the valve body Fig 45 15 Install spring retainer making sure converter valve spring is engaged on the tang and position squarely in the retainer Tighten the three retaining screws to 28 inch pounds Measure and if necessary align spring retainer Fig 14 16 Install the oil filter and tighten the three re taining screws
86. ly for free movement after installa tion 5 Install output shaft bearing and extension hous ing PARKING LOCK COMPONENTS Removal 1 Remove the extension housing 2 To replace the governor support and parking gear refer to governor and support 8 Slide shaft out of extension housing to remove the parking sprag and spring Fig 27 Remove snap ring and slide reaction plug and pin assembly out of the housing 4 To replace the parking lock control rod refer to Valve Body Removal and Installation Installation 1 Position sprag and spring in housing and insert the shaft Fig 27 Make sure square lug on sprag is toward the parking gear and spring is positioned so it moves sprag away from the gear 2 Install reaction plug and pin assembly in the housing and secure with snap ring 3 Install extension housing EXTENSION A 904 8 ywyw lt HOUSING SPRAG e 727 8 3 16 di Y d n e SPRING SNAP RING PLUG AND PIN CONTROL ROD Fig 27 Parking Lock Components VALVE BODY ASSEMBLY AND ACCUMULATOR PISTON Removal 1 Raise the vehicle on a hoist 2 Loosen oil pan bolts tap pan to break it loose allowing fluid to drain then remove the oil pan 8 Disconnect throttle and gearshift linkage from levers on the transmission Loosen clamp bolts and remove the levers Fig 5 4 Remove E clip Fig 28 securing parking lock
87. mainshaft Fig 22 10 Remove 1st gear and its stop ring from main shaft Fig 23 CLEANING AND INSPECTION Clean transmission case thoroughly using a suit able solvent dry with compresesd air Inspect case for cracks stripped threads in various bolt holes and ma chined mating surfaces for burrs nicks or any condi tion that wouid render the case unfit for further serv ice The front mating surface should be smooth if any burrs are present dress them off with a fine mill file If threads are stripped install Helicoil inserts GROOVE FOR BEARING SNAP RING 157 GEAR NO STOP RING ON REVERSE MAINSHAFT SIDE OF SYNCHRONIZER BEARING REVERSE GEAR PY653 Fig 20 Reverse Gear and Mainshaft Bearing Removal or Installation 3 SPEED MANUAL TRANSMISSION 21 61 1ST GEAR 1ST REVERSE SYNCHRONIZER v ASSEMBLY PY654 Fig 21 Snap 151 Synchronizer Clutch Gear Removal or Installation STOP RING 1ST GEAR 1ST REVERSE MAINSHAFT SYNCHRONIZER ASSEMBLY PY655 Fig 22 1st Reverse Synchronizer Assembly Removal or Installation Ball Bearings Wash ball bearings using a clean solvent and blow dry with compressed air CAUTION Do not spin bearings with air pressure turn slowly by hand Spinning unlubricated bearings may cause damage fo races and halls Be sure ball bearings are clean then lubricate them with light grade engine oil Inspect bearings for pitting
88. n the installing head Fig 52 Drive bushing into the shaft until tool bottoms 8 Thoroughly clean reaction shaft support assem bly before installation Assembly 1 Assemble pump rotors in the pump housing Fig 49 HEX NUT INSTALLING HEAD 5 5302 UM ES m REACTION REACTION SHAFT SHAFT SUPPORT REMOVAL INSTALLATION NP885 Fig 52 Replacing Reaction Shaft Bushing A 727 PISTON SEAL RING INNER PISTON PISTON RETAINER PISTON SEAL RING ASSEMBLY SPRINGS OUTER SPRING RETAINER TORQUEFLITE TRANSMISSION 21 41 CLUTCH PLATES SNAP RING SELECTIVE SNAP RING DRIVING DISCS PRESSURE PLATE ND13A Fig 53 Front Clutch Disassembled A 727 2 Install reaction shaft support and position vent baffle over the vent opening Install retaining bolts and tighten to 150 inch pounds 3 Place a new oil seal in opening of pump housing lip of seal facing inward using Tool C 3860 drive seal into housing until tool bottoms FRONT CLUTCH Disassembly Figure 53 shows a disassembled view of the front clutch assembly 1 Remove large selective snap ring that secures pressure plate in the clutch piston retainer Lift pressure plate and clutch plates out of the retainer 2 Install compressor Tool C 3863 over the piston spring retainer Fig 54 Compress springs and re move snap ring then slowly release tool until spring retainer is
89. nd ADAPTER LOCK RING ee eee SEAL NP2 Fig 42 Installing Speedometer Pinion Seal in Adapter 21 68 TRANSMISSION 3 SPEED MANUAL 2ND 3RD LEVER TST REVERSE LEVER INTERLOCK PAWL FWD 2ND 3RD ROD SPACER ASSEMBLED VIEW BUSHING FOR B NOS ENGINE OR HEAVY 2ND 3RD ROD DUTY ONLY TORQUE SHAFT SPRING WASHER PLAIN WASHER GROMMET BUSHING GROMMET BUSHING Ag PLAIN WASHER men PLAIN WASHER PLAIN WASHER 2ND 3RD ROD IST REVERSE ROD ac SS j PLAIN WASHER BRACKET IST REVERSE ROD DETAILS AT TRANSMISSION DETAILS AT STEERING COLUMN NUT AND WASHER M Fig 43 Column Gearshift Linkage CROSS OVER BLADE IN NEUTRAL clip Tighten swivel bolt to 100 inch pounds 7 Remove gearshift housing locating tool unlock 8 ignition switeh and shift column lever to neutral posi tion 8 Adjust 2nd 3rd rod swivel by loosening clamp bolt and sliding swivel along rod so it will enter 2nd 3 3rd lever at transmission Install washers and clip Tighten swivel bolt to 100 inch pounds 9 Remove tool from cross over blade at steering column and shift through all gears to check adjust ment and cross over smoothness gU 10 Check for proper operation of steering column I lock in reverse and second gear positions With proper linkage adjustment column should lock in reverse position and should not
90. nd snap ring over springs Compress springs with Tool C 3863 Fig 54 and seat snap ring in the hub groove 4 Lubricate all clutch plates install one steel plate followed by a lined plate until all plates are installed Install pressure plate and selective snap ring Make sure snap ring is properly seated 5 With front clutch completely assembled insert feeler gauge between pressure plate and snap ring Fig 59 The clearance should be 024 to 125 inch for 383 and 440 Cu In Eng or 066 to 123 inch for 440 High Performance Engine Install a snap ring of proper thickness to obtain specified clearance Snap FRONT CLUTCH CHART A 727 Engine Clutch Plate Piston Type Dises Clearance Springs 383 Cu In 4 024 to 125 8 High Perf 4 024 to 125 6 0 Cu In 4 024 to 125 6 High Perf 4 066 to 123 10 Fig 57 Front Clutch Piston Return Spring Location 8 Springs NU462 Fig 58 Front Clutch Piston Return Spring Location 6 Springs rings are the same as that used in rear clutch and are available in 060 062 074 076 and 088 090 inch thickness REAR CLUTCH Disassembly Figure 60 shows a disassembled view of the rear clutch assembly 1 Remove large selective snap ring that secures pressure plate in the clutch retainer Lift pressure plate clutch plates and inner pressure plate out of the retainer 2 Carefully pry one end of wave spring out of its groove in the clutch retainer
91. nd the thrust is taken on thrustwashers between the ends of 3 SPEED MANUAL TRANSMISSION 21 55 the gear and the transmission case The alignment of the needle type roller bearings within the gear is maintained by six thrust washers one being used between the rows of roller bearings and one at each end The reverse idler gear is also supported on needle type roller bearings The gearshifting is manually operated through shift control rods to the transmission Any forward gear may be engaged while the vehicle is in motion through the use of synchronizing clutches The transmission may be used as an aid to deceler ation by downshifting in sequence without double clutching or gear clashing due to the fact that all forward speeds are synchronized The service pro cedures covering the A 230 transmission used on all vehicles so equipped is identical to the following service procedures except where noted IMPORTANT Some internal transmission parts are different from standard on vehicles with high per formance engines These special parts are listed in applicable Parts Catalog therefore be sure they are used when replacement is necessary SERVICE DIAGNOSIS Condition Possible Cause Correction HARD SHIFTING a Incorrect clutch adjustment b Improper linkage adjustment a Refer to Clutch Group for corrections b Perform linkage adjustment as out lined in Gearshift Linkage Adjust ments c Synchro
92. nish installation of countershaft gear assembly by positioning it and the thrust washers so that the countershaft can be tapped into position Fig 26 Be careful to keep the arbor in contact with the countershaft to avoid parts dropping out of position and blocking the installation Install key in counter shaft as installation is finished 12 Carefully tap drive pinion forward to provide maximum clearance for mainshaft installation Fig 5 Mainshaft Fig 27 13 Sub assemble the synchronizer parts in the order shown in Figs 28 29 and 30 as follows Place a stop ring flat on the bench followed by the clutch gear and sleeve Drop the struts in their slots and snap in a strut spring placing the tang inside one strut Turn the assembly over on the stop ring and install second strut spring with tang in a different strut 14 Slide 1st gear and stop ring over rear end of mainshaft and against flange which separates 1st and 2nd gears Fig 23 ow RETAINING RING MAINSHAFT PILOT BEARING ROLLER PY640 Fig 25 Installing Rollers in Drive Pinion Gear ASSEMBLY ARBOR SPECIAL TOOL COUNTERSHAFT PY657 Fig 26 Countershaft installation 15 Slide 1st Reverse synchronizer assembly over mainshaft indexing the hub slots to Ist gear stop ring lugs Fig 22 16 Install clutch gear snap ring on mainshaft Fig 21 17 Slide reverse gear and mainshaft bearing in place and take to press to force bearing on s
93. nizer clutch sleeve damaged c d e Causes noted can only be d Synchronizer spring improperly in stalled rected by disassembling transmission and replacing damaged or worn parts e Broken or worn synchronizer stop rings Fig 1 A 230 Transmission Cutaway 4 eee need o 5 d i TYPICAL SHIFT LEVER dar DR yunpa Pee Yn NAT ane E Sl ph SPEEDOMETER DRIVE ASSEMBLY BACK UP LIGHT SWITCH DRAIN PLUG DRIVE PINION RETAINER CE FILL PLUG IDENTIFICATION NUMBER PAD PY628 Fig 2 A 230 Transmission Left and Right Sides 21 56 TRANSMISSION 3 SPEED MANUAL PY626 Fig 3 A 230 Transmission Disassembled Ref Ref Ref No Name No Name No Name 1 Gear First 14 Gasket 27 Shaft Output 2 Ring 15 Extension 28 Washer 3 Spring 16 Bushing 29 Roller 4 Sleeve 17 Seal 30 Washer 5 Struts 3 18 Yoke 31 Roller 5 Spring 19 Snap Ring 32 Washer Snap Ring 20 Ring 33 Countershaft 8 Bushing 21 Spring 34 Washer 9 Gear Reverse 22 Sleeve 35 Roller 10 Bearing 23 Struts 3 36 Washer 11 Snap Ring 24 Spring 37 Roller m Snap Ring 25 Ri 38 Washer 1 ing Retainer Gear Second Retainer Ref Ref Ref No Name No Name No 40 Gasket 53 Lever 66 Washer 41 Seal 54 Nut Locking 67 Roller 42 Snap Ring 55 Switch 68 Gear Idler 43 Snap Ring 56 Lever
94. nsmis sion installation 4 Inspect converter drive plate for distortion or cracks and replace if necessary Torque Drive Plate to Crankshaft bolts to 55 foot pounds When Drive Plate replacement has been necessary make sure transmission dowel pins are in engine block and pro x J p gt TRANSMISSION EXT gt ET HOUSING TORQUEFLIT X E TRANSMISSION 21 51 z4 DRAIN PLUG Ai a V MARK ND 10 erent Fig 79 Converter and Drive Plate Markings truding far enough to hold transmission in alignment 5 Coat converter hub hole in crankshaft with wheel bearing lubricant Place transmission and con verter assembly on a service jack and position assem bly under vehicle for installation Raise or tilt as necessary until transmission is aligned with the en gine 6 Rotate converter so mark on converter made during removal will align with mark on drive plate CENTER CROSSMEMBER 40 FT LBS NU48A Fig 80 Center Crossmember and Rear Engine Mount 21 52 TRANSMISSION TORQUEFLITE The offset holes in plate are located next to the 1 8 inch hole in the inner circle of the plate A stamped V mark identifies offset hole in the converter front cov er Fig 79 Carefully work transmission forward over engine block dowels with converter hub entering the crankshaft opening 7 After transmission is in position install con v
95. nstallation SNAP RING PLIERS PY643 Fig 14 Snap Ring 2nd 3rd Synchronizer Clutch Gear to Mainshaft Removal or Installation 2ND GEAR STOP RING STOP RING LUG 2ND 3RD SYNCHRONIZER ASSEMBLY PY644 Fig 15 2nd 3rd Synchronizer Assembly and Stop Ring Removal or Installation THRUST FLANGE ON MAINSHAFT FIRST GEAR SECOND GEAR PY645 Fig 16 2nd Gear Removal or Installation mainshaft By supporting front side of reverse gear it can push the bearing off shaft as pressure is applied to shaft Fig 19 When bearing clears shaft don t let parts drop through 7 Remove from press and slip off the end of shaft the mainshaft bearing and reverse gear Fig 20 8 Remove from mainshaft the snap ring which re tains the ist Reverse synchronizer clutch gear Fig 21 9 Slide 1st Reverse synchronizer 7 SNAP RING PLIERS assembly off GROOVE IN BEARING RACE MAINSHAFT BEARING P d RETAINER PY646 Fig 17 Snap Ring Spread to Remove or Install Retainer on Mainshaft Bearing SNAP RING MAINSHAFT SNAP RING REVERSE GEAR PY647 Fig 18 Snap Ring Mainshaft Bearing to Shaft Removal or installation SUPPORT MAINSHAFT 5 PRESS RAM TO AVOID FALL WHEN CLEAR OF r BEARING PLATES SUPPORTING REVERSE GEAR WHICH SLIDES AGAINST BEARING PRESS BED Fig 19 Using Press to Remove Mainshaft Bearing splines and remove from
96. olts have been loosened 7 Disconnect negative ground cable from bat tery 8 Remove the starting motor assembly 9 Disconnect wire from the neutral starting switch 10 Disconnect gearshift rod from the transmis sion lever Remove gearshift torque shaft from trans mission housing and left side rail Console Shift Remove two bolts securing gearshift torque shaft lower bracket to the extension housing Swing bracket out of the way for transmission re moval Disconnect gearshift rod from the transmis sion lever 11 Disconnect throttle rod from belicrank at left side of transmission bell housing 12 Disconnect oil cooler lines at transmission and remove oil filler tube Disconnect the speedometer cable 13 Mark parts for reassembly then disconnect pro peller shaft at rear universal joint Carefully pull shaft assembly out of the extension housing 14 Remove rear mount to extension housing bolts 15 Install engine support fixture Tool C 3487A and raise engine slightly Fig 30 16 Remove crossmember attaching bolts and re move the crossmember 17 Place a transmission service jack under transmission to support the assembly EY ENGINE SUPPORT 7 FIXTURE d E TRA Berens Fig 30 Engine Lifting Fixture Imperial Models Through openings on rear side of torsion bar rear anchor crossmember remove four large bolts securing rubber isolators to the center crossmember Remove six add
97. on Carefully pull shaft yoke out of transmission exten sion housing CAUTION Be careful not to scratch or nick ground surface on sliding spline yoke during removal and installation of the shaft assembly 3 Remove extension housing yoke seal Fig 34 with Tool C 3985 4 To install a new seal position seal in opening of extension housing and drive it into housing with Tool C 3972 Fig 36 5 Carefully guide front universal joint yoke into extension housing and on mainshaft splines Con nect propeller shaft to rear axle pinion shaft yoke aligning the marks made at removal 6 Fill transmission to level of fill plug Refer to Lubrication Section GEARSHIFT LINKAGE ADJUSTMENT A 230 Column Shift 1 Remove both shift rod swivels from transmission shift levers Fig 43 2 Make sure transmission shift levers are in neu tral middle detent position 3 Move shift lever to line up locating slots in bot tom of steering column shift housing and bearing housing Install suitable tool in slot and lock ignition Switch 4 Place screwdriver or suitable tool between cross over blade and 2nd 3rd lever at steering column 50 that both lever pins are engaged by cross over blade Fig 44 5 Set 1st Reverse lever on transmission to reverse position rotate clockwise 6 Adjust 1st reverse rod swivel by loosening clamp bolt and sliding swivel along rod so it will enter Ist reverse lever at transmission Install washers a
98. p the two larger balls The 3 8 inch diameter ball goes on the spring in the corner and is the high pres sure relief valve The 5 16 diameter ball in the large chamber is the front clutch ball check 8 Invert valve body and lay it on a clean cloth or paper Remove E clip and washer from throttle lever shaft Fig 44 Remove any burrs from shaft then while holding manual lever detent ball and spring in their bore with Tool C 3765 or similar tool slide manual lever off the throttle shaft Remove the detent ball and spring 9 Remove manual valve carefully slide it out of valve body with a rotating motion 10 Remove throttle lever and shaft from the vaive body 11 Remove shuttle valve cover plate Fig 44 Remove E clip from exposed end of the shuttle valve 12 Remove throttle lever stop screw assembly Fig 45 being careful not to disturb the setting any more than is necessary 13 Remove kickdown detent kickdown valve throttle valve spring and the throttle valve 14 Remove the governor plug end plate Fig 45 Tip up valve body to allow shuttle valve throttle plug spring shuttle valve and shift valve governor plugs to slide out into your hand Note longer stem on the 1 2 shift valve plug as a 5 16 DIA BALL 5 SMALLER STEEL BALLS 3 aa 1 DSA 3 8 DIA BALL AND SPRING HIGH PRESSURE RELIEF VALVE NU367 NS Fig 43 Steel Ball Locations A WASHER THROTTLE L
99. pecifications e Adjust low reverse band f Perform pressure tests to determine cause and correct as required g Remove valve body assembly and perform air pressure tests Repair as required h Inspect servo for damaged seals binding linkage or faulty band lining Repair as required i Perform hydraulic pressure tests ad just or repair as required a Refill to correct level with Automatic Transmission Fluid AQ ATF Suffix A or Dexron b Perform hydraulic pressure tests and adjust to specifications c Perform pressure tests to determine cause and correct as required d Perform hydraulic pressure tests ad just or replace as required e Remove valve body assembly and perform air pressure tests Repair as required f inspect and replace seal rings as re quired also inspect respective bores for wear Replace parts as required 21 16 TRANSMISSION TORQUEFLITE Condition NO DRIVE IN ANY POSITION NO DRIVE IN FORWARD DRIVE POSITIONS NO DRIVE IN REVERSE DRIVES IN NEUTRAL DRAGS OR LOCKS GRATING SCRAPING GROWLING NOISE Possible Cause Low fluid level b Hydraulic pressures too low c Oil filter clogged d Valve body malfunction or leakage e Faulty oil pump f Clutches or servos sticking or not operating a Hydraulic pressures too low b Valve body malfunction or leakage Clutches or servos sticking or not operating d Worn or faulty
100. ply pas sage Operation of servo is indicated by a tightening of the front band Spring tension on servo piston should release the band i 6 FRONT SERVO APPLY LINE PRESSURE TO ACCUMULATO ee ND PUMP PRESSURE FRONT CLUTCH eo d APPLY d REAR CLUTCH TO TORQUE CONVERTER 1 APPLY M FROM TORQUE Fj CONVERTER Fig 17 Air Pressure Tests 21 26 TRANSMISSION TORQUEFLITE Low and Reverse Servo Direct air pressure into servo apply passage Operation of servo is indicated by a tightening of the rear band Spring tension on servo piston should re lease the band If clutches and servos operate properly no upshift or erratic shift conditions indicate that malfunction exists in the valve body SPEEDOMETER PINION Removal and Installation Rear axle gear ratio and tire size determines pinion gear size requirements Refer to Speedometer Pinion Chart in Specifications for pinion usage 1 Remove bolt and retainer securing speedometer pinion adapter in the extension housing Fig 18 2 With cable housing connected carefully work adapter and pinion out of the extension housing 3 If transmission fluid is found in cable housing replace seal in the adapter Fig 19 Start seal and retainer ring in the adapter then push them into adapter with Tool C 4004 until tool bottoms Fig 20 CAUTION Before installing pinion and adapter as sembly make sure adapter flange and its
101. ply sealer m Replace switch and or gasket n See section on Fluid Leakage g h a Refill to correct level with Automatic Transmission Fluid AQ ATF Suffix A or Dexron b Adjust kickdown band c Adjust low reverse band d Inspect transmission cooling system clean and repair as required 21 18 TRANSMISSION TORQUEFLITE Condition Possible Cause Correction Cracked or restricted oil cooler tine inspect repair or replace as required or fitting f Faulty pump f Inspect pump for incorrect clearance repair as required g Insufficient clutch plate clearance in g Measure clutch plate clearance and front and or rear clutches a Incorrect gearshift control STARTER WILL NOT ENERGIZE IN NEUTRAL OR PARK adjustment starting switch Broken lead to neutral switch STALL TEST WARNING DURING TEST LET NO ONE STAND IN FRONT OF VEHICLE The stall test consists of determining the engine speed obtained 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 oil level should be checked and the engine brought to normal operating temperature be fore stall operation Both the parking and service brakes must be fully applied and front wheels blocked while making this test Do not hold the throttle open any longer than is neces
102. r adapter or drain trans mission 2 Remove bolt and retainer securing speedometer pinion adapter to extension housing Fig 40 8 With cable housing connected carefully work adapter and pinion out of extension housing 4 If transmission fluid is found in cable housing replace seal in the adapter Fig 41 Start seal and re tainer ring in adapter then push them into adapter with Tool C 4004 until tool bottoms Fig 42 5 Note number of gear teeth and install speed ometer pinion gear into adapter Fig 41 CAUTION Before installing pinion and adapter as sembly make sure adapter flange and its mating area on extension housing are perfectly clean and lubricated Dirt or sand will cause mis alignment re sulting in speedometer pinion gear damage 6 Rotate the speedometer pinion gear and adapter assembly so that the number on the adapter corre sponding to the number of teeth on the gear is in the 6 o clock position as the assembly is installed Fig 40 7 Install retainer and bolt with retainer tangs in adapter positioning slots Tap adapter firmly into ex tension housing and tighten retainer bolt to 100 inch pounds 8 Fill transmission to level of fill plug Refer to Lubrication Section 3 SPEED MANUAL TRANSMISSION EXTENSION HOUSING YOKE SEAL 21 67 Replacement 1 Place drain pan under yoke seal 2 Disconnect propeller shaft at rear universal joint Mark both parts to reassemble in same positi
103. r 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 in terference within the assembly indicate a defective torque converter To confirm that the noise originates within the converter operate the vehicle at light throttle in D and N on a hoist and listen under the transmission bell housing STALL SPEED SPECIFICATION CHART Engine Engine Model Transmission Speed C 1 D Type RPM 383 2 BBL A727 1850 2100 383 4 BBL A727 2350 2650 440 4 BBL A727 2000 2300 SERVICE PROCEDURES SERVICE IN VEHICLE Various transmission components can be removed for repairs without removing the transmission from vehicle The removal reconditioning and installation procedures for these components are covered here except valve body reconditioning which is described on Page 34 ALUMINUM THREAD REPAIR Damaged or worn threads in the aluminum trans mission case and valve body can be repaired by the use of Heli Coils Essentially this repair consists of drilling out the worn or damaged threads tapping the hole with a special Heli Coil Tap and installing a Heli Coil Insert into the tapped hole This brings the A TORQUEFLITE TRANSMISSION 21 19 inserting Extracting Heli Coil Insert Drill Tap Tool Tool Thread Part Insert Part Part Part
104. r deep scratches light scratches will not interfere with sealing of neoprene seals Inspect neo prene seals for deterioration wear and hardness In spect piston spring wave spring and spacer for dis tortion or breakage Inspect interlocking seal rings Fig 60 on input shaft for wear or broken locks make sure they turn freely in the grooves Do not remove rings unless conditions warrant Inspect bushing in the input shaft for wear or scores Inspect rear clutch to front clutch thrust washer for wear Washer thickness should be 061 to 063 inch replace if necessary Input Shaft Bushing Replacement 1 Clamp input shaft in a vise with soft jaws being careful not to clamp on seal ring lands or journals 2 Assemble remover Tool SP 3630 cup Tool SP 3633 and hex nut Tool SP 1191 3 With cup held firmly against clutch piston re tainer thread remover into bushing as far as possible by hand Fig 61 4 Using a wrench screw remover into bushing 3 to 4 additional turns to firmly engage threads in the bushing 5 Turn hex nut down against cup to pull bushing from the input shaft 6 Thoroughly clean input shaft to remove chips made by remover threads Make certain small lubri cation hole next to ball in end of shaft is not plugged HEX NUT SP 1191 TOOL HANDLE Pra SP 3549 REMOVER SP 3630 INSTALLING REAR CLUTCH HEAD RETAINER SP 3636 INPUT STEEL BALL SHAFT ND351A Fig 61 Replacing Input Sha
105. rag for broken edges also lugs on the parking gear for damage Inspect knob on end of con trol rod for nicks burrs and free turning To replace the parking gear refer to Governor and Support Disassembly and Assembly Assembly 1 Install reaction plug and pin assembly in the housing and secure with snap ring Fig 27 2 Position sprag and spring in the housing and insert the shaft Make sure square lug on sprag is toward parking gear and spring is positioned so it moves sprag away from the gear GOVERNOR AND SUPPORT Disassembly 1 Remove large snap ring from weight end of TOOL INSTALLING 1 BUSHING i PA y BUSHING TOOL REMOVING END INSTALLING END NU43 Fig 48 Replacing Extension Housing Bushing governor body and lift out the weight assembly 2 Remove snap ring from inside governor weight remove inner weight and spring from the outer weight 3 If the lugs on parking gear are damaged re moved the four bolts and separate support from the governor body Cleaning and Inspection Figure 26 shows a disassembled view of the gov ernor assembly Inspect all parts for burrs and wear Inspect inner weight for free movement in the outer weight and outer weight for free movement in the governor body Inspect valve for free movement in the governor body The weights and valve should fall freely in the bores when clean and dry Rough surfaces may be removed with crocus cloth Insp
106. rear clutch e Overrunning clutch not holding f Worn or broken input shaft and or reaction shaft support seal rings a incorrect gearshift control linkage adjustment b Hydraulic pressures too low c Low reverse band out of adjustment d Valve body malfunction or leakage e Front clutch or rear servo sticking or not operating f Low reverse servo band or linkage malfunction 2 Worn or faulty front clutch Incorrect gearshift control linkage adjustment b Valve body malfunction or leakage Rear clutch dragging a Kickdown band out of adjustment b Low reverse band out of adjustment c Kickdown and or low reverse servo band linkage malfunction d Front and or rear clutch faulty Planetary gear sets broken or seized f Overrunning clutch worn broken seized a Kickdown band out of adjustment b Low reverse band out of adjustment c Output shaft bearing and or bushing damaged Correction a Refill to correct level with Automatic Transmission Fluid AQ ATF Suffix A or Dexron b Perform hydraulic pressure tests and adjust to specifications c Replace oil filter d Perform pressure tests to determine cause and correct as required e Perform hydraulic pressure tests ad just or repair as required f Remove valve body assembly and perform air pressure tests Repair as required a Perform hydraulic pressure tests and adju
107. remove the rollers and springs If overrunning clutch cam and or roller spring retainer are found damaged or worn refer to index for replacement procedures Kickdown Servo 1 Compress kickdown servo spring by using en gine valve spring compressor Tool C 3422 then re move snap ring Fig 39 2 Remove rod guide springs and piston rod from the case Be careful not to damage piston rod or guide during removal 3 Withdraw piston from the transmission case Low and Reverse Servo 1 Compress low and reverse servo piston spring by using engine valve spring compressor Tool C 3422 then remove snap ring 2 Remove spring retainer spring and servo pis ton and plug assembly from the case RECONDITION SUB ASSEMBLIES The following procedures cover disassembly in spection repair and assembly of each sub assembly as removed from transmission Heli Coil inserts are recommended for repairing damaged stripped or worn threads in aluminum parts Refer to Aluminum Thread Repair Pre sized service bushings are available for re placement for most all bushings in the TorqueFlite transmission The two bushings in sun gear are not serviced because of the low cost of the sun gear as sembly If bushings are found worn or scored they should be replaced as outlined in the following recon ditioning procedures The bushing replacement tools listed by SP num bers part of Tool Kit C 3887 A The use of crocus
108. rm the ad justment The approximate adjustment is 1 5 16 inches measured from valve body to inner edge of the adjust ing nut Fig 15 However due to manufacturing tol erances the adjustment can be varied to obtain speci fied line pressure The adjusting screw may be turned with an Allen wrench One complete turn of adjusting screw changes closed throttle line pressure approximately 1 2 3 psi Turning adjusting screw counterclockwise increases pressure and clockwise decreases pressure Throttle Pressure Throttle pressure cannot be tested accurately Fig 14 Measuring Spring Retainer Location FNN72A Fig 15 Line Pressure Adjustment therefore the adjustment should be measured if a malfunction is evident 1 Remove valve body assembly from transmission to perform adjustment 2 Loosen throttle lever stop screw lock nut and back off approximately five turns Fig 16 3 Insert gauge pin of Tool C 3763 between the throttle lever cam and kickdown valve 4 By pushing in on the tool compress kickdown valve against its spring so throttle valve is completely bottomed inside the valve body 5 As force is being exerted to compress spring tighten throttle lever stop screw finger tight against throttle lever tang with throttle lever cam touching the tool and the throttle valve bottomed Be sure ad justment is made with spring fully compressed and valve bottomed in the valve body 6 Remove tool and tight
109. rmal operating posi tion with drain plug at the lowest point Remove drain plug and drain solvent Rotate turbine and stator and shake converter while draining to prevent dirt par ticles from settling Tool C 3963 A is available to do this job faster and more effectively This tool adapts a drill motor to an input shaft to spin the turbine and includes a drawing for a simple wooden fixture to hold the converter This fixture will hold the converter upright for the spinning and drain ing operations 4 Repeat flushing operation at least once or as many times as required until solvent or kerosene drained out is clear 5 After flushing shake and rotate converter sev eral times with drain plug out to remove any residual solvent and dirt Flush any remaining solvent from converter with two quarts of new transmission fluid This will prevent any adverse effect the solvent may have on the transmission seals Reinstall drain plug and tighten to 110 inch pounds 6 Flush and blow out the oil cooler and its lines MACHINE FLUSHING Machine cleaning is recommended using the type which rotates the converter while pumping cleaning fluid through it The machine automatically adds 21 32 TRANSMISSION TORQUEFLITE timed blasts of compressed air to the cleaning fluid as it enters the converter providing more thorough cleaning than the hand flushing operation PUMP OIL SEAL Replacement The pump oil seal can be replaced without remov
110. sary to obtain a maximum engine speed reading and never longer than five seconds at a time If more than one stall check is required operate the engine at approximately 1 000 rpm in neutral for 20 seconds to cool the transmission fluid between runs If engine speed exceeds the maximum limits shown release the accelerator immediately since transmission clutch slippage is indicated STALL SPEED ABOVE SPECIFICATION If stall speed exceeds the maximum specified in chart by more than 200 rpm transmission clutch slippage is indicated Follow the transmission oil pressure and air pressure checks outlined in the Ser vice on Vehicle section to determine the cause of slippage STALL SPEED BELOW SPECIFICATION Low stall speeds with a properly tuned engine indi correct with proper size snap ring linkage a Adjust control linkage b Faulty or incorrectly adjusted neutral b Test operation of switch with a test lamp Adjust or replace as required Inspect lead and test with a test lamp Repair broken lead cate torque converter stator clutch problems A road test will be necessary to identify the exact problem If stall speeds are 250 350 rpm 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 ab normally high throttle opening is required to main tain highway speeds the stato
111. screw in adjuster just enough to hold strut and anchor in place PLUG pao p bud ANCHOR afi e ADJUSTING SCREW AND LOCKNUT NDI7 Fig 74 Kickdown Band and Linkage TORQUEFLITE TRANSMISSION 21 49 Oil Pump and Reaction Shaft Support If difficulty was encountered in removing the oil pump assembly due to an exceptionally tight fit in the case it may be necessary to expand the case with heat during pump installation Using a suitable heat lamp heat the case in area of the pump for a few minutes prior to installing pump and reaction shaft support assembly If drive train end play was not within specifications 037 084 inch when measured replace the thrust washer on reaction shaft support hub with one of proper thickness Fig 49 The following selective thrust washers are avail able Thickness Color 061 063 inch Green 084 086 inch Red 102 104 inch Yellow Screw two pilot studs Tool C 3288 in oil pump opening in the case Fig 75 Install a new gasket over the pilot studs 2 Place a new rubber seal ring in the groove on outer flange of pump housing Make sure seal ring is not twisted Coat seal ring with grease for easy instal lation 3 Install pump assembly in the case tap it lightly with a soft mallet if necessary Place the deflector over vent opening and install four pump body bolts Remove pilot studs install remaining bolts and snug all bolts down evenly Rotate input and outpu
112. st to specifications b Perform pressure tests to determine cause and correct as required c Remove valve body assembly and perform air pressure tests Repair as required Disassemble and inspect clutch Re pair or replace as required Disassemble transmission and repair overrunning clutch as required f Inspect and replace seal rings as quired also inspect respective bores for wear Replace parts as required d e a Adjust control linkage b Perform hydraulic pressure tests and adjust to specifications c Adjust low reverse band d Perform pressure tests to determine cause and correct as required Remove valve body assembly and perform air pressure tests Repair as required f Inspect servo for damaged seals binding linkage or faulty band lining Repair as required g Disassemble and inspect clutch Re pair or replace as required e Adjust contro linkage b Perform pressure tests to determine cause and correct as required c Inspect clutch and repair as required a Adjust kickdown band b Adjust low reverse band c Inspect servo for sticking broken seal rings binding linkage or faulty band lining Repair as required d Disassemble and inspect clutch Re pair or replace as required e Inspect condition of planetary gear sets and replace as required f Inspect condition of overrunning clutch and replace parts as required a
113. t Assembly Removal or Installation case and remove through rear Fig 11 5 If bearing is to be replaced remove snap ring and press bearing off the pinion gear shaft Fig 12 6 Lift countershaft gear and arbor assembly out through rear of case Fig 13 Mainshaft Disassembly 1 Remove the snap ring from front end of main shaft which retains the 2nd 3rd synchronizer clutch gear Fig 14 2 Slide the 2nd 3rd synchronizer assembly off end of mainshaft along with the 2nd gear stop ring Fig 15 3 Remove 2nd gear from mainshaft Fig 16 4 Spread snap ring in mainshaft bearing retainer to disengage it from bearing groove and slide retainer off the bearing race Fig 17 5 Remove snap ring securing bearing to mainshaft Fig 18 6 Set up parts in arbor press to force bearing off ARBOR FOR ROLLERS COUNTERSHAFT GEAR PY635 Fig 9 Countershaft Removal 3 SPEED MANUAL TRANSMISSION 21 59 SNAP RING BEARING OUTER RACE COUNTERSHAFT GEAR AND ARBOR PY637 ASSEMBLY LYING IN BOTTOM OF CASE Fig 11 Drive Pinion and Bearing Assembly Removal or Installation H SNAP RING PLIERS DRIVE PINION GEAR SHAFT PY64 Fig 12 Snap Ring Pinion Shaft to Bearing Removal or Installation 21 60 TRANSMISSION 3 SPEED MANUAL RETAINER MOUNTING BOLT HOLES 4 HOLE FOR PINION BEARING RETAINER DRAIN PY638 Fig 13 Countershaft Gear and Arbor Assembly Removal or I
114. t shafts to see if any binding exists then tighten bolts to 175 inch pounds Check shafts again for free rotation PILOT STUDS bs TOOL Fig 75 Installing Pump and Reaction Shaft Support Assembly 21 50 TRANSMISSION TORQUEFLITE Governor and Support 1 Position support and governor body assembly on the output shaft Align assembly so governor valve shaft hole in governor body aligns with hole in the output shaft then slide assembly into place Install snap ring behind the governor body Tighten housing to support bolts to 100 inch pounds Bend ends of lock straps against the bolt heads 2 Place governor valve on valve shaft insert the assembly into the body and through governor weights Install valve shaft retaining snap ring Output Shaft Bearing and Extension Housing 1 Install a snap ring in the innermost groove on the output shaft Install bearing on the shaft with its outer race ring groove toward the front Fig 24 Press or tap bearing tight against front snap ring then install rear snap ring 2 Place a new extension housing gasket on the transmission case Position output shaft bearing re taining snap ring in the extension housing Spread snap ring as far as possible Fig 23 then carefully tap extension housing into place Make sure snap ring is fully seated in the bearing groove 3 Install and tighten extension housing bolts to 24 foot pounds 4 Install gasket plate and two screws on bottom o
115. tainer open end down on a clean smooth surface and place removing head Tool SP 3629 in the bushing Install handle Tool SP 3549 in removing head Fig 55 2 Drive bushing straight down and out of clutch retainer bore Be careful not to cock tool in the bore 3 Lay clutch retainer open end up on a clean smooth surface Slide a new bushing on installing head Tool SP 3628 and start them in clutch retainer bore 4 Install handle Tool SP 3549 in the installer Fig 55 Drive bushing into clutch retainer until tool bot toms 5 Thoroughly clean clutch retainer before assem bly and installation Assembly 1 Lubricate and install inner seal on hub of the clutch retainer Make sure lip of seal faces down and is properly seated in the groove Fig 53 2 Install outer seal on the clutch piston with lip of seal toward bottom of the clutch retainer Apply a coating of wax type lubricant or Door Ease to outer edge of seal for easier installation of the piston as sembly Place piston assembly in retainer and care fully seat piston in bottom of the retainer 3 Install springs as shown in Figures 56 57 or 58 TOOL HANDLE SP 3549 REMOVER HEAD SP 3629 FRONT CLUTCH RETAINER REMOVAL TOOL HANDLE SP 3549 INSTALLING HEAD SP 3628 INSTALLATION ND350A Fig 55 Replacing Front Clutch Retainer Bushing 727 Fig 56 Front Clutch Piston Return Spring Location 10 Springs Position spring retainer a
116. te followed by a steel plate until all plates are installed Install outer pressure plate and selective snap ring 8 Measure rear clutch plate clearance by having an assistant press downward firmly on the outer pressure plate then insert a feeler gauge between PISTON SPRING WAVE SPRING SPACER RING NK1387A Fig 62 Installing Rear Clutch Spring Spacer Ring and Wave Spring plate and snap ring Fig 63 The clearance should be between 025 to 045 inch If not install a snap ring of proper thickness to obtain specified clearance Low limit clearance is desirable Rear clutch plate clear ance is very important in obtaining proper clutch op eration The clearance can be adjusted by the use of various thickness outer snap rings Snap rings are available in 060 062 074 076 088 090 and 106 108 inch thickness PLANETARY GEAR TRAIN Measure end play of planetary gear assemblies sun gear and driving shell before removing these parts from the output shaft With the assembly in an up right position push rear annulus gear support down ward on the output shaft Insert a feeler gauge be tween rear annulus gear support hub and shoulder on the output shaft Fig 64 The clearance should be 010 to 037 inch If clearance exceeds specifications replace thrust washers and or necessary parts Disassembly 1 Remove thrust washer from forward end of the output shaft Fig 65 2 Remove selective snap
117. th the test lamp PY231 Fig 8 Console Gearshift Linkage 21 22 TRANSMISSION TORQUEFLITE LOW AND REVERSE BAND th BOLTS 10 ADJUSTING SCREW BACK UP LIGHT EM Ate AND NEUTRAL PER CAM 451 Fig 10 Bottom View of Transmission Pan Removed 5 Add fluid to transmission to bring up to proper level 6 The Back Up Light Switch Circuit is through the two outside terminals of the 3 terminal switch 7 To test switch remove wiring connector from switch and test for continuity between the two outside pins 8 Continuity should exist only with transmission in Reverse position 9 No continuity should exist from either pin to the case BAND ADJUSTMENTS Kickdown Band The kickdown band adjusting screw is located on left side of transmission case near the throttle lever shaft Fig 5 1 Loosen lock nut and back off approximately five turns Inspect adjusting screw for free turning in the transmission case 2 Using wrench Tool C 3380 with adapter C 3705 tighten band adjusting screw 47 to 50 inch pounds If adapter C 3705 is not used tighten adjusting screw to 72 inch pounds which is the true torque 3 Back off adjusting screw 2 turns Hold adjust ing screw in this position and tighten lock nut to 29 foot pounds Low and Reverse Band 1 Raise vehicle drain transmission fluid and re move oil pan 2 Loosen adjusting screw lock nut and back off nut approxim
118. tion of the clutches and bands Refer to Clutch Engagement and Band Application Chart STATOR FRONT PLANETARY GEAR SET TURBINE IMPELLER REAR CLUTCH REAR PLANETARY GEAR SET FRONT CLUTCH LOW AND REVERSE BAND OIL PUMP OVERRUNNING CLUTCH GOVERNOR OUTPUT SHAFT BEARING BUSHING SPEEDOMETER PINION EXTENSION HOUSING PARKING LOCK ASSEMBLY VALVE BODY KICKDOWN BAND OIL FILTER INPUT SHAFT SUN GEAR DRIVING SHELL FLEXIBLE DRIVE PLATE ENGINE CRANKSHAFT s NNI 168 Fig 1 TorqueFlite Transmission and Torque Converter A 727 2 12 31r1330080L1 NOISSINSNVMWI TORQUEFLITE TRANSMISSION 21 3 TORQUE CONVERTER OIL PRESSURES L 0 0 5 30 psi s PUMP SUCTION CONVERTER 5 30 psi LUBRICATION 5 30 25 1 hort d a wei B Lee TO Se 7 9 HIGH PRESS 9243 RELIEF VALVE i CONTROL SYSTEM IN d ES i OIL FILTER PARK ENGINE RUNNING NN34C REGULATOR rr TES a Park Hydraulic Circuits DET UE I m l H OIL PRESSURES Do TORQUE CONVERTER em nd UNE oo S psi Sy PUMP SUCTION C EE LE CONVERTER 30555 psi REGULATOR LUBRICATION 5 30 psi Te 108 HIGH PRESS e RELIEF V
119. transmission case at rear left side of the transmission case Fig 13 Connect a AN FRONT BAND RELEASE HNE PRESSURE ong FILEFR TUBE NU603 Fig 12 Pressure Test Locations Right Side of Case 21 24 TRANSMISSION TORQUEFLITE 0 100 psi pressure gauge Tool C 3292 to the tee fitting 2 At 1 000 engine rpm with throttle closed and transmission in direct the lubrication pressure should be 5 15 psi Lubrication pressure will be approximate ly doubled as throttle is opened to the maximum line pressure Rear Servo Apply Pressure 1 Connect a 0 300 psi pressure gauge Tool C 3293 to apply pressure take off point at rear servo Fig 13 2 With transmission control in R reverse posi tion and engine speed set at 1600 rpm the reverse servo apply pressure should be 230 to 300 psi Governor Pressure 1 Connect a 0 100 psi pressure gauge Tool C 3292 to governor pressure take off point located at lower left side of extension near the mounting flange Fig 13 2 Governor pressures should fall within the limits given in the Governor Pressure Chart If governor pressures are incorrect at the given vehicle speeds the governor valve and or weights are probably sticking GOVERNOR PRESSURE CHART Vehicle Speed To Axle Ratios Pressure Chrysler imperial Limits 2 76 1 3 23 2 94 1 psi 20 22 17 19 19 22 15 48 57 41 49 48 57 50 77 85 66 73 77 85 75 The governor pressure
120. 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 regu lator valve which controls line pressure at a value dependent on throttle opening The torque converter control valve maintains torque converter operating pressure and transmission lubricating pressure The governor valve transmits regulated pressure to TORQUEFLITE TRANSMISSION 21 11 the transmission in conjunction with throttle pres sure to control upshift and downshift speeds The throttle valve transmits regulated pressure to the transmission in conjunction with governor pres sure to contro upshift and downshift speeds Flow Control Valves The manual valve obtains the different transmis sion drive ranges as selected by the vehicle operator The 1 2 shift valve automatically shifts the trans mission from low to second or from second to low depending on the vehicle operation The 2 3 shift valve automatically shifts the trans mission from second to direct or from direct to second depending on the vehicle operation The kickdown valve makes possible a forced down shift from direct to second second to breakaway or direct to breakaway depending on vehicle speed by depress
121. uid to bring fluid level to the ADD ONE PINT mark 10 Recheck fiuid level after transmission is at normal operating temperature The level should be between the FULL mark and ADD ONE PINT mark Fig 3 CAUTION To prevent dirt from entering transmis sion make certain that dip stick cap is fully seated onto the filler tube GEARSHIFT LINKAGE ADJUSTMENT Column Shift Fig 4 1 Assemble all linkage parts leaving adjustable rod end free 2 Place gearshift selector lever in PARK position and lock steering column with ignition key 3 Move shift control lever on transmission all the way to rear in PARK detent Fig 5 4 Set adjustable rod to proper length and install with no load in either direction on linkage Fig 2 Converter Drain Plug 21 20 TRANSMISSION TORQUEFLITE ND167A Fig 3 Dip Stick Markings 5 Check Adjustment as follows a Shift effort must be free and detents feel crisp All gate stops must be positive b Detent position must be close enough to gate stops in neutral and drive to assure that hand lever will not remain out of detent position when placed against gate and then released c Key start must occur with shift lever held down against the park gate LINKAGE ADJUSTMENT Console Shift Fig 8 1 Assemble all linkage parts leaving adjustable rod ends free 2 At steering column upper end line up locating slots in bottom of shift hous
122. using Fig 35 with STEP Z INSTALL STRUTS IN CLUTCH GEAR SLOTS Tool C 3974 PL Slide new bushing installing of Tool C 3974 Align oil hole in bushing with oil slot hous ing then drive bushing into place Fig 35 4 To install a new seal position seal in opening of TANG ON SPRING INSIDE STRUT REVERSE IDLER GEAR ARBOR TOOL ROLLERS STEP INSTALL STRUT SPRING PY650 Fig 32 Reverse idler Gear Roller and Arbor Fig 30 Assembling Synchronizer Parts Assembly A LOCATING KEYWAY FOR BEARING RETAINER VENT PASSAGE EXTENSION HOUSING TO TRANSMISSION MOUNTING BOLT HOLES PY629 Fig 33 Extension Housing Front View extension housing and drive it into housing with Tool C 3972 Fig 36 Drive Pinion Bearing Retainer 31 Install the outer snap ring on the drive pinion bearing and tap the assembly back until the snap ring contacts case 32 Using Tool C 3789 Fig 37 install a new oil seal in retainer bore Position main drive pinion bear ing retainer and gasket on front of case Coat threads with sealing compound then install attaching bolts and tighten to 30 foot pounds Fig 2 Gearshift Mechanism and Housing Fig 38 33 If removed place the two interlock levers on TOOL NN361 TOOL INSTALLING BUSHING BUSHING TOOL REMOVING END INSTALLING END NU43 Fig 35 Replacing Bushing in Extension Housing 3 SPEED MANUA
123. with front lower than back so that accumulated fluid in converter housing will drain out Wipe bottom inside of converter housing as dry as possible A solvent spray followed by compressed air drying is preferable 3 Fasten test probe Fig 1 securely to convenient dust shield bolt hole Make certain converter is cleared by test probe Tool must be clean and dry 4 Run engine at approximately 2 500 rpm with transmission in neutral for about 2 minutes Trans mission must be at operating temperature 5 Stop engine and carefully remove tool 6 If upper surface of test probe is dry there is no converter leak A path of fluid across probe indicates a converter leak Oil leaking under the probe is com ing from the transmission converter area Fig 2 7 Remove transmission and torque converter as sembly from vehicle for further investigation The fluid should be drained from the transmission and converter Re install converter drain plug and oil pan with new gasket at specified torque Possible sources of transmission converter area fluid leakage shown in Fig 2 are 5 1 2 RAN SS B REEN BOTTOM OF CONVERTER HOUSING BOLT 1 32 SHEET METAL PY300 Fig 1 Locating Test Probe Tool VENT SHIELD USED A727 ONLY t f PY301 Fig 2 Transmission Converter Area 1 Converter Hub Seal a Seal lip cut check converter hub finish b Bushing moved and or worn
124. x months with engine and transmission at normal operating temperature Refer to Lubrication and Maintenance Group 0 The transmission should not be idled in gear for long periods Trailer Towing Service and Hard Usage If vehicle is used for trailer towing or is used in hard or severe service more frequent servicing is re quired as outlined Drain and refill transmission and replace filter initially at 36 000 miles or 3 years and every 12 000 miles or 12 months thereafter Drain and Refill 1 Raise vehicle on a hoist Place a drain container with a large opening under the transmission oil pan 2 Loosen pan bolts tap pan to break it loose al lowing fluid to drain then remove the oil pan 3 Remove access plate from in front of converter remove drain plug allowing the fluid to drain Fig 2 4 Install and tighten converter drain plug to 110 inch pounds and install the access plate 4 If necessary adjust the reverse band 5 Install a new filter on bottom of the valve body and tighten retaining screws to 35 inch pounds 6 Clean the oil pan and reinstall using a new gasket Tighten pan bolts to 150 inch pounds 7 Pour six quarts of Automatic Transmission Fluid AQ ATF Suffix A Dexron into the transmis sion 8 Start engine and allow to idle for at least two minutes With parking brake on move selector lever momentarily to each position ending in the neutral position 9 Add sufficient fl

TRANSMISSIONS

Contents

Download Pdf Manuals

Related Search

Related Contents