Installation Instructions Transpak
Contents
1. Installation Instructions Transpak 1980 1992 Ford AOD Part No 40227 2001 1994 B amp M Racing and Performance Products IMPORTANT this B amp M AOD Transpak will fit all 1980 thru 1992 AOD transmissions except for electronoic versions If you are in Stalling the kit in a four wheel drive vehicle you will have to purchase a special four wheel drive filter screen Ford p n E5TZ 7A098 C We do not recommend using the passenger car filter screen supplied with this kit in four wheel drive vehicle applications The tool list and parts list are on page 18 We recommend that you read through the instructions com pletely before beginning the in stallation so you can familiarize yourself with the installation pro cedure and tools required Check the tool list at the end of these instructions for the tools re quired to install your B amp M AOD Transpak Installation of the B amp M AOD Transpak can be accomplished by anyone with minimum mechanical ex perience It is however important to closely follow the instructions Read each step carefully before proceed ing if you do not understand go back and read the step again NOTICE The B amp M AOD Transpak is not a cure all for an ailing transmis sion If your transmission is slipping chatters or is in poor general shape the installation of this Transpak may worsen the condition However on a properly operating transmission in average condition the B amp M AOD2. kit replace them Purchase stock Ford gaskets for your specific year 6 and model vehicle STEP 14 Position separator plate gasket then separator plate on valve body Align gasket and separator plate holes with those in valve body Insert 2 long 1 56 valve body shoulder bolts through separator plate and valve body as illustrated in Figure 3 The shoulder bolts are required to maintain gasket and plate alignment during assembly The shoulder bolts must be installed in the holes indi cated for proper alignment Install 3 reinforcing plates with 11 short bolts tightening the bolts finger tight Install 1 Mex30mm 1 16 detent spring guide bolt See Fig 3 With all bolts just finger tight make sure all plate and gasket holes line up with valve body holes and the two alignment shoulder bolts can slide in and out freely Torque the 12 bolts to 80 100 9 11 Nm If you do not have a low range torque wrench run the bolts down until they stop wrist tight then turn bolt an addi tional one eighth 1 8 turn Remove the 2 shoulder bolts used for align ment 2 3 ACCUMULATOR MODIFICATIONS STEP 15 Remove retaining ring 2 3 accumulator cover 2 3 accumulator spring and 2 3 accumulator piston from 2 3 accumulator bore See Fig 6 Remove 2 seal rings from accu mulator piston Coat the 2 square cut rubber rings supplied in kit with clean AFT then install rings on piston Install piston back into
3. On later model valve bodies screw the M4x10 4 Replace stock outer pres long stem green or sure regulator spring with red spring in kit See step 5 Note 2 through 8 check balls are black rubber 7 checkball is not used Inner pressure regulator spring Pressure regula tor vajve Retaining clip NA Retainer z 2 WB Boost valve Boost valve sleeve 4mm metric screw supplied in kit in tapped hole to assist removing bore plug Early valve bodies do not have ahole in the bore plug so you will have to pry the plug out with a small flat screw driver Replace the stock spring with the GREEN spring supplied in kit Reassemble spring valve and bore plug tapped hole facing out and install spring clip SEPARATOR PLATE MODIFICATIONS IMPORTANT The B amp M AOD sepa rator plate was designed to work with any of the three versions of AOD valve bodies produced between 1980 and 1990 The following steps explain howto set up the B amp M AOD separator plate for your particular model valve body STEP 8 Place the stock separator plate on top of the B amp M plate with the valve body side of the plates facing up Install 2 of the short reinforce ment plate screws and nuts supplied in kit through the alignment holes as The existing holes at position C may be larger or smaller than 1 8 125 That s OK If these holes are present on your separator plate use them as tem plate
4. GAUGE BLOCK OF DRILL SHANK 1mm 17mm 397 007 INCH SERVICE TOOL USAGE ROB Tv CONTROL FRESSURE SERVICE TOOL D84P 70332 TV LEVER ADJUSTING SCREW T LEVER ADJUSTING SCREW TV LINKAGE CARBURETOR TV LINKAGE VER 2s CAUTION MAKE SURE GAUGE BLOCK DRILL CONTACTS SCREW POINT AND DOES NOT TOUCH HERE CARBURETOR THROTTLE LEVER NOTE USE ROD CONTROL PRESSURE GAUGE TOGL DBAP 70332 IF AVAILABLE IF NOT AVAILABLE USE ONE OF THE FOLLOWING DRILL SIZES LETTER X 16mm OR 25 64 LETTER X 10mm OR 25 84 DRILL Figure 10 gauge should have 2 4m 8 feet of flexible hose to make the gauge accessible while operating the en gine 4 3Obtain TV Control Pressure Gauge Block D84P 70332 A or fabricate a block 394 0 007 thick The following drill bit shanks may also be used in order of preference Letter X 397 inch 10mm 3937 inch or 25 64 3906 inch 4 4Operate the engine until normal operating tempera ture is reached and the throttle lever is offfastidle The transmission fluid temperature should be approxi mately 38 72 C 100 150 F Do not make pressure check if transmission fluid is cold or too hot to touch 4 5Set parking brake place shift selector in NEUTRAL remove air cleaner and shut off air conditioner If equipped with a vacuum operated throttle modulator disconnect and plug the vacuum line to this unit If equipped with a throttle solenoid positioner o
5. ahead of time of an overheated transmission The B amp M temperature gage is ex tremely accurate and dependable it comes with all necessary hardware and is easy to install DISASSEMBLY Automatic transmissions operate S 8 Short Mex30mm shoulder bolts L 17 Long M6x40mm shoulder bolts JN a E OES Orr qp P Figure 1 at temperatures between 150 F and 250 F We recommend that the ve hicle be allowed to cool for several hours before attempting disassembly to avoid serious burns from hot oil and parts The vehicle should be raised so there is at least 2 feet ground clear ance for ease of installation and safety MAKE SURE THE VEHICLE IS RIGIDLY AND SECURELY SUP PORTED JACK STANDS WHEEL RAMPS OR A HOIST WORK BEST DO NOT USE JACKS ALONE Have an oil drain pan ready to catch oil and a clean tray on which to put small parts so they won t get lost or dirty STEP 1 Since the AOD is not factory equipped with an oil pan drain plug use the following technique to drain 2 Figure 2 the transmission fluid Position your drain pan beneath the transmission to catch the oil Remove all but the two 2 front bolts from the oil pan Next loosen but do not remove the two front center bolts allowing the rear of Use shoulder bolt for alignment Separator plate 7 the pan to drop down Ifthe pan sticks to the gasket insert a flat screwdriver between the pan and case and pry down gently to break pan
6. engine running Lower vehicle and check fluid level again adjusting level as required Test drive vehicle and recheck for leaks while transmission is hot Ford Service Manuals available from Helms Inc Detroit MI 313 865 5000 Ford service tools available from OTC Tool and Equip Owatonna MN 507 455 7050 TROUBLESHOOTING GUIDE FOR THE FORD AOD TRANSMISSION The troubleshooting guide is intended to help you identify possible causes of malfunctions that could be related to incorrect assembly or adjustment of the transmission hydraulic system valve body and accumulator and or mechanical controls We recommend that you obtain an AOD service manual for problems related to the torque converter or transmission hard parts Slow initial engagement Low line pressure Fluid level low Harsh initial engagement Engine idle too high Loose U joints or engine mounts High line pressure Sticking valves in valve body 2 3 accumulator valve damaged No drive in any selector position Valve body leaking internally Valve body bolts loose Sticking valves in valve body Manual valve pin not engaged Fluid level low No drive forward but has reverse Worn or stuck governor Valve body bolts loose Sticking valves in valve body Damaged 2 3 accumulator seal Slips or chatters 1 gear TV linkage out of adjustment Selector in OD Low line pressure Valve body bolts loose Slips or chatters 274 gear Defective intermediate clutch
7. is satisfactorily road tested STEP 4 Remove 12 bolts holding separator plate to valve body See Fig 3 Remove 3 reinforcement plates and separator plate 1 large orange and 6 small black check balls and 2 relief valves with springs See Fig 4 NOTE Early 1980 valve bodies may have 7 black check balls Carefully remove any remaining gas ket material from reinforcement plates and valve body surfaces Make sure none of the gasket debris remains in the valve body channels to contami nate the valves Rinse off valve body with clean solvent to remove any dirt or grit Replace stock spring with spring from kit See steps 6 or 7 lt us Retaining Bore plug tapped hole faces out 1 2 Capacity modu lator valve Inslall in furthest bore in this direction VALVE BODY MODIFICATIONS IMPORTANT HINT The spring clips at the end of the valve body bores can fly off during removal To prevent losing the spring clips place a small rag over the clip when removing it this will help prevent the clip from flying off and becoming lost B amp M does not stock replacement spring clips If yours are lost or damaged see your local Ford parts supplier or try a transmission shop STEP 5 Heavy Duty and Street Pressure regulator Remove the re taining clip at the end of the pressure regulator bore See Fig 4 Use a screwdriver to hold the pressure regu lator assembly in while removing the retaining c
8. G CABLE Figure 25 17 away from the plastic rod Ensure gauge block is pushed in as far as it will go See Fig 24 WARNING THIS PROCEDURE REQUIRES WORK ING IN CLOSE PROXIMITY TO THE EGR SPACER ASSEMBLY WHICH MAY BE HOT 7 AOperate engine until normal operating temperature is reached The transmission fluid temperature should be approximately 38 72 100 150 F Do not make pressure check if transmission fluid is cold or too hot to touch 7 5Set parking brake and place shift selector in NEU TRAL With gauge tool in place and engine idling in NEUTRAL the TV pressure should be between 207 and 276 kPa 30 and 40 psi NOTE Do not check or set TV pressure in PARK 7 6lf TV pressure meets specification in Step 5 remove gauge tool allowing cable to return to its normal idle position With engine still idling in NEUTRAL TV MARK OR MEASURE LOCATION OF PLASTIC BLOCK ON NOTCHED ROD Figure 26 I PUSH OUT 1 LOCKING TAB FROM T 15 SIDE WHITE gis TAB 2 2 OUT COMPLETELY T eu T E T Em ld Figure 27 pressure must be at or near zero less than 34 kPa 5 psi 7 lf TV pressure does not meet specification in either or both Steps 5 and 6 remove gauge tool and readjust cable as outlined under Self locking TV Cable Adjust ment Then repeat steps 3 through 6 7 8lf TV pressure still does not meet specification it will be necessary to modify adjustment as follows 7 9R
9. MLY AGAINST IDLE STOP Figure 23 cable assembly out of grommet on throttle body lever See Fig 20 6 3Using a small screwdriver push out white locking tab 6 4Check to ensure plastic block with pin and tab slides freely on notched rod If it does not slide freely the white tab may not be pushed out far enough See Figs 21 amp 22 6 5While holding throttle lever firmly against its idle stop push grooved pin into grommet on throttle lever as far as it will go NOTE While pushing pin into grommet make sure you do not move throttle lever away from idle stop See Fig 23 6 6Install air cleaner cover and air inlet tube 7 Self locking TV cable adjustment using TV Control Pressure 7 1 Attach TV pressure gauge 0 60 PSI T86L 70002 A or equivalent to TV pressure tap See Fig 8 7 2Obtain Cable TV Gauge tool T86L 70332 A or equiva lent 7 3Inserttapered end of the tool between the crimped slug on the end of cable and plastic notched rod also on end of cable assembly Push in Cable TV Gauge Tool T86L 70332 A or equivalent forcing the crimped slug lt C EN mu SS Te aa 1 ES ra TR al eee NOTCHED ROD CRIMPED SLUG INSERT CABLE TV GAUGE TOOL T86L 70332 A BETWEEN CHIMPED SLUG ON END OF CABLE AND PLASTIC NOTCHED ROD Figure 24 Rs ha a pH MUS DT Eom Im AMET BRACKETRY GROMMET PRY GAOOVED PIN OUT OF GROMMET SELF LOCKIN
10. Selector OD OK in 1 Sticking valves in valve body Slips or chatters in Reverse Low line pressure Valve body bolts loose Starts in 2 or 3 Sticking governor Sticking valves in valve body Cross channel leaks between case or separator plate and valve body Incorrect shift points TV linkage out of adjustment Worn governor Sticking valves in valve body NO 1 2 upshift TV linkage out of adjustment Governor valve sticking Sticking valve in valve body Mushy 1 2 shift Out of tune engine Defective intermediate clutch TV linkage out of adjustment Low line pressure No 2 3 upshift Defective direct clutch Convertor damper hub broken Sticking valve in valve body Mushy 2 3 upshift Defective 2 3 accumulator piston or seals Low line pressure Mushy or rough 3 4 upshift Out of tune engine Defective OD band or reverse drum TV linkage out of adjustment No forced down shifts Defective clutch or band TV linkage damaged or out of adjustment Sticking valve in valve body Transmission overheats Too high idle speed or overheated engine Restriction in cooler or lines Converter overrun clutch seized Sticking valves in valve body Transmission noise Relief valve resonance buzzing Oil pump cavitation TV LINKAGE ADJUSTMENT Three different types of Throttle Valve TV linkages have been used on the Ford AOD transmission since its introduction The earliest linkage consisted of a bent rigid rod connecting the carburetor and trans
11. Transpak will provide the kind of transmission performance you are looking for INTRODUCTION The B amp M AOD Transpak can be installed in a few hours by carefully following the instructions Transmis sion components are precision fit work slowly and do not force any parts Burrs and dirt are the number one enemies of an automatic trans mission Cleanliness is very impor tant so a clean work surface from which oil can easily be removed is necessary This kit contains all the parts nec essary to obtain two different levels of shift performance depending on the vehicles intended use In several of the steps different instructions are given for each level 1 Heavy Duty Towing campers motor homes and 4 wheel drive ve hicles Heavy duty level produces firm noticeable shifts 2 Street Dual purpose performance vehicles street and strip performance cars Street level produces the firm positive shifts When installing your B amp M AOD Transpak there are several other B amp M products you may wish to con sider TRANSMISSION OIL COOLER We feel that itis very important that every vehicle used in heavy duty and hi performance applications racing tow ing RV etc should have anoil cooler Heat is the major cause of transmis sion failures and an oil cooler is an inexpensive safeguard against over heating and transmission failure B amp M offers a wide variety of transmission coolers to suit every application Avai
12. V torsion spring against the separator plate V notch See Fig 7 The TV torsion spring pushes the TV lever against the TV plunger Failure to position this spring properly will result in erratic shifting STEP 22 Make sure rubber grommet is installed in the new filter supplied with kit Install the cork filter gasket on filter using a dab of grease to hold it in place See Fig 2 Coat the filter grommet with clean ATF and install filter on valve body Push the filter straight on to avoid damaging the rubber grommet Install 3 M6x16 0 63 bolts and torque to 80 100 Ib in 9 11 Nm STEP 23 Remove any old pan gas ket material from pan and case pan rail Clean inside of pan with solvent If you recall what a mess draining the pan was you may want to install a B amp M Drain plug kit 80250 at this time Install the new pan gasket on the pan and align the holes Use grease or petroleum jelly to help hold the gasket in place during installation of pan Place pan up to case align holes and install all bolts finger tight After all bolts have been installed torque bolts to 72 124 Ib in 8 14 Nm If Line Pressure check On the AOD transmission two pressure readings must be taken One at idle closed throttle Zero TV Press and another at wide open throttle W O T Full TV Press Engine and transmission should be at normal operating temperature for test During test at W O T stall the wheels must be l
13. bore STEP 16 Heavy Duty only Replace stock 2 3 accumulator spring with the BLUE spring supplied in kit Install BLUE 2 3 accumulator spring cover and retaining ring into bore See Fig 6 STEP 17 Street only Replace stock 2 3 accumulator spring with the BLUE spring supplied in kit Install BLUE 2 3 accumulator spring B amp M 2 3 accu mulator spacer cover and retaining ring See Fig 6 FINAL ASSEMBLY NOTE If you are installing a B amp M shifter in other than a Mustang this is a good place to install the new shift lever Detent spring bolt Detent plate pin Manual valve T SEE Internal TV d 2 lt lt gt lt Detent lever spring plunger TV torsion spring in V notch Line pressure tap in m Left side of case SS CN TV AT tap ONE QE SE Un Forward Y clutch tap Direct clutch tap Right side of case Figure 8 STEP 18 Check your parts before proceeding you should have 3 stock springs and no check balls or relief valves left over Make sure the 12 valve body plate bolts are properly torqued STEP 19 Remove all old gasket ma terial from the case surface Install 2 M6x40mm 1 56 alignment pins Supplied in kit into the holes shown See Fig 6 Install case to separator plate gasket over alignment pins Use a few dabs of grease tho hold the gasket against the case CAUTION Valve body installation is one of the most important steps to insure proper op
14. by stops internal to the transmission The TV control cable is set and locked to its proper length during initial assembly by pushing down on the locking lever at the throttle body end of the cable assem bly When the lever is unlocked the cable is released for adjustment The take up spring at this end of the cable automatically tensions the cable when released With the slack taken up and the locking lever pushed the take up spring plays no part in the operation of the system Under normal circumstances it should not be neces sary to alter or readjust the initial setting of the TV control cable Situations requiring readjustment of the TV control cable include maintenance involving the removal and or replacement of the throttle body transmission TV cable assembly or installing a new main control assembly Readjustment of the TV control cable would also be necessary to correct complaints of poor transmission shift quality that would have been caused by a misadjustment of the TV control cable When the TV control cable is properly set the trans mission TV control lever will be at its internal idle stop lever to rear as far as it will travel when the throttle lever is at its idle stop Idle Speed Affect on TV Control Cable The EFI Electronic Fuel Injection engine uses an Air Bypass ISC that does not affect throttle position There fore idle automatic setting does not affect TV cable adjustment 5 Manual locking cable adj
15. d to the full mark on the dip stick We recom mend B amp M Trick Shift transmission fluid for all applications particularly for Street Level applications You will need approximately 6 to 8 quarts TV Linkage Adjustment STEP 25 TV Linkage Adjustment Normally the TV linkage does not need to be adjusted after installing the valve body Proper installation of this kit will not change the setting of the linkage follow instruction proce dures The linkage normally requires adjustment only when the transmis sion is installed in the vehicle or when there is a new carburetor or throttle body installed We recommend how ever performing a Line and TV pres sure check to check whether or not the TV Linkage is properly adjusted See Oil Pressure Chart If the pres sure check indicates TV linkage ad justment is required see the TV link age adjustment section on the follow ing pages The pressure test will also give you a good indication of the transmissions condition Line Pressure Test Results Low at idle in all ranges Check for low fluid level clogged or damaged filter loose valve body bolts stuck pressure regulator valve missing pressure regulator spring or oil tem perature too hot from excessive W O T test Low at W O T but O K at idle Check for low oil level clogged filter damaged or out of adjustment TV linkage Sticking TV or TV limit valve in valve body STEP 26 Inspect the transmission for leaks with
16. eck or set TV pressure in PARK 5 7 Using a screwdriver or pointed tool pry up white toggle lever on cable adjuster located immediately behind the throttle body cable mounting bracket See Fig 14 The adjuster preload spring should cause the adjusting slider to move away from the throttle body and TV pressure should increase 5 8Push on the slider from behind bracket until TV pres sure is 227 kPa 33 psi While still holding slider push down on toggle lever as far as it will go locking slider in position See Fig 15 NOTE Toggle lever must be completely down lying flat in cable adjuster assembly to lock properly 5 9Remove gauge tool allowing cable to return to its normal idle position With engine still idling in NEU TRAL TV pressure must be at or near 0 kPa 0 psi less than 34 kPa 5 psi If not reinstall gauge and repeat Steps 7 and 8 but set TV pressure to a pressure less than 227 kPa 33 psi but no less than 207 kPa 30 psi Remove gauge tool and recheck TV pressure to determine if it is at or near O kPa 0 psi CABLE TV GAUGE TOOL T86L 70332 A Figure 13 13 Figure 14 SA Figure 15 BELL HOUSING BRACKETRY Figure 16 Self locking type cable Throttle Valve TV Control Cable System 5 0 L HO and SEFI Engines The throttle valve TV control cable system consists of a cable attaching grommet on the throttle body throttle lever the TV control cable assembly the external TV control le
17. ecrease Less than 50 rpm The linkage lever adjustment screw has limited adjust ment capability See Fig 9 If it is not possible to adjust the TV linkage using this screw the length of the TV control rod assembly must be readjusted using the follow ing procedure This procedure must also be followed whenever a new TV control rod assembly is installed This procedure requires raising the vehicle to give access to the linkage components at the transmission TV control lever 3 1Set carburetor at its minimum idle stop as described in steps 1 3 Place shift lever in NEUTRAL and set parking brake Turn engine off 3 2 Set the carburetor linkage lever adjustment screw at approximately half travel 3 3 If a new TV control rod assembly is being installed connect the rod to the linkage lever at the carburetor CAUTION The following steps involve working in close proximity to the exhaust system Allow the exhaust system to cool before proceeding 3 4Raise vehicle so there is at least 2 feet ground clear ance for ease of access MAKE SURE THE VEHICLE IS RIGIDLY SUPPORTED ON JACK STANDS OR WHEEL RAMPS IF A HOIST IS NOT AVAILABLE DO NOT USE JACKS ALONE TO SUPPORT VE HICLE 3 5Loosen the bolt on the sliding trunnion block on the TV control rod assembly Remove corrosion and road grime from the control rod and free up the trunnion block so that it slides freely on the control rod 3 6Push up on the lower end of the control rod to ens
18. emove gauge tool and pry grooved pin out of grom met on throttle lever See Fig 25 7 10 or measure location of plastic block on notched rod See Fig 26 7 11 Push out locking tab See Fig 27 7 12 Using mark or measurement on plastic block as a reference move plastic block towards throttle body mounting bracket to raise TV pressure or move it away from bracket to lower TV pressure Push in white locking tab to lock block in position See Fig 28 7 13 Insert grooved pin back into grommet See Fig 29 7 14 Check TV pressure Refer to Steps through 6 NOTE For best transmission function the TV pres sure should be set as close as possible to 227 kPa 33 psi in NEUTRAL with gauge tool installed Since the TV pressure goes up approximately 14 kPa 2 psi when the shift lever is moved from NEUTRAL to a forward gear this will result in a TV pressure setting near the desirable 241 kPa 35 psi in forward gear Do not attempt to check TV pressure with the transmission in gear When the gauge tool is re moved the TV pressure should drop to less than 34 kPa 5 psi If the TV pressure does not drop to less than 34 kPa 5 psi reset the TV pressure to a value less than 227 kPa 33 psi with gauge tool installed but no less than 207 kPa 30 psi Verify that the TV pressure is less than 34 kPa 5 psi with gauge tool removed TOOL LIST Hydraulic jack Gasket scraper Jack stands or Wheel ramps 3 8 Drill moto
19. eration of the AOD transmission The valve body must be located flush against the case and carefully torqued exactly as described in the following step Failure to follow this procedure can result in sticking valves and unpredictable transmission opera tion If the valve body is warped or damaged due to improper assem bly it is not repairable and should be replaced STEP 20 Install valve body up to case being careful to align manual valve with pin in detent plate See Fig 7 You also have to manually engage the TV lever between the valve body and TV plunger DO NOT try to force the valve body into place it will go right into place with a little patience With the valve body sitting flush against the case install 1 bolt to hold the valve body in place Make sure the detent plate pin and internal TV lever are properly positioned then install 8 short Mex30mm 1 16 and 16 M6x40mm 1 56 shoulder bolts See Fig 1 Remove the alignment pins only after all but the last two bolts have been installed Install ALL bolts FINGER TIGHT The short bolts are installed 4 in front 1 in center and 3 in rear of valve body One of the shoulder bolts holds the detent lever spring Starting atthe center and work ing outward torque bolts to 80 100 Ib in 9 11 Nm If you do not have a low range torque wrench run the bolts down until they stop wrist tight then turn bolt an additional one eighth 1 8 turn STEP 21 Position the T
20. ial setting of the TV control cable Situations requiring readjustment of the TV control cable include maintenance involving the removal and or replacement of the throttle body transmission TV cable assembly or installing a new main control assembly Readjustment of the TV control cable would also be necessary to correct complaints of poor transmission shift quality that would have been caused by a misadjustment of the TV control cable When the TV control cable is properly set the trans mission TV control lever will be at its internal idle stop lever to rear as far as it will travel when the throttle lever is at its idle stop Idle Speed Affect on TV Control Cable The 5 0L and 5 0L HO 302 CID SEFI engine uses an Air Bypass ISC that does not affect throttle position There fore idle automatic setting does not affect TV cable adjustment 6 Self locking TV Cable Linkage Adjustment 6 1 Remove air cleaner cover and inlet tube from throttle body inlet to access throttle lever and cable assembly 6 2Using a wide blade screwdriver pry grooved pin on IMPORTANT HOLO THE THROTTLE LEVER FIRMLY AGAINST IDLE STOP WHILE PUSHING GROUND PIN INTO GROMMET ENSURE THAT YOU DO NOT MOVE THROTTLE LEVER AWAY FROM IDLE STOP Im SE IH ET e ii m pap r s GROOVED PIN PUSH GROOVED PIN INTO GROMMET WY VC 2 al fh m E mt MT ae AAA ARRAY Eh GROOVED PIN FULLY INSTALLED WHILE HOLGING THROTTLE LEVEA FIR
21. l able at your B amp M dealer TRICK SHIFT PERFORMANCE ATF Trick Shift performance automatic transmission fluid is the industry s only real performance ATF A spe cially blended oil with foam inhibitors extreme pressure agents and shift improvers this fluid assures protec tion while delivering the fastest pos sible shifts You literally Pour in per formance Available at your B amp M dealer DRAIN PLUG KIT 80250 The AOD transmission is not factory equipped with a drain plug The B amp M Drain plug kit is inexpensive and easy to install It eliminates the mess of pan removal and gasket replacement normally re quired when changing fluid B amp M SHIFTERS B amp M manufactures a complete line of automatic trans mission shifters ideally suited for use with the AOD These shifters provide you with positive transmission control Sections of these instructions include copyrighted materialfrom Ford Service Manuals Reprinted with permisson of Ford Motor Company Printed in the U S A 9500427 03 old filter gaskets as well as stylish appearance for your vehicles interior B amp M s shifters in clude a model especially designed for the popular 1980 1990 Ford Mustang Inquire about these shifters at your B amp M dealer TEMPERATURE GAUGE KIT 80212 Most transmission and converter fail ures can be traced directly to exces sive heat The B amp M transmission tem perature gage can save you a costly repair bill by warning you
22. lip If the sleeves stick in the bore lightly punch the sleeve with a small rod and a mallet allowing it to snap back out of the bore Remove Sleeve with Boost Valve and the out ermost pressure regulator spring Re place the stock outer pressure regula tor spring with the RED spring sup I ES o Ee Short stem TV pres sure relief valve green spring 3L INS im 07 Qe 1 orange check ball NY zl j 2d 8 Converter relief valve blue spring Figure 4 plied in the kit Reassemble pressure regulator in reverse order of disas sembly STEP 6 Heavy Duty Only 1 2 Ca pacity Modulator Remove the spring clip at the end of the 1 2 Capacity Modulator bore See Fig 4 Remove the bore plug 1 2 Capacity Modulator valve and spring from bore On later model valve bodies use the M4x40 4mm metric screw supplied in kit in tapped hole to assist removing bore plug Early valve bodies do not have hole in the bore plug so you will have to pry the plug out with a small screw driver Replace the stock spring with the YELLOW spring supplied in kit Reassemble spring valve and bore plug tapped hole facing out and install spring clip STEP 7 Street Only 1 2 Capacity Modulator Remove the spring clip at the end of the 1 2 Capacity Modu lator bore See Fig 4 Remove the bore plug 1 2 Capacity Modulator valve and spring from bore
23. loose Now slowly back the bolts out to permit draining the remaining oil Remove all old pan gasket material from the pan and case STEP 2 Remove three 3 screws holding the oil filter then pull the filter straight down from the valve body Remove the filter grommet and gas ket material from valve body See Figs 1 amp 2 STEP 3 Remove all of the valve body bolts except one near the center See Fig 1 Hold valve body up against case and remove the last bolt When removing valve body watch out for about a pint of oil trapped Reinforcement plates Figure 3 above it Place the valve body on a clean work surface WARNING Do not place the valve body on the ground or a dirty surface The valve body consists of precision fit valves and will not tolerate dirt or burrs Any dirt entering the fluid circuits will jam the shift valves and prevent the transmis sion from shifting VALVE BODY DISASSEMBLY IMPORTANT Pay special attention in the following steps where some steps refer to both Heavy Duty and otreet level modifications while other steps refer only to Heavy Duty or Street level modifications If neither performance level is specifically re ferred to it means both Heavy Duty and Street levels It is a good idea to 3 Use shoulder bolt for alignment Detent spring guide bolt retain all replaced parts separator plate springs etc for reference until after the installation is complete and the vehicle
24. mission while most late model AOD s use one of two different flexible cable type linkages NOTE Special tools and a pressure gage will be required depending on the particular TV linkage type you are working on Adjustment procedure for each of the TV linkage types are presented in the following sections 1 Carburetor adjustment Perform the following steps prior to adjusting TV linkage 1 1Check adjust the engine curb idle speed to specifica tion Refer to the Engine Emissions Diagnosis manual for procedures to adjust throttle solenoid applications Make sure the curb idle speed is set to specification with and without the throttle solenoid positioner anti dieseling solenoid energized if so equipped 1 2Shut engine off Remove air cleaner 1 3De cam the fast idle cam on the carburetor so that the throttle lever is against the idle stop or throttle solenoid positioner stop Rod type TV control system The TV control linkage system consists of a linkage lever on the carburetor the TV control rod assembly and an external TV control lever on the transmission See Fig 9 The TV control rod transmits motion between the carburetor linkage lever and the TV control lever on the transmission The carburetor linkage lever has an adjust ment screw for limited TV linkage Adjustment The exter nal TV control lever actuates the internal TV control mechanism which regulates TV control pressure The TV control rod is set to its proper le
25. ngth during initial assembly using the sliding trunnion block at the transmission end of the TV control rod assembly Under normal circumstances it should not be necessary to alter this Adjustment Any required adjustment can normally be made using the adjustment screw on the carburetor linkage lever When the linkage is correctly adjusted the TV control lever on the transmission will be at its internal stop position when the carburetor lever is at its minimum idle stop There will be light contact force between the throttle lever and the end of the linkage lever adjustment screw Due to the flexibility in the TV linkage the adjustment screw would have to be backed out several turns before a gap between the screw and throttle lever could be detected Before any engine TV linkage adjustment can be done the throttle lever at the carburetor or throttle body must be positioned at its minimum idle stop 2 Linkage Adjustment at Carburetor Adjust the TV control linkage at the carburetor using the following procedure See Fig 9 10 TYPICAL ROD CONTROL SYSTEM TV LEVER ADJUSTMENT SCREW TRANS LEVER Figure 9 2 1Set carburetor at minimum idle stop as described in steps 1 thru 3 Place shift lever in NEUTRAL and set parking brake CAUTION The transmission selector lever must be in NEUTRAL in when adjusting the TV linkage 2 2Back turn CCW the linkage lever adjusting screw all the way out until screw end is flush with le
26. ocked to prevent any vehicle motion DO NOT operate at W O T Stall for more than 10 seconds at a time followed by at least 2 minutes in Neutral at 1000 RPM to cool the oil Connect a 0 300 PSI 0 2000 kPa pressure gage to the line pressure port located just above the control levers on the right side of the transmission See Fig 8 The gage hose must be long enough to read gage while operating engine Connect a 0 100 PSI 0 690 kPa gage 300 PSI gage will work if it s all you have to the TV Pressure tap on the right hand side of the transmission See Fig 8 The gage hose must be long enough to read gage while operating engine Idle pressure must be read with throttle off the fast idle cam Pressures listed apply to stationary vehicle only In 3 and 4 gears line pressure is lower cut back than shown for all other ranges Oil Pressure Specifications Selector Position At idle In Reverse All Other Ranges At W O T Stall In Reverse 3 8L amp 4 9L All other engines All Other Ranges 3 8L amp 4 9L All other engines 109 129 74 94 264 304 1820 2096 275 315 1896 2172 200 220 1379 1517 209 229 1441 1579 TV Limit Pressure KPa 751 890 510 648 74 86 510 593 79 91 545 627 74 86 510 593 79 91 545 627 8 the bolts are over tightened the gas ket will deform excessively and lead to oil leaks STEP 24 Fill transmission with fresh automatic transmission flui
27. parator plate DOUBLE CHECK the stock plate against the B amp M plate to make sure all required holes have been drilled VALVE BODY ASSEMBLY STEP 11 Check ball placement See Fig 4 Place check balls in the valve body in the positions shown Use a 5 dab of grease or petroleum jelly to hold check balls in position The grease will have no effect on trans mission operation and will dissolve after an hour or two of operation Note the location of the ORANGE 1 check ball The orange and black check balls are not interchangeable STEP 12 Reinstall original converter and TV pressure relief springs and valves See Fig 4 Pay close atten tion to the spring color and relief valve stem length The long stem converter relief valve can have either a green or Alignment pin Retaining ring 2 3 Accumulator spring Replace stock spring with blue spring from kit Install soacer on street level only B amp M piston seal ring Install on piston 2 3 accumulator piston B amp M piston seal ring Install on piston Alignment pin 2 3 Accumulator modifications Figure 6 blue spring STEP 13 Visually check separator plate gaskets against the B amp M AOD separator plate to make sure no holes in the separator plate are covered by the gasket NOTE There will be holes in the gasket that do not have a corre sponding holes in the separator plate If your gaskets become damaged anytime during the installation of the
28. r Oil drain pan Fine cut flat file 3 8 drive ratchet wrench Wet or Dry sand paper 3 8 drive 4 extension Grease or petroleum jelly 8mm 10mm 13 mm Sockets Needle nose pliers Torque wrench omall flat screwdriver Funnel LOCK TAB Lm THAT a Mimi St Timm VT CHECK TO ENSURE PLASTIC SLOCK SLIDES FREELY ON NOTCHED ROG MOVE PLASTIC BLOCK TOWARD THROTTLE BODY MOUNTING BRACKET TO EE PRESSURE OR MOVE IT AWAY FROM BRACKET TO 2 TV PRESSURE THEN PUSH IN LOCK THROTTLE 8ODY MOUNTING BRACKET Figure 28 t A W 221 232232221 ns ATE GROOVED PIN FULLY INSTALLED WHILE HOLDING FHROTTLE LEVER FIRMLY AGAINST IDLE STOP Figure 29 PARTS LIST Separator plate Spring Red Pressure regulator Spring Green 1 2 capacity modulator valve Spring Yellow 1 2 capacity modulator valve Spring blue 2 3 accumulator Spacer gold 2 3 accumulator Seal ring 2 3 accumulator Seal ring 2 3 accumulator Drill 1 8 Alignment pin Screw M4 X 7 X 10 Nut M6 hex Gasket Plate to case Gasket Plate to valve body Gasket Oil pan Gasket Oil filter Oil filter 4 1 4 4 4 1 4 1 4 2 1 2 1 1 1 1 1
29. r an idle speed control do not disconnect either of these com ponents THROTTLE BODY KEYED HOLE BRACKET TOGGLE LEVER TV CABLE ASSY Figure 11 BELL HOUSING Figure 12 NOTE The following pressure check must be made with the engine idling at normal curb idle in NEUTRAL parking brake set and with no accessory load on engine Do not make pressure check in PARK 4 6With engine idling in NEUTRAL insert gauge block or drill shank between the carburetor throttle lever and adjust screw on the transmission linkage lever The TV pressure should be between 207 and 276 kPa 30 and 40 psi For best transmission function use the adjust ing screw to set the pressure as close as possible to 227 kPa 33 psi Since the TV pressure goes up approximately 14 kPa 2 psi when the shift lever is moved from NEUTRAL to a forward gear this will result in a TV pressure setting near the desirable 241 kPa 35 psi in forward gear Do not attempt to set TV pressure with the transmission in gear Turning the screw in will raise the pressure 10 3 kPa 1 5 psi per turn Backing out the screw will lower the pressure If equipped with idle speed control some hunting may 12 occur and average pressure reading will have to be determined If the adjusting screw does not have enough adjustment range to bring TV pressure within specification adjust rod at the transmission 4 7Remove gauge block allowing TV lever to
30. return to idle With engine still idling in NEUTRAL TV pressure must be less than 34 kPa 5 psi If not back out adjusting screw until TV pressure is less than 34 kPa 5 psi Install gauge block and check that TV pressure is not below 207 kPa 30 psi Manual Locking type cable Throttle Valve TV Control Cable System 3 8 L Thunderbird Cougar Engines The throttle valve TV control cable system consists of acable attaching stud on the throttle body throttle lever the TV control cable assembly the external TV control lever on the transmission and the cable mounting brack ets at the throttle body and transmission See Figs 11 amp 12 On 3 8 L EFI Thunderbird Cougar vehicles there is also a bellcrank assembly mounted on the transmission bell housing in the area of the TV lever and bracketry holding the cable in the upper bell housing area same as 5 0 L Thunderbird Cougar vehicles with column shift As the throttle is moved from idle to wide open throttle WOT the TV control cable pulls the transmission TV control lever from idle to WOT Return of the cable and transmission lever toward idle is accomplished by the return spring on the transmission end of the cable assem bly This spring and the end of the cable assembly is protected by a flexible rubber boot The transmission external TV control lever actuates the internal TV control mechanism which regulates the TV control pressure The travel of this lever is controlled
31. s to drill 1 8 holes in the B amp M separator plate NOTE There will be holes and slots in the stock separator plate which have no corresponding holes or slots in the B amp M separator plate They are not re quired for operation of B amp M AOD Transpak Install bolts and nuts in holes marked X for alignment during drilling The stock separator plate will have one of the follow ing 1 No holes or slots at A B or C 2 A slot at position A only 3 Slots at positions A and B and holes at position C Using existing slots and holes as templates drill two holes as shown using 1 8 drill supplied in kit If your stock separator plate has no holes or slots in these positions A B or C then the B amp M plate will not shown See Fig 5 Align both sepa rator plate holes and tighten the 2 bolts until they are just snug STEP 9 Using the stock separator plate as a template drill holes in the B amp M AOD separator plate as indi cated in Figure 5 Remove all sharp burrs from plate surface with a fine flat file Burrs can be removed from around the edge of the holes by lightly pressing a slightly larger drill bit to the hole and spinning it with your fingers IMPORTANT Drill only in the areas have to be drilled Figure 5 indicated There are other holes in the stock separator plate that are not used with this kit and should not be drilled in the B amp M plate STEP 10 Wash and wipe any loose chips from B amp M se
32. ure that the linkage lever at carburetor is touching firmly against the throttle lever Release force on rod Rod must stay up 3 Push the TV control lever on the transmission up against its internal stop with a firm force approxi mately 22 5 lbs Tighten the bolt on the trunnion block Do not relax force on lever until bolt is tightened 3 8Lower the vehicle and verify that the throttle lever is still against the minimum idle stop or throttle solenoid positioner stop If not repeat Steps 14 and 15 4 Rod type Linkage Adjustment Using TV Control Pressure Note This procedure requires the use of TV Pressure Gauge with Hose 0 60 psi T86L 70002 A or equivalent The results of the adjustment procedure depends on the accuracy of the pressure gauge The following procedure may be used to check and or adjust the throttle valve TV control linkage using the TV control pressure See Fig 10 4 1 Check adjust the engine curb idle speed to specifica tion required Refer to the Engine Emissions Diagno sis manual for appropriate procedure Ensure the curb idle speed is set to specification with and without the throttle solenoid positioner anti diesel solenoid ener gized if so equipped 4 2Attach Pressure Gauge 0 60 psi with Hose T86L 70002 A and Adapter Fitting D80L 77001 A or equiva lent to the TV port on the transmission The pressure ADAPTER FITTING DBOL 77001 A PRESSURE GAUGE AND HOSE TBBL 70002 A SHOP MADE
33. ustment using TV Control Pressure 5 1Attach TV pressure gauge 60 PSI with hose T86L 70002 A or equivalent to TV pressure tap See Fig 8 5 2Obtain Cable TV Gauge tool T86L 70332 A or equiva lent 5 3Inserttapered end ofthe tool between the crimped slug on the end of cable and plastic cable fitting that attaches to the throttle lever See Fig 13 Push in Cable TV Gauge Tool T86L 70332 A or equivalent forcing the crimped slug away from the plastic fitting Ensure gauge block is pushed in as far as it will go WARNING THIS PROCEDURE REQUIRES WORK ING IN CLOSE PROXIMITY TO THE EGR SPACER ASSEMBLY WHICH MAY BE HOT 5 4Operate engine until normal operating temperature is reached The transmission fluid temperature should be approximately 38 72 C 100 150 F Do not make pressure check if transmission fluid is cold or too hot to touch 5 5Set parking brake and place shift selector in NEU TRAL With gauge tool in place and engine idling in NEUTRAL the TV pressure should be between 207 and 276 kPa 30 and 40 psi For best transmission operation set TV pressure as close as possible to 227 kPa 33 psi using the following procedure 5 6Since the TV pressure goes up approximately 14 kPa 2 psi when the shift lever is moved from NEUTRAL to a forward gear this will result in a TV pressure setting near the desirable 241 kPa 35 psi in forward gear Do not attempt to set TV pressure with the transmission in gear NOTE Do not ch
34. ved pin is reinserted in the grommet the white locking tab is pushed in automatically locking the cable to its correct length When the cable is locked the take up spring plays no part in the operation of the system TRAM SIN THRCTTLE CABLE CABLE JEL EHCAHE ONLY BELL CRANK Au THAH SIMIS3ICIN VIEW 2 CDLUMN SHHT RETENTION SPRING THASMEMEISSKESN LEVER Figure 17 14 LINCOLH TOWN FORD CROWN VICTORIA MERCURY GRAND MARCHE T THAQTTLE 57 9099 A CE x H e De THANSMISSION 4 IRAMSMISSION M LEVER TRAHBAISSION BRACKET Figure 18 MARK VII THUNDERBIRD COUGAR 5 0L ESINES Flack SHIFT MST ABH BODY BAAC KEE THAT E PST AFIJLISTEH PLASTIC BLOCK VIEW T Ti CABLE TRAH iii EN TRAM SRA SSI VIE r is HIE BAM LE VL it ARK SM bee ATE EEEN 5 a Figure 19 15 Jj eS TE Hs ap ae ARACKETRY GROMMET PRY GROOVEO PIN SELF LOCKING CABLE OUT OF GROMMET Figure 20 PUSH OUT WHITE LOCKING TAB FROM THIS SIDE WHITE LOCKING TAB PUSHED OUT COMPLETELY ror ACT mmi LETS TU UU et TRI nmm T zx Fj CHECK TO ENSURE PLASTIC BLOCK SLIDES FREELY ON NOTCHED ROD Figure 22 Under normal circumstances it should not be neces sary to alter or readjust the init
35. ver face 2 3Turn the adjusting screw in CW until a thin shim of 127mm 0 005 inch maximum or piece of writing paper fits snug between end of screw and throttle lever NOTE To eliminate effect of friction push linkage lever forward tending to close gap and re lease before checking clearance between end of screw and throttle lever Do not apply any load on levers with tools or hands while checking gap 2 4Turn the adjusting screw in CW an additional three turns Three turns are preferred One turn minimum is permissible if screw travel is limited 2 5 If itis not possible to turn in adjusting screw atleast one additional turn from initial gap or if there was insuffi cient screw adjusting capacity to obtain an initial gap in Step 5 refer to Linkage Adjustment at Transmis sion Idle Speed Adjustment Whenever it is required to adjust idle speed by more than 50 rpm the adjustment screw on the linkage lever at the carburetor should also be readjusted as follows Idle Speed Change Linkage Adjustment at Carburetor Check TV lever adjustment at carburetor No change required 50 rpm or more Check TV lever adjustment increase at carburetor After making any idle speed adjustments always verify that the linkage lever and throttle lever are in contact with the throttle lever at its idle stop or throttle solenoid positioner and the shift lever is in NEUTRAL 3 Rod Linkage Adjustment at Transmission 90 rpm or more d
36. ver on the transmission and cable mounting brackets at the throttle body and transmission See Figs 16 17 18 amp 19 THUG EPS Pott THROTTLE Ep 3 51 ENGINE COLUMM SHIFTS On Thunderbird Cougar vehicles with column shift and 3 8 L engines there is also a bellcrank assembly mounted on the transmission bell housing in the area of the TV lever and bracketry holding the cable in the upper bell housing area As the throttle is moved from idle to wide open throttle WOT the TV control cable pulls the transmission TV control lever from idle to WOT Return of the cable and transmission lever toward idle is accomplished by the return spring on the transmission end of the cable assem bly This spring and the end of the cable assembly is protected by a flexible rubber boot The transmission external TV control lever actuates the internal TV control mechanism which regulates the TV control pressure The travel of this lever is controlled by stops internal to the transmission The TV control cable is set and locked to its proper length during initial assembly when the grooved pin on the upper end of the cable assembly is inserted in the grom met on the throttle body lever To release the cable locking mechanism it is necessary to pry the grooved pin out of the grommet and push out the white locking pin The take up spring at the end of the cable assembly tensions the cable and takes up the slack in the system When the groo
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