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TH125 Manual PDF

1. INPUT RING SNAP SELECTIVE INPUT DRUM SUN GR GEAR REACTION SUN H 125070 Figure 65 Input Components Internal gear 637 for gear tooth damage clutch hub damage or scored bearing surfaces e Sun gear 642 for damaged teeth or bearing surface Assemble Figure 65 1 Drum 643 onto the reaction sun gear 646 in the case 2 Input sun gear 642 groove facing up onto the reaction sun gear 646 3 Tanged thrust washer 641 onto the carrier assembly 640 retain with petrolatum 4 Carrier assembly 640 onto the sun gear 642 sun gear must engage the pinions 5 Thrust washer 639 6 Internal gear 637 FORWARD CLUTCH ASSEMBLY Disassemble Figures 66 and 67 Tools Required Arbor Press Compressor Snap ring 635 from clutch housing 624 Backing plate 634 Steel and composition clutch plates 633 Snap ring 632 use an arbor press or J 23456 Retainer and spring assembly 631 and guide 630 Piston 629 Insert 628 Piston seals 626 and 627 Inspect Figure 66 J 23456 Clutch Pack DOP QN Re tan po y 125 44 AUTOMATIC TRANSAXLE 635 621 J 23456 z J 25018 A J f NOT REQUIRED WITH CAST ALUMINUM PISTON SNAP RING SELECTIVE RING OIL SEAL HOUSING ASSEMBLY FORWARD CLUTCH SEAL FORWARD CLUTCH PISTON OUTER SEAL FORWARD CLUTCH PISTON INNER INSERT PISTON FORWARD CLUTCH GUIDE RELEASE SPRING RETAINER amp SPRING ASM FWD C
2. 1250 54 CASE COVER SIDE PUMP SIDE 1 1 PRESS SEAL FLUSH TO 0 5mm 0 020 ABOVE 5 SURFACE 354 BEARING ROLLER PUMP SHAFT 357 SEAL PUMP SHAFT Figure 94 Bearing Seal Dimension 125C 55 Pump Shaft Bearing Replacement Remove or Disconnect Tools Required J 28698 Pump Bearing Remover and Installer J 7079 2 Driver Handle Bearing with J 28698 and J 7079 2 Drive toward pump pocket AUTOMATIC TRANSAXLE 125C 55 Install or Connect Figures 92 93 and 94 Tools Required J 28698 Pump Bearing Remover and Installer J 7079 2 Driver Handle New bearing use J 28698 and J 7 79 2 install from pump pocket side bearing cup must be 0 45 0 15 mm 0 017 0 005 below pump pocket Assemble Figures 88 and 89 Oil pump assembly 1 Pump slide 348 into pump pocket 2 Slide seal support 349 and seal 350 into slide 348 3 Align side with pivot hole then install pin 345 4 Vane ring 351 into pump pocket 1 of 2 rings 5 Vanes 352 and rotor 353 pocket 6 Vane ring 351 top of rotor 7 OQ ring seal 349 on top of rotor 8 ring seal 346 slide to cover Auxiliary valve body Converter clutch regulator valve 342 spring 341 bore plug 340 and roll pin 306 Control valve 332 and plug 310 Switches 335 amp 338 Solenoid 333 with oil seal 337 and bolt 334 attach leads e Auxiliary valve body to valve body Position as shown
3. REQUIRES USE OF J 29829 H125 324B Figure 79 Turbine Shaft Seal Replacement Thrust bearing 121 for damage or wear Driven support thrust washer 123 for damage or wear See drive link inspection in Section 7A BEARING ASM DRIVEN SPROCKET THRUST 122 SPROCKET DRIVEN 123 WASHER DR SKT SUPPORT THRUST H 125C 76 Figure 78 Drive Link Assembly Turbine Shaft Seal and Drive Sprocket Replacement Procedure Remove or Disconnect Figure 4 and 79 e Seals 105 from turbine shaft cut with a knife e Snap ring 102 from turbine shaft Drive sprocket 103 from turbine shaft Install or Connect Figure 79 Tools Required J 29569 Turbine Shaft Seal Installer J 29829 Turbine Shaft Seal Installer Drive sprocket 103 onto turbine shaft Snapring 102 onto turbine shaft Slide installer J 29569 1 over the turbine shaft and coat with petrolatum Guide new seals 105 over tool into seal ring grooves Size the seals with sizing tool J 29569 2 Slide installer J 29829 1 over opposite end of turbine shaft and coat with petrolatum Guide new seal 148 over tool into seal ring groove Size the seal with sizing tool J 29829 2 DESCRIPTION COVER TRANSMISSION CASE NAMEPLATE SCREW NAMEPLATE VENT ASSEMBLY PLUG LINE PRESSURE PICKUP PIPE VALVE MANUAL SEAL O RING ELECTRICAL CONNECTOR AUTOMATIC TRANSAXLE 125 49 109 DRIVE SPROCKET SUPPORT STATOR SHAFT 115 SEAL CONVER
4. CONVERTER LUBE MAINLINE CONVERTER 10 COOLER 2 GOVERNOR 1 2 ACCUMULATOR CONVERTER CLUTCH REGULATOR VALVE ORIFICE ACCUM CHECK VALVE INTERMEDIATE SERVO DICT REVERSE sut LINE PRESSURE SOLENDID V PRESSURE RELIEF VALVE STRAINER 125 30 3 Figure A 3 Hydraulic Oil Circuit 125C 6 AUTOMATIC TRANSAXLE OONAN VALVE LINE BOOST LINE CONVERTER FEED APPLY SHIFT TV EXHAUST SHIFT TV ORIFICE CUP PLUG VALVE BODY PIPE DRIVE SLIDE COVER SEAL amp SEAL SUPPORT LO BLOW OFF GOVERNOR CLUTCH SLIDE SEAL amp SEAL SUPPORT VANE RING SPRING PRIMING ROTOR VANE SLIDE TO COOLER RELEASE EXHAUST DECREASE H 125C 7 2 SLEEVE STEEL CONVERTER FEED T C C APPLY CONVERTER SEAL DRAINBACK CONVERTER TO COOLER RELEASE SHAFT OIL PUMP DRIVE SPROCKET DRIVE WASHER THRUST RING OIL SEAL GREEN SHAFT TURBINE SEAL O RING BEARING ASSEMBLY SUPPORT DRIVE SPROCKET BUSHING RING OIL SEAL YELLOW H 125C 35 4 Figure 5 Converter Oil Passages Parts Cut Away View AUTOMATIC TRANSAXLE 125 7 1 CHECK BALL GOVERNOR RND DRIVE 2ND LO 1ST DIRECT CLUTCH 3RD LO DETENT SHIFT TV PART THROTTLE LUBE 1 2 ACCU
5. 2 43 2 53mm 0 095 0 099 2 63 2 73mm 0 103 0 107 PIN SPRING THERMO ELEMENT PIN THERMO ELEMENT PLATE THERMOPLASTIC ELEMENT THERMO ELEMENT WASHER THERMO ELEMENT DESCRIPTION WASHER THRUST CASE COVER TO DR SKT COVER TRANSMISSION CASE GASKET CASE TO CASE COVER CENTER NAMEPLATE GASKET CASE CASE COVER SCREW NAMEPLATE SPRING AND ROLLER ASM MANUAL DETENT VENT ASSEMBLY BOLT MAN DET SPRING CASE COVER PLUG LINE PRESSURE PICKUP PIPE SPRING 1 2 ACCUMULATOR PISTON VALVE MANUAL RING OIL SEAL 1 2 ACCUMULATOR PISTON SEAL O RING PISTON 1 2 ACCUMULATOR ELECTRICAL CONNECTOR PIN 1 2 ACCUMULATOR 1250202 Figure 19 Case Cover Case Side 125 28 AUTOMATIC TRANSAXLE Place the case cover 401 on the bench 1 2 accumulator side up Accumulator spring 419 Piston 421 Gasket 415 Drive sprocket thrust washer 414 Driven sprocket thrust washer 121 Turbine shaft ring Figure 21 uu poe 101 drive and driven sprockets 103 122 Drive sprocket support thrust washer 104 Driven sprocket support thrust washer 123 Case Cover Remove or Disconnect Figures 19 20 21 and 22 Tools Required Two M12 bolts 50 mm 2 long Rod 70 from manual valve 406 2 case cover attaching bolts including 2 TORX head bolts e Install two 2 M12 bolts 50 mm 2 long into dowel pin holes Bolts will self tap bottom and separate the case 112 and the 401
6. Plug 607 Figure 27 e Band 606 SUPPORT DRIVEN SPROCKET WASHER THRUST DRIVEN SPROCKET SUPPORT TO DIRECT CLUTCH HOUSING ROD AND LEVER ASSEMBLY LEVER ASSEMBLY DETENT SHAFT MANUAL PIN MANUAL SHAFT CASE RETAINING H125 20 1 Figure 25 Removing Manual Linkage 125C 30 AUTOMATIC TRANSAXLE 125 1432 NOT REQUIRED WITH CAST ALUMINUM PISTON Figure 26 Internal Components 624 626 627 628 629 630 631 632 633 634 635 636 637 638 639 640 641 642 DESCRIPTION BEARING ASSEMBLY SUPPORT ASSEMBLY DRIVEN SPROCKET BUSHING DRIVEN SPROCKET SUPPORT RING OIL SEAL WASHER THRUST BAND ASSEMBLY INTERMEDIATE PLUG BAND ANCHOR HOLE BUSHING DIRECT CLUTCH RETAINER amp BALL ASM CHECK VALVE HOUSING amp DRUM ASM DIRECT CLUTCH BUSHING DIRECT CLUTCH DRUM SEAL DIRECT CLUTCH PISTON OUTER SEAL DIRECT CLUTCH CENTER SEAL DIRECT CLUTCH PISTON INNER PISTON DIRECT CLUTCH APPLY RING amp RELEASE SPRING ASM RING SNAP PLATE DIRECT CLUTCH PLATE CLUTCH BACKING DIRECT RING SNAP SNAP RING SELECTIVE RING OIL SEAL BUSHING INPUT SHAFT HOUSING ASSEMBLY FORWARD CLUTCH SEAL FORWARD CLUTCH PISTON OUTER SEAL FORWARD CLUTCH PISTON INNER INSERT PISTON FORWARD CLUTCH GUIDE RELEASE SPRING RETAINER amp SPRING ASM FWD CL RING SNAP SPRING RETAINER PLATE FORWARD CLUTCH PLATE CLUTCH BACKING FORWARD RING SNAP WASHER INPUT SHAFT THRUST GEAR AND IN
7. SS 282 4 649 10 AND REVERSE CLUTCH HOUSING 125 32 Figure 60 Installing the Lo amp Reverse Clutch REACTION SUN GEAR Inspect Figure 65 Reaction sun gear 646 for cracks splits damaged splines worn gear or journal and plugged lubrication holes Install or Connect Sun gear 646 and selective snap ring 644 Selective Snap Ring End Play Measure Figures 61 and 62 Tools Required J 26958 Loading tool J 26958 11 Bracket J 26958 10 Adapter plug J 28588 Gage J 25025 7 Post 1 26900 12 or J 8001M Dial indicator l Install the tools as shown The loading tool should still be in place Seat sun gear 646 Position the gage extension between open ends of snap ring 644 Swing the gage under the extension shoulder Set the dial indicator at zero Position the snap ring 644 under extension shoulder Remove the gage from under the shoulder The dial indicator should read 0 33 to 0 13 mm 0 013 to 0 005 If not within tolerances for correct pato selection see Figure 62 Measure washer thickness new or used with micrometer 1 EXTENSION 2 FEELER GAUGE J 8001 M Figure 61 Selective Snap Ring End Play Sun Gear Input Drum REACTION SUN GEAR TO INPUT DRUM SELECTIVE SNAP RING 644 Thickness Identification Color 2 27 2 37 0 089 244 2 54mm 0 096 2 61 2 71mm 0 103 2 78 2 88mm 0 109 2 95 3 05mm 0 116 3 12 3 22mm 0 123
8. Speedometer Drive Gear T V Cable Automatic Shift Cable with a hot transaxle Overfilling can cause damage to transaxle FLUID CAPACITIES Pan removal 3 8 liters 4 qts Overhaul without converter drain 5 7 liters 6 qts Overhaul with converter drain 8 5 liters 9 qts SERVICE PROCEDURES FIGURE 1 Fig 7A1 1 Cable Removal Plug Type 7A1 2 DIAGNOSIS AND ON CAR SERVICE FIGURE 2 Fig 7A1 2 Cable Removal Without Plug SHIFT SYSTEM CABLE REMOVAL Removal procedure for automatic shift linkage cables shift and park lock with nylon ends Ifcable end has a plug reference Figure 1 push on plug to spread tangs then remove cable end from lever shifter transmission etc If cable end does not have a plug use screwdriver or flat tool as shown in Figure e Insert tool between lever and nylon end at the pin center line Rotate tool and cable end will snap off pin ADJUSTMENTS MANUAL LINKAGE The transaxle manual linkage must be adjusted so that the indicator quadrant and stops correspond with the transaxle detent If the linkage is not adjusted properly an internal leak could occur which could cause a clutch or band to slip CAUTION a manual linkage adjustment is made with the selector lever in the PARK position the parking should freely engage the reaction internal gear to prevent the car from rolling Transmission vehicle or person
9. lips facing capsule Piston 615 bid 125 46 AUTOMATIC TRANSAXLE 5 Apply ring and release spring assembly 616 6 Snap ring 617 7 Lubricate composition plates 618 8 Alternatel steel and composition plates 618 9 Backing plate 619 chamfered or highly polished side against composition plate 10 Snap ring 620 610 HOUSING DIRECT CLUTCH 624 HOUSING FORWARD CLUTCH 636 WASHER THRUST STEPPED SIDE OUT 67 KAA Ly TT 125 103 Figure 72 Assembled Height of Clutch Assemblies FORWARD AND DIRECT CLUTCH Assemble Figures 72 73 and 74 Direct clutch assembly onto the forward clutch assembly Rotate the direct clutch so that all clutch plates engage the clutch hub Thrust washer stepped side out 636 use petrolatum Measure Figure 72 e Assembled height 31 mm 1 7 32 Install or Connect Figures 73 and 74 Forward and direct clutch assemblies into case Measure Figure 74 Case face to housing 42 mm 1 11 16 A INPUT SHAFT 610 CLUTCH DIRECT 624 CLUTCH FORWARD 610 HOUSING amp DRUM ASM DIRECT CLUTCH 612 SEAL DIRECT CLUTCH PISTON OUTER 613 SEAL DIRECT CLUTCH CENTER 614 SEAL DIRECT CLUTCH PISTON INNER 615 PISTON DIRECT CLUTCH 616 APPLY RING amp RELEASE SPRING ASM 617 RING SNAP 618 STEEL CLUTCH PLATE B 618 COMPOSITION FACED PLATE 618 ALTERNATING STEEL amp PLATES 619 PLATE CLUTCH BACKING DIRECT evi 620
10. 3 29 3 39mm 10 129 0 3 46 3 56mm 0 136 0 Figure 62 Selective Snap Ring Chart Lo Roller Clutch Race Selective Spacer End Play Measure Figures 63 and 64 Tools Required Tools from previous measurement J 28585 Snap Ring Remover 1 Leave tools from Selective Snap Ring End Play Check in place 2 Pry upon internal gear 668 with J 28585 Do not pry against spacer 671 check Figure 63 Lo Roller Clutch Race Selective Spacer REVERSE CLUTCH HOUSING TO LO RACE SELECTIVE SPACER 60 Thickness Identification 220mm 0 039 0 043 1 52mm 0 056 0 060 1 94mm 0 072 0 076 2 36 0 089 0 093 2 78mm 0 105 0 320mm 0 122 0 H 125 320 Figure 64 Lo Race Selective Spacer Chart 3 Dial indicator reading should be 0 08 1 17 mm 0 003 0 046 For correct washer selection see Figure 64 4 Remove the dial indicator set and J 28588 INPUT UNIT PARTS Inspect Figure 65 Drum 643 for damage Thrust washer 641 for damage Carrier assembly 640 for Pinion damage Pinion tilt Pinion end play use the feeler gages end play range 0 24 0 69 mm 0 009 0 027 Thrust washer 639 for damage AUTOMATIC TRANSAXLE 125 43 I Ww WASHER INPUT SHAFT THRUST GEAR INPUT INTERNAL WASHER INPUT CARR IP INT GR THRUST CARRIER ASSEMBLY INPUT WASHER INPUT CARR IP SUN GR THRUST GEAR INPUT SUN
11. Figure 97 Spacer Plate amp Gaskets Install or Connect 1 Gasket 25 or apply R T V silicon sealant TORQUE ALL BOLTS TO 11 N m 8 FT LBS TORQUE ALL 8 BOLTS 24 N m 18 FT LBS wee ee 125C 10 Figure 98 Valve Body Bolt Location 2 Cover 26 3 Screws 27 Tighten Torque the screws 27 to 11 N m 8 ft Ibs Install or Connect Figure 101 l Shaft 29 into case 2 C ring 30 position with needle nose pliers 3 With J 28583 push on ring 30 AUTOMATIC TRANSAXLE 125C 57 MODEL USAGE BC BD BP CA CB CC CJ CK CL CM CT CU CX HL HU PA PD PF PH PJ PN PR PW MODEL HS 1 CLIP IN CASE COVER PRONGS D 333 SOLENOID ASSEMBLY 335 SWITCH 3RD CLUTCH PRESSURE 408 CONNECTOR ELECTRICAL 335 BODY OIL PUMP AND CONTROL VALVE SOLENOID ASSEMBLY SWITCH CLUTCH PRESSURE N O SWITCH GOV PRESSURE N O WIRE ASSEMBLY WHITE BODY AUXILIARY VALVE ELECTRICAL CONNECTOR iQ Figure 100A T C C Wiring Diagram LINE X BLACK 301 BODY OIL PUMP AND CONTROL VALVE 333 SOLENOID ASSEMBLY SWITCH 3RD CLUTCH PRESSURE N O SWITCH GOV PRESSURE N O WIRE ASSEMBLY WHITE BODY AUXILIARY VALVE ELECTRICAL CONNECTOR H125C 98 1 Figure 100 T C C Wiring Diagram 125 58 AUTOMATIC TRANSAXLE 29 SHAFT OUTPUT 30 RING SNAP ACTUATOR ASSEMBLY 710 BRACKET PARKING LOCK 711 BRACKET DIPSTICK
12. 665 for scoring or distortion Assemble Figure 56 and Figure 26 1 Thrust washer 663 into carrier assembly 665 2 Rollers into cage 662 3 Clutch assembly 662 4 Clutch race 661 rotate into place 5 thrust washer 666 use petrolatum to hold in position 6 Carrier 665 and clutch assembly into internal gear 668 7 Selective spacer 660 8 Reaction gear set 660 669 into case Make sure gear set does not contact spacer 671 LO AND REVERSE CLUTCH PLATES Inspect Figure 56 Backing plate 659 for damage or cracks Lo and reverse clutch composition and steel plates 658 for wear or burning Install or Connect Figure 56 and Figure 70 1 Backing plate 659 stepped side down into case 2 Lubricant on composition plates 658 before installation 3 Alternate composition plate first then steel plate See Figure 70 4 Waved steel plate 5 Spacer ring 650 ring is 1 07 mm 0 042 thick LO AND REVERSE CLUTCH HOUSING Disassemble Figure 57 Snap ring 656 push down on spring retainer 657 Waved spring 655 Clutch piston 653 Inner 652 and outer 651 seals from piston 653 Inspect Figure 57 Waved spring 655 for damage Inner 652 and outer 651 seals for nicks or rolling Clutch housing 649 for damage or plugged feed hole Clutch housing bushing for damage cracks or scoring Clutch piston 653 for distortion cracks or damage Ass
13. J 28544 Input shaft lifter J 25025 7 Dial indicator post J 26900 12 or J 8001 Dial indicator Install essential tools Push the lifter down and zero the dial indicator Pull the lifter up 401 COVER TRANSMISSION CASE Per A 406 VALVE MANUAL reading should 0 10 0 84 mm 701 ROD amp RETAINER ASSEMBLY Figure 84A Bopp See Figure 87 for snap ring selection correct as necessary 5 Remove tools CONTROL VALVE AND OIL PUMP ASSEMBLY Disassemble Figures 88 89 and 901 Control Valve Assembly Important Valves and springs are not interchangeable Keep them in the order shown Position as shown Start at the upper left and remove each valve Figure 85 Manual Valve train Lay out the valve train as shown 125 52 AUTOMATIC TRANSAXLE 304 304 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 373 304 310 309 308 37200 emm 312 311 um 304 310 gig 314 313 0 T CR 318 317 316 AL 3194 aria 323 3 32 31 30 18 BODY OIL PUMP AND CONTROL VALVE PLUG BORE LINE BOOST VALVE VALVE LINE BOOST PIN SPRING VALVE RETAINING PIN COILED SPRING LINE BOOST PLUG PIN COILED SPRING SLEEVE SPRING RETAINING VALVE SHIFT T V SPRING SHIFT T V PLUG VALVE BORE BALL PRESSURE RELIEF 9 525 DIA SPRING PRESSURE RELI
14. PLUG PIPE LINE PRESSURE PICKUP VALVE MANUAL THERMO ELEMENT 125 137 c IO0mmoo VOID DRAINBACK SEAL LUBE DRIVE REVERSE DIRECT CLUTCH LO REVERSE 2ND INTAKE ACCUMULATOR DIRECT CLUTCH GOVERNOR EXHAUST DIRECT CLUTCH ACCUMULATOR SUPPORT DRIVE SPROCKET ACCUMULATOR DIRECT CLUTCH CUP PLUG 125 291 PIPE LO REVERSE SUPPORT DRIVEN SPROCKET A B C D E F G H 9 K L Figure A 11 Case Case Cover Side 125C 10 AUTOMATIC TRANSAXLE DRAINBACK SEAL SEAL REMOVED COVER GOVERNOR SEAL ASSEMBLY CONVERTER PLUG CUP PARKING PAWL SHAFT PLUG GOVERNOR PRESSURE PICKUP SHAFT MANUAL Figure A 13 Case Right Hand Axle End LO amp REVERSE ACCUMULATOR DIRECT CLUTCH SEAL REVERSE OIL CASE TO HOUSING SPRING ACCUMULATOR EXHAUST VALVE ACCUMULATOR EXHAUST PIPE GOVERNOR OIL RING SEAL BACKUP SEAL O REVERSE PIPE TO CASE 125 181 2 H 125C 34 LUBE FEED FORWARD CLUTCH SLEEVE STEEL SHAFT INPUT RING OIL SEAL BUSHING INPUT SHAFT HOUSING ASSEMBLY FORWARD CLUTCH SEAL FORWARD CLUTCH PISTON OUTER SEAL FORWARD CLUTCH PISTON INNER INSERT PISTON FORWARD CLUTCH GUIDE RELEASE SPRING RETAINER SPRING ASM FWD CL RING SNAP SPRING RETAINER AUTOMATIC TRANSAXLE 125 11 qr lied XE GR 1d 125 294 Figure 14 Forward Clutch Assembly Cut Away View DRIVEN SPROCKET SUPPORT DIRECT CLUTCH LU
15. and watch for bubbles t APPLY LIQUID SOAP OR LEAK _ DETECTING SOLUTION POP RIVET LOCATION OF HOLE TO BE DRILLED Fig 7 Location of Hole to be Orilled N PROP CONVERTER UP IN SUITABLE CONTAINER FOR DRAINAGE THM 125C amp 180C will require a J 21369 40 Rubber Seal in addition to J 21369 B 2 e G20015 7A Fig 10 Pressure Testing Torque Converter The converter should be replaced if Either the auxiliary valve body cover or pump pocket are badly scored 620019 7 Internal converter failure such as the stator Fig 8 Draining Torque Converter overrun clutch not locking thrust bearing failure etc Such failures are also normally associated TORQUE CONVERTER EVALUATION with aluminized oil in the converter End play in the converter exceeds 020 to 024 Figures 9 10 and 11 0 5mm This measurement cannot be estimated but must be made with tool J 29830 Tools Required Leaks externally such as at the hub weld area J 21369 D Torque Converter Leak Test e Hub scored or otherwise damaged which could Fixture cause a front seal failure or front pump bushing failure 1 21369 40 125C Leak Test Adapter A broken damaged or illfitting converter pilot J 29060 End Play Checking Tool 200C which could cause the converter to either not fit 200 48 into the crankshaft bore properly or not be i correctly aligned with the crankshaft Play Checking Tool 32547 e Ifthe converter h
16. take the line pressure readings in the ranges and at the engine r p m s indicated in the chart below Full T V Line Pressure Check Full T V line pressure readings are obtained by tying or holding the T V cable to the full extent of its travel and with the brakes applied take the line pressure readings in the ranges and at the engine r p m s indicated in the chart below For line pressure tap location see Fig A 10 Item 405 CAUTION Brakes must be applied at all times NOTICE keine combination nance MINIMUM T V P S kPa BA BC BD BP CA PD CB CC JS CM PH JP PF PR PK PN PW HX PA Park 455 510 65 75 No T V pressure in Park CD H CK CL CT CU CX HL HN HS HU 1 000 RPM 510 585 75 85 Line pressure is the same JB JD JF JJ JK JM JN JR JW RD 395 440 55 65 as Park at Minimum T V 690 765 100 112 1400 1590 203 230 690 765 1600 1785 230 260 690 765 1185 1320 170 190 690 765 1510 1720 220250 760 840 1510 1680 220 245 780840 1635 1815 235265 40 5 265 Reverse 760 840 1955 255 285 780 860 2057 262 300 805 890 215 240 805 890 4710 220 248 805 890 235 270 805 890 1715 1910 250277 805 890 1750 1985 255 290 855 1020 130 148 1692 1912 245277 895 1020 1720 1980 250287 895 1020 18402115 267 307 395 437 915 1020 132 148 395 437 800 906 116 132 395 437 675 753 98 110 395 437 785 875 114 127 395 437 850 950 125 138 395 437 863 981
17. 125 143 Neutral 459 507 849 944 123 137 Drive 459 507 863 977 125 142 1000 459 507 930 1055 135 153 459 507 979 1090 142 158 459 507 998 1133 145 165 459 507 1065 1211 155 176 510 582 966 1091 140 158 CX CT 510 582 982 1130 142 164 CF CK CL CU HL HN SS HU 510 582 1050 1208 152 175 JD JF JK JM JN J 680 750 No T V pressure in BA BC BD BP CA CB CC CM C HX JP JS Ey PF PH PR PK PN PW Intermediate Intermediate or Lo JJ JR 10 Line pressure is the CD CF CK CL CT CU CX HL HN HS HU 1000 RPM same as Intermediate P 957 1057 139 154 Lo at Minimum T V Line pressure is basically controlled by pump output and the pressure regulator valve In addition line pressure is boosted in Reverse Intermediate and Lo by the reverse boost valve Also in the Neutral Drive and Reverse positions of the selector lever the line pressure should increase with throttle opening because of the T V system The T V system is controlled by the T V cable the throttle lever and bracket assembly and the T V link as well as the control valve pump assembly 125 29 7 Figure A 1 Preliminary Checking Procedure CAUSES OF BURNED CLUTCH PLATES OR BAND A burned clutch or band is generally caused by some condition such as low pressure and or leaks that prevent proper application During diagnosis or inspection this cause must be found cut or damaged seal may be the cause of
18. 684 and 686 and carrier for damage Assemble Figure 49 Side gears 687 and washer 686 into carrier Pinion thrust washer 684 to pinions 685 retain with petrolatum Pinions and thrust washers into carrier Pinion shaft 682 slide through both pinions for alignment then remove Rotate pinions into position then replace shaft 682 Retaining pin 683 Dr Assemble Figure 49 1 2 3 4 Thrust bearing 676 into carrier Sun gear 675 stepped side facing up Thrust bearing 674 outside race to internal gear Internal gear 673 onto carrier 683 PIN RETAINING 1 PUNCH 5mm 3 16 125 57 Figure 52 Pinion Shaft Retaining Pin Install or Connect Figure 52 Tool Required J 28545 Final Drive Remover and Installer l Thrust washer 680 onto carrier assembly retain with petrolatum 3 Inspect AUTOMATIC TRANSAXLE 125C 39 678 DIFFERENTIAL CARRIER H 125 38 Figure 53 Installing the Final Drive Assembly 2 Thrust bearing 681 onto carrier assembly inner race toward carrier retain with petrolatum Carrier assembly into case with J 28545 Spacer 671 for damage Snap ring 670 for damage Install or Connect Figure 49 Spacer 671 into the transmission case Important The spacer 671 must fit into the case so that the parking pawl operates freely Snap ring into the snap ring groove J 26900 12 OR lt 8001 M Figure 54 Final Drive End ctive
19. 8 ft Ibs 9 75 in Ibs 9 75 in Ibs 11 N m 8 ft Ibs H 125C 84 1 AUTOMATIC TRANSAXLE 125 63 J 3289 20 J 7079 2 Transmission Support Fixture J 28664 Torque Converter Pressurization Kit 3 21369 Dial Indicator Stand and Guide Pin r gt SSS J 25025 A Compressor Screw and Frame Universal Remover Universal Bushing Remover Set J 23456 J 23907 J 29369 Forward Clutch Spring Compressor 40 Torx Bit or Equivalent Axle Seal Installer J 23327 1 J 25359 5 J 29130 Adapter Forward Clutch Spring Converter Seal installer Compressor J 25018 A J 28540 Adapter Plug Adapter Bracket J 26958 10 J 26958 11 Intermediate Band Apply Pin Gauge E zi gt hp U J 28535 Es Torque Converter End Play Fixture J 28538 Output Shaft Aligning and Loading Tool Lo Reverse Clutch Housing Remover and Installer J 28542 Input Shaft Lifter J 28544 Final Drive Unit Remover and Installer C Ring Remover Output Shaft Ded Gauge Reaction Sun Gear Snap Ring and Reaction Carrier f Washer Selection J 28588 J 29023 J 28545 J 28583 Bearing Installer Sprocket Supports Pump Bearing Installer and Remover Thermo Element Height Gauge aera 5 J 28677 J 28698 Universal Bushing Installer Set Turbine Shaft Se
20. Coat both ends of the pipe 138 with loctite or equivalent 2 Pipe 138 into case 112 tap gently with a soft mallet AUTOMATIC TRANSAXLE 125C 37 3 Retainer 143 and bolt 142 torque to 24 N m 18 ft 165 Inspect 3rd oil cup plug 127 for cracks or loose fit 3rd Oil Cup Plug Replacement Procedure Remove or Disconnect Figure 48 e Plug 127 use 3 screw extractor with 13 mm 1 2 ground off Install or Connect e Plug 127 tap until seated in case use 6 mm 1 4 rod Inspect e Manual Shaft oil seal 113 for damage Manual Shaft Replacement Procedure Remove or Disconnect Seal 113 pry check bore for burrs Smooth with fine stone if necessary Install or Connect Seal 113 lipside up use 13 mm or 9 16 socket tap with mallet until seated 138 PIPE GOVERNOR OIL 1 PARTICLE BOARD 1 EXTRACTOR 3 MODIFIED 2 PLUG CUP DIRECT CLUTCH 3rd Figure 48 Cup Plug Removal 125C 38 AUTOMATIC TRANSAXLE RING SNAP SPACER FINAL DRIVE INTERNAL GEAR GEAR FINAL DRIVE INTERNAL BEARING THRUST SUN GEAR INT GEAR GEAR FINAL DRIVE SUN BEARING THRUST SUN GEAR CARRIER RING SPIRAL RETAINING DIFFERENTIAL CARRIER GEAR GOVERNOR DRIVE WASHER DIFF CARR CASE SEL THRUST BEARING ASM DIFF CARR CASE THRUST SHAFT DIFFERENTIAL PINION PIN DIFF PINION SHAFT RETAINING WASHER PINION THRUST PINION DIFFERENTIAL WASHER DIFF SIDE
21. GEAR THRUST GEAR DIFFERENTIAL SIDE 125 73 Figure 49 Final Drive Assembly DIFFERENTIAL AND FINAL DRIVE Disassemble Figure 49 l Internal gear 673 2 Thrust bearing 674 3 Sun gear 675 4 Thrust bearing 676 1 FEELER GAGE 2 PINION FINAL DRIVE 678 DIFFERENTIAL CARRIER 125 61 Figure 50 Final Drive Pinion End Play Inspect Figure 50 e Final drive pinions 678 for damage Excessive end play with a feeler gage End play range 0 24 0 63 mm 0 009 0 025 Internal gear 673 for damaged teeth or bearing surface Thrust bearing 674 for damage Sun gear 675 for damaged teeth or bearing surfaces Thrust bearing 676 for damage Governor drive gear 679 for wear 1 WASHER THICK FLAT 679 GEAR GOVERNOR DRIVE Figure 51 Governor Drive Gear Replacement Governor Drive Gear Replacement Remove or Disconnect Figure 51 Tool Required J 8433 Puller e Governor drive gear 678 with J 8433 place a thick flat washer or other protection on the hub to avoid damage Install or Connect Drive gear tap into position with a soft mallet Inspect Figure 49 Pinions 685 and side gears 687 for damaged teeth Pinion Gear Replacement Procedure Disassemble Figures 49 and 52 e Retaining pin 683 use a pin punch as shown e Pinion shaft 682 e Pinions 685 side gears 687 and washers 684 and 686 Inspect Figure 49 Washers
22. Inspect e Pin 129 for damage e Seals 134 and 132 for cuts or nicks proper scarf cut alignment Do not remove seals 132 and 134 unless replacement is necessary Spring 131 for damage Retainer 130 for damage Cover 137 for damage cracks porosity Piston 133 for cracks seal groove damage Measure Figures 105 and 106 Tools Required J 28535 Intermediate Band apply pin gage 1 Install J 28535 on the case 112 and the pin 129 into the gage 2 With a torque wrench apply 11 2 N m 100 inch pounds of torque 1 ROD 95mm 3 8 d 120 CUP PLUG LO AND REVERSE 1350 87 Figure 105 Checking for Proper Apply Pin AUTOMATIC TRANSAXLE 125C 59 INTERMEDIATE BAND APPLY PIN LENGTH IDENTIFICATION 2 Grooves 1 Groove No Grooves H 125 317 J H 125 134 4 amp 7 fi fo dt 125 SPRING 3RD ACCUMULATOR EXHAUST IE 126 VALVE 3RD ACCUMULATOR EXHAUST Figure 107 3rd Accumulator Exhaust Valve amp Spring 3 If the white line appears in window the pin length is correct If the white line does not appear select another length pin Figure 106 Repeat procedure 4 Remove pin gage Assemble Figure 103 1 Retainer 130 onto pin 129 2 Spring 131 against spacer 13 3 Piston 133 onto pin 4 1 ring 135 onto pin Install or Connect Figures 107 and 103 Spring 125 into bore 2 Check valve 126 into bore 5 2 AU
23. Install gasket 331 and cover 330 Tighten Torque the bolts 327 to 11 N m 8 ft 165 Assemble Figures 88 89 and 90L Control valve assembly valves springs bushings bore plugs and roll pins as shown Figure 95 heck Ball Locations 125 56 AUTOMATIC TRANSAXLE CASE ASSEMBLY BALL 6 3 DIA SHAFT OIL PUMP DRIVE GASKET SPACER PLATE PLATE VALVE BODY SPACER CONTROL VALVE amp OIL PUMP ASM LINK THROTTLE LEVER TO CABLE LEVER AND BRACKET ASM THROTTLE BOLT VALVE BODY CASE GASKET VALVE BODY COVER COVER VALVE BODY SCREW VALVE BODY COVER H 125C 67 Figure 96 Control Valve Pump Assembly Oil Pump Shaft CONTROL VALVE AND OIL PUMP ASSEMBLY etat or Connect Figures 95 96 97 98 99 and 0 1 Check 16 numbers 2 3 4 and 5 2 Gasket 19 3 Plate 20 4 Gasket 19 5 Check ball 16 number one on spacer plate 6 Shaft 18 through case cover 7 6mm guide pins 8 Body assembly 21 onto case cover 9 Retainer 328 10 Bolts 327 Refer to Figure 98 1 Coat bolt F Figure 98 with thread sealer 12 Wiring harness 13 Link 22 14 Bracket assembly 23 engage link 22 15 Remove 6 mm guide pins 16 Remaining bolts 327 DJ Tighten Torque the bolts 327 M6 11 N m 8 ft Ibs 8 24 N m 18 ft 1bs 1 PINS 6mm GUIDE 18 SHAFT PUMP DRIVE 19 amp 20 SPACER PLATE amp GASKETS 370 CHECK BALL 1 1
24. M6 x 1 0 x 20 0 M6 x 1 0 x 90 M6 x 1 0 x 16 Valve Body to Case Valve Body to Driven Sprocket Support Case Cover to Case Case Cover to Case Case Cover to Case Case Cover to Case Case Cover to Case Case to Drive Sprocket Support Oil Pan and Valve Body Cover Manual Detent Spring Assembly to Case Cooler Connector Line Pressure Take Off Intermediate Servo Cover Parking Lock Bracket to Case Pipe Retainer to Case Governor Cover to Case Speedometer Driven Gear to Governor Cover T V Cable to Case Pressure Switch 1 0 45 0 M8 1 25 x 85 0 M8 x 1 25 x 65 0 8 x 1 25 x 45 0 M8 x 1 25 x 55 0 MB x 1 25 x 40 0 8 x 1 25 x 25 0 8 x 1 25 x 25 0 M8 x 1 25 x 23 5 M8 x 1 25 x 16 0 M6 x 1 0 x 10 0 1 4 18 NPSF 1 8 27 NPTF M6 x 1 0 x 20 0 MB x 1 25 x 20 0 8 x 1 25 x 14 0 M6 x 1 0 x 25 0 M6 x 1 0 x 16 0 M6 x 1 0 x 16 0 1 8 27 NPTF Figure 111 Torque Specifications TORQUE ASSEMBLY 11 N m 8 ft Ibs 24 N m 18 ft Ibs 11 N m 8 ft Ibs 11 8 ft Ibs 11 8 ft Ibs VI N m 8 ftz Is 24 N m 18 ft Ibs 24 N m 18 ft Ibs 24 N m 18 ft Ibs 24 N m 18 ft Ibs 24 N m 18 ft Ibs 24 18 ft Ibs 24 N m 18 ft Ibs 24 18 ft Ibs 11 Nem 8 ft Ibs 11 8 ft ibs 38 23 ft Ibs 11 N m 8 ft Ibs 11 8 ft Ibs 24 N m 18 ft Ibs 24 N m 18 ft Ibs 11 Nem
25. START AND 12 SNAP SECURELY 9 GOVERNOR ASSEMBLY BACICUR ONTO PIN 10 RING OIL SEAL 5 BOLT NEUTRAL 13 GEAR SHIFT 11 RETAINER START SWITCH 2 SUPPORT 6 TRANSAXLE 14 NUT 23 Fig 7A1 7 Governor and Speedometer Sensor 7 BOLT BRACKET 17 FT LB Assembly Remove or Disconnect 520119 7A Fig 7A1 6 Transaxle Controls Cable Attachment and Neutral Start Switch Figure 7 8 1 Negative battery cable 7A1 6 DIAGNOSIS AND ON CAR SERVICE Electrical connector at sensor assembly Sensor assembly retainer Sensor assembly uo Important Reassemble using new O rings 4 gt Install or Connect 1 Speedometer drive gear to sensor 2 3 4 5 Sensor assembly Sensor assembly retainer Electrical connector at sensor assembly Negative battery cable Inspect Speedometer for proper operation SPEEDOMETER DRIVE GEAR Remove or Disconnect Figure 7A1 7 Negative battery cable Electrical connection at sensor Sensor assembly retainer Sensor assembly and gear Governor cover screw Governor cover O ring Speedometer thrust washer Speedometer drive gear Important Reassemble using new O rings 4 e Install or Connect 10 00 Ov tn J UB Fac 1 Speedometer drive gear 2 Speedometer thrust washer 3 O ring 4 Governor cover 5 Governor cover screw 6 Sensor assembly and gear 7 Sensor assembly retainer 8 Electrical connection at sensor 9 Negati
26. Selective Snap Ring Group 4 216 Direct Clutch Drum Bushing Group 4 169 24 Final Drive Internal Gear Bushing Group 4 319 Input Carrier To Input Sun Gear Thrust Washer Group 4 159 25 Differential Carrier To Case Thrust Brg Assy Group 4 176 Reaction Carrier To Lo Race Thrust Washer Group 4 180 26 Driven Sprocket Support Thrust Washer Group 4 131 Reaction Sun To Internal Gear Thrust Bearing Group 4 159 27 Input Shaft Bushing Group 4 158 Differential Carrier To Case Sel Thrust Washer Group 4 176 28 Thrust Washer Group 4 169 Input Internal Gear Bushing Group 4 158 29 Driven Sprocket Support Bushing Group 4 226 Input Carrier To Input Int Gear Thrust Washer Group 4 159 30 Reaction Sun Gear Bushing Group 4 159 Lo And Reverse Clutch Housing Bushing Group 4 158 31 Reverse Housing To La Race Selective Washer Group 4 180 Reaction Carrier To Int Gear Thrust Washer Group 4 180 32 Reaction Carrier Bushing Group 4 159 Sun Gear To Internal Gear Thrust Bearing Group 4 178 33 Sun Gear To Carrier Thrust Bearing Group 4 159 Case Bushing Group 4 319 H 125 287 Figure 110 Bushing amp Thrust Washer Locations D o SEED ES 7 Valve Body to Case Cover 125C 62 AUTOMATIC TRANSAXLE DESCRIPTION OF USAGE Valve Body to Case Cover Pump Cover to Case Cover Pump Cover to Valve Body Pump Cover to Valve Body Solenoid to Valve Body TORQUE SPECIFICATIONS QUANTITY SIZE 2 M6 x 1 0 x 65 0 8 x 1 25 x 130 00
27. Thrust Washer Measurement 680 Final Drive to Case End Play Measure Figures 54 and 55 Tools Required J 26958 10 Adapter J 25025 7 Post J 26900 12 or J 800 M Dial indicator J 28585 Snap ring remover Install the dial indicator set so that stem contacts the adapter With J 28585 through the governor bore lift up on the governor drive gear 679 125C 40 AUTOMATIC TRANSAXLE FINAL DRIVE TO CASE END PLAY SELECTIVE THRUST WASHER 680 IDENTIFICATION THICKNESS NO COLOR 0 Orange 1 White 2 Blue 3 Pink 4 Brown 1 40 1 50mm 0 055 0 059 1 50 1 60 0 059 0 062 1 60 1 70mm 0 062 0 066 1 70 1 80mm 0 066 0 070 1 80 1 90mm 0 070 0 074 2 00mm 0 074 0 078 5 Green G Black J Purple 8 amp White 9 amp Blue 2 00 2 10mm 0 078 0 082 2 10 2 20mm 0 082 0 086 2 20 2 30mm 0 086 0 091 2 30 2 40mm 0 091 0 095 H 125 321 2 Figure 55 Final Drive End Play Chart 3 Reading on the dial indicator should be 0 12 0 82 mm 0 005 0 032 For correct washer selection see Figure 54 4 Remove the dial indicator set and the adapter Leave the adapter in place 5 Install J 26958 and J 26958 11 turn knob until it bottoms REACTION CARRIER ASSEMBLY Inspect Figure 56 and Figure 26 e Sun gear shaft 669 for damage or wear Internal gear 668 for damage or wear Thrust bearing 667 for damage or
28. a clutch problem or may be the result of a burned clutch If a clutch is burned excessive piston travel may result and allow one or more of the piston seals to come out of the bore and become cut or folded When looking for the cause of the problem the condition of the piston seals should be considered but further inspection should be made to determine if some other area 15 the cause of the problem to prevent a repeat problem EXAMPLE A leak at an intermediate servo piston seal may be the cause of a burned direct clutch and or intermediate band because the oil pressure that applies the direct clutch also releases the servo piston In All Cases of Burned Clutch Plates or Band Check for 1 The Driven Sprocket Support a drive sprocket support seal rings may be leaking b The case cover gaskets are not sealing Case cover gasket leaking The driven sprocket support sleeve may be loose or mispositioned d To attaching bolts Torque to 24 N m 18 ft bs 2 Case Cover and Case a Blocked or interconnected oil channels b The sealing surfaces may be damaged or leaking check balls may be missing or out of location d Porosity 3 The Control Valve Pump Assembly a control valve pump assembly to case cover bolts may be loose b sealing surfaces on the control valve pump assembly spacer plate and or gaskets are damaged or leaking The valves may be leaking binding or
29. be in place 2 Position the gage extension between open ends of the snap ring 644 Reaction sun gear 646 must be properly positioned Swing the gage under the extension shoulder Zero the dial indicator Position the snap ring 644 under the extension Remove the gage from under the shoulder The dial indicator should read 0 33 to 0 13 mm 0 013 to 0 005 record the reading For correct snap ring selection See Figure 31 Measure washer thickness new or old with a micrometer NOM PY AUTOMATIC TRANSAXLE 125 33 Lo Roller Clutch Race Selective Spacer End REVERSE CLUTCH HOUSING Play TO LO RACE SELECTIVE SPACER 660 Measure Figures 32 and 33 Thickness Identification 1 re from Selective Snap Ring End Play 1 00 220mm 0 039 2 Pry upon internal gear 668 with J 28585 Do not 1 42 1 52mm 0 0567 pry against the spacer 671 1 84 1 94mm 0 072 0 3 dial indicator reading should be 0 08 1 17 mm 0 2 26 2 36mm 0 089 0 003 0 046 Record reading 2 68 2 78mm 0 105 0 For correct washer selection see Figure 33 3 10 3 20mm 0 122 0 4 Remove the dial indicator set and J 28588 gage 125 136 Figure 32 Lo Roller Clutch Race Selective Thrust Spacer REACTION UNIT PARTS Remove or Disconnect Figures 25 33 34 35 and 36 Tool Required J 28542 Lo Reverse Clutch Unit Remover and Installer Sun gear 646 Snap ring 644 ring is 2 36 mm 0 092
30. both cold and at operating temperature Shift control linkage Make sure the linkage does not bind and is properly adjusted Refer to Fluid Level Checking 7 2 AUTOMATIC TRANSAXLE TRANSMISSION At a speed of 25 30 mph 40 50 km h quickly open throttle approximately 3 4 Full Throttle Downshift speed of 50 mph 80 km h open throttle fully INTERMEDIATE range I or 2 3rd gear is inoperative at this setting Place gear selector into 2 DRAIN SREPILL b Accelerate car and observe 1 2 shift The CHECK FOR WATER shift point will vary with the throttle HIGH opening The 1 2 shift will be firmer than in the D range Observe 2 1 downshift Accelerate car to 20 mph 32 km h Quickly open the throttle to wide open and observe downshift 6 Test drive car CHECK FLUID NORMA LEVEL FILL UP CHECK FOR EXTER LOW NAL LEAKS AND FOR 2 DEFECTIVE VACUUM MODULATOR DRAIN EXCESS FLUID CHECK FOR COOLANT CONTAMINATION MAKE FUNCTIONAL Place gear selector into D open FOR COOLANT OR e Accelerate car to 50 mph 80 km h BURNED CLUTCHES e Close throttle move gear selector to 2 and observe downshift LOW range L or 1 2nd and 3rd gear should be inoperative at this setting Do not overspeed engine Observe 2 1 downshift Place gear selector into 2 and accelerate CHARTS AND to 40 mph 64 km h PRESSURE TESTS c Close throttle and move gear selector into 620027 7
31. converter has been removed the stator roller clutch can be checked by inserting a finger into the splined inner race of the roller clutch and trying to turn the race in both directions The inner race should turn freely clockwise but not turn or be very difficult to turn counterclockwise Do not use such items as the driven sprocket support or shafts to turn the race as the results may be misleading AUTOMATIC TRANSAXLE TRANSMISSION 74 9 TORQUE CONVERTER VIBRATION TEST PROCEDURE Inspect For missing or loose converter to flywheel bolts Tighten or replace as necessary 2 Converter for damage or missing balance weights If the converter is damaged or balance weights are missing replace the converter 3 Change position of converter to flywheel by 120 degrees at a time to cancel out engine and converter unbalance Recheck in each position for improvement 4 If the unbalance persists leave converter in the best balanced position Imbalance can be corrected by the use of balance weights clipped to the flexplate or install longer flywheel to converter bolts adding and removing washers until optimal balance is achieved Important Some engine transmission combinations cannot be balanced in this manner due to close clearances between the torque converter bolts and engine NOTICE Be sure the bolts are not bottoming in the lug nuts If bolts bottom cover could be dented causing internal clutch facing damage Always rotate th
32. crayon on the bottom side of the chain link See Figure 13 3 Push up in the same manner and put a second mark on the case making sure that both marks are made from the same point on the chain Measure The distance between the two marks If the distance exceeds 27 4 mm 1 1 16 inches replace the drive link chain SCRIBE MARKS IF DIMENSION EXCEEDS 1 016 INCH REPLACE DRIVE LINK G20026 7A Fig 13 Checking Drive Link Chain Wear DIAGNOSIS AND ON CAR SERVICE 7A1 1 SECTION 7A1 ON CAR SERVICE 125C AUTOMATIC TRANSAXLE Before diagnosis of any transmission complaint is attempted there must be understanding of oil checking procedure and what appearance the oil Should have Many times a transmission malfunction can be traced to low oil level or improper reading of dipstick Due to the transmission fluid that is now being used it may appear to be darker and have a stronger odor This is normal and not a positive sign of required maintenance or transmission failure Also when the dipstick is removed it should be noted whether the oil is devoid of air bubbles or not Oil with air bubbles gives an indication of an air leak in the suction lines which can cause erratic operation and slippage Water in the oil imparts a milky pink cast to the oil and can cause spewing CONTENTS General Description Maintenance and Adjustments 7 1 1 Drain Intervals 7 1 1 Fluid
33. low to normal Important INTERMEDIATE and REVERSE e T V cable misadjusted sticking or broken will not engage if the engine is Refer to T V Cable Diagnosis not at operating temperature e T V linkage binding or incorrect cable d Observe 3 2 downshift e Throttle valve stuck e Shift T V valve stuck e Part Throttle Downshift 3 Oil strainer plugged or damaged 4 Oil strainer seal leaking 5 Control valve and pump assembly bolts loose 6 Control Valve Assembly Check ball missing or off location Stuck or damaged valves valve and plunger Shift T V valve Pressure regulator valve T V boost valve Pressure relief valve Modulator valve 1 2 accumulator piston and or seal leaking or missing e Internal leaks 7 only Low blow off valve damaged check ball missing or off location 8 REVERSE only Low Reverse clutch housing to case cup plug assembly leaking Low Reverse oil pipe leaking where applicable 9 Pump vane seals cut or missing 10 Intermediate oil passages to pressure regulator blocked 11 Driven sprocket support to case cover leaking Causes of High Oil Pressure 1 T V system pressure high in NEUTRAL and DRIVE and normal to high in INTERMEDIATE and T V cable misadjusted sticking or broken Refer to T V Cable Diagnosis T V linkage binding or incorrect cable Throttle valve stuck Shift T V valve
34. new gasket Torque bolts to specification 3 Lower vehicle 4 Fill Transaxle Transmission with the proper quantity of Dextron 8 II or equivalent Refer to specific section for quantity Place gear selector into PARK 6 Start engine and run at slow idle Do not race the engine 7 Check fluid level Correct as required tA T V CABLE Figures 5 and 6 Adjustment Procedure Important Adjustment of the T V cable must be made by rotating the throttle lever at the carburetor or throttle body Do not use the accelerator pedal to rotate the throttle lever On Diesel engines the throttle link assembly must be correctly adjusted Before making the T V cable adjustment Adjust l Stop engine 2 Depress and hold down metal readjust tab at engine end of T V cable Move slider until it stops against the fitting Release readjustment tab Rotate the throttle lever to its full travel position 6 The slider must move Ratchet toward the lever when the lever is rotated to its full travel position Inspect Check that cable moves freely The cable may appear to function properly with the engine stopped and cold Recheck after the engine is hot e Road Test Vehicle RE ADJUST lt _ DIRECTION SLIDER AGAINST FITTING ZERO OR READJUST POSITION READJUST TAB FITTING CABLE SLIDER 520006 7A1 Fig 6 T V Cable Adjuster ENGINE COOLANT IN TRANS
35. sticking d Thechannels may be blocked or interconnected If low line pressure is present refer to the possible causes NOTICE Burned clutch plates can be caused by incorrect usage of clutch plates Engine coolant in the transmission fluid can cause severe damage to clutch plate material and result in pieces of composition material peeling off Burned Direct Clutch Only 1 The Direct Clutch Assembly seals may be cut missing or rolled out of groove b exhaust ball capsule in the housing may be damaged and not sealing c The piston or the housing may be damaged leaking d snap ring may not be fully seated 2 The Intermediate Servo Assembly a The wrong servo pin check selectivity AUTOMATIC TRANSAXLE 125 3 The seals may be missing or damaged The servo bore is scored or damaged The servo orifice bleed plug may be missing une band apply pin could be tight in the case 3 The Case Cover and Case a The 5 check ball missing or off location may be the case cover b The accumulator exhaust check valve may be missing or not sealing in the case ones Burned Forward Clutch Only 1 The Forward Clutch Assembly a The seal rings on the input shaft could be damaged or missing b The Input shaft feed passage or the orifice are restricted c Holes not drilled in piston or waved steel clutch plate not installed next to piston d The selective backing plate or
36. stuck T V lifter bent damaged or too short 2 Control Valve and Pump Assembly T V valve and plunger e Shift T V valve Pressure regulator valve e boost valve Pump slide stuck 3 LOW only Low blow off valve stuck closed 4 Internal pump or case cover leaking On the basis of the results of the road test and the oil pressure test consult the Diagnostic Charts for the appropriate model and determine the probable cause Important number of sub assemblies and systems can be repaired without removing the Automatic Transaxle Transmission Refer to the appropriate chart in the specific on car service section FLUID LEAK DIAGNOSIS Most fluid oil leaks are easily located and by visually finding the leak and replacing or repairing the necessary parts On some occasions a fluid leak may be difficult to locate or repair The following procedure may help in locating and repairing most leaks AUTOMATIC TRANSAXLE TRANSMISSION 7A 3 FINDING THE LEAK l Identify the fluid determine whether it is engine oil automatic transmission fluid power steering fluid etc 2 At what point is the fluid leaking from After running the vehicle at normal operating temperature park the vehicle over a large sheet of paper After a few minutes you should be able to find the approximate location of the leak by the drippings on the paper 3 Visually check around the suspected component Check a
37. transmission problems are caused by improper external adjustments Before attempting to service a transmission or transaxle the fluid level and external adjustments should be checked and corrected as necessary Transaxle Transmission Fluid Level 7 7 Fluid Level Checking Procedure Changing Fluid and Filter T V Cable Adjustment Procedure Engine Coolant n Transmission Oil Cooler and Cooler Line Flushing Torque Converter Clutch TCC Torque Converter Vibration Test Procedure Converter Flushing Procedure Torque Converter Evaluation Clutch Plate Diagnosis Composition Plates Steel Plates Causes of Burned Clutch Plates Case Porosity Repair Procedure Governor 7 11 Governor Driven Gear 12 Drive Link Assembly Chain 7A 12 Inspect 2 3 Warm up engine and transmission to operating temperature Fluid level Procedure Engine idle speed Important Do not attempt to proceed with the Preliminary Checking Procedure if the engine does not perform properly Correct any engine malfunction first T V cable for freedom of movement and returnability at cable activating lever Check to be sure that the T V cable is adjusted to the proper length The T V cable may function properly with the engine shut off and cold but may malfunction when hot Check
38. utmost importance therefore the bench tools and parts must be kept clean at all times Before installing cap screws into aluminum parts ALWAYS DIP SCREWS INTO TRANSMISSION OIL to present cap screws from galling the aluminum threads and also to prevent the screws from seizing Always use a torque wrench when installing cap Screws into aluminum parts to prevent the possibility of stripping the threads If tapped threads in aluminum parts are stripped or damaged the part can be made serviceable by the use of Heli coils or equivalent Seal protecting tools must be used when assembling the units to prevent damage to the seals The slightest flaw in the sealing surface of the seal can cause an oil leak The aluminum castings and the valve parts are very susceptible to nicks burrs etc and care should be exercised when handling them The internal snap rings should be expanded and the external snap rings compressed if they are to be reused This will ensure proper seating when installed Replace all rings gaskets and oil seals that are removed Teflon oil seal rings should not be removed unless damaged During assembly of each unit all internal parts must be lubricated with oil DIAGNOSIS AND SERVICE 7 1 5 ON CAR SERVICE SERVICEABLE COMPONENTS The following parts can be serviced with the transaxle in the car For part removal and installation procedures not listed in this section refer
39. 1 The 2 1 downshift should occur between 25 45 mph 40 72 km h 4 REVERSE R ROAD TEST PROCEDURE Place gear selector into R and observe reverse H 9 Important Do not place gear selector into R while vehicle is moving Perform the road test in an organized manner Carry out all steps in the sequence shown Note FLUID PRESSURE TEST PROCEDURE the results of each step for later evaluation with 1 Install pressure gage J 21867 or J 5907 A See specific transmission section the aid of the Diagnostic Charts in the Specific A ic T issi ion M utomatic Transaxle Transmission Section 2 Note transmission model code and refer to the appropriate chart in the specific transmission Inspect section for the correct pressure range and engine DRIVE range speeds CHECK TV CABLE 3 amp MANUAL LINKAGE ADJUSTMENT PERFORM ROAD a TEST REFER TO b DIAGNOSTIC Fig 1 Preliminary Check Procedure a Place gear selector into DRIVE D and accelerate car b Observe the 1 2 and 2 3 shift Shift points will vary with throttle pressure C Observe Torque Converter Clutch TCC engagement This should occur between CAUTION To avoid possible personal injury and or damage to the car brakes must be applied at all times during the test Causes of Low Oil Pressure 1 Low oil level 35 50 mph 57 80 km h Refer to TCC 2 T V system pressure low in NEUTRAL Diagnosis DRIVE and
40. 3 dVNS ONIH LNdLNO 13 5 31XV ONINIVL3Y DNIH 3A1VA MAYIS AG08 JAYA AGO8 LINSVD 3SVO AG08 3A1VA 1108 ITLLOUHL A18AA3SSV L35IOVH8 8 HIAIT 37892 OL H3A31 ITLLOUHL NIT 55 dWNd 110 TOHLNOD 832 45 AdOd 3ATVA 31V1d 31914 32 46 138599 IMYA 110 L4VHS 437000 HOLO3NNOO vid 9 71v8 A18W3SSV 3Sv2 HV3D 003345 1108 003345 H3NIVL3H 0 334 IAIITS ONIY 1935 HV39 093345 HONHIAOD H3AOD 3590 OL HONH3AOD MIYOS ONIY 1935 H3A02 HV39 A18W3SSY LSNYHL 93130003245 uv35 3197909 A183SSv HONY3A09 Was 110 DNIY H31H3ANOO DNIHSNE A18W3SSV H3 LH3ANOO 044135 3 Figure 3 External Components AUTOMATIC TRANSAXLE 125 23 DESCRIPTION LINK ASSEMBLY DRIVE RING SNAP SPROCKET DRIVE WASHER CASE COVER TO DR SKT THRUST RING OIL SEAL TURBINE SHAFT GREEN SHAFT TURBINE SEAL O RING TURBINE SHAFT BEARING ASSEMBLY SUPPORT DRIVE SPROCKET BUSHING DRIVE SPROCKET SUPPORT PIN DOWEL CASE COVER TO CASE CASE TRANSMISSION SEAL ASSEMBLY MANUAL SHAFT SCREW SOCKET BUTTON HEAD SEAL ASSEMBLY CONVERTER BUSHING CASE SEAL ASSEMBLY AXLE PLUG CUP PARKING PAWL SHAFT PLUG GOVERNOR PRESSURE PICKUP REVERSE OIL SEAL CASE TO HOUSING BEARING A
41. 7 0 06 LO amp REVERSE 2 2mm 1 194mm ALL 085 0 08 The direct and forward clutch flat steel clutch plates and the forward clutch waved steel plate should be identified by their thickness The direct and forward production installed composition faced clutch plates must not be interchanged For ser vice direct and forward clutch use the same compositioned faced plates The forward clutch backing plate is selective Refer to the Forward Clutch End Play Chart Measure the width of the clutch apply ring for positive identification 125C 46 8 Figure 70 Clutch Plate Usage Chart Inspect Housing 610 for Bad welding Band scoring Heat damage Housing bushings for cracks damage or scoring Piston 615 for damage or cracks Inner 614 outer 612 and center 613 seals for burrs nicks or brittleness Apply ring and release spring assembly 616 for damage and collapsed springs Clutch plates 618 for wear or burning Backing plate 619 for damage cracks or burning Snap rings 620 617 for damage Check ball capsule for free operation Check Ball Capsule Replacement Procedure Remove or Disconnect Usea 9 5 mm 3 8 drift to drive out the ball capsule assembly Install or Connect Seat the new capsule with the 9 5 mm 3 8 drift Assemble Figures 70 71 and A 15 Center seal 613 lips facing away from capsule Inner seal 614 lips facing capsule Outer seal 612
42. ADD and FULL Refer to Figure 4 for Automatic Transaxle Low fluid level may cause slipping when cold on a hill when accelerating or when turning NOTICE Do not overfill Overfilling causes foaming and loss of fluid through the vent and may damage the Automatic Transaxle Transmission 6 Refer to Figure 1 if unusually low or high fluid level is found if fluid foams excessively or has an unusual odor Fa vet LEVEL TO IN CROSS HATCHED AREA ON FLUID LEVEL INDICATOR BLADE CHECK AT OPERATING TEMPERATURE Fig 4 Fluid Level Indicator 125C Transaxle CHANGING FLUID AND FILTER 1 Raise vehicle and suitably support 2 Place drain pan under Transaxle Transmission oil pan Oil pan bolts from front and sides Loosen rear oil pan bolts approximately 4 turns Pry oil pan loose with a screwdriver and allow fluid to drain Remaining oil pan bolts pan and gasket Screen filter and seal m gt a 7 8 AUTOMATIC TRANSAXLE TRANSMISSION Inspect e Oil pan and screen for foreign material Metal particles Clutch facing material Rubber particles Engine coolant e Determine and correct source of contamination Clean e Gasket mating surfaces e Remove all traces of old gasket e Oil pan in solvent and blow dry Install or Connect 1 Screen using a new filter and seal Coat seal with petroleum jelly Torque screen to specification 2 Oil pan using a
43. AUTOMATIC TRANSAXLE CASE ASSEMBLY LEVER AND BRACKET ASM THROTTLE BALL 6 3 DIA BOLT VALVE BODY CASE SHAFT OIL PUMP DRIVE GASKET VALVE BODY COVER GASKET SPACER PLATE COVER VALVE BODY PLATE VALVE BODY SPACER SCREW VALVE BODY COVER CONTROL VALVE amp OIL PUMP ASM LINK THROTTLE LEVER TO CABLE D didi T NS N N P 24 31 125C 67 21 CONTROL VALVE AND OIL PUMP ASM N Yaya A DO NOT REMOVE THIS SCREW aoa IE Figure 14 Control Valve Pump Assembly Figure 15 Check Ball Locations Input Shaft to Case Cover Selective Snap Ring l Install the adapter plug J 26958 10 loading tool End Play Check J 26958 and bracket J 26958 11 Tighten the loading tool knob until tight Measure Figures 16 17 and 18 2 Install the dial indicator set and lifter I 3 Push the lifter down then zero the dial indicator Tools required 4 Pull the lifter up J 26958 10 Adapter Plug 5 Reading should be 0 10 0 84 mm 004 0 33 See Figure J 26958 Loading tool 18 For choice of selective snap rings for proper end play J 26958 11 Bracket ranges record the reading J 28544 Input shaft lifter 6 Remove the dial indicator set and the lifter J 25025 7 Dial indicator post J 26900 12 or 58001 M dial indicator AUTOMATIC TRANSAXLE 125C 27 INPUT SHAFT PEE CLIE SNAP RING 621 Thickness dentification Color 1 83 1 93mm 0 071 0 076 2 03 2 13mm 0 078 0 084 2 23 2 33mm 0 088 0 092
44. BE DRIVE REVERSE DIRECT CLUTCH DRAIN BACK 125 292 1 Figure 15 Driven Sprocket Support Cut Away View 125C 12 AUTOMATIC TRANSAXLE DRIVE T C C APPLY RND LO 1ST OR REV S T V EXH 3RD CL DIRECT OR REV 1 2 ACCUM 3RD CL DIRECT LUBE GOVERNOR INTERMEDIATE T V 3RD CL DIRECT ACCUM S T V SUCTION T C C EXHAUST TO COOLER 1 2 3 4 5 6 7 8 9 H 125C 36 3 Figure A 16 Valve Body Spacer Plate Typical NO UPSHIFTS DELAYED UPSHIFTS OR FULL THROTTLE UPSHIFTS CHECK AND ADJUST MANUAL LINKAGE AS REQUIRED SET T V CABLE TO SPECIFICATIONS CHECK TRANSMISSION LEVEL AND CORRECT IF NECESSARY ROAD TEST VEHICLE AUTOMATIC TRANSAXLE 125C 13 NORMAL UPSHIFT OCCURS ROAD TEST VEHICLE AT 30 MPH 48km h IN LO RANGE HOLD THROTTLE STEADY AND SHIFT TO DRIVE 0 RANGE NO UPSHIFT OR UPSHIFTS STILL DELAYED NO UPSHIFTS GOVERNOR COVER WORN THRUST WASHER GOVENOR SEAL WORN OR CUT SPRING WEIGHTS BINDING BALL MISSING DRIVEN GEAR STRIPPED CHECK INTERMEDIATE SERVO WRONG APPLY PIN SEALS CUT DAMAGED LEAKING PISTON DAMAGED POROSITY IN CASE BORE PISTON AND OR APPLY PIN STICKING CHECK CONTROL VALVE ASSEMBLY FOR STICKING VALVES AND SPACER PLATE GASKETS LEAKING OR IN CORRECTLY INSTALLEO CHECK VALVE BODY TO CASE SPACER PLATE GOVERNOR FEED ORIFICE TO 1 2 AND 2 3 VALVES AND DRIVE TO GOVERNOR ORI
45. C uA TG SEAL O RING STRAINER ASM TRANSMISSION OIL GASKET OIL PAN PAN TRANSMISSION OIL SCREW TRANSMISSION OIL PAN Figure 108 Bottom Pan amp Oil Strainer H125C 65 2 125 60 AUTOMATIC TRANSAXLE 3 RING OIL SEAL 4 GOVERNOR ASSEMBLY 5 GEAR SPEEDOMETER DRIVE 6 THRUST BEARING ASM GEAR COVER 7 SEAL O RING 9 COVER GOVERNOR 10 SPEEDO DRIVEN GEAR 11 SEAL O RING 12 SLEEVE SPEEDO DRIVEN GEAR 13 RETAINER SPEEDO GEAR 14 BOLT SPEEDO GEAR RETAINING Figure 109 Governor Assembly 3 Servo assembly 133 into servo bore 4 Gasket 136 5 Cover 137 6 Bracket 140 7 Screws 141 Bl Tighten Torque the screws 141 to 11 N m 8 ft Ibs OIL PAN AND STRAINER Install or Connect Figure 108 1 ring 32 onto the strainer tube 2 Strainer 33 into the case 3 Gasket 34 or apply R T V silicon sealant 4 Pan 35 onto the case 5 Bolts 36 BI Tighten Torque the pan bolts 36 to 11 N m 8 ft Ibs GOVERNOR AND SPEEDOMETER GEAR ASSEMBLY clean Governor assembly 4 Inspect Figure 109 Governor passage blocked Damaged springs Missing check balls Seal 3 damage Binding weights Seal Replacement Procedure Remove or Disconnect Seal 3 cut off Install or Connect e Seal 3 use petrolatum Inspect Gear 5 for wear Bearing 6 for damage Cover 9 for porosity or cracks Gea
46. CARRIER RING SPIRAL RETAINING DIFFERENTIAL CARRIER GEAR GOVERNOR DRIVE WASHER DIFF CARR CASE SEL THRUST BEARING ASM DIFF CARR CASE THRUST SHAFT DIFFERENTIAL PINION PIN DIFF PINION SHAFT RETAINING WASHER PINION THRUST PINION DIFFERENTIAL WASHER DIFF SIDE GEAR THRUST GEAR DIFFERENTIAL SIDE PLATE LO amp REVERSE CLUTCH WAVED LEGEND Figure 27L Legend 125 1432L 1256 32 AUTOMATIC TRANSAXLE e Directand forward clutch assemblies 610 624 by lifting input shaft 4 Thrust washer 636 5 Internal gear 637 Carrier 640 thrust washer 641 Input sun gear 642 e Input drum 643 A INPUT SHAFT 610 CLUTCH DIRECT 624 CLUTCH FORWARD Figure 29 Removing Forward amp Direct Clutches 1 EXTENSION 2 FEELER GAUGE J 26900 12 OR J 8001 M Figure 30 Selective Snap Ring End Play REACTION SUN GEAR TO INPUT DRUM SELECTIVE SNAP RING 644 Thickness Identification Color 231mm 0 089 2 54mm 0 096 221mm 0 103 288mm 0 109 3 05mm 0 116 3 22mm 0 123 0 3 39mm 0 129 3 56mm 0 136 0 125 319 2 Figure 31 Selective Snap Ring Chart Reaction Sun Gear to Input Drum End Play Measure Figure 30 amp 31 Tools Required J 26958 Loading tool J 26958 11 Bracket J 26958 10 Adapter plug J 28588 Gauge 1 25025 7 Post J 26900 12 or J 8001M Dial indicator 1 Install tools as shown The loading tool should already
47. CUMULATOR EXHAUST PRESSURE HOLE PLUGGED NOT DRILLED PRESSURE NORMAL PRESSURE LOW DIRECT CLUTCH EXHAUST VALVE CHECK BALL MISSING MISLOCATED LEAKING INTERMEDIATE SERVO PISTON CASE SEAL RING MISSING OR DAMAGED GASKETS LEAKING DAMAGED INCORRECTLY INSTALLED WRONG SPACER PLATE VALVE BODY THROTTLE VALVE AND PLUNGER BINDING SHIFT VALVE BINDING CHECK BALL 5 NOT SEATING SERVO PISTON DAMAGED SERVO BORE CASE DAMAGED T POROSITY IN DIRECT CLUTCH CASE COVER PASSAGES ORIFICE PLUG MISSING FROM CASE IN SERVO BORE AREA INCORRECT CASE COVER GASKETS DIRECT CLUTCH FEED ORIFICE IN SPACER PLATE RESTRICTED VALVE BODY SPACER PLATE ACCUMULATOR EXHAUST CHECK VALVE NOT SEATING IN DRIVEN SPROCKET SUPPORT PASSAGES CASE INTERCONNECTED LEAKING RESTRICTED DRIVEN SPROCKET SUPPORT OIL SEAL RINGS DAMAGED OR MISSING SLEEVE LOOSE OR OUT OF POSITION DIRECT CLUTCH CHECK BALL LEAKING CHECK BALL CAPSULE DAMAGED SEALS MISSING DAMAGED PISTON OR HOUSING CRACKED APPLY RING MISSING INCORRECT WRONG NUMBER OF CLUTCH PLATES SEE CHART IN SERVICE MANUAL H 125 310 Figure A 19 2 3 Shift Complaint 1256 16 AUTOMATIC TRANSAXLE NO 2 3 SHIFT OR DELAYED 2 3 HAS BOTH FIRST AND SECOND CHECK TRANSMISSION OIL LEVEL AND CORRECT IF NECESSARY SET T V CABLE SPECIFICATIONS CHECK AND ADJUST MANUAL LINKAGE AS REQUIRED ROAD TEST VEHICLE NORMAL UPSH
48. Capacities 7A1 1 Service Procedures 7AI 1 Shift System Cable Remova 7 1 2 Adjustments 7AI 2 Manual Linkage 7 1 2 Transmission Control Cable Adjustment 7 1 2 Park Lock Control Cable 7A1 2 GENERAL DESCRIPTION Refer to the 125C transaxle section for overhaul procedures MAINTENANCE AND ADJUSTMENTS DRAIN INTERVALS The transaxle operating temperature resulting from the type of driving conditions under which the car is used is the main consideration in establishing the proper frequency of transaxle fluid changes Change the transaxle fluid and replace strainer every 15 000 miles if the car is usually driven under one or more of the following severe transaxle service conditions a In heavy city traffic b Where the outside temperature regularly reaches 90 32 In very hilly or mountainous areas Frequent trailer pulling Commercial use such as taxi police car or delivery service f Operating dusty areas If you do not use your car under any of these conditions change the fluid and replace strainer as suggested in Section ao NOTICE DO NOT OVERFILL It takes only one pint to raise level from ADD to FULL Park Lock Cable 7A1 2 Neutral Safety and Backup Lamp Switch General Service Precautions On Car Service Serviceable Components Speedometer Driven Gear
49. DRIVE SPROCKET Figure 44 Installing Bearing Support Replacement Procedure Remove or Disconnect Figure 45 Tool Required 1 25359 5 40 Torx bit or equivalent l Converter oil seal 115 2 Screws 114 with J 25359 5 3 Support 109 from case Install or Connect Figure 45 l Support 109 into case 2 Screws 114 use thread locking compound Tighten Tools Required J 25259 40 Torx bit or equivalent e Screws 114 to 24 18 ft Ibs with J 25359 5 BEARING ASSEMBLY SUPPORT DRIVE SPROCKET CASE TRANSMISSION SCREW SOCKET BUTTON HEAD SEAL ASSEMBLY CONVERTER Figure 45 Sprocket Support Replacement 125 77 Inspect Parking pawl 706 for damage Parking Pawl Replacement Procedure Remove or Disconnect Figure 46 Cup plug with a screw extractor Retainer 708 Shaft 709 Return spring 707 Pawl 706 1 2 3 4 5 Install or Connect 1 2 3 4 5 Return spring 707 Pawl 706 Shaft 709 Retainer 708 Cup Plug with a 9 mm 3 8 rod Inspect Governor pipe 138 for damage or cracks 706 PAWL PARKING 707 SPRING PARKING PAWL 708 RETAINER PARKING PAWL SHAFT 709 SHAFT PARKING PAWL Figure 46 Parking Pawl Governor Pipe Replacement Procedure Remove or Disconnect Figure 47 Tool Required J 28585 Snap Ring Remover Pipe 138 with J 28585 pry out Use particle board to protect case Pipe is sealed in place Install or Connect 1
50. Diagnosis Preliminary Checking Procedure Road Test Procedure Fluid Pressure Test Procedure Causes of Low Oil Pressure Causes of High Oil Pressure Fluid Leak Diagnosis Finding the Leak Powder Method Black Light and Dye Method Repairing the Leak Gaskets Seals Possible Points of Oil Leak Torque Converter Clutch Diagnosis TCC Diagnosis Functional Check Procedure Preliminary Check Procedure AUTOMATIC TRANSAXLE TRANSMISSION 7A 1 SECTION 7A AUTOMATIC TRANSAXLE TRANSMISSION DIAGNOSIS AND GENERAL SERVICE The service procedures in this section are common to all automatic transaxles and automatic transmissions For on car service and overhaul procedures refer to the specific sections For vehicles sold in Canada and equipped with non closed loop engines also refer to the appropriate Canadian service manual supplement CONTENTS Checking Automatic T V Cable System Diagnosis 7A 5 Speedometer System Diagnosis 5 Noise and Vibration Diagnosis 7A 5 DIAGNOSIS Automatic transaxle transmission malfunctions are caused by one or a combination of the following Improper fluid level Low engine performance T V cable misadjustment Manual linkage misadjustment Internal fluid leaks Electrical failure Mechanical failure PRELIMINARY CHECKING PROCEDURE Figure 1 Most of the automatic transaxle
51. EF SPRING 1 2 ACCUMULATOR BUSHING 1 2 ACCUMULATOR VALVE 1 2 ACCUMULATOR VALVE 2 3 SHIFT VALVE 2 3 THROTTLE SPRING 2 3 THROTTLE VALVE BUSHING 2 3 THROTTLE VALVE VALVE 1 2 SHIFT VALVE 1 2 THROTTLE SPRING 1 2 THROTTLE VALVE BUSHING 1 2 THROTTLE VALVE 367 366 1 374 363 360 361 376 ap ot 1 9 90 375 37i 307 125C 62 3 BALL LO BLOW OFF SPRING amp PLUG ASSEMBLY LO BLOW OFF PLUG LO BLOW OFF VALVE SPRING 3 2 VALVE VALVE 3 2 CONTROL bJSHING T V amp REVERSE BOOST VALVE VALVE T V BOOST BUSHING REVERSE BOOST VALVE VALVE REVERSE BOOST SPRING PRESSURE REGULATOR VALVE PRESSURE REGULATOR BUSHING T V PLUNGER PLUNGER THROTTLE VALVE SPRING THROTTLE VALVE VALVE THROTTLE CHECK BALL 1 PIN T V amp REVERSE BOOST BUSHING PLUG BORE PRESSURE REGULATOR RETAINER PRESSURE REGULATOR SPRING PRESSURE REGULATOR ISOLATOR PLUG VALVE BORE ISOLATOR RING VALVE RETAINING Figure 88 Control Valve Pump Assembly Roll pins 307 they are under pressure Cover the bore when the pin is removed Blind hole pins must be removed with a 49 drill bit 1 85 mm or 073 Grind the taper off the bit Oil pump and auxiliary valve body assembly l Screw 327 2 Cover 330 and gasket 330 3 Screw 334 solenoid assembly 333 and O ring seal 337 Switches 335 amp 338 Auxiliary valve body 343 Converter clutch regulator valve pin bore plu
52. FICE INTERMEDIATE BAND BURNED OR WORN CHECK CASE COVER FOR POROSITY UNDRILLED HOLES OR MISSING CUP PLUGS CHECK CASE FOR LEAKS IN GOVERNOR PASSAGES AND OR PIPE 2ND PASSAGE IN CASE OR CASE COVER LEAKING NO GAP oe CHECK FOR CORRECT T V CABLE ASSEMBLY CHECK CABLE MOUNTING BRACKET DAMAGED BENT CORRECT POSITION CHECK FOR CORRECT T V LINK LEVER AND BRACKET ASSEMBLY DAMAGED BENT STICKING BUSHING RETAINING PIN MISSING OR MISPOSITIONED CABLE STICKS CHECK CABLE ROUTING FOR SHARP BENDS OR DAMAGE CHECK T V LINK END THAT GOES INTO THE TM CABLE FOR SHARAP BURR CHECK T V LEVER AND BRACKET ASSEMBLY FOR FREENESS AND PROPER ALIGNMENT CHECK FOR CORRECT T V CABLE Figure A 17 Upshift Complaint TRANSMISSION UPSHIFTS 1 2 13 n CHECK FOR BROKEN OR UNHOOKED T V CABLE AT CARBURETOR OR TRANSMISSION CHECK T V CABLE HOUSING FOR GAP AT THE CABLE HOUSING TO SNAP LOCK ASSEMBLY NORMAL GAP CHECK CABLE FOR STICKING AND BINDING MUST BE CHECKED WITH ENGINE RUNNING AND TRANSMISSION NEUTRAL PULL CABLE TO FULL T V AND RELEASE CABLE SHOULD RETURN TO O T V OR CLOSED THROTTLE POSITION T V CABLE FREE CHECK FOR CORRECT T V LINK T V LEVER ASSEMBLY STICKING BINDING LINE BOOST VALVE BROKEN MISSING CHECK T V PLUNGER AND T V VALVE FOR FREENESS CONTROL VALVE ASSEMBLY GASKETS SPACER PLATE LEAKING DA
53. IATE SERVO STICKING LEAKING OR DAMAGED ACCUMULATOR EXHAUST CHECK VALVE STICKING NOT SEATING 1 2 VALVE STICKING IN CONTROL VALVE PUMP ASSEMBLY SPACER PLATE GASKETS INCORRECTLY INSTALLED GOVERNOR FEED TO THE 1 2 VALVE BLOCKED INTERMEDIATE BAND APPLY FEED ORIFICE BLOCKED WRONG SPACER PLATE INTERMEDIATE SERVO APPLY PASSAGE 2ND OIL IN CASE OR CASE COVER BLOCKED INTERMEDIATE BAND IMPROPERLY INSTALLED BURNED OR BROKEN SEE CAUSES OF BURNED BAND NO FULL THROTTLE DETENT DOWNSHIFT 3 2 T V GABLE IMPROPERLY ADJUSTED BINDING T V LINKAGE OR CABLE WRONG T V CABLE OR LINK ACCELERATOR PEDAL AND OR LINKAGE WILL NOT OPEN CARBURETOR TO WIDE OPEN THROTTLE CONTROL VALVE PUMP ASSEMBLY SHIFT T V VALVE OR THROTTLE VALVE BINDING SPACER PLATE HOLES PLUGGED GASKETS MISPOSITIONED OR DAMAGED H 125 314 Figure A 23 Shift Complaint 125C 20 AUTOMATIC TRANSAXLE NO INTERMEDIATE RANGE NO OVERRUN BRAKING IN LO L1 2ND GEAR REVERSE OK SERVO OIL SEAL RING CHECK AND ADJUST MANUAL MISSING OR DAMAGED LINKAGE AS REQUIRED INTERMEDIATE BAND MISPOSITIONED LO REVERSE PIPE OR B OR BURNED LO REVERSE PISTON SEALS LEAKING CAUSES OF BURNED BAND o LO BLOW OFF VALVE ASSEMBLY 1 2 ACCUMULATOR PISTON OR PIN DAMAGED DAMAGED OR MISSING TRANSMISSION NOISY DURING ACCELERATION PARK NEUTRAL amp ALL DRIVING RANGES ANY GEAR TRANSMISSION OR COOLER LINES PUMP CAVITATION GR
54. IFT OCCURS NO 2 3 2 3 DELAYED FOR CORRECT T V CABLE BROKEN OR DISCONNECTED T V CABLE T V CABLE BINDING CHECK WITH ENGINE RUNNING TRANSMISSION IN NEUTRAL PULL CABLE TO FULL T V AND RELEASE GABLE SHOULD RETURN TO O T V OR GLOSEO THROTTLE POSITION GOVERNOR COVER WORN THRUST WASHER OMITTED GOVERNGA SEAL WORN QR CUT SPRING NOT SEATED WEIGHTS BINDING BALL MISSING DRIVEN GEAR STRIPPED OR LOOSE CHECK INTERMEDIATE SERVO INTERMEDIATE SERVO PISTON TO CASE OIL SEAL RING MISSING OR DAMAGED DAMAGED PISTON OR SERVO BORE INTERMEDIATE SERVO ORIFICE BLEED CUP PLUG IN CASE MISSING POROSITY IN THE CASE IN THE SERVO BORE AREA DIRECT CLUTCH ACCUMULATOR CUP PLUG LEAKING OR MISSING IN CASE THROTTLE LEVER AND BRACKET ASSEMBLY BINDING T V LINK UNHOOKED WRONG T V LINK CONTROL VALVE ASSEMBLY amp SPACER PLATE 2 3 SHIFT VALVE 13 V VALVE STICKING SHIFT T V VALVE STICKING GOVERNOR FEED TO 2 3 VALVE RESTRICTED DIRECT CLUTCH FEED ORIFICE RESTRICTED VALVE BODY SPACER PLATE OR GASKETS LEAKING DAMAGED INCORRECTLY INSTALLED I 36 CHECK BALL MISSING OR MISLOCATED CCUMULATOR EXHAUST CHECK VALVE CASE TO GOVERNOR SHAFT MISSING EKING SLEEVE DAMAGED OR MISSING OIL SEAL RINGS ON DRIVEN SPROCKET SUPPORT MISSING DAMAGED DIRECT CLUTCH PISTON SEALS DAMAGED MI
55. Inspect e Engine Performance Spark plugs and wires Timing Compression Refer to Section 6A Engine Torque Converter Balance Flywheel balance weights loose or missing Refer to Section 6A Torque converter out of balance Refer to Car Service Torque Converter Vibration Test Procedure GENERAL SERVICE PROCEDURES Important Keep work area and tools clean Always clean the exterior of the transaxle transmission before removing any parts Do not use wiping cloths or rags Do not use solvent on Neoprene seals Composition faced clutch plates Thrust washers Blow out all passages with compressed air Probe small passages with tag wire Handle parts with care to avoid nicks and scratches Inspect Linkage and pivot points for wear Bearing and thrust surfaces for wear and scoring Broken seal rings and damaged ring lands Gaskets mating surfaces seals and rings for damage Investigage and correct cause of damage Do not remove Teflon oil seal rings unless damaged Case for porosity Refer to Case Porosity Repair Procedure H Important Expand internal snap rings and compress external snap rings to assure proper seating Lubricate all internal parts as they are being installed When installing cap screws into aluminum parts Always use a torque wrench Always dip screw threads in transmission fluid or engine oil Stripped or damaged aluminum threads may
56. L RING SNAP SPRING RETAINER WAVED STEEL PLATE COMPOSITION FACED PLATE ALTERNATING STEEL amp COMP PLATES PLATE CLUTCH BACKING FORWARD RING SNAP H 125C 147 5 Figure 66 Forward Clutch Assembly 632 125 90 Figure 67 Forward Clutch Disassembly Forward clutch housing 624 for cracks broken welds Input shaft A splines and journals for damage Input sleeve for damage alignment and tightness sleeve must not turn and slot must line up with input shaft hole Seal rings 622 for damage do not remove unless replacing Piston 629 for damage or cracks Snap ring 621 for damage Insert 628 for damage Spring guide 630 for damage or distortion Retainer and spring assembly 631 for collapsed springs or bent retainer Composition and steel plates for wear or burning Waved steel plate 633 for wear or burning flatness Backing plate 634 for damage or cracks APPLY SIDE 5 B INNER SEAL C OUTERSEAL 125 82 Figure 68 Typical Apply Piston Assemble Figures 66 67 68 69 and 70 Tools Required J 26744 A Seal Installer J 23456 Clutch Pack Compressor 25018 Adapter Forward Compressor 1 Inner 627 and outer 626 seals lips facing housing 624 Figure 68 2 Insert 628 Spring AUTOMATIC TRANSAXLE 125C 45 3 Piston assembly 629 with J 26744 A Start inner seal 627 first Do not cut the seals on the snap rin
57. MAGED INCORRECTLY INSTALLED H 125 308 125C 14 AUTOMATIC TRANSAXLE 1 2 SHIFT COMPLAINT CHECK AND CORRECT OIL LEVEL SHIFTS NORMAL FIRM SHIFT QUICK HARSH AND GENERALLY AGGRESSIVE OR DELAYED SET T V CABLE TO SPECIFICATIONS ROAD TEST VEHICLE SHIFTS 1 3 HUNTS 1 2 1 AT LOW SPEEDS FEELS LIKE LOCKING UP OR BINDING ACCOMPANIED BY THUMPING NOISE CHECK FOR CORRECT T V CABLE CABLE BINDING DISCONNECTED RESET T V CABLE AND CHECK OIL PRESSURE IN NEUTRAL MINIMUM PRESSURE NORMAL COMPARE HIFT FEEL PART THROTTLE 1 2 DRIVE PART THROTTLE 1 2 INTERMEDIATE GOVERNOR SPRINGS DISTORTED WEIGHTS BINDING PRESSURE HIGH SEE CAUSES OF HIGH OIL PRESSURE CHECK INTERMEDIATE SERVO SEALS CUT DAMAGED LEAKING PISTON DAMAGED POROSITY IN CASE BORE SERVO ORIFICE BLEED CUP PLUG MISSING LEAK BETWEEN SERVO APPLY PIN AND CASE WRONG INTERMEDIATE APPLY PIN CHECK FOR CORRECT T V LINK CONTROL VALVE ASSEMBLY T V PLUNGER BINDING SHIFT T V VALVE BINDING 1 2 ACCUMULATOR VALV BINDING 1 2 ACCUMULATOR PISTON BINDING 1 2 ACCUMULATOR PISTON SPRING BAOKEN MISSING 1 2 ACCUMULATOR PISTON SEAL DAMAGED 1 2 ACCUMULATOR PISTON BORE DAMAGED INCORRECT SPACER PLATE AND OR GASKETS OR SPACER PLATE GASKETS INCORRECTLY INSTALLED 2ND PASSAGES IN CASE QR CASE COVER LEAKING PRESSURE NORMAL CHECK INTERMEDIATE SERVO SEALS CUT DAMAGED LEAKING PISTON DAMAGED LEAK BETWEE
58. MISSION NOTICE Antifreeze will attack the rubber seals on the selective spacer and the glue used to bond the clutch material to the pressure plate which may cause transmission damage If the transmission oil cooler has developed a leak allowing engine coolant to enter the transmission Disassemble transmission and replace all rubber type seals e Replace assemblies Replace all Nylon parts washers speedometers gears and governor gear e Replace the Torque Converter Thoroughly clean and rebuild transmission using new gaskets and oil filter Flush the cooler lines and cooler after the transmission cooler has been properly repaired or replaced OIL COOLER AND COOLER LINE FLUSHING Oil cooler and lines must be flushed if the transmission fluid has been contaminated by engine coolant or if metal rubber or clutch facing particles have become suspended in the fluid as the result of mechanical failure composition faced clutch plate E Clean Disconnect transmission 2 Place a hose over the end of the cooler inlet line from the bottom of the cooler and insert the hose into an empty container 3 Flush clean Oleum Solvent equivalent through the return line from the top of the cooler using an oil suction gun until clean solvent comes out of the hose 4 Remove the hose from the inlet cooler line and place it on the return line 5 Flush clean Oleum Solvent or equivalent through the inlet line u
59. MULATOR EXHAUST APPLY CONVERTER FEED TV EXHAUST DECREASE RNDI REVERSE VOID INTERMEDIATE LINE RELEASE TO COOLER INTAKE DRILLED HOLE DIRECT CLUTCH ACCUMULATOR 125C 8 CONVERTER FEED GOVERNOR 2 LINE SHIFT TV EXHAUST TO COOLER RELEASE 3RD CLUTCH APPLY DRILLED amp TAPPED HOLE NON C3 ONLY REGULATED LINE SOLENOID CIRCUIT AUXILIARY VALVE BODY COVER AUXILIARY VALVE BODY iiosc 24 Figure A 7 Auxiliary Valve Body and Cover 125C 8 AUTOMATIC TRANSAXLE COBDNAMAWN APPLY LINE EXHAUST RELEASE TO COOLER DIRECT CLUTCH 3RD GOVERNOR DRILLED amp TAPPED HOLE NON C3 ONLY SHIFT TV CONVERTER FEED Figure A 8 Auxiliary Valve Body Pump Side 36 37 39 40 4 4 Oo O00 REVERSE TV EXHAUST LINE TV EXHAUST DRIVE 1 2 ACCUMULATOR 2 DRIVE LUBE 1 2 ACCUMULATOR SHIFT TV DIRECT CLUTCH LO REVERSE LO 1ST 2ND VOID LO 1ST DRIVE GOVERNOR DRIVE 2ND 22 DIRECT CLUTCH Figure A 9 Case Cover Valve Body Side H 125C 1 DIRECT CLUTCH ACCUMULATOR INTAKE TO COOLER COOLER TO LUBE LO VOID CONVERTER FEED EXHAUST VOID SHIFT TV PART THROTTLE DETENT LO INTERMEDIATE DRIVE VOID LINE RNDI RND VOID 4 gt CHECK BALLS 125 9 AUTOMATIC TRANSAXLE 125 9 INTAKE ACCUMULATOR DIRECT CLUTCH 2ND VOID LO REVERSE DIRECT CLUTCH REVERSE DRIVE LUBE EXHAUST VENT ASSEMBLY
60. N SERVO SOFT SHIFT SLIPS OR LONG DRAWN OUT SHIFT WITH END BUMP MAY ALSO BE EARLY SHIFT CHECK FOR CORRECT CABLE CABLE BINDING DISCONNECTED CHECK OIL PRESSURE IN NEUTRAL PULL T V CABLE TO FULL T V PRESSURE LOW SEE CAUSES OF LOW OIL PRESSURE CONTROL VALVE ASSEMBLY T V PLUNGER BINDING SHIFT T V VALVE BINDING 1 2 ACCUMULATOR VALVE BINDING APPLY PIN AND CASE INTERMEDIATE SERVO BAND APPLY PIN BINDS IN CASE gure 18 1 2 Shift Complaint 1 2 ACCUMULATOR PISTON BINDING 1 2 ACCUMULATOR PISTON SPRING BROKEN MISSING 1 2 ACCUMULATOR PISTON SEAL 1 2 ACCUMULATOR PISTON BORE DAMAGED INCORRECT SPACER PLATE AND OR GASKETS SPACER PLATE GASKETS INCORRECTLY INSTALLED POROSITY IN CASE IN ZND OR SERVO APPLY PASSAGE AND OR 1 2 ACCUMULATOR PASSAGE INTERMEDIATE BAND BURNED CHECK F R CAUSE IMPROPER TORQUE ON CASE COVER H 125 309 AUTOMATIC TRANSAXLE 125C 15 2 3 SHIFT COMPLAINT CHECK TRANSMISSION OIL LEVEL AND CORRECT IF NECESSARY 1 SET T V CABLE TO SPECIFICATIONS CHECK AND ADJUST MANUAL LINKAGE AS REQUIRED ROAD TEST VEHICLE SOFT SHIFT SLIPS OR LONG SLIGHT DELAY AND HARSH UPSHIFT DRAWN OUT SHIFT WITH END BUMP MAY ALSO BE EARLY RESET T V CABLE AND CHECK OIL PRESSURE IN NEUTRAL SHIFT MINIMUM T V CHECK OIL PRESSURE IN NEUTRAL PULL T V CABLE TO FULL T V PRESSURE NORMAL DIRECT CLUTCH CHECK FOR CAUSE OF HIGH AC
61. NEUTRAL OR SLIPS LEAK BETWEEN CASE COVER AND DRIVEN SPROCKET SUPPORT PASSAGES CHECK FOR CORRECT GASKETS ACTS LIKE NEUTRAL CONVERTER TO FLEX PLATE BOLTS MISSING CHECK LINE PRESSURE IN DRIVE RANGE AT 1000 RPM SEE OIL PRESSURE CHART PRESSURE OK MANUAL LINKAGE NOT MOVING MANUAL VALVE CHECK EXTERNAL LINKAGE CHECK INTERNAL LINKAGE INPUT SHAFT TO FORWARD CLUTCH DRUM BROKEN LOOSE REACTION CARRIER BROKEN AT LO ROLLER CLUTCH CAM PRESSURE LOW PRESSURE REGULATOR VALVE STICKING IN BUSHING CHECK FOR WORN PUMP SEALS SEE CAUSES OF LOW PRESSURE SEE CAUSES OF BURNED CLUTCH PLATES H 125 312 Figure A 21 No Drive 1256 18 AUTOMATIC TRANSAXLE NO DRIVE IN ANY FORWARD RANGE REVERSE OK ACTS LIKE NEUTRAL OR SLIPS CHECK PRESSURE DRIVE RANGE AT 1000 RPM PRESSURE LOW SEE CAUSES OF LOW PRESSURE PRESSURE OK MANUAL LINKAGE NOT MOVING MANUAL VALVE DRIVE OIL PASSAGE IN DRIVEN SPROCKET SUPPORT OR DRIVEN SPROCKET SUPPORT TO CASE COVER GASKET RESTRICTED DRIVE OIL PASSAGE LEAK IN CASE COVER SLEEVE IN ORIVEN SPROCKET SUPPORT LOOSE OR MISLOCATED FORWARD CLUTCH BURNED SEG CAUSE VALVE BODY PIPE IN CONTROL VALVE PUMP ASSEMBLY LEAKING MISSING NO REVERSE ALL FORWARD RANGES OK TIES UP PULLS ENGINE DOWN DRIVE OR CREEP IN NEUTRAL FORWARD CLUTCH WILL NOT RELEASE CLUTCH PLATES BURNED SEVERELY SEAL RING OFF PISTON EXHAUST CHECK BALL STICKING SEE CAUSES OF F
62. OISE FAULTY SPEEDOMETER HEAD CABLE AND OR CASING 15 KINKED CABLE 15 WEAK IF NOISE STILL EXISTS AFTER PERFORMING THE ABOVE PROCEDURES REMOVE SPEEDOMETER FOR REPAIR REFER TO NOISY CABLE AND OR CASING KINKED IF EXAMINATION DOES NOT REVEAL KINKED CABLE AND OR CASING REPLACE WITH A NEW AND PROPERLY LUBRICATEO CABLE AND RECHECK FOR POINTER FLUTTER STICKY SPEEDO POINTER BINDS OR HANGS UP SPEEDO POINTER IS BENT AND RUBS REMOVE SPEEDOMETER CLUSTER FROM PANEL AND INSPECT FOR A RUBBING POINTER STRAIGHTEN POINTER UNTIL IT IS FREE TO MOVE REPLACE SPEEDOMETER CLUSTER IN PANEL AND RECHECK SPEEDO OPERATION FAULTY SPEEDOMETER REMOVE HEAD FOR REPAIR SPEEDO DOESN T WORK BROKEN OR DISCON NECTED CABLE FAULTY SPEEDOMETER HEAD IF NEITHER THE SPEEDOMETER POINTER NOR ODOMETER OPERATES CHECK TO SEE THAT CABLE IS IN PLACE AND TIGHT AT TRANSMISSION AND SPEEDOMETER STILL INOPERATIVE REPLACE CABLE IF ONLY THE ODOMETER IS INOPERATIVE OR IF THE ABOVE PROCEDURE IS NOT SATISFACTORY REMOVE THE SPEEDOMETER FOR REPAIR INCORRECT CALIBRA TION WRONG TRANSMISSION ADAPTER ORIVEN GEAR OR SLEEVE CHECK SPEEDOMETER GEAR REFERENCE CHART FOR CORRECT APPLICATION AND REPLACE IF NECESSARY OVERSIZE OR UNDERSIZE TIRES CHECK CALIBRATION USING CORRECT TIRE SIZE FAULTY SPEEDOMETER HEAD REMOVE SPEEDOMETER FOR REPAIR G20010 7A Fig 2 Speedomet
63. ORWARD CLUTCH PLATES BURNED ACTS LIKE NEUTRAL OR SLIPS CHECK LINE PRESSURE IN REVERSE SEE CHART LINE PRESSURE LOW CHECK CAUSES OF LOW LINE PRESSURE LINE PRESSURE CASE LO AND REVERS CLUTCH HOUSING CUP PLUG ASSEMBLY RESTRICTEO NOT FULLY SEATED AIR CHECK LO AND REVERSE CLUTCH FOR S ALS OR PISTON LEAKS O RING OR WASHER ON LO AND REVERSE PIPE DAMAGED OR MISSING INCORRECT GASKET FOR DRIVEN SPROCKET SUPPORT HEIGHT CASE COVER LEAKING DAMAGED PLUGGED OR MISSING LO 15 ORIFICE IN SPACER PLATE SEE CAUSE OF DIRECT CLUTCH BURNEO SEE CAUSE OF LO AND REVERSE CLUTCH SURNED 125 313 Figure 22 No Reverse SECOND SPEED START MISSES 15 AT TIMES GOVERNOR SPRINGS DISTORTED OR OUT OF PLACE WEIGHTS BINDING SHIFT VALVE OR 1 2 THROTTLE VALVE STICKING IN UPSHIFTED POSITION PRESSURE NORMAL FORWARD CLUTCH AUTOMATIC TRANSAXLE 125C 19 SHIFTS 3 1 AT HIGH SPEEDS FOR PASSING GEAR DETENT DOWNSHIFTS INSPECT GOVERNOR INTERMEDIATE SERVO STICKING DIRECT CLUTCH ORIFICE CONTROLLED BY 2 CHECK BALL RESTRICTED 1 2 ACCUMULATOR PISTON MISSING SEAL LEAKING SLIPS CHATTERS IN 1ST CHECK OIL LEVEL CABLE NOT ADJUSTED WRONG CABLE CHECK OIL PRESSURE PRESSURE LOW BURNED FORWARD CLUTCH SEE CAUSES OF BURNED CLUTCH PLATES ROUGH MACHINE SURFACE ON DRIVEN SPROCKET SUPPORT INCORRECT CASE COVER GASKETS SHIFTS 1 3 MISSES 2ND INTERMED
64. OUNDED TO UNDERBODY OIL LEVEL LOW MOTOR MOUNTS LOOSE OR BROKEN PLUGGEO OR RESTRICTED STRAINER DAMAGED O RING SEAL POROSITY CASE INTAKE AREA WATER IN OIL DRIVE LINK ASSEMBLY WORN OR DAMAGED MAY SOUND LIKE POPCORN POPPING DRIVE LINK ASSEMBLY SPROCKET SUPPORT RUBBING ON CASE COVER NEEDLE BEARINGS WORN DAMAGED PUMP OR DRIVEN SPROCKET NEEDLE BEARING ASSEMBLY IMPROPERLY INSTALLED REFER TO SERVICE MANUAL SQUEAL AT LOW VEHICLE CONVERTER SPEEDS ESPECIALLY HOT LOOSE BOLTS CONVERTER TO FLEX PLATE CONVERTER DAMAGED CRACKED OR BROKEN FLEX PLATE SPEEDOMETER DRIVEN GEAR SHAFT SEAL REQUIRES LUBRICATION OR REPLACEMENT IF SPEEDOMETER DRIVEN GEAR SHAFT APPEARS TWISTED CHECK FOR PRESENCE OF ENGINE COOLANT IN TRANSMISSION CHECK ALL DRIVING RANGES TRANSMISSION COOLER FOR LEAKS DEPENDING ON RANGES 4ST AND OR REVERSE 2ND AND OR TURNS INPUT GEAR SET FINAL DRIVE GEAR SET REACTION GEAR SET FINAL DRIVE GEAR SET DIFFERENTIAL GEAR SET FINAL DRIVE GEAR SET 5 ALSO SEE DIFFERENTIAL GEAR SET DIFFERENTIAL GEAR SET BALANCING PLANETARY GEAR SET 1 THOROUGHLY CLEAN DRY amp INSPECT CLOSELY THE ROLLER THRUST BEARINGS AND THRUST RACES FOR A PITTING OR ROUGH CONDITION 2 INSPECT GEARS FOR DAMAGE WEAR PITTING AND PINIONS FOR TILT H 125 315 Figure A 24 Transmission Noisy DISASSEMBLY Remove or Disconnect 1 J 21366 Converter holding strap 2 Converter 1 Install or Connect F
65. PUT INTERNAL BUSHING INPUT INTERNAL GEAR WASHER INPUT INT GR THRUST CARRIER ASSEMBLY INPUT WASHER INPUT SUN GR THRUST GEAR INPUT SUN DRUM INPUT RING SNAP SELECT INPUT DRUM SUN GEAR 649 651 652 653 654 655 656 657 658 659 660 661 662 663 664 665 666 667 668 669 670 671 672 673 674 675 676 677 678 679 680 681 682 683 684 685 686 687 688 NOT REQUIRED WITH CAST ALUMINUM PISTON AUTOMATIC TRANSAXLE 125C31 BUSHING REACTION SUN GEAR GEAR REACTION SUN RING SNAP BUSHING LO amp REVERSE CLUTCH HOUSING HOUSING LO AND REVERSE RING SNAP SEAL LO amp REVERSE PISTON OUTER SEAL LO amp REVERSE PISTON INNER PISTON LO AND REVERSE CLUTCH INSERT LO amp REVERSE CLUTCH PISTON SPRING LO amp REVERSE CLUTCH RELEASE RETAINER LO amp REVERSE CLUTCH SPRING RING SNAP PLATE LO amp REVERSE CLUTCH PLATE LO amp REVERSE CLUTCH BACKING SPACER REV HOUSING LO RACE SELECTIVE RACE LO ROLLER CLUTCH ROLLER ASSEMBLY LO CLUTCH WASHER REACTION CARR INT GR THRUST BUSHING REACTION CARRIER CARRIER ASSEMBLY REACTION WASHER REACTION CARR INT GR THRUST BEARING REACTION SUN INT GR THRUST GEAR REACTION INTERNAL SHAFT FINAL DRIVE SUN GEAR RING SNAP SPACER FINAL DRIVE INTERNAL GEAR BUSHING FINAL DRIVE INTERNAL GEAR GEAR FINAL DRIVE INTERNAL BEARING THRUST SUN GEAR INT GEAR GEAR FINAL DRIVE SUN BEARING THRUST SUN GEAR
66. R 343 BODY AUXILIARY VALVE 344 SLEEVE AUXILIARY VALVE BODY 345 PIN SLIDE PIVOT 346 RING OIL SEAL SLIDE TO COVER 347 SEAL RING SLIDE 348 SLIDE PUMP 349 SUPPORT PUMP SLIDE SEAL 350 SEAL PUMP SLIDE 351 RING PUMP VANE 352 VANE PUMP 353 ROTOR OIt PUMP I ae gt BUSHING 1 2 ACCUMULATOR VALVE 1 2 ACCUMULATOR VALVE 2 3 SHIFT VALVE 2 3 THROTTLE SPRING 2 3 THROTTLE VALVE BUSHING 2 3 THROTTLE VALVE VALVE 1 2 SHIFT VALVE 1 2 THROTTLE SPRING 1 2 THROTTLE VALVE BUSHING 1 2 THROTTLE VALVE BALL LO BLOW OFF SPRING amp PLUG ASSEMBLY LO BLOW OFF PLUG LO BLOW OFF VALVE BOLT AUXILIARY V B VALVE BODY RETAINER VALVE BODY PIPE BOLT AUXILIARY VALVE BODY TO CASE COVER AUXILIARY VALVE BODY GASKET AUXILIARY VALVE BODY COVER VALVE CONVERTER CLUTCH CONTROL SOLENOID ASSEMBLY BOLT SOLENOID SWITCH PRESSURE SEAL RING SWITCH GOVERNOR PRESSURE DIESEL ONLY HARNESS SOLENOID WIRE PLUG VALVE BORE 354 BEARING ASSEMBLY ROLLER PUMP SHAFT 355 SPRING 3 2 VALVE 356 VALVE 3 2 CONTROL 357 SEAL PUMP SHAFT 358 PLUG SPRING RETAINING 359 SPRING PUMP PRIMING 360 BUSHING T V amp REVERSE BOOST VALVE 361 VALVE T V BOOST 363 VALVE REVERSE BOOST 364 SPRING PRESSURE REGULATOR 365 VALVE PRESSURE REGULATOR 366 BUSHING T V PLUNGER 367 PLUNGER THROTTLE VALVE 368 SPRING THROTTLE VALVE 369 VALVE THROTTLE 371 PIN T V amp REVERSE BOOST BUSHING 372 PL
67. RING SNAP 125 1463 SN UN ed S Figure 71 Direct Clutch Assembly Figure 73 Installing the Clutch Assemblies 610 HOUSING amp DRUM ASM DIRECT CLUTCH tad 72 42mm 1 11 16 lt L 77 5 ANY z 606 BAND ASSEMBLY INTERMEDIATE 7 607 PLUG BAND ANCHOR HOLE 125 52 1 Figure 75 Intermediate Band Anchor Hole Plug INTERMEDIATE BAND ASSEMBLY Inspect Band 606 burns flaking or damage Install or Connect Figure 75 1 Band 606 must engage the case lug 2 Plug 607 DRIVEN SPROCKET SUPPORT Inspect Figure 76 and 26 Support 602 for cracks burrs or damage oil passage surface must be flat and smooth Bushing 603 for damage Thrust washer 605 for damage e Oil seal rings 604 for nicks cuts or damage Bearing Replacement Procedure Remove or Disconnect Figure 76 Tools Required J 26941 Transmission Case Bearing Remover J 6125 1 Slide Hammer Bearing assembly 601 use J 26941 and J 6125 1 Inspect race for damage AUTOMATIC TRANSAXLE 125C 47 601 BEARING ASSEMBLY 602 SUPPORT ASSEMBLY DRIVEN SPROCKET Figure 76 Bearing Replacement SUPPORT DRIVEN SPROCKET WASHER THRUST DRIVEN SPROCKET SUPPORT TO DIRECT CLUTCH HOUSING ROD AND LEVER ASSEMBLY LEVER ASSEMBLY DETENT SHAFT MANUAL PIN MANUAL SHAFT CASE RETAINING H125 20 1 Figure 77 Driven Sprocket Support amp Manual Linkag
68. SM DRIVEN SPROCKET THRUST SPROCKET DRIVEN WASHER DR SKT SUPPORT THRUST PLUG CUP 3RD OIL SPRING ACCUMULATOR EXHAUST VALVE ACCUMULATOR EXHAUST PLUG ORIFICE RING OIL SEAL INTER BAND APPLY PIN PIN INTERMEDIATE BAND APPLY RETAINER INTERMEDIATE SERVO SPRING SPRING INTERMEDIATE SERVO CUSHION RING OIL SEAL OUTER INT SERVO PISTON INTERMEDIATE SERVO RING OIL SEAL INNER INT SERVO RING SNAP GASKET INTERMEDIATE SERVO COVER COVER INTERMEDIATE SERVO PIPE GOVERNOR OIL PIPE REVERSE OIL RETAINER REVERSE OIL PIPE BOLT INTERMEDIATE SERVO COVER BOLT PIPE RETAINER CASE RETAINER GOVERNOR amp REVERSE OIL PIPE RING SEAL BACKUP SEAL O REVERSE PIPE TO CASE RETAINER OIL WEIR OIL WEIR 125 19 3 RING OIL SEAL TURBINE SHAFT YELLOW Figure 4 Drive Link Assembly Servo Oil Pipes 125C 24 AUTOMATIC TRANSAXLE O O RING SEAL STRAINER ASM TRANSMISSION OIL GASKET OIL PAN PAN TRANSMISSION OIL SCREW TRANSMISSION OIL PAN H125C 65 2 Figure 5 Bottom Pan amp Oil Strainer Bottom Pan Oil Strainer Oil Pipes Remove or Disconnect Figures 3 and 5 1 Bolts 36 2 Pan 35 Leave two bolts in place finger tight tap with a rubber mallet to break the R T V sealant bead or gasket set 3 Strainer 33 and ring 32 Remove or Disconnect Figures 4 and 6 1 Bolts 141 and 142 Brackets 140 and retainers 143 Servo cover 137 and gasket 136 Se
69. SSING PISTON OR HOUSING CRACKED DELAY IN DRIVE AND REVERSE CLUTCH PLATES DAMAGED MISSING BACKING PLATE SNAP RING OUT OF GROOVE CHECK BALL CAPSULE DAMAGED LEAKING CHECK OIL LEVEL CHECK LINE PRESSURES LINE PRESSURE LOW LINE PRESSURE OK PART ENGINE OFF OR MIN OR LONGER LINE PRESSURE WITH ENGINE OFF 60 MIN OR LONGER CONVERTER ORAINBACKI CASE CENTER GASKET LEAKING INCORRECT CASE COVER BOLTS LOOSE DRIVEN SPROCKET SUPPORT PASSAGES INTERCONNECTED LEAKING RESTRICTED DRIVEN SPROCKET SUPPORT OIL SEAL RINGS DAMAGED MISSING SLEEVE LOOSE OR OUY OF POSITION TEFLON SEALS ON TURBINE SHAFT DAMAGED REPLACE TURBINE SHAFT SCARF CUT TEFLON SEALS WITH SOLID SEALS Figure A 20 No 2 3 or Delayed 2 3 125 311 AUTOMATIC TRANSAXLE 125 17 NO DRIVE IN DRIVE OR INTERMEDIATE RANGE LO AND REVERSE OK LO ROLLER CLUTCH ASSEMBLY 1 NOT HOLDING NO DRIVE IN FORWARD RANGES REVERSE TIES UP SLEEVE TURNED DRIVEN SPROCKET SUPPORT NO DRIVE FORWARD OR REVERSE ANY RANGE KE TIED UP PULLS ENGINE DOWN INTERNAL MECHANICAL DAMAGE DIFFERENTIAL BROKEN UP OBJECT BETWEEN LINK AND SPROCKET LOCKING LINK ASSEMBLY NO DRIVE IN DRIVE RANGE INTERMEDIATE LOW AND REVERSE OK CHECK OIL LEVEL MAY ONLY OCCUR WITH COLD ENGINE AT COLD OR FAST ENGINE IDLE FORWARD CLUTCH FEED IN INPUT SHAFT RESTRICTED ACTS LIKE
70. STOP 742 BOLT PARKING LOCK BRACKET CASE Reverse Pipe and Parking Bracket Install or Connect Figures 102 and 103 Weir 147 Bracket 143 Retainer 143 Screw 142 Bracket 710 Stop 711 Screw 712 Inspect Actuator Assembly 705 for proper action Install or Connect Figure 104 e plug 120 use 9 5 mm 3 8 drift OPE UN S Assemble Figure 103 Washer 144 onto pipe 139 ring 145 retain with petrolatum Pipe assembly 139 Bracket 143 Screw 142 nU EOS H 125C 80 2 Figure 102 Dipstick Stop amp Parking Lock SPRING ACCUMULATOR EXHAUST VALVE ACCUMULATOR EXHAUST PLUG ORIFICE RING OIL SEAL INTER BAND APP PIN PIN INTERMEDIATE BAND APPLY RETAINER INTER SERVO SPRING SPRING INTER SERVO CUSHION RING OIL SEAL OUTER INTER SERVO PISTON INTERMEDIATE SERVO RING OIL SEAL INNER INT SERVO RING SNAP GASKET INTERMEDIATE SERVO COVER COVER INTERMEDIATE SERVO PIPE REVERSE OIL RETAINER REVERSE OIL PIPE BOLT INT SERVO COVER BOLT PIPE RET CASE RETAINER GOVERNOR AND REV OIL PIPE RING SEAL BACKUP SEAL O REVERSE PIPE TO CASE RETAINER OIL WEIR OIL WEIR H 125C 66 Figure 103 Oil Pipe amp Servo Tighten Torque the screws 142 712 142 to 24 N m 18 ft 1bs INTERMEDIATE SERVO Disassemble Figure 103 E ring 135 from pin 129 Piston 133 from pin 129 Spring 131 Retainer 130
71. Seal amp Cooler Fittings e Element 412 Element plate 411 Assemble Figure 82 and 83 Set thermo pin height with J 29023 Install the element plate 411 Install the element 412 Install the washers 413 use J 29023 to set the washer height Inspect Figure 84 Left hand axle seal 31 for damage AUTOMATIC TRANSAXLE 125C 51 Seal Replacement Procedure Remove or Disconnect e Seal 31 Install or Connect Seal 31 use J 26938 or J 29130 Assemble Figure 81 Case cover Thrust washer 414 use petrolatum to hold in place Pin 422 chamfered end first Piston 421 Spring 419 Gasket 415 use petrolatum to hold in place 1 2 3 4 5 6 Install or Connect Loctite 515 or equivalent both sides of gasket 416 INPUT SHAFT TO CASE COVER SELECTIVE SNAP RING Gasket 416 to case cover 621 Case cover 401 to case Thickness Identification Color Coat bolt A with thread sealer Figure 84A Retainer 701 to manual valve 406 Figure 85 1 93mm 0 0717 0 076 2 13mm 0 078 0 0847 233mm 0 088 0 092 2 53mm 0 095 0 099 273mm 0 103 0 107 125 318 2 Figure 87 Selective Snap Ring Chart Input Shaft End Play jme Va 4 12 T Measure Figures 86 and 87 z is 5 ios ES E Tools required ERE a J 26958 10 Adapter plug J 26958 Loading tool and J 26958 11 bracket
72. TER OIL 107 SEAL O RING 106 SHAFT TURBINE Q T H 125C 16 1 Figure 80 Turbine Shaft O Ring Seal Install or Connect Figures 78 and 80 I Thrust washer 123 onto sprocket 122 and retain with petrolatum 2 Thrust washer 104 onto sprocket 103 and retain with petrolatum 3 Drive 103 and driven 122 sprockets into link assembly 101 colored guide link up 4 Link assembly 101 and sprockets 103 and 122 into case 112 5 New O ring 107 onto the turbine shaft from the converter side of case Figure 80 6 Thrust bearing 121 onto sprocket 122 402 403 PIN SPRING THERMO ELEMENT PIN THERMO ELEMENT PLATE THERMOPLASTIC ELEMENT THERMO ELEMENT WASHER THERMO ELEMENT WASHER THRUST CASE COVER TO DR SKT GASKET CASE TO CASE COVER CENTER GASKET CASE TO CASE COVER SPRING AND ROLLER ASM MANUAL DETENT BOLT MAN DET SPRING CASE COVER SPRING 1 2 ACCUMULATOR PISTON RING OIL SEAL 1 2 ACCUMULATOR PISTON PISTON 1 2 ACCUMULATOR PIN 1 2 ACCUMULATOR H 125C 20 2 Figure 81 Case Cover Case Side 125C 50 AUTOMATIC TRANSAXLE CASE COVER ASSEMBLY Clean Figures 81 and 84 Apply gasket remover then scrape the case cover gasket surface with a plastic scraper Inspect Case cover 401 see Section 7A for case cover repair Casting porosity Oil passage damage lt 1 2 accumulator bore damage accumulator piston 421 seal 420 and s
73. TH IDENTIFICATION ACTUATOR ASSEMBLY BRACKET PARKING LOCK BRACKET DIPSTICK STOP BOLT PARKING LOCK BRACKET CASE Figure 9 Dip Stick Stop amp Brackets LOW AND REVERSE SEAL AND OUTPUT SHAFT Remove or Disconnect Figure 11 amp 12 Tool Required J 28583 ring remover output shaft Modified No 4 screw extractor 1 Lo and reverse seal 120 Use a modified No 4 screw extractor 2 Output shaft ring 30 with 1 28583 Push ring with remover rotate shaft 29 pull the ring with needle nose pliers 3 Output shaft 29 from case AUTOMATIC TRANSAXLE 125C 25 ef 125 SPRING ACCUMULATOR EXHAUST 126 VALVE 3RD ACCUMULATOR EXHAUST Figure 10 3rd Accumulator Exhaust Valve amp Spring 2 gt 1 MODIFIED 4 Cron 120 CUP PLUG LO AND REVERSE 125 138 I H 125 133 Figure 12 Expanding C Ring SIDE COVER AND CONTROL VALVE PUMP ASSEMBLY Remove or Disconnect Figures 13 and 14 1 Screws 27 Leave two screws finger tight tap the cover 26 with rubber mallet Cover 26 3 Bolts 24 Do not remove the screw marked Figure 14 Bracket assembly 23 and T V cable link 22 Valve body 21 Do not place the machined side on the bench Number one check ball 16 Pump shaft 18 Spacer plate 20 and gaskets 19 Five check balls Figure 15 A gt 125C 26
74. UG BORE PRESSURE REGULATOR 373 RETAINER PRESSURE REGULATOR 374 SPRING PRESSURE REGULATOR ISOLATOR 375 PLUG VALVE BORE ISOLATOR 376 RING VALVE RETAINING LEGEND H 125C 21 3 Figure 90L Contro Valve and Oil Pump Ass y Legend Oil Pump Rotor and Slide Replacement important M re Figure easure Fig 91 Measurement of rotor slide must be made on undamaged Tool Required surfaces Select similar size replacements Figure 91 Lightly One Inch Micrometer hone both sides of replacement rotor or slide to remove any Pump Rotor 353 Thickness nicks or burrs Oil Pump Slide 348 Thickness OIL PUMP ROTOR SELECTION CHART THICKNESS mm THICKNESS 17 917 17 929 0 7055 0 7059 17 930 17 942 0 7060 0 7064 17 943 17 955 0 7065 0 7069 17 956 17 968 0 7070 0 7074 17 969 17 981 0 7075 0 7079 OIL PUMP SLIDE SELECTION CHART THICKNESS mm THICKNESS in 17 955 17 967 1 0 7070 0 7074 17 968 17 980 0 7075 0 7079 17 981 17 993 0 7080 0 7084 17 994 18 006 0 7085 0 7089 18 007 18 020 0 7090 0 7094 H125C 96 348 OIL PUMP SLIDE 353 OIL PUMP ROTOR Figure 91 Oil Pump Rotor and Slide Selection PUMP SIDE 354 BEARING ROLLER PUMP SHAFT 357 SEAL PUMP SHAFT H 125C 53 SN CASE COVER SIDE 1 PRESS BEARING 1 0mm TO 1 2mm 040 047 ABOVE THIS SURFACE 354 BEARING ROLLER PUMP SHAFT Figure 93 Bearing Dimension
75. __ Alternate tightening of the bolts DO NOT PRY CASE COVER 401 Pen ava 1 BOLT M12 x 1 75 x 50 401 CASE COVER SHAFT TURBINE 107 SEAL O RING 109 DRIVE SPROCKET SUPPORT STATOR SHAFT SEAL CONVERTER OIL 125 16 1 Figure 20 Case Cover Removal LINK ASSEMBLY DRIVE 121 BEARING ASM DRIVEN SPROCKET THRUST 103 SPROCKET DRIVE 122 SPROCKET DRIVEN 104 WASHER CASE COVER TO DR SKT THRUST 123 WASHER DR SKT SUPPORT THRUST 106 SHAFT TURBINE 108 BEARING ASSEMBLY SUPPORT DRIVE SPROCKET CASE TRANSMISSION 1259 76 Figure 22 Drive Link Assembly DESCRIPTION ROD amp RETAINER ASSEMBLY PIN SPRING DETENT LEVER TO SHAFT LEVER amp HUB ASSEMBLY MANUAL DETENT SHAFT MANUAL ACTUATOR ASSEMBLY PARKING LOCK PAWL PARKING LOCK SPRING PARKING PAWL RETURN RETAINER PARKING PAWL SHAFT SHAFT PARKING LOCK PAWL BRACKET PARKING LOCK BRACKET DIPSTICK STOP BOLT PARKING LOCK BRACKET CASE PIN MANUAL SHAFT CASE RETAINING H 125C 17 1 Figure 23 Manual Linkage AUTOMATIC TRANSAXLE 125C 29 1 RAG 2 PUNCH 5mm 3 16 703 LEVER DETENT 704 SHAFT MANUAL Figure 24 Retaining Pin Removal INPUT UNIT PARTS Remove or Disconnect Figures 23 24 25 26 27 and 28 1 702 713 Detent lever 703 Manual shaft 704 Actuator rod 705 00000 Driven sprocket support 602 Thrust washer 605 from direct clutch side
76. al Installer and Sizer Turbine Shaft Seal Installer and Sizer 2 Seals 1 Seal Age wr G3 8 J 29369 J 29569 29829 Figure 112 Tool List
77. al injury may occur if not properly adjusted TRANSMISSION CONTROL CABLE Adjust Figure 7A1 4 and 7A1 6 1 Place shift lever neutral position 2 Place transmission lever in neutral position Obtain neutral position rotating transmission lever clockwise from thru into neutral 3 Insert threaded pin part of shift cable asm upward through slotted hole in lever and hand start nut Lever must be held out of park when torquing nut Impact type tools must not be used Tighten Nut to 20 34 N m 15 25 Ib ft PARK LOCK CONTROL CABLE Park Lock Cable Remove or Disconnect Figure 7A1 4 and 7A1 5 Remove console covers hush panel and lower steering column as necessary for access to park lock cable 1 Negative battery cable 2 Shift lever in park position 3 Ignition key to run position 4 Cable from inhibitor NOTICE To release cable from inhibitor insert screwdriver blade into inhibitor slot depress cable latch and pull cable from inhibitor 5 Cable from park lock lever pin 6 Cable from shifter base 7 Cable Install or Connect Shift lever in park position Snap cable connector lock button to up position Snap cable connector to base Ignition key to OFF position Snap cable into inhibitor housing Ignition key to position Snap cable to park lock lever pin Push cable connector nose forwa
78. as an imbalance which cannot J 29830 End Play Checking Tool 125C be corrected the converter should be replaced 440 4 Refer to Converter Vibration Test Procedure e Converter contaminated with engine coolant containing antifreeze The converter should not be replaced if e The oil has an odor is discolored and there is no evidence of metal or clutch facing particles There is no indication that there is internal damage nor any pump damage Dump out as much oil as possible from the converter and replace only the oil filter in the pan Thethreads in one or more of the three converter bolt holes are damaged Correct with thread insert Refer to Section 6A Fig 11 Checking Torque Converter End Play CLUTCH PLATE DIAGNOSIS Composition Plates Inspect Dry plates and inspect for pitting flaking wear glazing cracking charring and chips or metal particles imbedded in lining If a composition plate shows any of the above conditions replacement is required Steel Plates Wipe plates dry and check for heat discoloration If the surfaces are smooth even if color smear is indicated the plate should be reused If severe heat spot discoloration or surface scuffing is indicated the plate must be replaced Important e Ifthere is evidence of extreme heat or burning in the area of the clutch the springs should be replaced Causes of Burned Clutch Plates Burned clutch plates can be caused by incorre
79. be reconditioned with thread inserts Refer to Section 6A Replace all gaskets seals and rings Always use seal protectors Do not use gasket cement or sealers except where noted 7 6 AUTOMATIC TRANSAXLE TRANSMISSION DIAGNOSIS SPEEDOMETER SYSTEM COMPLAINT CAUSE PROCEDURE SPEEDO POINTER FLUTTERS LOOSE FERRULE AT SPEEDO HEAD PUSH FERRULE AGAINST SPEEDO HEAD AND RECHECK FOR NOISE BEND CABLE TIP AT SPEEDO HEAD CABLE IS WHIPPY BEFORE REMOVAL KV REPLACE CABLE LUBRICATE LOWER TWO THIROS OF CABLE WITH A THIN COAT OF SPEEDOMETER CABLE LUBRICANT BENT CABLE AFTER REMOVAL PP Dee BENT CABLE TIP HOLD CABLE IN POSITION SHOWN AND ROTATE A CABLE DOES NOT TURN SMOOTHLY BUT JUMPS IF THIS CONDITION EXISTS REPLACE WITH A NEW CABLE LUBRICATE LOWER TWO THIRDS OF CABLE WITH A THIN COAT OF SPEEDOMETER CABLE LUBRICANT AND RECHECK FOR NOISE WHIPPY CABLE JUMPS WHEN ROTATED CAUSE NOT PART OF SPEEDO METER SYSTEM FAULTY DRIVEN GEAR IN TRANSMISSION PROCEDURE WITH CABLE REMOVED FROM CASING FERRULE AND RECHECK FOR NOISE IF NOISE STILL EXISTS GEARS THAT DRIVE THE CABLE AT THE TRANSMISSION MAY BE AT FAULT REMOVE DRIVEN GEAR FROM TRANSMISSION CHECK FOR FREE ROTATION OF GEAR IN SLEEVE CHECK FOR BURRS FLASH OR UNUSUAL WORN SPOTS IF GEAR APPEARS FAULTY REPLACE WITH NEW PART AND RECHECK FOR N
80. ct usage of clutch plates Engine coolant in the transmission fluid can cause severe damage such as AUTOMATIC TRANSAXLE TRANSMISSION 7A 11 large pieces of composition clutch plate material peeling off Inspect 1 Forward Clutch Check ball in clutch housing damaged stuck or missing e Clutch piston cracked seals damaged or missing e Low line pressure e Pump cover oil seal rings missing broken or undersize ring groove oversize Case valve body face not flat or porosity between channels 2 Intermediate Clutch or Band e Intermediate clutch piston seals damaged or missing e Intermediate band damaged or missing e Low line pressure Case valve body face not flat or porosity between channels 3 Direct Clutch Clutch piston seals damaged or missing valve body face not flat or porosity between channels Transaxles driven internal leakage CASE POROSITY REPAIR PROCEDURE External leaks caused by case porosity can be repaired with the transmission in the car Road test and bring the transmission to operating temperature approximately 93 C 200 F 2 Raise and support car with the engine running Check for leaks in all operating positions A mirror may be helpful in finding leaks 3 Shut engine off and thoroughly clean area to be repaired with a cleaning solvent and air dry 4 Using instructions of the manufacturer mix a sufficient amount of epoxy GM 1360016 or equivalent to mak
81. e Install or Connect New bearing manufacturing identification faces up Assemble Figure 77 and Figure 26 Thrust washer 605 retain with petrolatum Support assembly 602 into the case Do not allow the direct clutch bushing to cut the oil seals MANUAL SHAFT Inspect Figure 77 Rod and retainer assembly 701 for distortion or damage 125 48 AUTOMATIC TRANSAXLE Detent lever 703 for damage Manual shaft 704 for damaged threads raised edges on flats Parking lock actuator assembly 705 for damage broken retainer lugs Assemble l Actuator 705 to manual shaft 704 2 Detent lever 703 into case 3 Slide the manual shaft 704 into the case and engage the detent lever 703 47 Tap the roll pin 702 into the detent lever with a 5mm 3 16 drift 5 nail 703 into place DRIVE LINK ASSEMBLY Inspect Figure 78 e Drive and driven sprockets 103 122 teeth and Splines for nicks burrs scoring or wear e Shaft 106 for damage wear Seals 105 for damage Thrust washer 104 for damage or wear e Link assembly 101 for damage or loose links LINK ASSEMBLY DRIVE SPROCKET DRIVE WASHER CASE COVER TO DR SKT THRUST SHAFT TURBINE BEARING ASSEMBLY SUPPORT DRIVE SPROCKET CASE TRANSMISSION 121 J 29569 2 105 RING SOLID SEAL TURBINE SHAFT GREEN 106 SHAFT TURBINE 148 RING SOLID SEAL TURBINE SHAFT YELLOW
82. e Adjustment Illustration 7A1 4 DIAGNOSIS AND ON CAR SERVICE 1 FUEL LINES 7 HARNESS 2 CABLE ASSEMBLY 8 ACCELERATOR CABLE 3 CLIP 9 HARNESS 4 RADIATOR HOSE 10 VACUUM HOSE 5 AIR INTAKE DUCT 11 ENGINE HARNESS 6 REAR BODY HARNESS 12 EMISSION PIPE 13 FUEL LINES 14 FUEL LINE CLIPS 15 A INSTALL CLIP BETWEEN FUEL LINE CLIPS 5201187 Fig 7 1 5 Transaxle Control Cable Routing Neutral Safety and Backup Lamp Switch Adjust 2 Figure 7 1 6 1 Place transmission shaft in NEUTRAL position e 2 Align flats in switch insert with flats on transmission shaft and push switch over shaft Lossely assemble bolts to transmission case 4 Insert 2 34 dia gage pin or rounded shank end and a 3 32 inch drill bit into service adjustment hole Rotate the switch until the gage pin drops to a depth of 9mm 5 Tighten attaching bolts to recommended torque 6 Remove gage pin GENERAL SERVICE PRECAUTIONS When servicing the transaxle it is recommended that upon disassembly of a unit all parts should be cleaned and inspected The unit should reassembled before disassembly of other units to avoid confusion and interchanging of parts Before disassembly of the unit thoroughly clean the exterior Disassembly and reassembly of the unit and the subassemblies must be made on a clean work bench As in repairing any hydraulically operated unit cleanliness is of the
83. e converter by hand after adding washers to check for clearance See flexplate balance in Section 6A General Engine Mechanical CONVERTER FLUSHING PROCEDURE Figures 7 thru 10 Tool Required 71 21369 Leak Tester 1 Drilla 11 32 8 5 mm hole in the converter between two vane extrusions and adjacent to the converter weld seam edge Figure 7 Drill the hole to approximate completion e Remove the drill bit from the started hole and coat it with grease to retain any metal chips e Complete drilling the hole at low speed NOTICE To prevent converter damage drill at right angles to the surface and sleeve the drill bit So it can enter no deeper than 1 4 6 25 mm 2 Apply grease to a 1 8 x 27 NPSF tap and thread the hole 3 Drain fluid by propping converter in a drain pan with the drilled hole at the bottom Figure 8 Drain approximately 15 minutes 4 Chargeconverter hub with air to remove as much contaminated transmission fluid as possible Set converter on pilot pour in two quarts of cleaning solvent and agitate Drain converter and to blow dry 5 Coata 1 8 x 27 NPTF pipe plug GM 9427802 or equivalent with Teflon pipe sealant or equivalent and install 7A 10 AUTOMATIC TRANSAXLE TRANSMISSION 6 Torque to 96 in Ibs USING TOOL J 21369 CHECK CONVERTER FOR LEAKS AT 80 PSI AIR PRESSURE For leaks at 80 psi using Tool 1 21369 Put liquid gt soap or leak detecting solution on the pipe plug
84. e repair CAUTION EPOXY MAY IRRITATE servo piston seals sprocket support THE SKIN AND CAUSE EYE DAMAGE OBSERVE THE MANUFACTURER S HANDLING INSTRUCTIONS READ THE LABEL ON THE CONTAINERI 5 While the transmission case is still HOT apply epoxy clean dry soldering acid brush can be used to clean the area and also to apply the epoxy cement Make certain the area to be repaired is fully covered 6 Allow epoxy cement to cure for three hours before starting engine 7 Road test and check for leaks GOVERNOR Figure 12 Refer to specific section for removal and replacement procedure 7A 12 AUTOMATIC TRANSAXLE TRANSMISSION All parts of the governor assembly with the exception of the driven gear are a select fit and each assembly is calibrated The governor including the driven gear is serviced as a complete assembly The driven gear can also be serviced separately DRIVEN GEAR 2 varve 6 sPRINGS 2 3 SLEEVE AND PRIMARY WEIGHT 2 CARRIER SECONDARY WEIGHT 2 S THRUST G20010 7A2 Fig 12 Governor Assembly Typical Inspect 1 The governor cover O ring seal for damage 4 GEAR RETAINING PIN 2 Governor for missing exhaust check balls 3 Governor cover for damage or wear in its bore 4 Speedometer drive gear and thrust washer for excessive wear 5 Governor driven gear teeth for excessive wear or damage If excessively worn or damaged closely inspect the govern
85. ee Section 7A for Case Repair Lug damage Snap ring groove damage Oil passage damage Servo bore damage Casting porosity Stripped threads Case bushing 116 for scoring e Converter seal 115 see drive sprocket support inspection replace Axleseal 117 for damage uc SUPPORT DRIVE SPROCKET CASE TRANSMISSION SEAL ASSEMBLY CONVERTER SEAL ASSEMBLY AXLE 125C 78 Figure 42 Converter Seal and Axle Seal Installation 125 36 AUTOMATIC TRANSAXLE Seal Replacement Procedure Remove or Disconnect Figure 41 Seal 115 or 117 pry out Install or Connect Figure 42 Tools Required 1 26938 or J 29130 Axle Seal Installer J 28540 Converter Seal Installer Seal 115 with J 28540 Seal 117 with J 26938 or J 29130 Inspect Figure 41 Drive sprocket support bearing 108 If new bearing is required be sure to inspect drive sprocket 106 race for damage or wear Bearing Replacement Procedure Remove or Disconnect Figure 43 Tools Required J 26941 Bearing puller J 6125 1 or J 2619 01 Slide hammer J 6471 8 Adapter Bearing 108 with J tools Install or Connect Figure 44 Tools Required J 28677 Bearing Installer J 8092 Handle Bearing 108 identification side up with J 28677 and J 8092 Inspect Drive sprocket support 109 for scoring HL 108 BEARING ASM ROLLER 109 SUPPORT DRIVE SPROCKET Figure 43 Removing Bearing pM 109 SUPPORT
86. emble Figures 57 58 and 59 Seals 651 and 652 onto piston 653 Piston 653 with J 26744 A inner seal 652 first then outer seal 3 Waved spring 655 4 Retainer 656 cupped side down 5 Snapring 657 push down on spring retainer 656 FUNCTIONAL CHECK Apply air max 90 psi to feed hole Piston must apply and release when pressure is removed AUTOMATIC TRANSAXLE 125 41 um tb ep NOT REQUIRED WITH CAST ALUMINUM PISTON HOUSING LO AND REVERSE SEAL LO AND REVERSE PISTON OUTER SEAL LO AND REVERSE PISTON INNER PISTON LO AND REVERSE CLUTCH INSERT OIL DISPLACEMENT SPRING LO amp REVERSE CLUTCH RELEASE RETAINER LO amp REVERSE CLUTCH SPRING RING SNAP H 125C 149 4 Figure 57 Lo amp Reverse Clutch Assembly Install or Connect Figure 61 1 Lo and reverse clutch housing 649 with J 28542 into case Align the clutch housing oil feed hole with the case feed hole If housing 649 does not go past snap ring groove remove J 28542 and install sun gear 646 Rotate sun gear back and forth until the housing is properly positioned Loosen J 26958 as needed 2 Snap ring 647 ring is 2 36 mm 0 092 thick APPLY SIDE a A PISTON B INNER SEAL C OUTERSEAL D OIL DISPLACEMENT INSERT NOT REQUIRED WITH CAST ALUMINUM PISTON Figure 58 Typical Lo amp Rev Clutch Apply Piston 125 42 AUTOMATIC TRANSAXLE 649 HOUSING LO REVERSE 653 PISTON AND SEAL ASM Z s cur
87. er System Diagnosis TRANSMISSION TYPE IDENTIFICATION RPO CODE 125 9 AUTOMATIC TRANSAXLE TRANSMISSION 74 7 DRIVE GEAR REFERENCE SPEED GEAR REFERENCE TIRE SIZE P185 75R14 P195 70R14 P215 60R15 COLOR NO OF NO OF COLOR TEETH TEETH GREEN 10 THM125 MD9 P185 75R14 P195 70R14 GREEN 10 5 spd MT2 P185 75R14 BLUE 35 4 5 spd MG2 P195 70R14 P18s 75m14 P195 70R14 P215 60R15 NATURAL 35 4 4 spd M17 CHECKING AUTOMATIC TRANSAXLE TRANSMISSION FLUID LEVEL Important level should be checked with the Transaxle Transmission at temperature 150 2007F 83 93 This temperature is reached after at least 15 miles 24 km of highway driving An accurate fluid level reading cannot be obtained if the car has recently been operated under the following conditions In high ambient temperature above 90 F 32 At sustained high speed In heavy city traffic in hot weather Pulling a trailer In commercial service taxi police etc Fluid Fluid Level Checking Procedure Figure 4 1 2 3 4 5 Park ca r on level ground Apply parking brake Run engine at slow idle Move gear selector through all gear positions Move selector to PARK and read fluid level Maintai n fluid level between P185 75R14 P195 70R14 P215 60R15 NATURAL 35 Fig 3 Speedometer Gear Chart operating
88. g and spring 306 340 41 4 C C Control valve 332 and plug 310 Pin 345 and slide 348 Vanes 352 and rotor 353 Pump vane ring 351 gt Valve body 301 and auxiliary valve body 340 with solvent air dry Lo blow off assembly 326 325 324 must be replaced valves bushings and springs with solvent air dry inspect Valve body 301 and auxiliary valve body 343 Oil passage damage Casting porosity Machine face damage Scored valve bores Pump pocket for damage Auxiliary valve body sleeve for damage Valves bushings and springs Scored or cracked valves Scored or cracked bushings Collapsed springs e Pump rotor and vanes Rotor damage 353 Vane damage 352 Vane rings for damage 351 Slide seals 350 Slide rings seals 346 amp 347 Pump shaft bearing 354 for damage AUTOMATIC TRANSAXLE 125 53 t LZ OSZL Figure 89 Control Valve amp Oil Pump Assembly 125 54 AUTOMATIC TRANSAXLE BODY OIL PUMP amp CONTROL VALVE PLUG BORE LINE BOOST VALVE VALVE LINE BOOST PIN VALVE RETAINING SPRING PIN COILED SPRING LINE BOOST PLUG PIN COILED SPRING SLEEVE SPRING RETAINING VALVE SHIFT T V SPRING SHIFT T V PLUG VALVE BORE BALL PRESSURE RELIEF 9 525 DIA SPRING PRESSURE RELIEF SPRING 1 2 ACCUMULATOR 341 SPRING CONVERTER CLUTCH REGULATOR 342 VALVE CONVERTER CLUTCH REGULATO
89. g groove 4 Spring guide 630 5 Spring and retainer assembly 631 6 Snap ring 632 Use arbor press or J 23456 and J 23018 A 7 Wave plate 633 8 Lubricate composition plates 633 9 Alternately composition and steel plates 633 10 Backing plate 633 LD side up ti Snap ring 632 12 New seal rings 622 if required Measure Snap ring 635 to backing plate 634 end play range with a feeler gage must be 1 0 1 5 mm 040 0607 For correct backing plate selection see Figure 69 INPUT SHAFT 1 FEELER GAGE 1 0 1 5mm 04 06 624 HOUSING ASSEMBLY FORWARD CLUTCH 634 PLATE FORWARD CLUTCH BACKING 635 RING SNAP BACKING PLATE THICKNESS MM 61 60 IDENTIFICATION Inches CODE 0 24 0 23 1 0 21 0 20 0 19 0 18 3 H 125C 49 4 Figure 69 Forward Clutch Backing Plate Selection 5 4 5 3 47 46 DIRECT CLUTCH ASSEMBLY Disassemble Figure 70 Snap ring 620 Backing plate 619 Composition and steel clutch plates 618 Snap ring 617 Apply ring and release spring assembly 616 Piston 615 Inner 614 and outer 612 seals Center seal 613 from housing RSS 125C CLUTCH PLATE AND APPLY RING USAGE CHART FLAT WAVED STEEL FACED PLATE PLATE PLATE Thick Thick ness ness 2 3mm 7 00 09 CLUTCH DIRECT CJ CT CD CX CF PJ PA CU 23 aut omens 4 FORWARD iemm 1 25mm ALL 0 08
90. g is missing or not sealing properly b The direct clutch accumulator cup plug is missing 125C 4 AUTOMATIC TRANSAXLE 1 or 2 check balls are missing or off location d The 1 2 accumulator piston is missing or the seal is leaking 4 The Control Valve Pump Assembly a The 1 2 accumulator valve is sticking See also above section labeled IN ALL CASES OF BURNED CLUTCH PLATES OR BAND THE CAUSES OF LOW OIL PRESSURE 1 Low oil level 2 The T V system the pressure is low in Neutral Drive and low to normal in Intermediate and Reverse a The T V cable is misadjusted or sticking b The T V linkage may be binding incorrect cable The throttle valve may be stuck in the bore d The shift T V valve is stuck 3 oil strainer is plugged 4 The oil strainer O ring seal is leaking or damaged 5 Thecontrol valve and pump assembly bolts are loose 6 Thecontrol Valve Assembly a The 5 or 6 check ball is missing or off location b The below listed valves may be stuck or damaged 1 The T V valve and plunger 2 The Shift T V valve 3 The pressure regulator valve 4 The T V boost valve 7 8 9 10 5 The pressure relief valve The 1 2 accumulator piston and or seal is leaking or missing d Internal leaks Lo only The Lo blow off valve is damaged 4 check ball is missing or off location Reverse only The Lo Reverse clutch housing to case cup plug assembly is lea
91. igure 1 Tools Required J 28664 Transaxle Holding Fixture J 3289 20 Fixture Base CAUTION To reduce the possibility of personal injury or transaxle damage make sure when doing the next step that all the bolts for the support fixture J 28664 are installed as shown and torqued to 11 N m 8 ft Ibs 1 1 28664 fixture 2 Fixture into J 3289 20 base 3 Drain the transmission fluid Governor Assembly Remove or Disconnect Figure 2 Bolt 14 and retainer 13 Speedo sleeve 12 and gear 10 Screws 8 Governor cover 9 and ring 7 Bearing 6 Gear 5 Governor assembly 4 AUTOMATIC TRANSAXLE 125C 21 J 28664 HIGH PROFILE TRANSMISSION TRANSMISSION CASE SUPPORT FIXTURE BELL HOUSING FIXTURE BASE LOCATING PIN 128664 LOW PROFILE TRANSMISSION TRANSMISSION CASE SUPPORT FIXTURE LET HOUSING 1 3288 20 2 TRANSMISSION SUPPORT FIXTURE BASE LOCATING RING OIL SEAL GOVERNOR ASSEMBLY GEAR SPEEDOMETER DRIVE THRUST BEARING ASM GEAR COVER SEAL O RING SCREW GOVERNOR COVER TO CASE COVER GOVERNOR SPEEDO DRIVEN GEAR SEAL O RING SLEEVE SPEEDO DRIVEN GEAR RETAINER SPEEDO GEAR BOLT SPEEDO GEAR RETAINING H 125C 64 Figure 2 Governor Assembly 125C 22 AUTOMATIC TRANSAXLE 81 2SZL 801231102 L3NDVIA NYd 710 NOISSINSNVH L N 3H9S NOISSINSNVHL NVd 110 NOISSIASNVH L A18W3SSV H3NIVHIS 9 40 1935 UO 31XV A1aW3SSV 19
92. is T V CABLE SYSTEM DIAGNOSIS Inspect CAUTION To avoid possible personal injury and or damage to the car brakes must be applied at all times during the test od Install line pressure gage Install engine tachometer Warm up engine to proper operating temperature Run engine at 1000 RPM Apply parking brake Place gear selector in PARK and note oil pressure Place gear selector into DRIVE Oil Pressure should be equal or not more than 10 psi 34 kPa higher than in PARK 7 Increase engine speed to 1400 RPM If oil pressure does not increase adjust T V cable Refer to T V Cable Adjustment SPEEDOMETER SYSTEM DIAGNOSIS Figures 2 and 3 Refer to Figure 2 for diagnosis of speedometer complaints For verification of axle ratio tire size speedometer gear combinations refer to Figure 3 NOISE AND VIBRATION DIAGNOSIS 1 Vibration with the car in motion Inspect Engine and transmission mounts damaged or loose Refer to Sections 6A 7A1 and 7A2 Tires out of balance or unevenly worn Snow tires mixed sizes or mixed radial and bias ply Refer to Section 3 Drive shaft bearings worn Refer to Section 4A Shock absorbers worn or loose Refer to Section 3 Front suspension worn loose or misaligned Refer to Section 3 2 Vibra on in PARK and NEUTRAL Worse at idle tends to disappear as engine speed is increased AUTOMATIC TRANSAXLE TRANSMISSION 74 5
93. ission section Functional Check Procedure Inspect l Install a tachometer 2 the vehicle until proper operating temperature is reached 3 Drive vehicle at 50 55 mph 80 88 Km h with light throttle road load 4 Lightly touch the brake pedal and check for a slight bump when the TCC releases and a slight increase in engine RPM 5 Release the brake and check for a re apply of the converter clutch and a slight decrease in engine RPM Preliminary Checking Procedure The purpose of the preliminary checking procedure is to isolate external electrical problems from internal electrical or mechanical ones Refer to General Service Procedures for individual component test procedures Important Use only scale type ohmmeter High impedance type ohmmeters and those with a digital readout will not work ALCL scanner may be used to verify the ground path Remember a completed ground does not indicate that the circuit carries current Do not bench test using an automotive type battery Accidentally crossed wires will destroy the internal diodes of the TCC solenoid External Controls b 19 Inspect Connect voltmeter between transmission connector and ground e Turn key e If 12 volts are present at the connector refer to the specific transmission section for TCC internal diagnosis e low voltage is found refer to Sections 6E and 8A for electrical diagnos
94. king The pump vane seals are cut or missing The intermediate oil p ssages to pressure regulator is blocked 11 The driven sprocket support to case cover is leaking CAUSES OF HIGH OIL PRESSURE 1 The T V system the pressure is high in the Neutral Drive and normal to high in intermediate and Reverse a The T V cable is misadjusted sticking or broken b The T V linkage is binding or incorrect cable The throttle valve is stuck d The shift T V valve is stuck T V lifter is bent damaged or too short The control Valve and Pump Assembly valves may be sticking or damaged T V valve and plunger b The shift T V valve The pressure regulator valve d The T V boost valve pump slide stuck Lo only The Lo blow off valve may be stuck closed The internal pump or case cover may be leaking RANGE REFERENCE CHART DIRECT CLUTCH PARK NEUT INTERMEDIATE BAND FORWARD CLUTCH ROLLER CLUTCH LO REVERSE CLUTCH FIRST SECOND THIRD FIRST SECOND FIRST DRIVE APPLIED INTERMEDIATE LO APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED APPLIED HOLDING HOLDING HOLDING APPLIED REVERSE APPLIED APPLIED H 125C 33 2 Figure A 2 Range Reference Chart AUTOMATIC TRANSAXLE 125 5 CONVERTER CLUTCH CONTROL VALVE PRESSURES INTAKE 8 DECREASE P
95. km h and closed or throttle move the selector lever to INTERMEDIATE RANGE The transaxle should downshift into 2nd An increase in engine r p m and an engine braking effect should be noticed Lo Range Position the selector lever in LO RANGE and accelerate the vehicle No upshift should occur in this range At 40 m p h 64 km h with throttle closed move the selector lever to Lo A 2 1 downshift should occur in the speed range of approximately 45 to 25 m p h 72 to 40 km h depending on valve body calibration The 2 1 downshift at closed throttle will be accompanied by increased engine r p m and an engine braking effect should be noticed Stop vehicle Reverse Range Position the selector lever in REVERSE POSITION and check for reverse operation Converter Clutch Install an engine tachometer Engine must be at normal operating temperature Position the selector lever in drive range With vehicle speed between 40 45 mph 64 72 km h in third gear the converter clutch will apply Observe the tachometer A drop of about 200 rpm s will occur 125C 2 AUTOMATIC TRANSAXLE PRELIMINARY CHECK PROCEDURE CHECK TRANSMISSION OIL LEVEL CHECK AND ADJUST T V CABLE CHECK OUTSIDE MANUAL LINKAGE AND CORRECT CHECK ENGINE TUNE INSTALL OIL PRESSURE GAGE CONNECT TACHOMETER TO ENGINE CHECK OIL PRESSURES IN THE FOLLOWING MANNER Minimum T V Line Pressure Check Set the T V cable to specification and with the brakes applied
96. lay Selective Thrust Washer Measurement 680 FINAL DRIVE TO CASE END PLAY SELECTIVE THRUST WASHER 680 IDENTIFICATION THICKNESS NO COLOR 0 0 1 White 1 40 1 50mm 0 055 0 059 1 50 1 60mm 0 059 0 062 1 60 1 70 1 80 1 90 2 00 2 10 2 20 2 30 170mm 0 0627 1 80mm 0 066 1 90mm 0 070 2 00mm 10 074 2 10mm 10 078 2 20mm 0 082 2 30mm 0 086 240mm 0 091 0 066 0 070 0 074 0 078 0 082 0 086 0 091 0 095 5 Green 6 Btack 7 Purple 8 Purple amp White 9 Purple amp Blue H 125 321 2 Figure 38 Final Drive End Play Chart pr Lift up on the governor drive gear 679 with J 28585 4 Reading on the dial indicator should be 0 12 0 82 mm 0 005 0 032 Record reading For correct washer selection see Figure 37 Remove the dial indicator set and the adpater 5 3 aoe or Disconnect Figures 26 38 39 and Tool Required J 28545 Final Drive Unit Remover and Installer Snap ring 670 Ring is 2 36 mm 0 092 thick Spacer 671 Final drive assembly 673 688 with J 28545 Thrust bearing 681 Selective washer 680 WP weno F 2 V ren SNAP RING FINAL DRIVE SPACER 671 SPACER FINAL DRIVE 125 47 1 Figure 40 Removing Final Drive Assembly AUTOMATIC TRANSAXLE 125C 35 CASE ASSEMBLY Clean e Case 112 thoroughly with solvent and air dry Inspect Figure 40 Case s
97. ler clutch and a provide the friction elements required to obtain the desired function of the planetary gear sets A hydraulic system pressurized by a vane type pump provides the working pressure required to operate the friction elements and automatic controls DIAGNOSIS ROAD TEST PROCEDURE Drive Range Position the selector lever in DRIVE RANGE and accelerate the vehicle 1 2 and 2 3 shift should occur at these throttle openings The shift points will vary with the throttle openings Check the part throttle 3 2 downshift at 30 m p h 50 km h by quickly opening the throttle approximately three fourths At 50 m p h 80 km h the transmission should downshift 3 2 by depressing the accelerator fully Intermediate Range Position the selector lever in INTERMEDIATE RANGE and accelerate the vehicle A 1 2 shift should occur UNIT REPAIR Transaxle Disassembly Torque Specifications Chart Required Special Tools Thrust Washer amp Bearing Locations 125 21 125C 62 125C 63 125C 61 at all the throttle openings No 2 3 shift can be obtained in this range The 1 2 shift point will vary with the throttle opening Check the detent 2 1 downshift at 20 m p h 32 km h The transaxle should downshift 2 1 The 1 2 shift in INTERMEDIATE RANGE is somewhat firmer than in DRIVE RANGE This is normal Position the selector lever in DRIVE RANGE With the vehicle speed at approximately 50 m p h 80
98. ntil clean solvent comes out the return line Remove remaining solvent from cooler with compressed air applied to the return line and flush with transmission fluid 6 Reconnect oil cooler lines and torque nuts to 17 N m 12 ft Ibs Steel tubing should be double flared TORQUE CONVERTER CLUTCH TCC DIAGNOSIS e See TCC Diagnosis in this section TORQUE CONVERTER STATOR The Torque Converter Stator roller clutch can have one of two different type malfunctions A Stator Assembly freewheels both both cooler lines from the directions B Stator Assembly remains locked up at all times Condition A The car tends to have poor acceleration from a standstill At speeds above 30 35 mph 50 55 km h the car may act normal If poor acceleration is noted it should first be determined that the exhaust system is not blocked the engine timing is correct and the transaxle is in first 1st gear when starting out If the engine freely accelerates to high r p m in NEUTRAL it can be assumed that the engine and exhaust system are normal Driving the vehicle in REVERSE R and checking for poor performance will help determine if the stator is freewheeling at all times Condition B Engine r p m and car speed limited or restricted at high speeds Performance when accelerating from standstill is normal Engine may over heat Visual examination of the converter may reveal blue color from over heating If the
99. o transaxle mounting bracket Snap cable to shift lever Clip cable in place at fuel line Cable to shifter bracket Cable end to shift lever pin Carrier assembly console Radio Heater control Carpet clips and rivits at console 1 909 WN DIAGNOSIS AND ON CAR SERVICE 7A1 7 11 12 13 14 Carrier reinforcements E C M E C M Electrical connections Front pad assembly 15 16 17 18 Front pad trim plate Rear console pad assembly Shift trim plate and shift knob Negative battery cable AUTOMATIC TRANSAXLE 125C 1 SECTION 125C AUTOMATIC TRANSAXLE DIAGNOSIS AND UNIT REPAIR CONTENTS GENERAL DESCRIPTION 125C 1 DIAGNOSIS Road Test Procedure 125 1 Cause of Burned Clutch Plates 125 3 Component Illustrations 125 6 Systematic Trouble Shooting Charts 125 13 GENERAL DESCRIPTION The 125C automatic transaxle is a fully automatic unit consisting primarily of a 4 element hydraulic torque converter compound planetary gear set and dual sprocket and drive link assembly In addition this transaxle incorporates a differential and final drive gear set The 4 element torque converter contains a pump a turbine a pressure plate splined to the turbine and a stator assembly The pressure plate when applied provides a mechanical direct drive coupling of the engine to the planetary gears Three multiple disc clutches a rol
100. or drive gear on the output shaft for nicks or damage 6 The governor secondary weight may be bent and cause the governor weights to bind and not have free motion The secondary weight is thinner and lighter than the primary weight There must be more clearance between the weights If no clearance exists carefully place small Screwdriver between the weights at the pin and pry to create enough clearance to provide free motion of the weights At the same time make sure to maintain some clearance between the secondary weight and the governor shaft 7 The primary and secondary springs must stand straight and not be mis positioned or tilted If improperly positioned or tilted position it properly using a small screwdriver Governor Driven Gear Figure 12 Disassemble 1 Remove retaining ring 2 Remove washer 3 Remove gear from shaft e Donot attempt to disassemble the governor any further Clean e Wash govenror assembly in solvent Dry and lubricate with transmission fluid Assemble l Place gear on shaft 2 Place washer on shaft of hole 3 Replace retaining ring DRIVE LINK ASSEMBLY CHAIN When disassembling any 125 125C inspect the drive link assembly chain for wear Inspect 1 Remove the case side cover to expose the drive link chain 2 Midway between the sprockets and at right angles to the chain push the slack strand bottom strand of the chain until all slack is removed and mark with
101. pring 419 Cracked or damaged piston Cut or nicked seal Distorted spring Vent assembly 404 for damage Vent Assembly Replacement Procedure Remove or Disconnect e Vent assembly with pliers Install or Connect Apply thread sealant to the vent 404 vent Tap the vent 404 into case cover with a soft mallet Inspect Figure 81 and 84 Detent spring and roller 417 for damage replace as necessary Cooler fittings 17 for thread damage Cooler Fitting Replacement Procedure Disassemble Figure 84 Cooler fittings 17 from case cover Assemble Apply thread sealer to cooler fittings Cooler fittings 17 into case cover 38 23 ft Ibs Inspect e Electrical connector 408 for damage e Casecover sleeve for feed hole alignment e Manual valve 406 for damage must slide freely in the bore e Thrust washer 414 for damage Thermostatic element 409 413 for damage Thermostatic Element Replacement Procedure Disassemble Figure 82 Tool Required 3 29023 e Washers 413 D 409 Pini 410 ROLL PIN CAPPED 125 178 Figure 82 Setting Center Roll Pin Height 411 PLATE THERMOPLASTIC ELEMENT 412 THERMO ELEMENT 413 WASHER THERMO ELEMENT 414 WASHER THRUST CASE COVER DR SPRKT gt 2 yey 17 CONNECTOR COOLER FITTING 31 SEAL ASSEMBLY AXLE OIL 125 85 Figure 84 Left Hand Axle
102. r 10 for wear ring 11 for nicks or cuts Sleeve 12 for scoring Install or Connect Figure 109 Governor 4 assembly into case Gear 5 onto governor Bearing 6 onto gear New ring 7 into cover 9 Cover 9 Make sure shaft 4 is piloted into cover Screw 8 6 Di Tighten Torque the screw 8 to 11 N m 8 ft Ibs Assemble Figure 109 ring 11 onto sleeve 12 Gear 10 into sleeve 12 Install or Connect 1 Sleeve 12 into cover 9 2 Retainer 13 3 Screw 14 Tighten AGA DEE Torque the screw 14 to 9 N m 75 inch pounds Install or Connect Transaxle into transmission jack Remove or Disconnect e J 28664 Install or Connect Tool Required J 21366 Converter Holding Strap 1 Converter 1 2 1521366 Converter retaining strap AUTOMATIC TRANSAXLE 125C 61 27 29 30 26 28 31 32 Pump Shaft Roller Bearing Assy Group 4 226 18 Driven Sprocket Thrust Bearing Assembly Group 4 131 Case Cover To Driven Sprocket Thrust Washer Group 4 131 19 Bearing Assembly Group 4 131 Bearing Assembly Group 4 131 20 Selective Snap Ring Group 4 169 Case Cover To Drive Sprocket Thrust Washer Group 4 131 21 Direct Clutch Bushing Group 4 169 Converter Bushing Group 4 115 22 Input Shaft Thrust Washer Group 4 158 Drive Sprocket Support Bushing Group 4 226 23
103. rd toward connector to remove slack 9 With no load applied to nose snap cable connector lock button down Ri Tighten 1 Shift lever in park position 2 Ignition key to lock position 3 Shift lever should not be able to move to another position Ignition key should be removable from column 4 Ignition key to position 5 With shift lever in Neutral ignition key should not be removable from column pe f BEG NOTICE If the above functional checks were met adjustment is complete If key can be removed in Neutral snap connector lock button to up position and repeat Steps 8 and 9 If key cannot be removed in Park position snap connector lock button to up position and move cable connector nose rearward until key can be removed from ignition Snap connector lock button down DIAGNOSIS AND SERVICE 7 1 3 1 PARK LOCK 7 TRANSMISSION CABLE ASSY SHIFT CABLE 2 TO SHIFTER 8 SHIFTER BASE 3 BRAKE SUPPORT 9 CONNECTOR NOSE ASSY 10 PARK LOCK 4 TO STEERING LEVER PIN COLUMN 11 STEERING 6 LOCK BUTTON COLUMN UNIT 6 SHIFTER LEVER Fig 7A1 3 Park Lock Cable Routing OFF ag AUN START w ACCESSORY 1 PARK LOCK LEVER PIN 2 IGNITION SWITCH 3 SLOT FOR SCREWDRIVER 4 INHIBITOR 5 SHIFTER BASE 6 LOCK BUTTON IN UP POSITION 7 CABLE CONNECTOR NOSE Fig 7A 1 4 Park Lock Cabl
104. round the suspected component Check around all gasket mating surfaces for leaks A mirror is useful for finding leaks in areas that are hard to reach 4 If the leak still cannot be found it may be necessary to clean the suspected area with a degreaser steam or spray solvent Clean the area well then dry the area Operate the vehicle for several miles at normal operating temperature and varying speeds After operating the vehicle visually check the suspected component If you still cannot locate the leak try using the powder or black light and dye method Powder Method 1 Clean the suspected area 2 Apply an aerosol type powder such as foot powder to the suspected area 3 Operate the vehicle under normal operating conditions 4 Visually inspect the suspected component You should be able to trace the leak path over the white powder surface to the source Black Light and Dye Method A dye and light kit is available for finding leaks Refer to the manufacturers directions when using the kit 1 Pour specified amount of dye into leaking component 2 Operate the vehicle under normal operating conditions as directed in the kit 3 Direct the light toward the suspected area The dyed fluid will appear as a brightly colored path leading to the source e See kit directions for the color of the fluid and dye mix REPAIRING THE LEAK Once the leak has been pinpointed and traced back to its source the cause of the leak m
105. rvo assembly 129 135 E ring 135 from pin 129 Pin 129 from piston 133 Measure Figures 7 and 8 Tool Required J 28535 Intermediate band apply pin gage 1 Install J 28535 on case 112 and pin 129 into the gage 2 With a torque wrench apply 11 2 m 100 inch pounds of torque 3 Ifthe white line appears in the window the pin length is correct If the white line does not appear select another length pin Figure 6 Repeat procedure 4 Remove pin gage Remove or Disconnect Figures 9 amp 10 Bolt 712 Stop bracket 711 Bracket 710 Bolts 146 Weir 147 Check valve 126 and spring 125 Pipe 139 backup ring 144 and Ring 145 CA SB papas es SPRING ACCUMULATOR EXHAUST VALVE ACCUMULATOR EXHAUST PLUG ORIFICE RING OIL SEAL INTER BAND APP PIN PIN INTERMEDIATE BAND APPLY RETAINER INTER SERVO SPRING SPRING INTER SERVO CUSHION RING OIL SEAL OUTER INTER SERVO PISTON INTERMEDIATE SERVO RING OIL SEAL INNER INT SERVO RING SNAP GASKET INTERMEDIATE SERVO COVER COVER INTERMEDIATE SERVO PIPE REVERSE OIL RETAINER REVERSE OIL PIPE BOLT INT SERVO COVER BOLT PIPE RET CASE RETAINER GOVERNOR AND REV OIL PIPE RING SEAL BACKUP SEAL O REVERSE PIPE TO CASE RETAINER OIL WEIR OIL WEIR H 125C 66 Figure 6 Oil Pipes amp Servo Assembly Figure 7 Checking for Proper Apply Pin INTERMEDIATE BAND APPLY PIN LENG
106. snap ring may be incorrectly installed or incorrect selective backing plate e The piston seals may be missing or damaged f piston insert may be missing piston housing or shaft could be damaged leaking 2 The Control Valve Pump Assembly a The valve body pipe is loose or leaking b Pressure regulator valve roll pin damaged or worn Burned Lo and Reverse Clutch Only 1 The and Reverse Clutch Assembly a housing seals are damaged b The piston or seals are damaged c Wrong number of clutch plates 2 The Control Valve Pump Assembly a reverse boost valve is sticking 3 Case Cover and Case a The 4 or 5 check ball is missing or off location in the case cover b The Lo and Reverse pipe is leaking in the case bore c The Lo and Reverse clutch housing to case cup plug assembly is restricted damaged or not seated properly d The Lo and Reverse pipe to case O ring and or seal backup ring is damaged or missing Burned Intermediate Band Only 1 The Intermediate Band a The band is not properly installed and aligned in the case b The apply pin is not engaged 2 The Intermediate Servo Assembly The wrong servo pin check the selectivity b The seals are missing or damaged C The servo bore is scored or damaged d The band apply pin is tight or undersize in the case bore 3 Case Cover and the Case a The accumulator check valve and or sprin
107. thick E housing 699 vik 128542 668 GEAR REACTION INTERNAL Output carrier and roller clutch assemblies and lo 669 SHAFT FINAL DRIVE SUN GEAR reverse clutch plates 658 thru 668 by lifting shaft Figure 35 Removing Reaction Components 669 Figure 35 660 SPACER SELECTIVE 665 CARRIER REACTION Und Eee 1256 34 AUTOMATIC TRANSAXLE SNAP RING HOUSING ASM LO amp REVERSE CLUTCH RING SNAP PLATE LD amp REVERSE CLUTCH PLATE LO amp REVERSE CLUTCH BACKING SPACER REV HOUSING LO RACE SELECTIVE RACE LO ROLLER CLUTCH ROLLER ASSEMBLY LO CLUTCH WASHER REACTION CARR INT GR THRUST BUSHING REACTION CARRIER CARRIER ASSEMBLY REACTION WASHER REACTION CARR INT GR THRUST BEARING REACTION SUN INT GR THRUST GEAR REACTION INTERNAL SHAFT FINAL DRIVE SUN GEAR PLATE LO amp REVERSE CLUTCH WAVED H 125C 72 Figure 36 Reaction Components Disassembly e Disassemble Figure 26 and 36 Clutch plates 658 amp Backing plate 658 Roller clutch assembly 665 Internal gear 668 Shaft 669 FINAL DRIVE ASSEMBLY Measure Figures 37 38 39 and 40 Tools Required J 26958 10 Adapter J 25025 7 Post J 26900 12 or J 8001M Dial indiactor J 28585 Snap ring remover 1 Remove J 26958 and J 26958 11 Leave J 26958 10 adapter in place 2 Install the dial indicator set so that stem contacts the adapter J 26900 12 OR J 8001 M 125 35 Figure 37 Final Drive End P
108. to the disassembly and reassembly sections 1 Throttle valve control cable and or sleeve seal 2 Filler pipe and or sleeve seal 3 Governor assembly and speedometer gear assembly 4 Intermediate servo assembly and direct clutch accumulator check valve 5 Valve body assembly spacer plate gaskets throttle lever and bracket assembly pump shaft valve body cover and gasket TCC solenoid switch and wiring Converter to flexplate bolts Oil pan and or gasket strainer assembly and ring 8 and Reverse pipe ring seal and oil seal 9 Dip stick stop bracket parking pawl and return spring 10 Output shaft axle joint retaining ring snap ring shaft and axle oil seals 11 Cooler fittings manual valve and electrical connector spring and seal thermostatic element assembly manual detent spring and roller assembly sprockets drive link and thrust washers 12 3rd clutch pressure switch solenoid auxiliary valve body cover and gasket 13 Park Neutral and back up lamp switch Speedometer Driven Gear 1 SENSOR ASSEMBLY 2 SEAL O RING SPEEDOMETER 4 COVER GOVERNOR 5 SCREW GOVERNOR COVER TO CASE 1 NUT CABLE ASSY 8 BRACKET 2 NUT SHIFTING 9 CABLE ASSY LEVER 10 RETAINER 6 SEAL O RING 3 LEVER SHIFTING ASSY 7 WASHER SPEEDO GEAR THRUST 4 SWITCH NEUTRAL 11 T HANDLE 8 GEAR SPEEDOMETER DRIVE
109. ust be determined in order for it to be repaired properly If a gasket is replaced but the sealing flange is bent the new gasket will not repair the leak The bent flange must be repaired also Before attempting to repair a leak check to be sure that the following conditions are correct as they may cause a leak Gaskets l Fluid level pressure is too high 7A 4 AUTOMATIC TRANSAXLE TRANSMISSION 2 Plugged vent 3 Improperly torqued fasteners or dirty damaged threads 4 Warped flanges or sealing surface 5 Scratches burrs or other damage to the sealing surface 6 Damaged or worn gasket 7 Cracking or porosity of the component 8 Improper sealant used where applicable Seals E sn Fluid level pressure is too high Plugged vent Damaged seal bore scratched burred or nicked Damaged or worn seal Improper installation Cracks in component Shaft surface scratched nicked or damaged Loose or worn bearing causing excess seal wear Oo EON UA Nor Possible Points of Oil Leak 1 Transaxle Transmission pan or valve body cover Attaching bolts not correctly torqued e Improperly installed or damaged gasket pan or valve body cover mounting face not flat 2 Case Leak e Filler pipe multi ip seal damaged or missing Filler pipe bracket mislocated e T V cable multi lip seal damaged or improperly installed e Governor cover and O rings damaged or missing Speedometer dri
110. ve battery cable Inspect Speedometer for proper operation T V CABLE Remove or Disconnect 1 Air cleaner assembly 2 T V cable at injector 3 Bolt securing T V cable at transaxle Speedometer drive gear from sensor assembly Important Pull up on cable cover at transaxle until cable is seen Disconnect cable from transaxle rod Remove or Disconnect 1 Clip securing T V cable at valve cover Install or Connect 1 T V cable at transaxle Tighten Torque T V cable bolt to 7 10 N m 6 7 Ib ft Install or Connect 1 T V cable at injector 2 Clip securing T V cable to valve cover 3 Air cleaner assembly Adjust Make all necessary adjustments to T V cable as outlined above AUTOMATIC SHIFT CABLE Remove or Disconnect l Negative battery cable 2 Front trim plate and shift knob 3 Shift trim plate rear console pad assembly and front pad assembly 4 E C M electrical connection 5 6 Front carrier to reinforcement 7 Carrier reinforcement 8 Carpet clips and rivits at console 9 Heater control 10 Radio 11 Carrier 12 Shift cable from shifter control assembly 13 Cable from shift lever at transaxle 14 Yoke clip securing shift cable to transaxle mounting bracket 15 Pull cable through body into the passenger compartment Install or Connect 1 Pilot cable from passenger side through body into engine compartment Clip cable t
111. ven gear speed sensor seal damaged Manual valve bore plug loose Oil cooler connector fittings loose or damaged Axle oil seals worn or damaged Parking pawl shaft cup plug loose Governor pressure pickup plug loose Line pressure pickup pipe plug loose Case to case cover gasket damaged Porous casting 3 Leak at converter end e Converter seal damaged Seal lip cut Check converter hub for damage Bushing moved forward and damaged Garter spring missing from seal Converter leak in weld area Refer to Torque Converter Porous casting Case or drive sprocket support Turbine shaft oil seal worn or damaged 4 Fluid comes out vent pipe or fill tube Over filled e Water in fluid missing Case porous Incorrect dipstick e Plugged vent Drain back holes plugged TORQUE CONVERTER CLUTCH TCC DIAGNOSIS The TCC is applied by fluid pressure which is controlled by a solenoid located inside the Automatic Transaxle Transmission assembly The solenoid is energized or released by making or breaking ground contact thru a combination of external switches and sensors TCC Diagnosis For electrical diagnosis of refer to the specific carline section in Section 8A Electrical Diagnosis For diagnosis of emission control related components of TCC Refer to the specific section of 6E Driveability and Emissions For the diagnosis Hydraulic Controls refer to the specific Transm
112. wear l Internal gear 668 onto sun gear shaft 669 2 Thrust bearing 667 inner race against internal gear 668 LO ROLLER CLUTCH ASSEMBLY 6 Disassemble Figure 56 Selective washer 660 Race 661 Clutch assembly 662 Lo race thrust washer 663 Reaction carrier thrust washer 666 Inspect Selective spacer 660 for damage Lo roller clutch cam 665 Carrier bushing 664 for damage Reaction carrier pinions 665 for damage rough bearings or tilt Measure Pinions 665 end play with feeler gage end play range 0 24 0 69 mm 0 009 0 027 inspect Figure 56 and Figure 26 647 649 650 658 659 660 661 662 663 664 665 666 667 668 669 688 LE SNAP RING HOUSING ASM LO amp REVERSE CLUTCH RING SNAP PLATE LO amp REVERSE CLUTCH PLATE LO amp REVERSE CLUTCH BACKING SPACER REV HOUSING LO RACE SELECTIVE RACE LO ROLLER CLUTCH ROLLER ASSEMBLY LO CLUTCH WASHER REACTION CARR INT GR THRUST BUSHING REACTION CARRIER CARRIER ASSEMBLY REACTION WASHER REACTION CARR INT GR THRUST BEARING REACTION SUN INT GR THRUST GEAR REACTION INTERNAL SHAFT FINAL DRIVE SUN GEAR 1256 72 PLATE LO amp REVERSE CLUTCH WAVED Figure 56 Reaction Components Clutch race 661 for damage cracks or wear Rollers springs and cage 662 for damage or wear Carrier 4 tanged thrust washer

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