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1. 151 INDUSTRIAL DRIVE ASHLAND MISSISSIPPI 38603 http www tciauto com lt TELEPHONE 662 224 8972 FAX LINE 662 224 8255 E MAIL tech tciauto com TCI 386000 Trans Scat Kit Installation Instructions for Turbo 2004R 1981 1991 This kit will allow you to modify your 2004R transmission for your particular driving requirements Street Plus This type of modification is the modifications TCI used when building a StreetFighter transmission The shift feel is very positive and sharp Heavy Duty This type of modification is used for towing campers motor homes police taxi and other vehicles that put a lot of stress on the transmission The shift is firm but not harsh NOTE This kit is not intended for installation in a transmission in poor general condition It will not correct a malfunctioning or slipping transmission This Kit Contains Qty Description One One Line Bias Blocker Rod Filter seal One 1 Separator Plate Two 2 Gaskets One 1 Valve Body marked VB or V One 1 Case Gasket marked C One 1 1 2 Accumulator Plate Gasket One 1 Transmission Pan Gasket One 1 Purple Pressure Regulator Spring One 1 Tan Line Bias Spring 1 1 Step 1 Drain transmission oil pan You will need a pan to catch fluid Remove transmission oil pan bolts When removing bolts remove so pan will not drop completely off but will be held in place so that one side will allow the fluid to be drained Af2. assembly When the slider stops against the fitting release readjust tab By hand open the throttle lever to full or wide open throttle stop position This will automatically adjust cable Release the throttle lever and check the cable to see that it is not binding or sticking REMEMBER DO NOT USE ACCELERATOR PEDAL TO ROTATE THE THROTTLE LEVER YOU MUST ROTATE BY HAND AT THE CARBURETOR Step 21 Now that the adjustment is complete road test With moderate acceleration your transmission should shift q gear aii 15 20 MPH 2 GEA usd winnaar 25 30 MPH 3rd gear 40 45 MPH If the Throttle Valve Cable is not adjusted properly the transmission will shift into 1st 2nd and 3rd within seconds of acceleration DO NOT CONTINUE TO DRIVE VEHICLE IF THIS HAPPENS Readjust cable If you continue to have problems please contact TCI s tech department for assistance WARNING IMPORTANT NOTICE AFTER INSTALLATION ADJUSTMENT It is imperative that after your new 2004R transmission has been installed that the Throttle Valve Cable TV Cable has been adjusted properly If this adjustment has not been made properly DAMAGE will occur to the transmission voiding warranty If you are unsure about the proper adjustment needed call our tech line for help or refer to a Motors or Service manual for additional information and reference Function of Throttle Valve Cable Many people believe that this is an automatic downshift cable and that is the onl
3. bracket assembly Assembly is located near the torque converter clutch solenoid and is held in place with one bolt Disconnect TV cable link from bracket assembly See Photo 1 If your transmission has a lifter wire and spring assembly in area indicated by arrow it may be discarded as it will not be reused Photo 1 Step 5 Remove detent roller and tube bracket Assembly is held in place with one bolt See Photo 2 Photo 2 Step 6 Remove all remaining valve body bolts Remove the center bolt last After you have removed all but this one bolt use your hand to steady the valve body Remove bolt and slowly lower valve body housing The valve body contains check balls This will help you keep the check balls in place not lose any parts Step 7 See Photo 3 Remove four 4 1 2 accumulator housing bolts indicated by the stars and remove the assembly You must remove remaining bolt indicated by the triangle that holds the accumulator spacer plate to separator plate When this bolt is removed lower plate making sure that the check balls are not lost during removal See Photo 3 Photo 3 Step 8 After the separator plate has been removed the 3 4 accumulator may drop out No modifications are needed See Photo 4 for reassembly Step 9 Valve Body Modifications Street Plus Locate line bias valve assembly Remove roll pin by using a scribe or heavy wire to push it out The line bias valve assembly has a spring that will
4. mbly with the new spring as shown Install the retaining ring making sure that it s fully seated in the groove Pressure Regulator Spring Reverse Boost Valve Reverse Boost Valve Sleeve T V Boost Valve T V Boost Valve Sleeve Snap SP Figure 1 NOTE The boost valves and low reverse boost valves can easily be installed incorrectly Incorrect assembly will cause the transmission to function improperly BE SURE these parts are installed in the correct order facing the right direction The TV boost valve and sleeve may be replaced with a 0 500 diameter TCI 374301 or a 0 570 diameter TCI 374401 assembly to further increase pressures Additionally for more pressure in manual first and second gears replace your low reverse boost valve with a 0 400 diameter TCI 374410 Step 11 Servo Modifications Locate the servo on the passenger side of the transmission case Since the transmission has not been removed from the vehicle you may have to remove and reinstall the catalytic converter before you can get to the servo Remove the snap ring holding the servo cover in place Remove cover and servo assembly from case Remove and discard small servo spring Remove Teflon ring and discard from inner piston assembly See Photo 6 Now you are ready to reinstall servo assembly maig TE sa STE oy he ele eG S i Bin a Tat gt s S 7 r RS 4 rs hon Servo Return Spring DISCARD Servo Apply Pin Servo Spring Re
5. push the assembly out of the bore when the roll pin is removed Make sure that you catch hold of the assembly and remove Remove OEM spring and discard Replace spring with blocker rod supplied with kit Reassemble valve assembly and reinstall into valve body See Photo 5A Phot o5 Heavy Duty Locate line bias valve assembly Remove roll pin by using a scribe or heavy wire to push it out The line bias valve assembly has a spring that will push the assembly out of the bore when the roll pin is removed Make sure that you catch hold of the assembly and remove Remove OEM spring and replace with spring supplied with kit Reassemble valve assembly and reinstall into valve body See Photo 5B Step 10 Pressure Regulator Modifications All Applications See Figure 1 Note It is not necessary to remove the pump from the transmission The figure shows a loose pump for clarity purposes Remove the pressure regulator assembly from the transmission pump Push down on the TV boost valve sleeve while removing the retaining ring Be careful as there is heavy spring tension behind it Slowly lower the sleeve to relieve spring tension Remove the TV boost valve sleeve and valve the low reverse boost sleeve and valve and the pressure regulator spring The pressure regulator valve may also drop out If it does not do not remove Replace the pressure regulator spring with the purple spring supplied Reinstall the pressure regulator asse
6. tainer Servo Cushion Spring Inner Piston DI SCARD SEALI NG RI NG Outer Piston Servo Cover Photo 6 Step 12 Separator Plate Modifications See Photo 7 Street Plus The separator plate supplied with this kit will need to have one hole drilled Match your OEM plate with the TCI plate and mark location of torque converter clutch hole Size the hole in your OEM plate and drill TCI plate to same diameter Deburr and wash plate Heavy Duty Match the separator plate supplied with this kit with your OEM plate You will need to drill two 2 new holes Drill the converter relief hole and the 1 2 accumulator hole Drill the accumulator hole to 3 16 in the TCI plate Deburr and wash plate See Photo 7 All Applications Converter Clutch Hole Heavy Duty 1 2 Accumulator ole Photo 7 Step 13 Check Ball Locations in Case Street Plus Install check balls in case as indicated See Photo 8 You may use grease to hold check balls in place Install four 4 check balls only You will not be using three 3 remaining check balls just discard Heavy Duty Install check balls in case as indicated See Photo 8 You may use grease to hold check balls in place Install five 5 check balls in the case You will not be using the two 2 remaining check balls just discard ig N 7y fa MY a SEN gt eavy Duty Only Ie ay eatin a OTD i Photo 8 Step 14 1 2 Accumulator Modifications Street Plus Do not reins
7. tall 1 2 accumulator piston and spring Heavy Duty Reinstall complete 1 2 accumulator piston and spring assembly Install case side separator plate gasket separator plate valve body side gasket and accumulator spacer plate Note that the gaskets are stamped at the top with a C for case and VB for valve body side Use the small bolt to hold the accumulator housing plate in place See Photo 3 Next install accumulator housing Use the four 4 1 2 accumulator bolts Step 15 Check Ball Location in Valve Body Street Plus and Heavy Duty Install one 1 check ball and discard remaining two 2 check balls See Photo 9 Photo Step 16 Reinstalling Valve Body to Transmission Case When installing valve body you must connect manual valve to transmission linkage See Photo 10 Photo 10 Step 17 After the valve body has been reassembled torque the valve body bolts to 10 foot pounds Step 18 Complete reassembly Step 19 Fill transmission to proper fluid level Since the converter is already full the transmission will need approximately 6 quarts of fluid Do not over fill transmission TCI recommends the use of our RTF transmission fluid that is formulated for heat reduction and high stress applications Step 20 Adjustment of the Throttle Valve Cable in a Gasoline Engine Adjustment is made with engine not running Locate the readjust tab Depress tab and move slider through the fitting away for the lever
8. ter the fluid has drained remove the rest of the bolts and pour out the remaining fluid Turbo 2004R transmissions do not have a drain plug You may want to install a TCI 805800 universal drain plug kit into your pan now that you have the pan off the transmission Step 2 Carefully remove the oil filter by pulling it straight down Remove the pickup tube O rings from the pump if they do not come out with the filter Double check Many transmissions came from the factory with two 2 O rings on the filter Inspect the oil filter Replace the filter if it is dirty or has not been changed in over 25 000 miles TCI 386850 filter will fit this application if needed Step 3 There are several different wiring arrangements that are found in the 2004R transmission valve body Different engine sizes and emission standards dictate what wiring was needed for your particular application Before you remove any wires or switches take time to draw your own diagram of the location of your valve body wiring terminal locations and connections Some of the wiring is held in place by a retaining clip that is connected by valve body bolts Remove these bolts first to remove wiring harness Remove the converter clutch solenoid The wiring harness does not have to be completely removed from transmission just remove from the valve body area You can let the harness hang loose since you are working only with the valve body Step 4 Remove the throttle lever and
9. y function of this cable In actuality the Throttle Valve Cable controls line pressures shift points shift feel part throttle downshifts and detent downshifts The cable is very similar to the functions of both a vacuum modulator and detent downshift cable in other transmissions Throttle Valve Cable Connections The transmission valve body is linked to the throttle lever and bracket assembly and from there the TV Cable is linked to the carburetor or injection of the vehicle Between the carburetor and transmission a TV cable adjustment is used to set proper adjustment 4 13 04
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