Installation Instructions 1980-1992 Ford AOD Shift Improver Kit
Contents
1. OR TOOL LIST 8mm 10mm 13 mm Sockets Wet or Dry sand paper Grease or petroleum jelly Needle nose pliers Torque wrench Small flat screwdriver Funnel 3 8 drive 4 extension2. Installation Instructions 1980 1992 Ford AOD Shift Improver Kit Part No 40263 B amp M Racing amp Performance Products 1997 IMPORTANT We recommend that you read through the instructions com pletely before beginning the installa tion so you can familiarize yourself with the installation procedure 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 Shift Improver Kit Installation of the B amp M AOD Shift Improver Kit can be accomplished by anyone with minimum mechanical experience 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 Shift Im prover Kit is not a cure all for an ailing transmission your transmis sion is slipping chatters or is in poor general shape the installation of this Shift Improver Kit may worsen the condition However on a properly op erating transmission in average con dition the B amp M AOD Shift Improver Kit will provide the kind of transmis sion performance you are looking for INTRODUCTION The B amp M AOD Shift Improver Kit can be installed in a few hours by carefully following the instructions Transmission components are preci sion fit work slowly and do not force any parts Burrs and dirt are the num ber one enemies of an automatic trans mission Cleanline
3. SEPARATOR PLATE MODIFICATIONS STEP 8 Heavy Duty and Street Drill holes shown as in Figure 5 Re move all sharp burrs from plate sur face with a fine flat file Burrs can be 4 Replace stock outer pres Note 2 through 8 check balls are black rubber 7 checkball is not used Pay close attention to component location and orientation when removing valve trains from bores Inner pressure regulator spring Retaining clip Pressure regula Boost valve vajve sleeve 7 Jff Da pA ico fl Boost valve Retaining clip groove 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 Wash and wipe any loose chips from theseparator plate IMPORTANT Drill only the holes in dicated Replacement AOD separa tor plates are NOT available from Ford so be very careful not to mislocate any of the holes If you should damage your separator plate you will have to find a complete used valve body of same year and model at ajunk yard or transmission shop least expensive or purchase a new valve body from Ford Alternatetively you can purchase a B amp M universal AOD separator plate which can be modi fied to fit any model year AOD trans mission VALVE BODY ASSEMBLY STEP 9 Check ball placement See Fig 4 Place check balls in the valve body in the positions shown Use a dab of grease or petroleum jelly to SEPARA
4. 4 Remove the bore plug 1 2 Capac ity 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 bod ies 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 1 w E UE 1 Sip A h L E l 2222 Short stem TV pres Converter relief valve sure relief valve long stem green or sure regulator spring with green spring red spring kit See step 5 1 orange check ball 35 ll i Al blue spring Figure 4 supplied in kit Reassemble spring valve and bore plug tapped hole fac ing out and install retaining clip STEP 7 Street Only 1 2 Capacity Modulator Remove the retaining 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 On later model valve bodies screw the M4x10 4mm metric screw supplied in kit in tapped hole to assist removing bore plug Early valve bodies do not have a hole 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 retaining clip
5. 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 occur and an 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 atthe transmission 4 7 Remove gauge block allowing TV lever to 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 a cable attaching stud on the throttle body throttle lever the TV control cable assembly the external TV control lever on 11 the transmission and the cable mounting brackets 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 Co
6. transmission is hot Ford Service Manuals available from Helms Inc Detroit MI 813 865 5000 Ford service tools available from OTC Tool and Equip Owatonna MN 507 455 7050 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 operat ing temperature for test During test at W O T stall the wheels must be locked 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 Connecta 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 TV Limit Pressure kPa kPa Sele
7. Available at your B amp M dealer DRAIN PLUG KIT 80250 The AOD transmission is not factory equipped with adrain 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 as well as stylish appearance for your vehicles interior 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 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 Sections of these instructions include copyrighted material from Ford Service Manuals Reprinted with permisson of Ford Motor Company Printed in U S A 9500537 01 old filter gaskets DISASSEMBLY Automatic transmissions nor mally operate at temperatures be tween 150 F and 250 F We recom mend that the vehicle be allowed to cool for several hours before at tempting disassembly to avoid seri ous burns from hot oil and parts The vehicle should be raised so there is at least 2 feet ground clear ance for ease of installati
8. set TV pressure to a pressure less than 227 kPa 33 psi butno less than 207 kPa 30 psi Remove gauge tool oe and recheck TV pressure to determine if it is at or near 0 Q kPa 0 psi j 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 lever on the transmission and cable mounting brackets at the throttle body and transmission See Figs 16 17 18 amp 19 On Thunderbird Cougar vehicles with column shift and BELL HOUSING 3 8 Lengines there is also a bellcrank assembly mounted on BRACKETRY 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 assembly 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 Figure 16 12 THUMOE
9. ILABLE USE ONE OF THE FOLLOWING BRILL SIZES LETTER X 10mm OR 25 64 LETTER 10mm OR Figure 10 reached and the throttle lever is off fast idle 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 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 or an idle speed control do not disconnect either of these compo nents 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 adjusting 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 THROTTLE BODY HOLE iN BRACKET TOGGLE LEVER TY CABLE ASSY BELL HOUSING BRACKETRY Figure 12
10. LUG ON END OF CABLE AND PLASTIC NOTCHED ROD Figure 24 2 BRACKETRY GROMMET PRY GACOVED OUT OF GROMMET Figure 25 SELF LOCKING CABLE MAAK OR MEASURE LOCATION OF PLASTIC BLOCK ON NOTCHED AOD PUSH GUT 1 LOCKING FROM 15 SIDE WHITE LOCKING TAB FU OUT COMPLETELY age lt 5 Figure 27 16 y CHECK TO ENSURE PLASTIC BLOCK SLIDES FREELY ON NOTCHED MOVE PLASTIC BLOCK TOWARD THROTTLE BODY MOUNTING BRACKET TO RAISE PRESSURE OR MOVE IT AWAY FROM BRACKET TO LOWER TV PRESSURE THEN PUSH IN LOCK TAB THROTTLE 8OD MOUNTING BRACKET Figure 28 H lt P E mS mh om ae GROOVED PIN FULLY INSTALLED WHILE HOLDING THROTTLE LEVER FIRMLY AGAINST OLE STOP Spring Red Spring Green Spring Yellow Figure 29 PARTS LIST Pressure regulator 1 2 capacity modulator valve 1 2 capacity modulator valve Spring blue Spacer gold Seal ring Seal ring Drill Alignment pin Screw Nut Gasket Gasket Gasket Gasket Hydraulic jack Gasket scraper Jack stands or Wheel ramps 3 8 Drill motor Oil drain pan Fine cut flat file 3 8 drive ratchet wrench 2 3 accumulator 2 3 accumulator 2 3 accumulator 2 3 accumulator 1 8 6 X 40mm M4 X 7 X 10mm M6 hex Plate to case Plate to valve body Oil pan Oil filter
11. RS AD TRANSMISSION ET 3 81 COLUMN SHIFT BARACK DY CABLE TY CABLE TRAN SAAS SION WEW Z LEVEA ae COLUM SHHT TY CABLE RETENTION SPRING TRANSMISSION ASSY JEL OLY Figure 17 LINCOLN TOWN FORD CAOWH VICTORIAS MERCURY GRAND MARCH T poia Le TRANSMISSION P w32 TRANSMISSION VIE TAAnRSM BACK ET VEW 2 TRANSMISS 08 Figure 18 13 il THUNDERBIRD 5 0L FLOOR SHIFT MUST AHHA THAT TRAM 511 WEW LE vl it BAAC KE PRS ETRE F AMJUSTEH PLASTIC TL CABLE SPY Figure 19 4 OGY lt lt o_o 124 A _ a Wa Bpa ARACKETRY GROMMET PRY GROOVEOD OUT OF GROMMET Figure 20 SELF LOCKING CABLE ar CHECK TO ENSUAE PLASTIC BLOCK SLIDES FAEELY ON NOTCHED AOD Figure 22 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 grommet on the throttle body lever To release the cable locking mechanism itis necessary to pry the grooved pin out of the grommet and push o
12. Raise vehicle so there is at least 2 feet ground clearance 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 VEHICLE 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 6 Push up on the lower end of the control rod to ensure that the linkage lever at carburetor is touching firmly against the throttle lever Release force on rod Rod must stay up 3 7 Push the TV control lever on the transmission up against its internal stop with a firm force approximately 22 N 5 los Tighten the bolt on the trunnion block Do not relax force on lever until bolt is tightened 3 8 Lower the vehicle and verify that the throttle lever is still against the minimum idle stop or throttle solenoid posi tioner 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 specification
13. TOR PLATE MODIFICATIONS There are three versions of AOD CO separator plates Your separator plate may differ slightly from this 0 illustration The holes to be modified Q CO are common to all three versions oU a a 0 gt _ i gt oS 90000 8 ta a 1 8 125 gt 2118 125 o 0 o 09 0 o O hole only if C present 1988 1992 lt O _ 1 8 125 Q O 3 32 094 Heavy Duty 1 8 125 Street hold check balls in position The grease will have no effect on transmission operation and will dis solve after an hour or two of opera tion Note the location of the OR ANGE 1 check ball The orange and black check balls are not inter changeable STEP 10 Reinstall original con verter and TV pressure relief springs and valves See Fig 4 Pay close attention to the spring color and relief valve stem length The long stem converter relief valve can have either a green or blue spring STEP 11 Visually check separator plate gaskets against the modified AOD separator plate to make sure no holes in the separator plate are Caution Be careful to drill ONLY those holes shown See step 8 for details Figure 5 covered by the gasket NOTE There will be holes i
14. a pint of oil trapped above it Place the valve body 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 Street level modifications while other steps refer only to Heavy Duty or Street level modifications If neither Reinforcement plates Figure 3 performance level is specifically re ferred to it means both Heavy Duty and Street levels It is a good idea to retain all replaced parts springs etc for reference until after the installa tion is complete and the vehicle 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 3 Use shoulder bolt for alignment Detent spring guide bolt nate the valves Rinse off
15. adjusted 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 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 following procedure This procedure must also be followed whenever a new TV control rod assembly is installed 50 rpm or more decrease Less than 50 rom 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 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 4
16. alves in valve body Manual valve pin notengaged Fluid level low Worn or stuck governor Valve body bolts loose Sticking valves in valve body Damaged 2 3 accumulator seal Harsh initialengagement No drive in any selector position No drive forward but has reverse Slips or chatters 1 gear Selector in TV linkage out of adjustment Low line pressure Valve body bolts loose Defective intermediate clutch Sticking valves in valve body Low line pressure Valve body bolts loose Sticking governor Sticking valves in valve body Cross channel leaks between case or separator plate and valve body Slips chatters in 2 gear Selector OK 1 Slips or chatters in Reverse Starts 2 or 3 4 Incorrect shift points NO 1 2 upshift No 2 3 upshift Mushy 2 3 upshift overheats Transmission noise TV linkage out of adjustment Worn governor Sticking valves in valve body TV linkage out of adjustment Governor valve sticking Sticking valve in valve body Out of tune engine Defective intermediate clutch TV linkage out of adjustment Low line pressure Defective direct clutch Convertor damper hub broken Sticking valve in valve body Defective 2 3 accumulator piston or seals Low line pressure Mushy or rough Out of tune engine 3 4 upshift Defective OD band or reverse drum TV linkage out of adjustment No forced down Defective cl
17. ccumulator piston B amp M piston seal ring Install on piston 2 3 Accumulator modifications Figure 6 2 3 ACCUMULATOR MODIFICATIONS STEP 13 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 ATF then install rings on piston Install piston back into bore STEP 14 Heavy Duty only Replace stock 2 3 accumulator spring with the BLUE spring supplied in kit Install BLUE 2 3 accumulator spring cover and retain ing ring into bore See Fig 6 6 STEP 15 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 accumulator spacer cover and retaining ring See Fig 6 FINAL ASSEMBLY STEP 16 Check your parts before proceeding you should have 3 stock springs and no check balls except 1 for 1980 models or relief valves left over Make sure the 12 valve body plate bolts are properly torqued NOTE If you are installing a B amp M shifter in other than a Mustang this is good place to install the new shift lever STEP 17 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 fe
18. ctor Position At idle In Reverse All Other Ranges 74 94 510 648 At W O T Stall In Reverse 3 8L amp 4 9L 264 304 1820 2096 74 86 510 593 All other engines 275 315 1896 2172 79 91 545 627 All Other Ranges 3 8L amp 4 9L 200 220 1379 1517 74 86 510 593 All other engines 209 229 1441 1579 79 91 545 627 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 temperature 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 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 initialengagement Low line pressure Fluid levellow Engine idle too high Loose U joint or engine mount High line pressure Sticking valves in valve body 2 3 accumulator valve stuck Valve body leaking internally Valve body bolts loose Sticking v
19. d the gasket will deform exces sively and lead to oil leaks STEP 21 Fill transmission with fresh automatic transmission fluid to the full mark on the dip stick We recommend B amp M Trick Shift transmission fluid for all applications particularly for Street Level applications You will need ap proximately 6 to 8 quarts TV Linkage Adjustment STEP 22 TV Linkage Adjustment Normally the TV linkage does not need to be adjusted after installing Line pressure tap Left side of case Forward clutch tap Right side RZ WE 201 Direct clutch tap Figure 8 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 has been removed and is rein Stalled in the vehicle or when there is a new carburetor or throttle body stalled We recommend however performing a Line and TV pressure check to check whether or not the TV Linkage is properly adjusted See Oil Pressure Chart If the pressure check indicates TV linkage adjust ment is required see the TV linkage adjustment section on the following pages The pressure test will also give you a good indication of the transmissions condition STEP 23 Inspect the transmission for leaks with engine running Lower vehicle and check fluid level again adjusting level as required Test drive vehicle and recheck for leaks while
20. f 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 adjustment screw for limited TV linkage Adjustment The external TV control lever actuates the internal TV control mechanism which regulates TV control pressure The TV control rod is set to its proper length during initial assembly using the sliding trunnion block at the transmission end of the TV control rod assembly Under normal circum stances 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
21. f grommet on throttle lever See Fig 25 7 10Mark or measure location of plastic block on notched rod See Fig 26 7 11 Push out locking tab See Fig 27 7 12Using 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 13lnsert grooved back into grommet See Fig 29 7 14Check TV pressure Refer to Steps 3 through 6 NOTE For best transmission function the TV pressure 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 ina 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 removed the TV pressure should drop to less than 34 kPa 5 psi Ifthe TV pressure does not drop to less than 34 kPa 5 psi reset the TV pressure to avalue 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 Se mn A SA R s ZT i NOTCHED ROD CRIMPED SLUG INSERT CABLE TY GAUGE TOOL TS6L 70332 4 BETWEEN CRIMPED S
22. ift selector in NEUTRAL 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 6 Since the TV pressure goes up approximately 14 kPa 2 psi when the shift lever is moved from NEUTRAL to a cae forward gear this will result ina TV pressure setting near TOOL 861 70332 the desirable 241 kPa 35 psi in forward gear Do not attempt to set TV pressure with the transmission in gear NOTE Do not check 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 8 Push on the slider from behind bracket until TV pressure 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 adjuster assembly to lock properly 5 9 Remove gauge tool allowing cable to return to its normal idle position With engine still idling in NEUTRAL 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
23. l operating temperature is reached The transmission fluid temperature should be approximately 38 72 C 100 150 F Do not make pres sure check if transmission fluid is cold or too hot to touch 7 5Set parking brake and place shift selector in NEUTRAL 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 Step 5 remove gauge tool allowing cable to return to its normal idle position With engine still idling in NEUTRAL TV pres sure 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 and6 remove gauge tool and readjust cable 15 IMPORTANT THE THROTTLE LEVER FIAMLY AGAINST IDLE STOP WHILE PUSHING GROUND PIN INTO GROMMET ENSURE THAT YOU DO MOVE THAOTTLE LEVER AWAY IDLE STOP fl a sN 2 RIN GROOVED PIN PUSH GAOOVED PIN INTO GROMMET WY N A a 77 GROOVED FIN FULLY INSTALLED WHILE THROTTLE LEVEA FIRMLY AGAINST iDLE STOP Figure 23 as outlined under Self locking TV Cable Adjustment 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 9Remove gauge tool and pry grooved pin out o
24. linkage at the carburetor using the following procedure See Fig 9 2 1 Set 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 TYPICAL ROD CONTROL SYSTEM LEVER ADJUSTMENT SCREW TRANS LEVER Figure 9 2 2 Back turn CCW the linkage lever adjusting screw all the way out until screw end is flush with lever face 2 3 Turn the adjusting screw 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 release 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 4 Turn the adjusting screw CW an additional three turns Three turns are preferred One turn minimum is permissible if screw travel is limited 2 5 If it is not possible to turn in adjusting screw at least one additional turn from initial gap or if there was insufficient screw adjusting capacity to obtain an initial gap in Step 5 refer to Linkage Adjustment at Transmission Idle Speed Adjustment Whenever it is required to adjust idle speed by more than 50 rom the adjustment screw on the linkage lever at the carburetor should also be re
25. n the gasket that do not have corresponding holes in the separator plate If your gaskets become dam aged anytime during the installation of the kit replace them Purchase stock Ford gaskets for your spe cific year and model vehicle STEP 12 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 shoulder bolts are required to maintain gasket and plate alignment during assembly 5 The shoulder bolts must be installed in the holes indicated for proper alignment Install 3 reinforcing plates with 11 short bolts tighten ing the bolts finger tight Install 1 M6x30mm 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 Ib in 9 11 Nm If you do not have alow range torque wrench run the bolts down until they stop wrist tight then turn bolt an additional one eighth 1 8 turn Remove the 2 shoulder bolts used for alignment y Retaining ring Cover 2 3 Accumulator spring Replace stock spring with blue spring from kit Install spacer on street level only A B amp M piston seal ring 52 2 Install on piston p 2 3 a
26. nts 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 transmis sion 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 adjust ment 5 Manual locking cable adjustment 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 3 Insert tapered end of the 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 WORKING IN CLOSE PROXIMITY TO THE EGR SPACER ASSEM BLY 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 pres sure check if transmission fluid is cold or too hot to touch 5 5 Set parking brake and place sh
27. on and safety MAKE SURE THE VEHICLE 15 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 aclean tray on which to put small parts so they won t get lost or dirty S 8 L 16 5643 Figure 1 STEP 1 Since the AOD is not factory equipped with an oil pan drain plug use the following technique to drain 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 the pan to drop down If the pan sticks to the gasket insert a flat screwdriver between the pan and case and pry down gently to break pan 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 2 Short M6x30mm shoulder bolts Long M6x40mm shoulder bolts as Figure 2 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 Use shoulder bolt for alignment Separator plate 7 against case and remove the last bolt When removing valve body watch out for about
28. required Refer to the Engine Emissions Diagnosis manual for appropriate procedure Ensure the curb idle speed is set to specification with and without the throttle solenoid positioner anti diesel solenoid energized if so equipped 4 2Attach Pressure Gauge 0 60 psi with Hose T86L 70002 A and Adapter Fitting D80L 77001 A equiva lent to the TV port on the transmission The pressure gauge should have 2 4m 8 feet of flexible hose to make the gauge accessible while operating the engine 4 3 Obtain 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 4 Operate the engine until normal operating temperature is ADAPTER FITTING PRESSUAE 77001 GAUGE AND HOSE 70002 N i p 1 of sf r 2 r SHOP MAGE GAUGE BLOCK DRILL SHANK 1Omm 617mm L397 007 INCH SERVICE TOOL USAGE ROO CONTROL PRESSURE SEAVICE TOOL D amp 4P 70332 4 TY LEVER ADJUSTING SCREW T LEVER ADJUSTING SCREW TY LINKAGE CARBURETOR LINKAGE VER CAUTION MAKE SURE GAUGE BLOCK OF DAILL CONTACTS SCREW POINT AND DOES NOT TOUCH HERE CARBURETOR THROTTLE LEVER VIEW NOTE USE ROD CONTROL PRESSURE GAUGE 70332 AVAILABLE iF NOT AVA
29. ss is very impor tant so a clean work surface from which oil can easily be removed is necessary This kit contains the parts neces sary 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 and 4 wheel drive vehicles Heavy duty level produces firm noticeable shifts 2 Street Dual purpose performance vehicles street and strip performance cars Street level produces firm posi tive shifts When installing your B amp M AOD Shift Improver Kit there are several other B amp M products you may wish to consider TRANSMISSION OIL COOLER We feel that it is very important that every vehicle used in heavy duty and hi performance applications racing tow ing RV etc should have an oil 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 Avail 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
30. t 6 1 Remove air cleaner cover and inlet tube from throttle body inlet to access throttle lever and cable assembly 6 2 Using a wide blade screwdriver pry grooved pin on cable assembly out of grommet on throttle body lever See Fig 20 6 3 Using 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 5 While 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 6 Install 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 equivalent to TV pressure tap See Fig 8 7 2Obtain Cable TV Gauge tool T86L 70332 A or equiva lent 7 3 Insert tapered 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 away from the plastic rod Ensure gauge block is pushed in as far as it will go See Fig 24 WARNING THIS PROCEDURE REQUIRES WORKING IN CLOSE PROXIMITY TO THE EGR SPACER ASSEM BLY WHICH MAY BE HOT 7 4Qperate engine until norma
31. tent lever spring Starting at the cen ter and working 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 19 Position the TV 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 prop erly will result in erratic shifting STEP 20 Make sure rubber grommet is installed in the filter 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 gasket material from pan and case pan rail Manual valve TV plunger Internal TV Clean inside of pan with solvent If you recall what a mess draining the pan was you may want to installa 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 8 14 Nm If the bolts are over tightene
32. ugar 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 assembly 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 by pushing down on the locking lever at the throttle body end of the cable assembly 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 necessary 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 replace ment 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 complai
33. ut the white locking pin The take up spring at the end PUSH OUT WHITE LOCKING TAB FROM THIS SIDE WHITE LOCKING TAB PUSHED OUT COMPLETELY Figure 21 of the cable assembly tensions the cable and takes up the slack in the system When the grooved 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 partin the operation ofthe system Under normal circumstances it should not be necessary 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 replace ment of the throttle body transmission TV cable assembly or installing anew main control assembly Readjustment 14 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 transmis sion 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 802 CID SEFI engine uses an Air Bypass ISC that does not affect throttle position Therefore idle automatic setting does not affect TV cable adjustment 6 Self locking TV Cable Linkage Adjustmen
34. utch or band shifts TV linkage damaged or out of adjustment Sticking valve in valve body engine Restriction in cooler or lines Converter overrun clutch seized Sticking valves in valve body Relief valve buzzing Oil pump cavitation ransmission 8 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 transmission 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 1 Check adjust the engine curb idle speed to specification 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 3 De 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 o
35. valve body with clean solvent to remove any dirt or grit VALVE BODY MODIFICATIONS IMPORTANT HINT The retaining clips at the end of the valve body bores can fly off during removal To preventlosing the retaining clips place a small rag over the clip when remov ing it this will help prevent the clip from flying off and becoming lost B amp M does not stock replacement re taining clips If yours are lost or dam aged see your local Ford parts sup plier 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 Replace stock spring with spring from kit See steps 6 or 7 Retaining Bore plug tapped hole faces out Retaining clip groove 1 2 Capacity modulator valve Located in first bore on this end of valve body screwdriver to hold the pressure regu lator assembly in while removing the retaining clip 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 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 re taining clip at the end of the 1 2 Capacity Modulator bore See Fig
36. w dabs of grease to hold the gasket against the case CAUTION Valve body installation is one of the most important steps to insure proper operation 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 18 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 posi tioned then install 8 short M6x30mm 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 In stall ALL bolts FINGER TIGHT The short bolts are installed 4 in front 1 in center and 3 in rear of valve body Detent lever pin Detent spring bolt Detent lever spring AN TV torsion spring in separator plate V notch Figure 7 One of the shoulder bolts holds the de
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