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TORQUEFLITE TRANSMISSION — 1 Group 21 TRANSMISSION (TORQUE CONVERTER) TORQUEFLITE TRANSMISSION CONTENTS Paragraph A c c u m u l a t o r Piston I n s t a l l a t i o n Page 105 59 44 39 83 51 Back-Up L i g h t S w i t c h 12 26 Band Levers I n s t a l l a t i o n 94 55 41 38 9 22 Inspection 79 50 Installation—Kickdown 92 55 93 55 40 37 39 37 78 49 103 58 31 34 76 48 64 . 45 69 47 ' 65 46 Removal - - - Inspection Removal Band Adjustments .............................................................. Kickdown Low-Reverse Low-Reverse Removal—Kickdown Low-Reverse Clutch — F r o n t — Assembly Checking E n d Clearance—After Assembly Before Disassembly............ Disassembly .. Clutch O v e r r u n n i n g — Disassembly -. .- Clutch — Rear — Piston Retainer Assembly Disassembly Eccentric Dowel C h a r t 70 2— TORQUEFLITE TRANSMISSION Paragraph Extension Housing - Inspection - 23 30 51 41 101 57 33 35 53 41 52 41 14 26 7 21 - 12 26 - 24 31 56 42 54 41 100 57 - Installation - . Removal - Extension Housing — Page Bushing Installation - Removal - —- Gearshift Control Cable Removal Installation -- Gearshift Control Cable A d j u s t m e n t Installation Removal Gearshift Control U n i t . Installation Removal Back-Up L i g h t Switch Replacement . Governor - — Assembly -- Disassembly - Installation - - - - Removal ( U n i t out of Vehicle) ._ _ - 34 36 Servicing i n Vehicle - --- 24 31 116 68 5 18 11 24 21 29 82 50 Housing Face and Bore Runout (Torque Converter) Bore Runout Face Runout H y d r a u l i c Control System H y d r a u l i c Pressure — Checks and A d j u s t m e n t Governor Line Lubrication Throttle T h r o t t l e Compensated K i c k d o w n Piston - - - Removal Installation Inspection - TORQUEFLITE TRANSMISSION — 3 Paragraph Page 8 22 6 20 19 28 ----- 107 60 -- 29 34 19 28 - 89 53 - 85 52 45 39 25 32 99 56 34 36 Servicing i n Vehicle 25 32 Inspection 55 42 3 13 22 29 35 36 57 42 98 56 32 35 102 57 4 15 36 36 58 42 Neutral Starter Switch Removal Installation - Oil Leaks Oil Pan Removal Installation - - - - - - - - Oil Pan and Gasket Installation - Removal Out of Car . .- Replacement i n Car - 1 - Oil Pump -— F r o n t Installation Oil Seal Replacement . - Removal - Oil Pump — Rear - - - Installation Removal ----- Operating Principles - O u t p u t Shaft Rear Oil Seal Removal Installation . O u t p u t Shaft Support Inspection Installation Removal - . _ P a r k i n g Brake Installation Removal - Power Flow i n the Transmission Power T r a i n U n i t No. 1—Output Shaft, K i c k d o w n Planet P i n i o n Carrier and Intermediate Shaft Assemblies Disassembly - TORQUEFLITE TRANSMISSION Paragraph Page Power T r a i n (Continued) Installation 97 56 Reassembly 63 44 Removal 36 36 59 43 37 36 Assembly 75 48 Disassembly 64 45 96 55 37 36 66 46 38 37 Disassembly 76 48 Installation 95 55 78 49 38 37 77 13 49 26 17 28 86 52 88 53 46 39 Service Diagnosis C h a r t — 9 Service Diagnosis E x p l a n a t i o n 2 10 91 55 42 38 90 54 43 39 - Inspection —— U n i t No. 2 — S u n Gear, Reverse Planet P i n i o n Carrier, O v e r r u n n i n g Clutch and Rear Clutch Assembly .... Installation - Removal - Inspection - - - - - U n i t N o . 3 — F r o n t C l u t c h P i s t o n Retainer and I n p u t Shaft Assemblies Reassembly - Removal - - Inspection Push B u t t o n L a m p Replacement - Regulator Valve Assembly Removal . Installation Regulator V a l v e Body Inspection — Includes Valves Installation - Removal Servos L o w — Reverse — I n s t a l l a t i o n Removal Kickdown — installation Removal S h i m Thickness Chart - TORQUEFLITE TRANSMISSION — 5 Paragraph S t a r t e r Pang Gear Removal Installation 114 67 15 27 10 23 27 33 18 28 113 66 115 68 49 40 87 53 47 40 26 33 108 60 50 40 —- 51 41 .- 20 28 — 111 63 110 63 109 60 106 59 30 34 Speedometer P i n i o n and C h a r t Throttle Linkage Adjustment - — Torque Converter — F l u s h i n g Page Torque Converter Control Valve Assembly Removal Installation Torque Converter and H o u s i n g Removal Installation — Torque Converter H u b Runout Checking H u b Runout C o r r e c t i n g H u b Runout Torque Converter Reaction Shaft Inspection - Installation Removal - - Torque Reference Transmission Removal - Installation --- - ....... Transmission Case Inspection - -- - Extension H o u s i n g Valve Body and Transfer Plate Assembly — Cleaning and Inspection Disassembly , Installation Removal - 6 — TORQUEFLITE TRANSMISSION AND SPECIFICATIONS Type - - A u t o m a t i c Three Speed w i t h Torque Converter Torque Converter Diameter (inches) 12 /2 - 1 Oil Capacity of Transmission and Torque Converter (Refill) - 21 pts. A u t o m a t i c Transmission F l u i d Type Method of Cooling // - a A " Suffix " A " Water GEAR RATIOS l_First 2—Second D_Drive R_Reverse N—Neutral 2.45 1.45 1.00 2.20 FRONT — R E A R PUMPS Type E n d Clearance ( F r o n t P u m p ) E n d Clearance (Rear P u m p ) T i p Clearance Outer Rotor D i a m e t r a l Clearance to to to to 1 1 1 1 Gear ( R o t a r y ) .001 to .0025 inch .001 to .0025 inch .005 to .008 inch .008 inch m a x i m u m THRUST WASHERS I n p u t Shaft . 115 .097 .078 .059 to to to to .117 .099 .080 .061 inch ( N a t u r a l ) inch (Black) inch (Red) inch (Orange) F r o n t Clutch and Sun Gear .062 to .064 inch O u t p u t Shaft .062 to .064 Inch SNAP RINGS K i c k d o w n Annulus Gear _ .060 to .062 inch .064 to .066 inch Rear Clutch .060 to .062 inch Low-Reverse Planet Pinion Carrier .060 to .062 inch .064 to .066 Inch .068 to .070 inch F r o n t Clutch .060 to .062 inch Mode! Engine Kickdown ( C u . In.) Band Front Clutch Cushion No. Spring Discs Accumulator Spring Clutch Spring Rear Discs * High Governor Temperature Seals (Type) PS-1 361 214 turns Yes 4 16 5 280 A No PS-3, PC-1, PC-2 383 214 turns Yes 4 16 5 280 A No PS-1, PS-3 (Ram Engine) 383 2 turns Yes 4 None 5 180 C Yes PC-3-300 413 2 turns No 4 None 5 180 C Yes 5 280 A No PC-3, PY-1 413 Lbs. Spring Tension 2% t u r n s Yes 4 16 Governor Assemblies "A" "C" Type—Standard Type—Ram TORQUEFLITE TRANSMISSION — 7 C-3355—Straightedge C-3380—Wrench C-3461—Fixture C-3487—Support C-3527—Gauge C-3528—Stand— (pr.) Valve Body H o l d i n g C-3529—Compressor Servo Spring C-3531—Tool C-3575 or 3533—Compressor C-3583—Adapter—for C-3380 Torque W r e n c h C-3689—Bushing Remover C-3690—Remover C-3691—Oil Seal D r i v e r C-3692—Installer DD1150—Tachometer C-452—Puller C-484—Pliers C-589—Wrench C-760—Pliers C-811—Wrench C-3203A—Jack C-3276—Pilots C-3280—Stand C-3281—Wrench 0-3283—Pilots C-3288—Pilots C-3292—Gauge C-3293—Gauge C-3301—Pliers C-3339—Set-Dial Indicator TIGHTENING REFERENCE A c c u m u l a t o r Cover Screws Foot-Pounds Inch-Pounds — 180 — 120 — 180 — 90 - Compensated T h r o t t l e Pressure Tap . - F r o n t Pump Housing to Transmission Case ~ Governor Body to Support L o c a t i n g Screw - - Oil Pressure Take-Off P l u g Line Pressure Take-Off P l u g Oil Pan Bolts . _ _ . - Rear Clutch Pressure Tap --- Pump Housing to Support Oil Pressure Tap . - Suction Pressure Tap - ---- — 70 — 120 —- 120 — 175 — 120 — 120 — 180 — 180 — 120 Transfer Plate to Transmission Case — 180 Valve Bodies to Transfer Plate — Servo A p p l y Pressure Tap . — Body E n d Cover 55 ' 25 B a n d Lever Shaft Plug 35 — Extension to Transmission Case 25 — F i l l e r Tube N u t 40 — I n t e r m e d i a t e Support L o c a t i n g Screw 25 — Case to Converter Housing 40 — K i c k d o w n Band A d j u s t i n g Screw N u t 35 — L i n e Pressure Regulator Valve Retainer 50 — Low-Reverse Band A d j u s t i n g Screw N u t 35 — — M a n u a l Valve Control Cable H o u s i n g N e u t r a l Starter S w i t c h — I n i t i a l Electrical Contact plus / to / T u r n l l 3 2 75 M a x . 200 — 8 —TORQUEFLITE TRANSMISSION TIGHTENING R E F E R E N C E S (Continued) Foot-Pounds O u t p u t Shaft Support to Case Propeller Flange N u t 25 — 175 — — 120 40 — 25 — 30 — 50 — Torque Converter Cooler L i n e F i t t i n g Control V a l v e Retainer Reaction Shaft to Case Inch-Pounds - Torque Converter H o u s i n g H o u s i n g to E n g i n e B l o c k — % i n c h screws 7/16 i n c h screws.. D u s t Cover — 200 D u s t Plate — 130 Torque Converter Crankshaft N u t or B o l t - Pan D r a i n P l u g - - Converter D r a i n P l u g D r i v e Flange Stud LUBRICATION \ PRESSURE - INTERMEDIATE SUPPORT dm f / REAR \ CLUTCH / TEST i wm. L I N E PitESSL TAKE-OFF P „ i. NEUTIAL STA«7£r< S W I T C H 60x35 \ 130 35 — y / PLUG / m y —• I N T E R M E D I A T E SUPPORT LOCATING SCREW LOW AND REVERSE BAND TORQUE CONVERTER ADJUSTING SCREW , CONTROL VALVE •[ U PRESSURE * — —• LOCATING SCREW ^^^^^^^^^^^^^^^^^^^^^^^^^ m 55 50 5 y-- h^MM VALVE HOB ADJUSTING SCREW pi GOVERNOR PRESSURE TAKE-OFF PLUG K I C K D O W N BAND ADJUSTING Fig. 1—Transmission Case (Left Side) SCREW REGULATOR mm THROTTLE PRESSU TEST HOLE PLUG _ FILLER T U B E CONNECTOR (COMPENSATED) F i g . 2—Trcnsmission Case ( l i g h t Side) 57x237B TORQUEFLITE TRANSMISSION — 9 TROUBLE DIAGNOSIS CHART (TorqueFlite T r a n s m i s s i o n ) DIFFICULTY A. D. Pressure C h e c k s — L i n e , L u b e , etc. E. K.D. B a n d . A d j . F. Low-Reverse Band A d j . G. * E n g i n e I d l e N e u t r a l Str. S w . I. Parking Brake J. Regulator—Valve Spring K. Converter Control Valve O u t p u t S h a l t Rear Bushing N. T. C. C o o l i n g O. K. D. S e r v o Band-Linkage P. L-R S e r v o Band-Linkage Q. O i l Strainer R. Valve B o d y — B o l t s — M a t i n g Surface S. Accumulator T. A i r Pressure U. Governor # m Rear P u m p R e g u l a t o r Valve B o d y , Gasket, Surface c. Front Clutch m d. Rear C l u t c h m e. P l a n e t a r y G e a r Set f. Overrunning Clutch Manual Valve Lever m • • m m • m • • • • # m • • • • • • • • • • • m m m • • • m m m m m j m m m • m m m m • • m m m m m m m m m m m m m m * A l w a y s C h e c k Items A . B . C . a n d G . b e f o r e p e r f o r m i n g a n y other operation. • • # Q • # m Starter Won't Energize impossible to Push Start Trans. Overheats Trans. Hard to FillOil Blows Out Fil. Tb. m m • • • • • Grating, Scraping, Etc. Noises Drags or Locks Drives in N (Neutral) No Drive In 1 (Reverse) [ No Drive in Forward Ranges No Drive in Any Position Slips in All Positions Slips in Reverse Only Slips in Forward Drive Positions • • • • • • • • • • • • • • m • • • Check b. m • • m m • • • • • o m Front P u m p — Drive Sleeve Shifts Erratically No K.D. or Normal Downshift No Upshift Upshift and 3-2 K.D. m # a. g. ® • • • • • • • • • • • • • • • • Breather M. V. • • © H. L. m m B. * T h r o t t l e Link A d j . C. * G e a r s h i f t C o n t r o l Cable A d j . ' • *Oil L e v e l Runaway on D ITEM Delayed INDEX N to Perform Items: A , B, C , and G first Harsh N to D or N to R See "Explanation of I n d e x i t e m s " Miscellaneous Response Shift A b n o r m a l i t i e s CHECK Harsh Upshift and 3-2 K.D. TO Bulling Noises OPERATING 11 c m s • • • • • • 10 —TORQUEFLITE TRANSMISSION E R V I C E DIAGNOSIS CHART L SERVICE DIAGNOSIS C H A l f The Trouble Diagnosis C h a r t has the operating difficulties listed i n three general groups. A f t e r road testing, m a t c h the t r o u b l e found to i t s p a r t i c u l a r group and the specific difficulty under t h a t group. The Index and I t e m i n t h e " I t e m s to Check" column are next checked against t h e " E x p l a n a t i o n of Index I t e m s . " Capital l e t t e r items refer to those operations w h i c h m a y be performed w i t h o u t r e m o v i n g the transmission. T h e small l e t t e r items refer to those operations done after removal o f the transmission f r o m the car. 2. SERVICE DIAGNOSIS — EXPLANATION OF INDEX ITEMS Never remove a transmission f r o m a vehicle u n t i l a l l of t h e possible " i n vehicle" causes have been checked for the operation difficulty and the o i l pan has been removed to check f o r d i r t , m e t a l chips, band mater i a l , broken band ends and burned or scored band contacting surfaces, also, check t h e m a n u a l c o n t r o l cable and t h r o t t l e linkage f o r a d j u s t m e n t and wear. L Parking Brake — • Check f o r excessive drag. Refer to Brakes Section f o r method of a d j u s t i n g p a r k i n g brake. j . Regulator Valve, Spring — The regulator valve m a y be removed b y r e m o v i n g the regulator valve s p r i n g retainer, w h i c h is on the r i g h t side of the transmission case ( F i g . 2 ) . Check f o r a stuck or badly scratched valve a n d / o r buckled spring. Be sure s p r i n g cup is correctly positioned and not b i n d i n g i n valve body bore. k. Converter Control Valve, Spring — The conv e r t e r control valve m a y be removed b y r e m o v i n g the converter control valve s p r i n g retainer, w h i c h is on the r i g h t side of the transmission case ( F i g . 2 ) . Check f o r a stuck or badly scratched valve and/or buckled s p r i n g . W ' -• ' ' V / • a. O i l L e v e l — Refer to the l u b r i c a t i o n Group 0 of t h i s manual. I f o i l appears t o be emulsified, check for possible o i l cooler leak. b. T h r o t t l e L i n k a g e — Refer t o P a r a g r a p h 1 0 . c. Gearshift Control Cable—Refer to P a r a g r a p h 7. d. Pressure Tap Check —- H y d r a u l i c pressure taps have been provided to check the f o l l o w i n g pressures: line, l u b r i c a t i o n , governor, rear clutch apply, and t h r o t t l e (compensated). These pressures should f a l l w i t h i n the specified l i m i t s stated i n t h e H y d r a u l i c Control Pressure Check C h a r t . e. K i c k d o w n Band A d j u s t m e n t — the k i c k d o w n band a d j u s t m e n t screw is f o u n d on the l e f t side o f the transmission case ( F i g . 1 ) . Refer to P a r a g r a p h 9(a). f. L o w and Reverse B a n d A d j u s t m e n t — T h e l o w and reverse band a d j u s t m e n t screw is found on t h e r i g h t side of the t r a n s m i s s i o n case ( F i g . 2 ) . Refer to P a r a g r a p h 9 ( b ) . g. E n g i n e Idle — A d j u s t t o 475 to 525 r . p . m . i n Neutral. h. Neutral Starter Switch — I f t h e s t a r t e r w i l l not energize, the n e u t r a l s t a r t e r s w i t c h and connections should be tested. A —GOVERNOR PRESSURE B — REAR PUMP INLET C —REAR CLUTCH 'APPLY' (Line pressure) D — LOW AND REVERSE SERVO 'APPLY' (Line pressure) E—KICKDOWN SERVO 'APPLY' (Throttle compensated pressure) F — LOW AND REVERSE SERVO (Location) G—KICKDOWN SERVO (Location) H —KICKDOWN SERVO 'APPLY' (Line pressure) J — KICKDOWN SERVO 'RELEASE' (Line pressure) K —ACCUMULATOR (Location) I — FRONT CLUTCH AND ACCUMULATOR 'APPLY' (Line pressure) M —LINE PRESSURE N — FRONT PUMP INLET O—-REVERSE UPSET (Reverse blocker 'Apply') (Line pressure) P—LINE ^'USZJRE GAUGE 56x712A Fig. 3—Oil Passages in Transmission Case TORQUEFLITE TRANSMISSION — 11 1. B r e a t h e r — Check to determine w h e t h e r t h e breather is free o f d i r t and undercoating. m . O u t p u t Shaft Rear B u s h i n g — Check for r o u g h , scored or w o r n bushing. n . Torque Converter — Check o i l cooler lines f o r being bent, k i n k e d or h a v i n g loose connections. o. K i c k d o w n Servo, Band and L i n k a g e — Check f o r broken seal r i n g s , stuck servo pistons or broken linkage. p. L o w and Reverse Servo, B a n k and L i n k a g e — Check f o r t o r n seal, broken band and/or linkage. q. O i l S t r a i n e r — Check f o r possible a i r leakage or clogged screen. r . Valve B o d y A t t a c h i n g Bolts and M a t i n g Surface — Check f o r loose bolts, b u r r s or scratches on m a t i n g surfaces. Clean valve body assembly. Check f o r stuck valves, d i r t , scratched valves or body, and b u r r s on valves. Torque valve body bolts to specifications. s. A c c u m u l a t o r — Check accumulator p i s t o n f o r sticking, r o u g h bore i n case, and/or r i n g s . t . A i r Pressure Check — The f r o n t clutch, rear clutch, k i c k d o w n servo, and low reverse servo m a y be checked b y a p p l y i n g a i r pressure t o t h e i r respect i v e passage w h e n the valve body is removed. To make the complete a i r pressure check, proceed as f o l l o w s : (Refer to F i g . 3.) CAUTION Compressed a i r supply m u s t be free o f a l l d i r t and moisture. ( 1 ) Raise the vehicle on a hoist, d r a i n t h e transmission fluid and remove the transmission o i l pan. Remove t h e accumulator cover and valve bodies assembly. ( 2 ) A p p l y a i r pressure to the f r o n t clutch passage as shown i n F i g u r e 3 ( L ) . L i s t e n f o r a d u l l " t h u d " w h i c h indicates t h a t the f r o n t clutch is opera t i n g . H o l d the a i r pressure on f o r a few seconds and observe f o r excessive o i l leaks i n the system. (3) A p p l y a i r pressure t o the rear c l u t c h passage, as shown i n F i g u r e 3 ( C ) . L i s t e n f o r a d u l l " t h u d " w h i c h indicates t h a t t h e rear clutch is operating, also check f o r excessive o i l leaks. (4) A p p l y a i r pressure to the k i c k d o w n " a p p l y " (line) pressure passage, as shown i n F i g u r e 3 ( H ) . Observe t h e operation of the k i c k d o w n servo, lever and band w h e n a i r pressure is applied. (5) A p p l y a i r pressure t o the k i c k d o w n " a p p l y " (compensated t h r o t t l e ) pressure passage, as shown i n F i g u r e 3 ( E ) . Observe the operation of the kickdown servo. (6) A p p l y air pressure to the low and reverse servo passage as shown i n F i g u r e 3 ( F ) . Observe the operation of the low and reverse servo, lever, and band w h e n a i r pressure is applied. I f t h i s usually occurs when line pressure fails, an e r r a t i c or no u p s h i f t condition exists and the clutches and servos operate properly, i t indicates t h a t a possible m a l f u n c t i o n i n g exists i n the control valve body assembly. Disassemble, clean, inspect and service the valve body assembly as described i n the "Recondit i o n i n g o f t h e Valve B o d y and T r a n s f e r Plate A s semblies," P a r a g r a p h 109. U p o n completion o f the a i r pressure check, and servicing the valve body assembly, install the valve body assembly and the transmission o i l pan. F i l l the transmission to proper level w i t h fluid, and adjust the control cable and t h e t h r o t t l e linkage. u . Governor — Clean assembly, check w e i g h t assembly and valve f o r b u r r s , scratches or s t i c k y operation. E x a m i n e the governor valve shaft, snap rings and seal r i n g s . v. Rear P u m p — Clean and inspect assembly f o r side and d i a m e t r a l clearance. Note w h e t h e r the rear oil p u m p pinion ball is i n place. E x a m i n e the o u t p u t shaft support face f o r scoring. a. F r o n t P u m p D r i v e Sleeve — Inspect assembly f o r side and d i a m e t r a l clearance. E x a m i n e oil pump inner and outer r o t o r f o r heavy scoring. Check f r o n t p u m p drive sleeve seal r i n g s . b. Regulator Valve Body, M a t i n g Surfaces and Gasket — Clean and inspect the valve body f o r heavy scratches and scoring on the valve bores and face w h i c h bears against the f r o n t p u m p housing. E x amine the valve body to determine i f the secondary reaction orifice is free of d i r t . Check gasket f o r uniformness of compression by t h e valve body. c. F r o n t Clutch — Clean and inspect discs, plates, d r i v e hub, r e t u r n spring, piston levers and retainer. Check the f o l l o w i n g f r o n t clutch c i r c u i t f o r leakage possibilities: (1) V a l v e body and valve body t o case m a t i n g surface. ( 2 ) A c c u m u l a t o r small and large p i s t o n r i n g s . ( 3 ) Regulator valve body to case m a t i n g surface. ( 4 ) Torque converter reaction shaft seal r i n g . ENGINE CRANKSHAFT REAR CLUTCH PRESSURE PLATE j T O R Q U E C O N V E R T E R OVERRUNNING CLUTCH / K I C K D O W N BAND T O R Q U E C O N V E R T E R IMPELLER \ / FRONT OIL PUMP H O U S I N G DUST SEAL \ 1 / ' INTERMEDIATE SUPPORT ASSEMBLY O V E R R U N N I N G CLUTCH ASSEMBLY 1 INPUT SHAFT ASSEMBLY LOW-REVERSE B A N D REAR OIL PUMP ; LOW-REVERSE B A N D DRUM / / / REVERSE A N N U L U S G E A R 1 / / / , / I / / / / S R E A R / CLUTCH ASSEMBLY / ' j /T O/R Q FRONT U E C O NCLUTCH V E R T E R PRESSURE R E A C T I O N PLATE SHAFT FRONT O I L PUMP T O R Q U E CONVERTER STATOR / / / / / TRANSMISSION CASE j I j I KICKDOWN ANNULUS GEAR OUTPUT SHAFT SUPPORT / // EXTENSION GOVERNOR ASSEMBLY SPEEDOMETER PINION OIL STRAINER: REVERSE SUN G E A R LOW-REVERSE PLANET P I N I O N CARRIER ASSEMBLY H A N D BRAKE ASSEMBLY V A L V E BODIES A N D TRANSFER PLATE ASSEMBLY INTERMEDIATE SHAFT ASSEMBLY TORQUE CONVERTER TURBINE 56x707C Fig. 4—Typical TorqueFlite Transmission a n d Torque Converter TORQUEFLITE TRANSMISSION—13 (5) I n p u t shaft small and large seal r i n g s . (6) I n t e r m e d i a t e shaft No. 1, 2, and 8 seal r i n g s . (7) F r o n t clutch o i l feed tube. (8) F r o n t clutch piston inner and outer seal r i n g s . (9) F r o n t clutch retainer ball check. d. Rear Clutch — Clean and inspect discs, plates, r e t u r n s p r i n g and piston. Check t h e f o l l o w i n g rear clutch c i r c u i t f o r leakage possibilities. (1) Valve body and valve body to case m a t i n g surface. (2) O u t p u t shaft support t o case m a t i n g surface. (3) O u t p u t shaft small and large seal r i n g s . (4) I n t e r m e d i a t e shaft N o . 4, 5, and 6 seal r i n g s . (5) Rear clutch o i l feed tube. (6) Sun gear rear clutch seal r i n g s . (7) Rear clutch piston inner and outer seal r i n g s . ( 8 ) Rear clutch retainer ball check. ( 9 ) K i c k d o w n piston rod guide seal r i n g and r o d guide t o k i c k d o w n r o d fit. (10) L a r g e k i c k d o w n piston seal r i n g . e. Planetary Gear Set — Clean and inspect gear set f o r w o r n t h r u s t washers, nicked or r o u g h gear teeth, and excessive pinion end clearance. f. L o w Speed Over-Running C l u t c h — Clean and inspect the o v e r r u n n i n g clutch assembly f r o m b r i n nelled rollers a n d / or cam and i m p r o p e r l y assembled rollers or springs. Check the cam roller ramps f o r being w o r n . g. M a n u a l V a l v e Lever — A loose or badly w o r n manual valve lever cam should be replaced. I f loose, i t m a y be silver soldered only so as not to r e q u i r e h i g h temperatures t h a t could destroy i t s hardness, otherwise i t should be replaced. T O R Q U E F L I T E TRANSMISSION 3. TORQUEFLITE OPERATING PRINCIPLES The transmission, as shown i n F i g u r e 4, combines a torque converter and an automatic p l a n e t a r y three speed transmission. The torque converter extends torque m u l t i p l i c a t i o n over a wide range o f engine speeds. The transmission consists of t w o m u l t i p l e disc clutches, an o v e r r u n n i n g c l u t c h , t w o bands, and t w o planetary gear sets to provide t h r e e f o r w a r d ratios and a reverse r a t i o . a. Gearshift Control Unit The transmission is operated by a gearshift c o n t r o l u n i t consisting of five push buttons, identified b y R (reverse), N ( n e u t r a l ) , D ( d r i v e ) , 2 (second) and 1 (first). Mechanical connection between t h e gearshift cont r o l housing and the transmission manual c o n t r o l valve is obtained t h r o u g h the use of a single pushpull cable, as shown i n F i g u r e 5. One end o f t h e w i r e cable is secured to the cable actuator i n the g e a r s h i f t control housing, w h i l e the other end enters t h e t r a n s mission case to engage t h e manual control valve lever assembly. Should the R (reverse) b u t t o n be pushed i n , above a p p r o x i m a t e l y 10 to 12 M P H , i t w i l l move the m a n u a l control lever t o t h e n e u t r a l position and w h e n t h e car speed drops below 10 to 12 M P H , i t w i l l again be necessary to re-engage the R (reverse) push b u t t o n . A back-up l i g h t s w i t c h (when so equipped) is i n corporated i n t h e gearshift control housing and is operated b y the R (reverse) push b u t t o n slide. b. Operating Instructions Starting the Engine As a safety precaution, always apply p a r k i n g or foot brake. The transmission N ( n e u t r a l ) control b u t t o n m u s t always be pushed i n before the car can be started. T h i s is necessary since t h e s t a r t e r electrical c i r c u i t is completed only w h e n the n e u t r a l safety s w i t c h on the transmission is closed, thus p r e v e n t i n g the car f r o m being accidentally s t a r t e d while i n gear. Push Starting Should the need arise, the engine can be started as follows by h a v i n g t h e car pushed: (1) Push i n the N ( n e u t r a l ) b u t t o n . (2) T u r n on the i g n i t i o n s w i t c h . (3) W h e n a speed of a p p r o x i m a t e l y 20 M . P . H . has been attained, push i n the 1 ( f i r s t ) b u t t o n and t h e engine should s t a r t . T o w i n g the car to s t a r t is n o t recommended due t o the sudden surge of power w h e n the engine starts. g. How to Drive the Vehicle (1) A f t e r t h e engine is started, better fuel economy and quicker engine w a r m up can be obtained b y 14 —TORQUEFLITE TRANSMISSION LOCK UNLATCHED POSITION LATCHED POSITION NEUTRAL OPERATING AND ENGINE STARTING SLIDE CONTROL CABLE ACTUATOR TO TRANSMISSION PUSH BUTTONS CONTROL CABLE 57xl74A Fig. 5—Typical Gearshift Control Unit (Operational Sketch) s t a r t i n g to d r i v e i m m e d i a t e l y . I f the engine is cold (engine on fast i d l e ) , apply the foot brake l i g h t l y so as to prevent a tendency of vehicle to creep w h e n m a k i n g a push b u t t o n selection. ( 2 ) D (drive b u t t o n ) . A l l n o r m a l f o r w a r d d r i v i n g w i l l be done i n t h i s range. The vehicle w i l l have a s l i g h t tendency to creep a f t e r p u s h i n g t h e b u t t o n f r o m N ( n e u t r a l ) t o D ( d r i v e ) a t idle. T h i s can be prevented b y a p p l y i n g the f o o t brake l i g h t l y . A s soon as the accelerator is depressed, the vehicle w i l l move f o r w a r d i n the d r i v e ( b r e a k a w a y ) range. Depending on the amount the accelerator is depressed, the t r a n s m i s s i o n w i l l a u t o m a t i c a l l y u p s h i f t t o second. A s t h e vehicle speed increases, the t r a n s m i s s i o n w i l l a u t o m a t i c a l l y u p s h i f t f r o m second to direct. W h e n s l o w i n g the vehicle down ( a t closed t h r o t t l e ) t h e t r a n s m i s s i o n w i l l a u t o m a t i c a l l y d o w n s h i f t to breakaway a t a p p r o x i m a t e l y 10 M . P . H . ( 3 ) 2 (second) p o s i t i o n provides d r i v i n g characteristics s i m i l a r to D ( d r i v e ) except t h a t t h e t r a n s mission w i l l r e m a i n i n second u n t i l wide open 2-3 u p s h i f t speed is attained, as indicated i n t h e S h i f t P a t t e r n S u m m a r y C h a r t below. A s soon as t h e accelerator is depressed, t h e vehicle w i l l move f o r w a r d i n the d r i v e ( b r e a k a w a y ) range. Depending on t h e a m o u n t of accelerator is depressed and car speed, t h e transmission w i l l a u t o m a t i c a l l y u p s h i f t i n t o second: I f t h e vehicle speed falls before 8 M . P . H . , or i f t h e accelerator is completely depressed provided vehicle speed is below 30 M . P . H . , t h e transmission w i l l a u t o m a t i c a l l y d o w n s h i f t to breakaway. I t is possible to push t h e b u t t o n s f r o m 2 (second) to D ( d r i v e ) at any speed. Shifts D ( d r i v e ) to 2 (second) may be made a t any speed and the transmission w i l l d o w n s h i f t to second gear w h e n speeds below t h e 3-2 k i c k d o w n l i m i t are obtained. N O T E : A l l s h i f t speeds v a r y somewhat due t o prod u c t i o n tolerances, t i r e sizes and rear axle r a t i o s . A l l s h i f t s , however, should be smooth, responsive, and w i t h no noticeable engine r u n a w a y . ( 4 ) 1 ( f i r s t ) provides d r i v i n g characteristics simi l a r to D (drive-breakaway) except t h a t the t r a n s mission w i l l not u p s h i f t i n t o any other range r e g a r d less of vehicle speed and t h r o t t l e opening. To prevent overspeeding of engine, do not operate vehicle above 40 m p h i n 1 ( f i r s t ) position. I t is possible t o push t h e b u t t o n s f r o m D ( d r i v e ) to 1 (first) at any speed; however, the transmission w i l l n o t d o w n s h i f t t o low i f vehicle is above speeds shown i n S h i f t P a t t e r n S u m m a r y C h a r t (above 3-1 K i c k d o w n l i m i t ) . (5) R ( r e v e r s e ) . Stop t h e vehicle and w i t h foot b r a k e l i g h t l y applied, push the R (reverse) button, i n . TORQUEFLITE TRANSMISSION — 15 SHIFT P A T T E R N SUMMARY CHART PS1&3 Closed T h r o t t l e 1-2 U p s h i f t 8-13 8-15 8-15 9-15 9-16 10-15 11-15 Closed T h r o t t l e 2-3 U p s h i f t 10-16 12-18 12-19 12-19 13-20 14-19 13-20 W i d e Open T h r o t t l e 1-2 U p s h i f t .... 29-41 31-46 31-47 32-48 33-49 37-42 38-44 Wide Open T h r o t t l e 2-3 U p s h i f t .... 61-74 67-83 68-84 69-86 72-90 60-74 61-75 3-2 K i c k d o w n L i m i t 58-71 63-80 64-82 66-83 69-87 57-65 58-67 3-1 K i c k d o w n L i m i t 28-39 30-43 31-44 32-45 33-47 36-42 37-43 6-11 6-13 6-13 6-13 7-14 8-12 8-13 ( 6 ) K i c k d o w n (forced d o w n s h i f t ) . A t speeds below the 3-2 or 3-1 k i c k d o w n speed l i m i t s shown i n S h i f t P a t t e r n S u m m a r y Chart, a f t e r t h e t r a n s m i s sion has upshifted, i n t o D ( d r i v e ) or 2 (second) the transmission w i l l d o w n s h i f t to the n e x t lowest gear b y completely depressing the accelerator; thereby g i v i n g m a x i m u m acceleration f o r passing or climbi n g steep grades. The transmission w i l l a u t o m a t i cally u p s h i f t to second i f the accelerator is released or speeds shown i n S h i f t P a t t e r n S u m m a r y C h a r t ( w i d e open t h r o t t l e 1-2 u p s h i f t ) are reached. I n D ( d r i v e ) range f r o m second gear, the transmission w i l l automatically u p s h i f t i n t o direct i f t h e accelerat o r is p a r t i a l l y released or i f speeds as shown i n S h i f t P a t t e r n S u m m a r y C h a r t (wide open t h r o t t l e 2-3 ups h i f t ) are reached. PC2 PC3 PY1 PC3 C300 Ram Man. Condition Closed T h r o t t l e D o w n s h i f t PCI PSI & 3 Ram Man. load or when p u l l i n g a t r a i l e r , the 2 (second) or 1 (first) position should be selected on upgrades w h i c h require heavy t h r o t t l e f o r y mile or more. L o w e r ratios reduce the possibility of overheating t h e transmission under these conditions. 1 (first) position is f o r severe operation and to provide better control when descending steep grades. 2 d. Transmission Inoperative T o w the vehicle w i t h the rear end picked up or remove the propeller shaft. e. Transmission Operating Properly The vehicle m a y be towed safely i n N ( n e u t r a l ) at moderate speeds. F o r long distances t o w i n g (over 100 m i l e s ) , the propeller shaft should be removed. 4. POWER F L O W IN THE TRANSMISSION c. Mountain Driving D (Drive) Position Breakaway (see Fig. 6) W h e n d r i v i n g i n t h e mountains w i t h either heavy The power flow is f r o m t h e converter t u r b i n e t h r o u g h FRONT CLUTCH APPLIED OVER-RUNNING CLUTCH (LOCKS WHILE D R I V I N G FREE WHILE COASTING) DRIVE P O S I T I O N - B R E A K A W A Y Fig. 6—Power Flow in D (Drive) Position—Breakaway 56x689 16 —TORQUEFLITE TRANSMISSION 56x690 Fig. 7—Power Flow in D (Drive) Position—2nd Speed and 2 (Second) Position 2nd Speed the i n p u t shaft and f r o n t clutch r e t a i n e r (one u n i t ) . The f r o n t clutch is applied and the d r i v e continues t h r o u g h the clutch h u b t o the intermediate shaft and the k i c k d o w n annulus gear (one u n i t ) . The k i c k down annulus gear drives the k i c k d o w n planet p i n i o n gears, r o t a t i n g t h e m i n the same direction. The k i c k d o w n planet gears are meshed w i t h the k i c k down sun gear w h i c h i n t u r n is i n t e g r a l w i t h the reverse sun gear. B o t h sun gears are forced t o r o t a t e i n a reverse d i r e c t i o n b y the reaction of t h e k i c k down planet p i n i o n carrier together w i t h the reverse annulus gear, b o t h of w h i c h are splined to t h e outp u t shaft d r i v i n g housing. The reverse planet p i n i o n FRONT AND REAR CLUTCHES carrier is attached to and prevented f r o m t u r n i n g backward b y an o v e r r u n n i n g clutch and becomes stat i o n a r y i n f o r w a r d drive (overruns on coast). Therefore, the reverse planet carrier pinions are forced to r o t a t e i n a f o r w a r d direction and force t h e reverse annulus to r o t a t e i n the same direction t r a n s m i t t i n g the power flow to the o u t p u t shaft w i t h the r e s u l t i n g r a t i o of the k i c k d o w n and reverse planetary gear sets of 2.45 to 1. D (Drive Position — 2nd S p e e d a n d 2nd (Second) Position — 2nd S p e e d (see F i g . 7) The power flow is f r o m the torque converter t u r b i n e APPLIED 56x688 Fig. 8—Power Flow in D (Drive) Position—Direct TORQUEFLITE TRANSMISSION—17 FRONT CLUTCH APPLIED L O W AND REVERSE BAND APPLIED Fig. 9—Power Flow in 1 (First) Position—low Speed t h r o u g h the i n p u t shaft to the f r o n t c l u t c h ( w h i c h is applied). the annulus gear, t h u s p r o v i d i n g a gear r a t i o o f 1.45 to 1. F r o m the f r o n t clutch t h r o u g h t h e i n t e r m e d i a t e shaft to t h e annulus gear o f the k i c k d o w n ( r e a r ) planetary gear set. The k i c k d o w n band is applied w h i c h holds t h e sun gear s t a t i o n a r y . The annulus gear drives the k i c k d o w n planet pinions w h i c h r o t a t e i n the same d i r e c t i o n as the i n p u t and intermediate shafts. T h e k i c k d o w n planet pinions. are meshed w i t h the sun gear; therefore, t h e y w a l k around t h i s gear and exert force t h r o u g h the k i c k d o w n planet pinion shafts to r o t a t e the k i c k d o w n planet pinion carrier. T h e carrier, w h i c h is splined t o t h e o u t p u t shaft d r i v e housing, rotates at a slower speed t h a n D (Drive Position) — Direct (see Fig. 8) The power flow f r o m the torque converter goes d i r e c t l y t h r o u g h the transmission because the plane t a r y elements o f t h e gear t r a i n are locked up b y t w o m u l t i p l e disc clutches and b o t h bands are released. The torque converter provides all o f t h e torque multiplication. Kickdown (Forced Downshift) i n D (Drive) Position Below 25 VLPJSL T h i s w i l l force t h e transmission to d o w n s h i f t and t h e power flow w i l l be t h e same as D ( d r i v e ) position (breakaway). 56x692 Fig. 10—Power Flow in R (Reverse) Position 18 —TORQUEFLITE TRANSMISSION Kickdown (Forced 3-2 Downshift) i n D (Drive) Position 25 to 70 M.P.H. T h i s w i l l force the transmission to downshift and the power flow w i l l be the same as D ( d r i v e ) position 2nd speed. N (Neutral) Position A l l f r i c t i o n elements are released. Hence, there is no drive connection between the engine and the rear wheels. Power Flow Summary 1 (First Position) — First Speed (see Fig. 9) I n 1 (first) position the power flow is the same as D ( d r i v e ) position (breakaway) or 2 (second) posit i o n (breakaway) w i t h one exception, the low-reverse band is applied, locking the o v e r r u n n i n g clutch t o provide engine b r a k i n g . The c h a r t summarizes power flow conditions i n the various ranges as regards to gear t r a i n elements i n volved and the ratios obtained. 5. THE HYDRAULIC CONTROL SYSTEM T h e h y d r a u l i c control system has f o u r i m p o r t a n t functions t o p e r f o r m . R (Reverse) Position (see Fig. 10) The rear clutch and t h e low-reverse band are applied. A l l other f r i c t i o n elements are released. The power flow is f r o m the torque converter t u r b i n e t h r o u g h t h e i n p u t shaft t o the rear clutch hub ( p a r t o f the f r o n t clutch r e t a i n e r ) . The rear clutch is splined t o the reverse sun gear. The c a r r i e r of the reverse ( f r o n t ) planetary gear set is held s t a t i o n a r y b y t h e low-reverse b a n d ; therefore, t h e se.t acts as a reverse t r a i n t h r o u g h the reverse planet pinions to t h e reverse annulus ( w h i c h is splined to the o u t p u t shaft d r i v e housing) and provides a reverse r a t i o o f 2.20 to 1. T h e pressure supply system, the clutches and band servos, the pressure r e g u l a t i n g valves and the flow control valves. a. The Pressure Supply System Front Pump Under a l l n o r m a l operating conditions (up to a f o r w a r d speed of approximately 35 m p h ) the f r o n t pump, d r i v e n at engine speed, provides o i l needed f o r torque converter pressure, control pressures, and lubrication. C L U T C H ENGAGEMENT AND BAND APPLICATION CHART Button Position and Drive Condition Front Clutch Rear Clutch Over Running Clutch Front (Kickdown) Band Neutral Disengaged Disengaged Over Runs Released Released Drive "D" Breakaway 2.45 to 1 Engaged Disengaged Holds Released Released D r i v e "D" Second 1.45 to 1 Engaged Disengaged Over Runs Applied Released D r i v e "D" Direct 1.00 to 1 Engaged Engaged Over Runs Released Released Second 2" 1.45 to 1 Engaged Disengaged Over Runs Applied Released First " 1 " Engaged Disengaged No Movement Released Applied No Movement Released Applied u Reverse " R " 2.20 to 1 Disengaged Engaged (Low Rear & Rev.) Band TORQUEFLITE TRANSMISSION—19 The f r o n t p u m p delivers o i l at a p p r o x i m a t e l y 90 psi to fulfill these conditions at all engine speeds above a p p r o x i m a t e l y 700 r p m . I n reverse, the f r o n t pump pressure is increased t o approximately 225 psi i n order to handle the h i g h torque loads imposed d u r i n g reverse operation. source of line pressure to the regulator valve seconda r y reaction area, w i t h the result t h a t a line pressure of 225 psi, applied to the p r i m a r y reaction area, is required to overcome the force of the r e g u l a t o r valve s p r i n g . Hear Pump T h i s valve maintains an o i l pressure of a p p r o x i m a t e l y 30 psi w i t h i n t h e torque converter. O i l is fed f r o m the regulator valve t h r o u g h a r e s t r i c t i n g hole i n the regulator valve body to the torque converter. The rear pump (smaller t h a n the f r o n t pump and driven by the o u t p u t shaft) furnishes all of t h e o i l required by the transmission i n n o r m a l d r i v i n g at all vehicle speeds above approximately 35 m p h . b. Clutches and Band Servos Front Clutch The f r o n t clutch t r a n s m i t s f u l l engine and converter torque i n all f o r w a r d d r i v e positions. I n order to develop the required capacity, a system of eight levers is used to actuate the clutch apply plate. Rear Clutch The rear clutch locks t h e gear t r a i n f o r direct drive operation i n the f o r w a r d range and t r a n s m i t s f u l l i n p u t torque to the gear t r a i n i n reverse operation. Kickdown Servo The k i c k d o w n piston actuates the k i c k d o w n band t h r o u g h the k i c k d o w n lever, s t r u t , and anchor, holdi n g the sun gear of the rear planetary set stationary and r e s u l t i n g i n a f o r w a r d r a t i o of 1.45 to 1 t h r o u g h the rear planetary gear set. Low-Reverse Servo The low-reverse servo has t w o functions w h i c h are performed independently. The first reverse servo piston is moved h y d r a u l i c a l l y t o apply the first reverse band t h r o u g h t h e first reverse band lever, s t r u t , and anchor ( F i g . 1 0 ) . Accumulator A n accumulator helps to cushion the f r o n t clutch engagement when a f o r w a r d drive b u t t o n is pushed in and t h e application of the k i c k d o w n band i n t h e upshift f r o m breakaway to second. I t is connected in parallel and to t h e passage w h i c h supplies line pressure to the apply side of the k i c k d o w n servo. c. Pressure Regulating Valves Regulator Valve The regulator valve controls line pressure a t a value of a p p r o x i m a t e l y 90 psi f o r all operating conditions except reverse. F o r reverse operation, o i l m u s t be at a pressure o f 225 psi. T h i s is accomplished b y s h u t t i n g off t h e Torque Converter Control Valve Oil is routed f r o m the torque converter control valve t h r o u g h the transmission l u b r i c a t i o n system t o lubricate the gear t r a i n at approximately 10 to 30 psi pressure. Governor Valve The governor valve assembly t r a n s m i t s a h y d r a u l i c pressure to the transmission w h i c h is proportional t o car speed. This governed pressure, i n conjunction w i t h t h r o t t l e pressure, controls upshift and downs h i f t speeds. Throttle Valve The t h r o t t l e valve assembly t r a n s m i t s a h y d r a u l i c pressure to t h e transmission w h i c h is p r o p o r t i o n a l to the amount of t h r o t t l e opening. The t h r o t t l e valve allows o i l t o flow f r o m t h e line pressure p o r t to the t h r o t t l e pressure port, w h i c h is connected by a passage to the reactions area of the t h r o t t l e valve. T h r o t t l e pressure w i l l v a r y w i t h the amount o f carburetor t h r o t t l e opening f r o m a value of 0 (zero) pressure at closed t h r o t t l e to a value of a p p r o x i m a t e l y 90 psi at w i d e open t h r o t t l e . Throttle Compensator Valve The t h r o t t l e compensator valve amplifies the v a r i a tions i n t h r o t t l e pressure. T h r o t t l e compensator pressure w i l l v a r y w i t h the amount of carburetor t h r o t t l e opening f r o m a value of a p p r o x i m a t e l y 10 to 16 psi ( w i t h the 1 piece valve body) at closed t h r o t t l e to a value o f 90 psi at a p p r o x i m a t e l y % throttle. d. Flow Control Valves Front and Rear Pump Check Valves The f r o n t p u m p check valve prevents back flow f r o m the rear pump i n t o t h e pressure side of the pump w h e n the p u m p is e i t h e r s t a t i o n a r y or merely circul a t i n g o i l at a v e r y low pressure. The check valve separates f r o n t and rear pump. Manual Valve The manual valve obtains t h e different transmission d r i v e ranges as selected by the vehicle operator. 20 — TORQUEFLITE TRANSMISSION Reverse Blocker Valve The reverse blocker valve mechanically blocks t h e m a n u a l valve f r o m m o v i n g Into reverse position t o prevent accidental reverse engagement above app r o x i m a t e l y 10-15 m p h . 1- 2 S h i t Valve This valve determines w h e t h e r the transmission is either i n first gear r a t i o or second gear r a t i o , depending upon w h e t h e r the valve is i n the upshifted or down-shifted position. 2- 3 Shift Valve T h i s s h i f t valve a u t o m a t i c a l l y shifts the t r a n s m i s sion f r o m i n t e r m e d i a t e t o direct gear. 1-2 Relay Valve T h i s valve provides f o r a quick application and release of the k i c k d o w n band and rear c l u t c h at low speeds w h i l e s m o o t h i n g out t h e i r apply and release at h i g h speeds. Kickdown Valve The k i c k d o w n valve makes s h i f t f r o m d i r e c t t o second and d i r e c t to breakaway b y t o r pedal past the detent throttle. possible a forced down— second t o breakaway depressing the accelera" f e e l " near wide open Shuttle Valve, Shuttle Valve Plug, and Servo Pressure Bleed Valve The s h u t t l e valve has t w o separate functions and p e r f o r m s each independently o f the other. T h e first is t h a t of p r o v i d i n g fast release of the k i c k d o w n band, and delayed smooth rear clutch engagement w h e n the d r i v e r makes a " l i f t - f o o t " u p s h i f t f r o m second to direct. The second f u n c t i o n of the s h u t t l e valve is to regulate the application of the k i c k d o w n piston w h e n m a k i n g h i g h speed (above a p p r o x i m a t e l y 30 m p h ) kickdowns. e. Operational Summary W i t h the D (drive) b u t t o n pushed i n , t h e manual valve is positioned to govern the f u l l range of operat i o n of the transmission. W i t h the manual valve I n t h e drive position, the f r o n t clutch is engaged and the transmission w i l l t r a n s m i t d r i v e torque i n breakaway. P u s h i n g I n the 2 (second) b u t t o n of t h e control u n i t moves the manual valve so t h a t line pressure is directed to the k i c k d o w n c i r c u i t of the 2-3 s h i f t valve. Pushing i n t h e 1 (first) b u t t o n of the control u n i t positions the manual valve so t h a t line pressure Is directed to the k i c k d o w n c i r c u i t o f the 1-2 s h i f t valve. Pushing i n t h e N ( n e u t r a l ) b u t t o n moves t h e manual valve to a position w h i c h shuts off o i l flow to the valve body. The torque converter and lubricat i o n system remains pressurized. P u s h i n g i n the R (reverse) b u t t o n of the control u n i t positions the manual valve so t h a t o i l pressure is directed to apply the rear clutch and low-reverse band. MAINTENANCE, ADJUSTMENTS AND T E S T S CAUTION For safety reasons and to prevent possible damage to the transmission . . . wide open throttle stall test operations should not be attempted under any circumstances. Good transmission operation depends d i r e c t l y upon good engine performance. Therefore, i t is o f u t m o s t importance t h a t the engine is o p e r a t i n g at f u l l efficiency and at proper idle speed before a t t e m p t i n g to diagnose or correct any transmission operation. The engine and t r a n s m i s s i o n should be w a r m e d up to o p e r a t i n g temperature. A s h o r t drive, a p p r o x i m a t e l y five t o t e n miles, w i t h frequent stops and s t a r t s w i l l produce n o r m a l o p e r a t i n g temperatures to the t r a n s m i s s i o n and engine. Check o i l level. A l l s h i f t s and k i c k d o w n s should occur w i t h i n t h e speed ranges given i n the S h i f t P a t t e r n S u m m a r y Chart. N O T E : A l l shift speeds may vary somewhat due to production tolerances, type of engine, rear axle ratios and tire sizes. A l l shifts, however, should be smooth, responsive and with no noticeable engine runaway. 6* OIL LEAKS Leaks Which may be Corrected with Transmission in Vehicle Transmission o u t p u t shaft rear bushing o i l seal. E x tension gasket, Speedometer d r i v e pinion assembly. Oil pan to filler tube connector. O i l pan t o transmission case. Regulator valve and torque converter cont r o l valve s p r i n g retainers. Regulator valve adjusti n g screw. Gearshift control cable seal r i n g and housing gasket. Governor, l i n , l u b r i c a t i o n , rear TORQUEFLITE TRANSMISSION — 21 clutch apply and t h r o t t l e (compensated) pressure check plug's I n t r a n s m i s s i o n case or support (pressure test h o l e s ) . N e u t r a l s t a r t i n g s w i t c h . Oil cooler connections. I f o i l is found inside the torque converter housing, determine w h e t h e r i t is A u t o m a t i c Transmission F l u i d or engine oil. Check t h e torque converter d r a i n p l u g f o r tightness. Leaks at these locations should be corrected, regardless o f how l i g h t . Correct b y t i g h t e n i n g loose screws or plugs. W h e r e t h i s does not remedy the s i t u a t i o n , replace t h e necessary gaskets, seals or plugs. " O " RING SEAL 4 Ifi CABLE GUIDE CABLE HOUSING / 4f ADJUSTMENT WHEEL 60x34 Leaks Requiring Removal of Transmission from Vehicle Fig. 12—Gearshift Control C a b l e a n d Adjustment Wheel Damaged transmission case. Damaged f r o n t o i l p u m p housing. F r o n t oil p u m p housing screws or damaged sealing washers. F r o n t oil p u m p housing seal (located i n the large f r o n t bore of the f r o n t o i l p u m p h o u s i n g ) . Torque converter. Leaks at these locations m a y be corrected b y t i g h t e n i n g loose bolts o r replacing damaged or f a u l t y parts. ( 5 ) Back the adjustment wheel off on cable housi n g (counter-clockwise) u n t i l only t w o or t h r e e threads are showing behind t h e wheel on t h e housing (Fig. 12). 7. GEARSHIFT CONTROL C A B L E ADJUSTMENT Gearshift Control Cable Adjustment (Fig. 11) (1) Engage the R (reverse) push b u t t o n and d r a i n a p p r o x i m a t e l y t w o quarts of fluid f r o m the t r a n s mission. ( 2 ) Remove t h e control cable a d j u s t m e n t wheel lock screw. (3) Remove the n e u t r a l s t a r t i n g switch, cupped washer and seal. ( 4 ) Have an assistant f i r m l y hold t h e R (reverse) b u t t o n u n t i l the transmsision end of cable adjustm e n t has been completed. N O T E : Check the wheel f o r housing. Remove any d i r t o r of t h e cable housing t h a t m a y the cable housing threads w i t h mission fluid. free t u r n i n g on t h e b u r r s i n the threads interfere. Lubricate a few drops o f trans- ( 6 ) Push the control cable housing into t h e case w i t h j u s t enough force to overcome the " O " r i n g f r i c t i o n and to b o t t o m the assembly. H o l d the cable assembly centered i n t h e bore, and apply an i n w a r d pressure of 2 to 3 pounds against the reverse detent. Rotate the a d j u s t i n g wheel t o j u s t contact the case. (7) T u r n t h e wheel clockwise j u s t enough t o make the n e x t adjustment hole i n the wheel line up w i t h t h e screw hole i n the case. (8) C o u n t i n g t h i s hole as "number one," continue t u r n i n g the wheel clockwise u n t i l the " f i f t h " hole lines up w i t h the screw hole i n the case. ( 9 ) I n s t a l l the lock screw, t i g h t e n 30 t o 50 i n c h pounds torque. THRO':;';.:: L I N K * 3c NEUTRAL STARTER / SWITCH CUPPED WASHER "O" RING CONTROL CABLE LOCK SCREW / ADJUSTMENT WHEEL Fig. 11 —Gearshift Control C a b l e Adjustment 60x32 SWITCH 56x228 Fig. 13—Neutral Starting Switch a n d Seal 22 — T O R Q U E F L I T E TRANSMISSION (10) I n s t a l l the n e u t r a l s t a r t i n g s w i t c h as outlined i n Paragraph 7. Refill the transmission w i t h automatic transmission fluid (Type " A " — S u f f i x "A") to proper level. 8. NEUTRAL STARTING SWITCH — INSTALLING A N D TESTING (Fig. 13) a. Installation and Tests I n s t a l l the concave s p r i n g (cupped) washer over the threads of t h e n e u t r a l s t a r t i n g s w i t c h so t h a t the concave (cupped) side of the washer Is towards t h e transmission case. I n s t a l l the " 0 " r i n g seal over the threads of the n e u t r a l s t a r t i n g s w i t c h and up against the washer. b. Switch Lever Alignment Check t h e location of the n e u t r a l s t a r t i n g s w i t c h lever Inside the transmission, as i l l u s t r a t e d i n F i g u r e 14. Fig. 15—Neutral Starting Switch ( 1 ) Machine 1/32" f r o m the seating surface of the switch, as I l l u s t r a t e d i n F i g u r e 15. ( 2 ) Clean the switch, replace the concave (cupped) washer and " 0 " r i n g seal, and Install the s w i t c h . ( 3 ) T i g h t e n the s w i t c h u n t i l the test l i g h t j u s t l i g h t s , t h e n t i g h t e n another % to / t u r n . l The lever should be dead center of the n e u t r a l starter s w i t c h m o u n t i n g hole ( w h e n the lever Is i n the n e u t r a l d e t e n t ) . Operation o f the s w i t c h is accomplished t h r o u g h the contacting plunger of the s w i t c h and t h e manual lever. I n instances w h e r e t h e lever Is not aligned properly, i t is recommended t h a t the lever be bent w i t h a screwdriver, or other suitable tool, to the proper location. W i t h the proper cable adjustment assured and the N ( n e u t r a l ) b u t t o n depressed, make certain t h a t t h e s w i t c h lever is properly aligned i n the center of the n e u t r a l s t a r t i n g s w i t c h hole ( F i g . 1 4 ) . W i t h the test leads connected to the b a t t e r y c u r r e n t and t e r m i n a l of the s w i t c h , screw the s w i t c h i n t o t h e transmission case u n t i l test l i g h t l i g h t s , t h e n t u r n the s w i t c h an additional % to / t u r n . l 2 Should the test l i g h t s t i l l f a i l to l i g h t and the seati n g surfaces have been cleaned to obtain a good ground, i t is recommended t h a t the f o l l o w i n g modification be performed to the n e u t r a l s t a r t i n g s w i t c h . 2 N O T E : The s w i t c h m u s t be t i g h t enough to prevent oil leakage. I f i t is not, add a t h i n washer and retighten. Refill the transmission to t h e proper level as outlined i n t h e L u b r i c a t i o n Group 0 . Check starter operation by pushing the various push buttons and r e t u r n i n g to neutral. CAUTION N e u t r a l s t a r t i n g s w i t c h failure may occur due to v e r y h i g h amperage c u r r e n t i o w l n g t h r o u g h the s w i t c h . T h i s results when a j u m p e r w i r e or remote control s t a r t i n g s w i t c h is i m p r o p e r l y connected, w h e n placed i n t h e c i r c u i t when t a k i n g compression readings. I t Is I m p o r t a n t t h a t the j u m p e r leads be connected to the b a t t e r y t e r m i n a l and to the starter s w i t c h t e r m i n a l ( t o w a r d s rear of c a r ) . 9. BAND ADIUSTMENTS a. Kickdown Band The k i c k d o w n band a d j u s t i n g screw is located on the left side of the transmission case ( F i g . 1 ) . ( 1 ) Loosen the locknut and back off 5 t u r n s and check the freeness of the a d j u s t i n g screw I n the transmission case. INCORRECT CORRECT 5 8 X 16 Fig. 14—Lever Alignment (2) U s i n g an inch-pound torque w r e n c h Tool C3380 w i t h adapter C-3583 or C-3705 (depending upon the accessibility due to type of engine and exhaust equipment) t i g h t e n the a d j u s t i n g screw to a reading of 47 to 50 inch-pounds torque. T O R Q U E F L I T E T R A N S M I S S I O N — 23 N O T E : T h i s w i l l be a t r u e torque of 70 t o 75 Inchpounds, w h i c h should be used I f t h e torque w r e n c h Tool C-3380 Is used w i t h o u t the adapter Tool C-3583 or Tool C-3705 (as m a y be done I f t h e adjustment Is made w i t h the transmission removed f r o m the vehicle). N O T E : A l l DeSoto models w i l l take a 2 t u r n adjustment. ( 3 ) Back off the a d j u s t i n g screw according to t h e specifications applicable t o t h e car model. ( Refer t o C h a r t on Specification page.) ( 4 ) H o l d i n g the a d j u s t i n g screw, t i g h t e n t h e lock nut 30 to 35 foot-pounds torque. b. Low-Reverse Band The low-reverse band a d j u s t i n g screw is located on the r i g h t side of t h e transmission case ( F i g . 2). (1) Loosen the lock n u t and back off 5 t u r n s and check f o r freeness o f t h e a d j u s t i n g screw I n t h e transmission case. (2) U s i n g w r e n c h Tool .C-3380 w i t h adapter Tool C-3583 or Tool C-3705, t i g h t e n t o a r e a d i n g of 47 t o 50 Inch-pounds torque. T h i s w i l l be a t r u e torque o f 70 t o 75 inch-pounds, w h i c h should be used i f t h e torque w r e n c h Tool C-3380 is used w i t h o u t the adapter Tool C-3584 (as m a y be done I f adjustment Is made w i t h the transmission removed f r o m the vehicle). (3) Back off the a d j u s t i n g screw exactly 214 t u r n s (all models). (4) H o l d i n g the a d j u s t i n g screw, t i g h t e n t h e lock nut to specifications 30 to 35 foot pounds torque. Fig. 17—Checking Line Pressure 10. THROTTLE LINKAGE ADJUSTMENTS (Refer to Fig. 1 6 ) ( 1 ) W i t h t h e engine a t operating temperature, carburetor off t h e fast Idle cam and transmission i n n e u t r a l , a d j u s t idle speed 475 to 500 r p m (use t a c h o m e t e r ) , ( r a m m a n i f o l d 725 t o 750 r p m ) . (2) Loosen t h e t h r o t t l e linkage adjustment lock n u t s o n b o t h the c a r b u r e t o r r o d and the transmission t h r o t t l e valve r o d . ( 3 ) I n s e r t a 3 / 1 6 " locating p i n r o d or d r i l l b i t i n t h e hole and t h e accelerator shaft bracket and i n t o the elongated hole of t h e t h r o t t l e lever. ( 4 ) W i t h t h e r o d i n p o s i t i o n , hold t h e t r a n s m i s sion t h r o t t l e valve lever a l l the w a y f o r w a r d (closed p o s i t i o n ) , and t i g h t e n transmission t o accelerator lever assembly r o d a d j u s t i n g l o c k n u t "A". ( 5 ) Remove t h e l o c a t i n g p i n or t h e r o d f r o m the accelerator lever, shaft and b r a c k e t assembly. (6) W i t h t h e carburetor t h r o t t l e lever off t h e fast idle cam and against t h e idle stop screw, move the r e a r h a l f of t h e c a r b u r e t o r t h r o t t l e r o d r e a r w a r d u n t i l the stop i n the t r a n s m i s s i o n is felt, and t i g h t e n locknut W\ H ADJUSTMENT LOCK NUT " A " 60x171 Fig. 16—Throttle Linkage Adjustments (7) T h e accelerator pedal should be a t an angle o f 114 degrees t o the horizontal. I f necessary t o correct, adjust t h e pedal angle b y r e m o v i n g the accelerator pedal end of the bellcrank t o pedal rod, and shorteni n g or l e n g t h e n i n g t h e r o d b y loosening t h e l o c k n u t at t h e swivel end and r o t a t i n g the swivel. Reinstall 24 — TORQUEFLITE TRANSMISSION ( 1 ) Remove t h e pipe p l u g f r o m the line pressure take-off hole located on t h e left side o f t h e t r a n s m i s sion case ( F i g . 1 ) . I n s t a l l t h e gauge, Tool C-2393 (300 p s i ) , a t t h i s p o i n t ( F i g . 1 7 ) . I f the line pressure is n o t correct, adjust as f o l l o w s : ( 2 ) Loosen the lock n u t on the r e g u l a t o r valve a d j u s t i n g screw ( F i g . 2 ) . ( 3 ) T u r n t h e a d j u s t i n g screw clockwise to i n crease or counter-clockwise t o decrease line pressure. L i n e pressure adjustment m u s t be made i n D (drive) position w i t h the engine at 1200 r p m , w i t h wheel t u r n i n g and transmission upshifted i n t o direct speed. A l l line pressure adjustments should f a l l w i t h i n the l i m i t s specified i n t h e table shown f o r a l l other push b u t t o n positions. Fig. 18—Checking Governor Pressure t h e r o d and t i g h t e n t h e l o c k n u t . Be sure the r o d is p r o p e r l y aligned t o prevent b i n d i n g . Poor engine performance due to the carburetor t h r o t t l e n o t openi n g f u l l y o r lack o f k i c k d o w n m a y r e s u l t i f accelerat o r pedal angle is incorrect. *For cars equipped w i t h " R a m M a n i f o l d " engines ref e r t o Service I n f o r m a t i o n a t t h e end o f t h i s section. 11. H Y D R A U L I C CONTROL PRESSURE C H E C K S A N D ADJUSTMENTS a. L i n e Pressure L i n e Pressure a d j u s t m e n t m u s t be made i n D ( d r i v e ) position w i t h engine a t 1200 r p m and wheels free t o t u r n . O i l m u s t be a t n o r m a l o p e r a t i n g t e m p e r a t u r e ( 1 5 0 ° F . to 2 0 0 ° F . ) . I f line pressure cannot be s a t i s f a c t o r i l y adjusted, check "Service Diagnosis C h a r t . " b. G o v e r n o r Pressure (see F i g . 18) ( 1 ) Remove t h e pipe p l u g f r o m the governor pressure take-off hole located on the lower left side o f the o u t p u t shaft support ( F i g . 1 ) . ( 2 ) I n s t a l l gauge, Tool C - 3 2 9 2 (100 p s i ) . N O T E : F o r cars equipped w i t h " R a m M a n i f o l d " engines, r e f e r t o Governor Pressure C h a r t under Service I n f o r m a t i o n , P a r a g r a p h — - . I f the governor pressure doesn't correspond to the car speed, check the line pressure and t h e "Service Diagnosis C h a r t . " c. Lubrication Pressure ( 1 ) Remove the oil cooler line and fitting f r o m the l u b r i c a t i o n pressure hole located on t h e left side o f t h e t r a n s m i s s i o n case ( F i g . 1 ) . *LINE P R E S S U R E CHART Push Button Position R N D (Shifted into Direct) 2 1 D Rear Wheels Free to _ Free t o Free t o Free • t o Free to N O T E : F o r cars equipped w i t h " R a m M a n i f o l d " engines I n f o r m a t i o n at t h e end o f t h i s section. Turn Turn Turn Turn Turn Engine Speed (rpm) Line Pressure (psi) 1600 1200 1200 1200 1200 3500 200-240 85-95 89 - 91 85-95 85-95 93 - 100 refer to L i n e Pressure C h a r t under Service TORQUEFLITE TRANSMISSION — 25 GOVERNOR P R E S S U R E CHART Push B u t t o n Position Rear Wheels Models 2 (Second) D (Drive) D (Drive Governor Pressure Car Speed PS-1, PS-3 Free t o T u r n Free t o T u r n Free to T u r n 15-20 37-44 61-68 ( 2 ) I n s t a l l gauge, Tool C-3292 (100 p s i ) . W i t h engine r u n n i n g at 800 r p m i n n e u t r a l , l u b r i c a t i o n pressure should be a p p r o x i m a t e l y 10 t o 30 psi. I f the pressure is e x t r e m e l y h i g h (above 50 psi) remove t h e Torque Converter Control Valve ( F i g . 2) and inspect f o r a d i r t y o r s t i c k i n g valve, or a dist o r t e d s p r i n g or regulator valve body. PC-1 PC-2 PC-3 PY-1 18-22 41-50 69-77 18-22 43-51 72-80 18-23 43-51 72-80 19-24 45-54 75-83 15 psi 50 psi 75 psi t h e n r e t u r n i t to closed t h r o t t l e . Compensated t h r o t t l e pressure should rise to approximately 80 to 90 psi and t h e n f a l l smoothly w i t h o u t hesitation and should always r e t u r n to a consistent reading at closed t h r o t t l e . F a i l u r e t o do t h i s indicates f a u l t y t h r o t t l e compensated valve or t h r o t t l e valve operation. The valve body assembly should t h e n be t h o r o u g h l y cleaned and these steps repeated before c o n t i n u i n g w i t h a t h r o t t l e pressure adjustment. d. Throttle Compensated Pressure ( 1 ) Raise vehicle off the turn). floor (wheels free to ( 2 ) I n s t a l l gauge, Tool C-3292 (100 psi) at t h r o t t l e compensated pressure take-off p l u g (refer t o F i g . 2 ) . ( 3 ) Disconnect the bell crank to t h r o t t l e linkage at the transmission. transmission ( 4 ) S t a r t engine and place the transmission i n " 2 " (second) position. ( 5 ) W h i l e h o l d i n g the transmission t h r o t t l e lever towards t h e closed t h r o t t l e position (against t h e i n t e r n a l stop) increase engine speed slowly (using accelerator pedal or suitable t h r o t t l e control fixture) to a p p r o x i m a t e l y 850 r p m t o obtain an u p s h i f t i n t o 2nd speed. A f t e r the s h i f t takes place, compensated t h r o t t l e pressure should read 10 t o 16 psi. ( 6 ) Move t h r o t t l e lever ( a t transmission) slowly towards f u l l t h r o t t l e . Compensated t h r o t t l e pressure should begin to rise a f t e r a p p r o x i m a t e l y 5 degrees movement of the t h r o t t l e lever. I f compensated t h r o t t l e pressure rises i m m e d i a t e l y w h e n the lever is moved, or i f the pressure is above 16 p s i b u t fails to rise a f t e r a p p r o x i m a t e l y 5 degrees movement, the t h r o t t l e pressure should be adjusted (refer to Paragraph E ) . ( 7 ) Before stopping t h e engine, advance the t h r o t t l e control lever ( a t transmission) slowly and e. Adjusting Compensated Throttle Pressure N O T E : Check the " T h r o t t l e Compensated Pressure" as o u t l i n e d i n P a r a g r a p h 10-D before m a k i n g t h i s a d j u s t m e n t . T h e n proceed as f o l l o w s : ( 1 ) I f t h e gauge r e a d i n g is outside t h e 10 t o 16 psi l i m i t s , adjust the t h r o t t l e valve l i n k (at t h e slotted lower end) F i g u r e 19 t o o b t a i n t h i s reading. U s u a l l y t o o b t a i n t h e smoothest 1-2 u p s h i f t , i t is recommended t h a t the pressure r e a d i n g be a t t h e h i g h l i m i t 16 psi. T i g h t e n t h e slotted l i n k clamp THROTTLE LINKAGE ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ M ! • , JMBSBEBI THROTTLE LEVER CONTROL CABLE \ 'i^^^^^^^^^^^^^^^^^^^^^^S^W MgB^ j^-rr^ " •; • Wm^ 60x1250 Fig. If—Throttle Compensated Pressure Adjustment 26 — TORQUEFLITE TRANSMISSION bolt. The transmission t h r o t t l e linkage a d j u s t m e n t is now correct, however, f o r a i d i n g i n f u t u r e adjustments, i t is recommended t h a t t h e t h r o t t l e valve stop screw be correctly set. ( 2 ) Push i n the " N " N e u t r a l b u t t o n . Block t h e carburetor choke i n t h e open position. (3) Drain the transmission fluid. Remove the transmission o i l pan. ( 4 ) A d j u s t the transmission t h r o t t l e valve stop screw so t h a t the end of the stop screw j u s t contacts the t h r o t t l e lever w i t h t h e accelerator pedal released. T i g h t e n the stop screw lock n u t . ( 5 ) I n s t a l l the transmission o i l pan u s i n g a new gasket. Refill the transmission to proper fluid level. SERVICING T H E G E A R SHIFT CONTROL UNIT 12. REMOVAL A N D INSTALLATION a. Removal (1) Disconnect one b a t t e r y cable. ( 2 ) Disconnect the back-up l i g h t s w i t c h w i r e connectors o f push b u t t o n control, and t h e i l l u m i n a t i n g lamp leads f r o m the rear of the i n s t r u m e n t panel. N O T E : On Imperial Models, in order to get access to the control unit from the rear of the instrument panel, the speedometer should be removed. Refer to the Electrical Group 8 of this Manual under "Instruments" for removal procedures. ( 3 ) Remove the screws of push b u t t o n face plate and remove the push buttons b y p u l l i n g i t off push b u t t o n slide. Remove the lamp bulb. ( 4 ) Remove t h e control housing s t u d n u t s t h a t are now accessible and remove t h e control and the cable f r o m the rear of t h e i n s t r u m e n t panel. ( 5 ) Remove t h e clip a t t a c h i n g control cable to the actuator and the screws holding t h e cable bracket to the control housing. ( 4 ) Connect the back-up l i g h t s w i t c h and the push b u t t o n i l l u m i n a t i n g l a m p wires. c. Back-Up Light Switch Replacement (when so equipped) Remove the gearshift control housing assembly. The back-up l i g h t s w i t c h is fastened to the control b y f o u r tabs. S t r a i g h t e n t h e tabs to remove s w i t c h . I n s t a l l the replacement s w i t c h and secure to control housing b y bending tabs. I n s t a l l the gearshift cont r o l housing and reconnect the s w i t c h and lamp wires. 13. PUSH BUTTON UNIT LAMP "BULB REPLACEMENT The push b u t t o n i l l u m i n a t i n g bulb can easily be replaced b y r e m o v i n g the push b u t t o n face plate and r e m o v i n g one or more of the center push buttons. 14. GEARSHIFT CONTROL CABLE (TRANSMISSION END) a. Removal (Fig. 20) (1) Raise the vehicle on a hoist and d r a i n t w o quarts ( a p p r o x i m a t e l y ) of o i l f r o m t h e transmission. CAUTION Oil may be hot! b. Installation (1) I n s e r t t h e end o f cable on t h e actuator and reassemble the clip. Place the cable bracket on the control u n i t and i n s t a l l the screws securely. (2) Carefully guide the u n i t i n t o p o s i t i o n f r o m the r e a r o f the i n s t r u m e n t panel and i n s t a l l t h e a t t a c h i n g stud nuts f r o m t h e f r o n t side of i n s t r u m e n t panel. ( 3 ) I n s t a l l the l a m p b u i l t i n the push b u t t o n cont r o l and r e i n s t a l l the push b u t t o n s onto t h e control actuator slides. Replace the face plate. ( 2 ) Engage the 1 (first) push b u t t o n . ( 3 ) Remove the control cable adjustment wheel lock screw. ( 4 ) Remove n e u t r a l s t a r t e r s w i t c h , cupped washer and seal. ( 5 ) W i t h a screwdriver, inserted t h r o u g h the s w i t c h hole, push g e n t l y against u p w a r d p r o j e c t i n g p o r t i o n o f the control cable adapter s p r i n g and p u l l o u t w a r d on cable and remove the cable assembly f r o m the transmission case. TORQUEFLITE TRANSMISSION — 27 THROTTLE C O N T R O L LEVER " ^ v i ^ H H H k ' - it. " ^ 'li^^^Kl^^^H xSi^iHBBBk'-' €^ ^^W^^^^^^B ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ M AA A M I t A i MANUAL CONTROL CABLE i^^if^^KS^fiBHHHr M^lf^^^HHHBS^Li ; 4 :; J slide the cable housing i n t o the case w i t h j u s t force t o overcome " 0 " r i n g f r i c t i o n and the lever assembly bottoms against t h e reverse P u l l out on the cable to make sure t h a t the s p r i n g has engaged t h e cable end. enough manual detent. adapter ( 4 ) H o l d t h e c o n t r o l cable assembly centered i n t h e bore o f the hole i n the transmission case and apply an i n w a r d pressure o f a p p r o x i m a t e l y 2 to 3 pounds against the reverse detent. Rotate the adj u s t i n g wheel clockwise u n t i l i t j u s t contacts t h e transmission case. ^^^^ 60x33 ( 5 ) T u r n the wheel clockwise j u s t enough to make the n e x t adjustment hole i n the wheel line up w i t h t h e screw hole i n t h e case. Fig. 20—Removal of the Gearshift Control Cable b. Installation (Fig. 12) ( 1 ) Have an assistant engage t h e R (reverse) b u t t o n and hold i t f i r m l y engaged u n t i l the cable attachment operation is completed. ( 2 ) Back the adjustment wheel off on the cable housing (counter-clockwise) u n t i l only t w o or three threads are s h o w i n g behind the wheel on the guide. ( 3 ) L u b r i c a t e t h e cable housing w i t h t r a n s m i s sion fluid, insert t h e cable w i r e i n the adapter, and ( 8 ) C o u n t i n g t h i s hole as "number one," continue t u r n i n g the wheel clockwise u n t i l the f i f t h hole lines up w i t h the screw hole i n the case. (7) I n s t a l l t h e lock screw, t i g h t e n 30 t o 50 i n c h pounds torque. ( 8 ) I n s t a l l the n e u t r a l s t a r t i n g s w i t c h as outlined i n P a r a g r a p h 8. Refill the transmission w i t h A u t o m a t i c Transmission F l u i d Type " A " , Suffix " A " to proper level. SERVICING O F COMPONENT PARTS WITH TRANSMISSION IN V E H I C L E t h e speedometer pinion and sleeve assembly t h e transmission extension. Refer to chart. 15. SPEEDOMETER PINION a. Removal Disconnect the speedometer cable and the housing f r o m t h e drive p i n i o n and sleeve assembly. Remove b. Installation I n s t a l l the speedometer p i n i o n and sleeve assembly S P E E D O M E T E R PINION USAGE CHART (TorqueFlite Transmission) T i r e Size A x l e Ratio—Speedometer P i n i o n Operation I n d i c a t i n g N u m b e r o f P i n i o n Gear Teeth and Color ^ A x l e Ratios ( A l l Models) 2.93:1 *3.31:1 **3.54:1 8.00 x 14 8.50 x 14 *9.00xl4 17 - Red 17 - Red 19 - L . Purple 20 - L . Blue 19 - L. Purple —— 21 - Yellow 20 - L . Blue ^ • S t a n d a r d on C-300F only. **DeSoto Cars o n l y . ^ from ^ **3.73:1 21-Yellow 21 - Yellow 28 — TORQUEFLITE TRANSMISSION In the transmission extension and t i g h t e n 40 to 45 foot-pounds torque. 16. NEUTRAL STARTING SWITCH a. Removal D r a i n a p p r o x i m a t e l y three quarts of fluid f r o m the transmission b y disconnecting filler tube at o i l pan connector ( m a y be necessary to loosen the filler tube support bracket s c r e w ) . Remove w i r e at s w i t c h t h e remove s w i t c h . b. Installation W i t h the assistance of the r e t r i e v i n g tool, place valve i n position and seat p r o p e r l y i n regulator valve body. I n s t a l l torque converter control valve spring, gasket and retainer and t i g h t e n to 40 foot-pounds torque. 19. OIL PAN a. Removal Refer to P a r a g r a p h 8. The o i l pan m a y be removed a f t e r disconnecting the filler tube and d r a i n i n g the o i l f r o m the transmission. Remove screws and drop pan. 17. REGULATOR V A L V E ASSEMBLY b. Installation a. Removal U s i n g a new gasket, i n s t a l l the o i l pan and t i g h t e n bolts 12 to 17 foot-pounds torque. Reconnect filler tube and refill transmission w i t h A u t o m a t i c Transmission F l u i d (Type " A " — Suffix " A " ) . Refer t o L u b r i c a t i o n Group D . b. Installation Remove the transmission r e g u l a t o r valve s p r i n g retainer, the gasket, cup, s p r i n g and sleeve. U s i n g a mechanical r e t r i e v e r or a piece of welding r o d ( 5 / 3 2 " ) inserted i n end of valve, remove valve ( F i g . 21). 20. V A L V E BODY AND TRANSFER PLATE ASSEMBLY O R A C C U M U L A T O R PISTON b. Installation W i t h the assistance o f the r e t r i e v i n g tool, place t h e valve i n position and seat p r o p e r l y i n regulator valve body. I n s t a l l r e g u l a t o r valve spring, sleeve, cup, gasket and retainer and t i g h t e n t o 50 foot-pounds torque. Check the line pressure and adjust i f necessary. 18. TORQUE CONVERTER CONTROL VALVE ASSEMBLY a. Removal Remove t h e torque converter control valve s p r i n g retainer, gasket and s p r i n g . U s i n g a mechanical ret r i e v e r or a piece o f w e l d i n g r o d ( % " ) inserted i n end o f valve, remove valve. a. Removal (1) Engage R (reverse) push b u t t o n and remove oil pan and clean off the d i r t around t h e t h r o t t l e shaft. ( 2 ) Disconnect t h r o t t l e linkage t h r o t t l e valve lever and washer. and remove ( 3 ) Remove the manual control lever to the cable adapter stud n u t . ( 4 ) Remove the o i l strainer and t r a n s f e r plate bolts and lower valve body and t r a n s f e r plate assemb l y . Be careful not to lose the accumulator piston s p r i n g and cable adapter. b. Installation (1) Clean the m a t i n g surfaces and check f o r b u r r s on b o t h the transmission case and t h e valve body t r a n s f e r plate. ( 2 ) Place manual lever i n the reverse position (all the way i n ) . TRANSMISSION KFGUi A ' .> VAIVE-^ ^ PIECE O F WELDING RO» > • *. f 53x55 A Fig. 21—Removing Regulator V a l v e ( 3 ) I n s t a l l the accumulator piston s p r i n g i n t o recess i n top of the t r a n s f e r plate and carefully guide t h e s p r i n g up i n t o t h e accumulator p i s t o n as the t r a n s f e r plate and valve body are placed up against t h e transmission case. A t the same t i m e index the cable adapter stud i n t o the manual control lever. I n s t a l l the t r a n s f e r plate bolts and washers (leaving f o u r holes vacant to a t t a c h o i l s t r a i n e r ) d r a w d o w n evenly and t i g h t e n 14 to 16 foot-pounds torque. I n s t a l l and t i g h t e n the stud n u t securely. I n s t a l l o i l TORQUEFLITE s t r a i n e r and t i g h t e n the r e m a i n i n g bolts 14 to 16 foot-pounds torque. TRANSMISSION — 29 TOOL ( 4 ) I n s t a l l t h e t h r o t t l e valve lever and washer and reconnect the t h r o t t l e linkage. ( 5 ) I n s t a l l o i l pan and refill the transmission w i t h A u t o m a t i c Transmission F l u i d ( T y p e " A " — Suffix " A " ) to proper level. • ( 6 ) A d j u s t the t h r o t t l e linkage. 21. I I C 1 D O W N PISTON - 4-' 57x98 Fig. 23—Removing Handbrake Drum a n d a. Removal Flange Assembly ( 1 ) Remove oil pan and valve body assembly. ( 2 ) Loosen the k i c k d o w n band a d j u s t i n g screw lock n u t and back out screw sufficiently to remove anchor and s t r u t . ( 3 ) I n s t a l l compressing Tool C-3529 or C-3289 (modified), apply sufficient pressure on k i c k d o w n piston r o d guide and remove snap r i n g . ( 4 ) Remove tool, piston r o d guide, piston s p r i n g and r o d . U s i n g C-484 pliers, remove the k i c k d o w n piston f r o m transmission case ( F i g . 2 2 ) . Refer to K i c k d o w n Piston Inspection, P a r a g r a p h 82. b. Installation case and place k i c k d o w n piston r o d guide over s p r i n g , compress s p r i n g and i n s t a l l snap r i n g . Remove compressing tool. ( 4 ) Place the k i c k d o w n band s t r u t i n t o position i n the band and lever and compress band end sufficiently t o i n s t a l l the anchor over t h e a d j u s t i n g screw. ( 5 ) A d j u s t k i c k d o w n band as outlined under "Maintenance, A d j u s t m e n t s and Tests," P a r a g r a p h 9A). ( 6 ) I n s t a l l valve body assembly and o i l pan. ( 1 ) L u b r i c a t e the piston seal r i n g s and place pist o n i n position, compress outer r i n g and s t a r t assemb l y i n t o case. W i t h t h e piston properly centered so as not to damage r i n g s , tap l i g h t l y u n t i l piston bottoms i n case. ( 2 ) Place the k i c k d o w n piston r o d assembly i n piston and slide piston s p r i n g over k i c k d o w n piston rod. ( 3 ) I n s t a l l Tool C-3529 or C-3289 (Modified) on 22. OUTPUT SHAFT REAR OIL SEAL a. Removal ( 1 ) Disconnect t h e f r o n t universal j o i n t . ( 2 ) A p p l y p a r k i n g brake or use wrench Tool C3281 ( F i g . 23) and remove flange nut. Release the p a r k i n g brake ( i f applied) and remove the p a r k i n g brake flange and d r u m assembly. Use puller Tool C-452, i f necessary. ^TOOL "JCKDOWN •WO PISTON REAR TOC EXTENSION "OOL -4 " * ..C6x661 A Fig. 22—Removal a n d Installation of Kickdown Piston 60x30 Fig. 24—Removing Output Shaft Rear Bearing Oil Seal 30 — TORQUEFLITE TRANSMISSION ( 3 ) Remove the brake s p r i n g and grease shield. support grease shield ( 4 ) I f screwdriver or sharp i n s t r u m e n t is used i n p e r f o r m i n g t h i s operation, care m u s t be exercised not to damage t h e neoprene sealing surface at bott o m of the shield. I n s t a l l puller, Tool C-3690 and remove t h e transmission o u t p u t shaft rear b u s h i n g o i l seal ( F i g . 2 4 ) . b. Installation REAR EXTENSION^ ( 1 ) U s i n g d r i v e r , Tool C-3691, i n s t a l l the o u t p u t shaft rear o i l seal ( w i t h m e t a l p o r t i o n of seal f a c i n g down i n housing bore) u n t i l tool bottoms on extension, as shown i n F i g u r e 25. 60x29 ( 2 ) I n s t a l l brake support grease shield on extension housing. I n d e n t on grease shield m u s t m a t c h groove i n extension f o r correct positioning. Also, shield m u s t be located on extension f a r enough to p e r m i t i n s t a l l a t i o n of s p r i n g . I n s t a l l grease shield s p r i n g w i t h opening i n s p r i n g t o w a r d a d j u s t i n g sleeve. ( 3 ) Reinstall p a r k i n g b r a k e flange and d r u m assembly, washer (convex side t o w a r d n u t ) and n u t . A p p l y p a r k i n g brake or use wrench, Tool C-3281, and t i g h t e n n u t to 175. foot-pounds torque-. ( 4 ) Reconnect f r o n t universal j o i n t and t i g h t e n bolts 33 to 37 foot-pounds torque. Check the t r a n s mission fluid level and refill i f necessary. 23. EXTENSION HOUSING OR BUSHING .. a. Removal ( 1 ) D r a i n a p p r o x i m a t e l y t w o quarts o f fluid f r o m the transmission. ( 2 ) Disconnect f r o n t universal j o i n t . St " REAR EXTENSION 60x31 Fig. 25—Installing Output Shaft Rear Bearing Oil Seal Fig. 26—Removing Output Shaft Rear Bushing ( 3 ) Remove the propeller shaft flange and p a r k i n g brake d r u m assembly, using puller Tool C-452, i f necessary. ( 4 ) Disconnect p a r k i n g brake and speedometer cables. Remove the speedometer drive pinion sleeve assembly. I f the o u t p u t shaft rear bushing is to be replaced, the o i l seal m u s t be removed a t t h i s p o i n t ; otherwise, step N o . 5 should not be performed. ( 5 ) I n s t a l l puller, Tool C-3690, and remove o u t p u t shaft o i l seal. ( 6 ) I n s t a l l the engine support fixture, Tool C3487. Refer to Paragraph 26, Step N o . 10. A d j u s t fixture to support t h e w e i g h t of the engine. Raise engine s l i g h t l y , remove the crossmember t o t o r s i o n bar bracket bolts. (Rear m o t o r support and bracket m a y be left on transmission extension f o r t r a n s m i s sion repairs or t r a n s f e r r e d to new parts after extension housing has been removed). Remove the t w o screws h o l d i n g the extension housing to support plate and i n s t a l l guide studs, Tool C-3283 and t h e n remove the balance of t h e screws. Due to interference at the insulator, i t w i l l be necessary to back the lower screw out as the extension is removed. Do not allow the o u t p u t shaft support to slide away f r o m transmission case w h i l e extension is being removed. Remove extension and p a r k i n g brake as one assemb l y . I f care is used, i t is not necessary t o remove t h e p a r k i n g brake support and shoe assemblies f r o m extension to replace the o u t p u t shaft rear b u s h i n g . ( 7 ) W i t h the larger end o f the extension housing on a flat surface, use bushing r e m o v i n g d r i v e r , Tool TORQUEFLITE TRANSMISSION —31 Fig, 27—Installing Output Shaft Rear Bushing Fig. 29—Removal a n d Installation of Governor V a l v e Shaft a n d V a l v e C-3689, and d r i v e b u s h i n g out of housing. (Refer t o Fig. 26). b. Installation ( 1 ) Place a new b u s h i n g on d r i v e burnisher, Tool C-3692, w i t h l u b r i c a t i o n hole i n bushing t o w a r d end of the tool. A l i g n the hole i n b u s h i n g w i t h l u b r i cation hole i n the housing and d r i v e the b u s h i n g into housing u n t i l the tool bottoms (refer to F i g . 2 7 ) . ( 2 ) W h i l e h o l d i n g the screw of tool ( F i g . 28) to prevent t u r n i n g , t u r n n u t on tool u n t i l b u r n i s h e r is pulled back out of b u s h i n g to c o r r e c t l y size bushing. Recheck i n d e x i n g of l u b r i c a t i o n hole i n b u s h i n g w i t h housing. over guide studs i n t r a n s m i s s i o n case up against outp u t shaft support. Do n o t use sealing m a t e r i a l on gasket. ( 5 ) S t a r t extension to case screws. Due to i n t e r ference of the m o u n t i n g insulator, i t w i l l be necessary to s t a r t t h e b o t t o m extension housing t o case screw as the extension is pushed i n t o position against the support. Remove the guide studs and install t h e r e m a i n i n g screws and t i g h t e n 25 to 30 foot-pounds torque. T u r n o u t p u t shaft to make sure i t t u r n s freely. ( 6 ) L o w e r the t r a n s m i s s i o n and install crossmember bolts. Remove engine support fixture. ( 3 ) Use d r i v e r , Tool C-3691, i n s t a l l o u t p u t shaft oil seal ( w i t h m e t a l p o r t i o n of seal f a c i n g down i n housing bore) u n t i l tool bottoms on extension. ( 7 ) Reconnect p a r k i n g brake cable. I n s t a l l speedometer p i n i o n sleeve and t i g h t e n 40 to 45 foot-pounds torque and connect cable. ( 4 ) U s i n g a new gasket, slide extension assembly ( 8 ) I n s t a l l the propeller shaft flange and d r u m assembly, washer and n u t and t i g h t e n to 175 footpounds torque. Connect f r o n t universal j o i n t and t i g h t e n n u t s 33 to 37 foot-pounds torque. ( 9 ) Refill t h e transmission to proper fluid level. 24. GOVERNOR a. Removal ( 1 ) Remove extension assembly as described i n previous section. ( 2 ) Remove governor valve shaft snap r i n g f r o m the w e i g h t end of the shaft and remove the shaft and valve ( F i g . 2 9 ) . Fig. 28—Burnishing Output Shaft Bushing ( 3 ) U s i n g Tool C-3229, remove the governor w e i g h t assembly snap r i n g (large) and remove governor w e i g h t . T h e p r i m a r y cause of governor opera t i n g failures is due to i m p r o p e r operation o f the 32 — TORQUEFLITE TRANSMISSION governor valve w h i c h m a y be s t i c k i n g i n housing or t r a v e l restricted b y chips or other f o r e i g n m a t t e r . I f inspection reveals necessity f o r f u r t h e r governor servicing, t h e n remove t h e governor support l o c a t i n g screw and remove governor and support assembly f r o m rear oil pump housing ( F i g . 3 0 ) . N o r m a l servicing does not require removal of the governor body f r o m the governor support. I f condition warr a n t s removal of governor body f r o m governor supp o r t , do not t i g h t e n governor body screws w h e n reassembling u n t i l governor body support is located on o u t p u t shaft. b. Installation ( 1 ) Slide the governor body and support assemb l y into oil pump housing. I t w i l l be necessary to compress seal r i n g s on governor support. D o n o t force. ( 2 ) A l i g n the locating hole i n o u t p u t shaft w i t h hole i n governor support, i n s t a l l set screw and t i g h t en to 60-80 inch-pounds. I f the governor body had been removed f r o m support, the f o u r governor body screws should now be t i g h t e n e d . ( 3 ) Place the governor w e i g h t assembly (seconda r y w e i g h t snap r i n g f a c i n g o u t ) i n t o governor body, use pliers, Tool C-3229, and i n s t a l l snap r i n g , convex side f a c i n g out. ( 4 ) Slide the governor valve over governor valve shaft, insert the shaft and w e i g h t i n t o governor w e i g h t and install snap r i n g securely ( F i g . 3 1 ) . Check operation of governor w e i g h t assembly and valve b y t u r n i n g o u t p u t shaft. B o t h should f a l l freely i n body. ( 5 ) I n s t a l l the transmission extension. SNAP RINGS 57x37 Fig. 31—Positioning Governor V a l v e Shaft Snap Rings in Grooves 25. BEAR OIL PUMP a. Removal ( 1 ) Remove the transmission extension and governor assembly as outlined i n Paragraph 24. ( 2 ) Remove oil pump housing to o u t p u t shaft supp o r t screws and install guide studs, Tool C-3288. Remove pump housing and gear f r o m o u t p u t shaft. Use dye (or other suitable m a t e r i a l ) to m a r k pump gears i n r e l a t i o n to t h e p u m p housing face. N O T E : Do not use scribe. O i l pump pinion is keyed to o u t p u t shaft pinion by a s m a l l ball. Use care w h e n r e m o v i n g pinion so as not to lose ball. b. Installation ( 1 ) Slide the governor support and body assemb l y i n t o position i n rear o i l p u m p housing. Compress the seal r i n g s as support enters o i l pump housing. D o not force. ( 2 ) Place t h e oil p u m p p i n i o n ball i n ball pocket i n o u t p u t shaft. Place the rear o i l pump p i n i o n (as m a r k e d w h e n removed) over o u t p u t shaft and i n t o position a l i g n i n g k e y w a y i n the pinion w i t h the ball i n shaft. ( 3 ) W i t h the rear oil p u m p gear properly positioned i n p u m p housing (check m a r k i n g ) , slide the rear o i l pump and governor assemblies over o u t p u t shaft and guide studs into position against support. There are t w o e x t r a holes i n housing w h i c h are used f o r vents. Make definitely sure y o u do n o t a t t e m p t t o i n s t a l l screw i n these holes. ( 4 ) Remove t h e guide studs, i n s t a l l o i l p u m p housi n g t o o u t p u t shaft support screws and t i g h t e n 10 t o 12 foot-pounds torque. T u r n o u t p u t shaft to make sure p u m p gears are free to rotate. I f not, remove p u m p to determine cause of b i n d i n g . ( 5 ) A l i g n locating hole i n o u t p u t shaft to locating screw hole i n governor s u p p o r t ; install locating screw and t i g h t e n . Fig. 30—Removal a n d installation of Governor Body a n d Support A s s e m b l y Check operation of the governor w e i g h t assembly and valve by t u r n i n g o u t p u t shaft. B o t h w e i g h t s should f a l l freely i n body. ( 6 ) I n s t a l l t h e transmission extension. TORQUEFLITE TRANSMISSION — 33 DISASSEMBLY, INSPECTION AND A S S E M B L Y OF COMPONENT PARTS 26. R E M O V A L O F TRANSMISSION F R O M VEHICLE (1) Disconnect b a t t e r y . (2) Engage t h e R (reverse) push b u t t o n . I t w i l l be necessary f o r the control cable adapter to be i n t h i s position ( f o r accessibility) when r e m o v i n g cable f r o m transmission. (3) D r a i n transmission and torque converter. W h e n the fluid has drained, replace torque conv e r t e r d r a i n p l u g and t i g h t e n . (4) Disconnect the f r o n t universal fasten the propeller shaft out of t h e w a y . joint and (5) Remove the brake a d j u s t i n g screw cover plate and loosen cable clamp bolt on p a r k i n g brake support. Disengage the ball end of t h e cable f r o m the opera t i n g lever and remove cable f r o m brake support. (6) Disconnect the speedometer cable and housi n g at transmission extension, n e u t r a l s t a r t e r s w i t c h w i r e and t h r o t t l e control linkage f r o m t h r o t t l e lever a t transmission. ( 7 ) Remove the push b u t t o n control cable adjustment wheel locking screw and the n e u t r a l s t a r t e r switch. ( 8 ) I n s e r t a screwdriver t h r o u g h t h e n e u t r a l s w i t c h hole, contact t h e top end of the cable-toadapter locking s p r i n g and while releasing the lock, p u l l o u t the cable ( F i g . 2 0 ) . (9) Disconnect transmission. the o i l cooling lines f r o m the (10) I n s t a l l t h e engine support fixture, Tool C3487. (On some models i t m a y be necessary to remove the s t a r t e r to provide clearance f o r fixture support ends.) I n s e r t hooks o f fixture firmly i n t o holes i n side of f r a m e member w i t h support ends up against the underside of o i l pan flange. (11) A d j u s t the fixture to support the w e i g h t of the engine. Raise engine s l i g h t l y , remove crossmember to t o r s i o n bar bracket bolts. CAUTION W h e n using fixture, Tool C-3487, do not lower engine more t h a n three inches f r o m floor pan to avoid disr u p t i n g t h e set position of the w a t e r hose and other engine attachments. Rear m o t o r support and bracket m a y be l e f t on t r a n s m i s s i o n extension d u r i n g transmission repairs. W h e n i t is necessary t o replace the extension housing, i t can be t r a n s f e r r e d on the bench. (12) Remove the t w o transmission case to torque converter housing screws and lockwashers f r o m the r i g h t side and install guide studs, Tool C-3276. W i t h the t r a n s m i s s i o n supported, remove t h e t w o transmission case to torque converter housing screws and lockwashers f r o m left side. Slide the transmission s t r a i g h t back to avoid damage to the f r o n t oil p u m p d r i v i n g sleeve, t h e n lower to the floor. 27. FLUSHING TORQUE CONVERTER I n the event t h a t any p a r t of the transmission has failed, i t w i l l be necessary to flush t h e torque conv e r t e r to insure t h a t fine metallic particles are n o t later t r a n s f e r r e d into t h e transmission controls. (1) U s i n g a long spouted can, slowly pour 2 quarts of new, clean kerosene i n t o the torque converter hub. Before t h i s can be done, i t w i l l be necessary to reach i n t o t h e torque converter w i t h a screwdriver and t u r n the torque converter stator h u b counterclockwise (large splined h u b ) b y l i f t i n g on t h e r i g h t side of the spline so t h a t one of the % " x % rectangular slots on t h i s assembly is visible at the top. Since there is a second slot d i r e c t l y below, an adequate opening is provided f o r t h e kerosene ( i f poured s l o w l y ) . A f t e r the kerosene is i n the torque converter, close the hub opening w i t h m a s k i n g tape. / / (2) Disconnect the coil w i r e to prevent the engine f r o m s t a r t i n g and r o t a t e the converter a p p r o x i m a t e l y 10 seconds by c r a n k i n g the engine w i t h the starter. (3) D r a i n the converter by r e m o v i n g t h e d r a i n p l u g and m a s k i n g tape. Realign the s t a t o r h u b and repeat t h e above procedure at least once (or i f there is excessive contamination, u n t i l t h e kerosene drained out is clear). To complete t h e flushing procedure, r o t a t e the converter w i t h the d r a i n p l u g removed. T h i s w i l l remove any residual solvent and trapped d i r t . Reinstall the d r a i n p l u g or plugs. 28. PRECAUTIONS TO OBSERVE DURING DISASSEMBLY The f o l l o w i n g precautions should be observed d u r i n g 34 —TORQUEFLITE TRANSMISSION disassembly of t h e t r a n s m i s s i o n : Cleanliness t h r o u g h the entire disassembly and assembly cannot be overemphasized. U n i t should be t h o r o u g h l y cleaned w h e n removed f r o m the vehicle, preferably b y steam. W h e n disassembling, each p a r t should be placed i n a suitable solvent, washed, t h e n dried b y compressed air. Do not wipe parts w i t h shop towels. A l l of the m a t i n g surfaces i n the transmission are accurately machined; therefore, careful h a n d l i n g of parts m u s t be exercised to avoid nicks or b u r r s . The use o f crocus cloth is permissible where necessary, p r o v i d i n g i t is used carefully. W h e n used on valves, use extreme care so not to r o u n d off the sharp edges. T h e sharp edge p o r t i o n is v i t a l l y i m p o r t a n t t o t h i s type valve. Sharp edges prevent d i r t and foreign m a t t e r f r o m g e t t i n g between t h e valve and body, thus reducing the possibilities of s t i c k i n g . W h e n a vehicle has accumulated considerable mileage and i t becomes necessary to r e c o n d i t i o n the transmission, i n s t a l l new seal r i n g s on p a r t s r e q u i r i n g t h e i r usage. The f o l l o w i n g procedures are based on the assumption t h a t the u n i t has been removed f r o m vehicle and prepared f o r disassembly. 29. OIL P A N REMOVAL A t t a c h stand, Tool C-3280, t o the t r a n s m i s s i o n and i n v e r t , as shown i n F i g u r e 32. Remove t h e o i l pan. 30. V A L V E BODY A N D TRANSFER PLATE— REMOVAL (1) Remove washer. the t h r o t t l e valve lever (2) Remove t h e cable adapter stud n u t . (3) Remove the o i l strainer. and flat (4) Remove a t t a c h m e n t n u t f r o m cable adapter stud at manual lever and remove the adapter. 4M 60x10 Fig. 33—Removal of the V a l v e Body Assembly 31. CHECKING FRONT C L U T C H END C L E A R A N C E P r i o r to removal o f propeller shaft flange and d r u m assembly, measure the end clearance of f r o n t clutch piston r e t a i n e r assembly. (1) I n s t a l l dial indicator, Tool C-3339, as shown i n F i g u r e 34. ( 2 ) To make t h i s measurement, p r y f r o n t clutch f o r w a r d b y carefully i n s e r t i n g screwdriver between the f r o n t and rear clutch piston retainers. ( 3 ) Remove screwdriver and w i t h the dial i n d i cator p o i n t contacting edge of f r o n t clutch retainer, set dial indicator to zero. ( 4 ) P r y t h e f r o n t clutch piston retainer assembly r e a r w a r d against rear clutch, remove screwdriver and take indicator reading. T h i s clearance should be f r o m .020" to .050". I f the clearance exceeds t h e specified l i m i t , p a r t i c u l a r a t t e n t i o n should be paid ( 5 ) Remove the t r a n s f e r plate bolts and remove the valve body assembly f r o m the t r a n s m i s s i o n ( F i g . 3 3 ) . M a t i n g surfaces are m a c h i n e d : Use ext r e m e care so as not to damage these surfaces. Place valve body i n stand, Tool C-3528. (6) mm WfWm FRONT CLUTCH PISTON RETAINER ASSEMBLY FOOL I mi (: Remove the accumulator piston s p r i n g . REAR CLUTCH P I S T O N RETAINER ASSEMBLY' -STAND-TOOL 56x600 Fig. 32—Transmission A s s e m b l y Inverted in Stand \ 1 • . 56x605 A Fig. 34—Checking Front Clutch Piston Retainer Assembly End C l e a r a n c e TORQUEFLITE TRANSMISSION — 35 EXTENSION GOVERNOR BODY-"-^ GOVERNOR VALVE SHAFT BI" —-Hj X if GOVERNOR • ; " Fig. ••' 35—Removal 56x606 A of Extension 32. PARKING BRAKE ASSEMBLY — REMOVAL ( 1 ) Remove the transmission flange n u t and washer. Use wrench, Tool C-3281, to hold t h e brake d r u m and flange assembly, see F i g u r e 23. ( 2 ) A t t a c h puller, Tool C-452, i f necessary, and remove the propeller shaft flange and t h e d r u m assembly. Inspect l i n i n g contact surfaces on brake d r u m assembly f o r scoring and inspect the brake l i n i n g f o r wear. brake VALVE \ 56x608 A Fig. 37—Removal a n d Installation of Governor to t h e condition of the i n p u t shaft t h r u s t washer w h e n disassembling transmission and a t h r u s t washer o f the correct thickness selected d u r i n g assembly. ( 3 ) Remove t h e transmission grease shield spring. >u - • '? support extension. I f a screwdriver or sharp i n s t r u m e n t is used i n r e m o v a l of t h i s shield, care m u s t be exercised not to damage the neoprene sealing surface at b o t t o m o f shield. N o t e the indent on the grease shield f o r correct p o s i t i o n i n g on the extension. ( 6 ) U s i n g a suitable d r i f t , remove p i n w h i c h attaches the brake shoe anchor i n t h e extension housi n g . Slide the balance of p a r k i n g brake assembly i n t a c t f r o m extension housing. Inspect the spacer (neoprene) on back of support plate f o r deteriorat i o n and note the steel sleeve used between neoprene space and extension. 33. EXTENSION HOUSING — ( 4 ) Remove C type retainer. ( 5 ) Remove the brake support grease shield f r o m Valve a n d Shaft REMOVAL ( 1 ) Remove the speedometer d r i v e pinion and sleeve assembly. N y l o n gear can be easily damaged mw mm SNAP GOVERNOR SUPPORT RING ill •.V-\\ n SNAP RING r'. w , in k GOVERNOR^ LOCATING SCREW 56x607A Fig. 36—Removal a n d Installation of Governor V a l v e Shaft Snap Ring it ^ xm - A 4 in / • 1 56x609 A Fig. 38—Removal a n d Installation of Governor Weight Assembly 36 — TORQUEFLITE TRANSMISSION I f extension Is removed w i t h o u t first r e m o v i n g the speedometer d r i v e pinion and sleeve assembly. ^^^^^ UNIT N O . 1 ( 2 ) Inspect the o u t p u t shaft rear o i l seal and remove ( i f necessary) using p u l l e r Tool C-3690. I f the transmission extension housing o i l seal or b u s h i n g are to be replaced, the seal m u s t be removed a t t h i s t i m e before extension housing is removed f r o m transmission case. ( 3 ) Remove t h e transmission extension t o case bolts and lockwashers. I n s t a l l guide studs, Tool C3283 and remove extension f r o m o u t p u t shaft supp o r t assembly b y t a p p i n g housing l i g h t l y w i t h a soft hammer. H o u s i n g m a y be separated b y using a p r y bar against support screw, as shown i n F i g u r e 35. Remove t h e extension gasket. 34. GOVERNOR A N D REAR OIL PUMP HOUSING— REMOVAL ( 1 ) U s i n g a small screwdriver, remove the governor valve shaft snap r i n g f r o m t h e w e i g h t assembly end, as shown i n F i g u r e 36. (2) 37). Remove governor valve shaft and valve ( F i g . ( 3 ) U s i n g pliers, Tool C-3229, remove governor snap r i n g (large) as shown i n F i g u r e 38 and remove governor w e i g h t assembly. ( 4 ) Remove t h e governor locating screw f r o m the governor support. ( 5 ) Remove the oil p u m p housing, gear, p i n i o n and governor assembly f r o m o u t p u t shaft. Use dye and m a r k the face o f the p u m p gear i n r e l a t i o n to) p u m p housing, f o r reassembly purposes. D O N O T S C R I B E . Remove o i l p u m p pinion ball. 35. OUTPUT SHAFT SUPPORT — REMOVAL (1) Slide t h e o u t p u t shaft rear support assembly 56x613 Fig. 40—Removal a n d Installation of Unit No. 1 and gasket f r o m transmission case, as shown i n F i g ure 39. I f the rear support is stuck to the transmission case, i t can be loosened b y t a p p i n g l i g h t l y w i t h a soft hammer. ( 2 ) Remove the t h r u s t washer f r o m f r o n t end of support plate or output shaft. ( 3 ) Remove the guide studs, Tool C-3283, f r o m transmission case. 36. REMOVING POWER TRAIN UNIT N O . 1 (OUTPUT SHAFT, KICKDOWN PLANET PINION CARRIER A N D INTERMEDIATE SHAFT ASSEMBLIES) — REMOVAL Remove b y sliding t h e u n i t out rear of the transmission case, F i g u r e 40. Support u n i t as m u c h as possible, w h e n removing, to prevent damage to seal r i n g s on intermediate shaft. 37. REMOVING POWER UNIT N O . 2 (SUN GEAR, REVERSE PLANET PINION CARRIER, OVERRUNNING CLUTCH A N D REAR CLUTCH ASSEMBLIES) — REMOVAL (1) Loosen the lock nuts on low-reverse and k i c k down band a d j u s t i n g screws and back a d j u s t i n g screws out 2 to 3 t u r n s . (2) Remove the three intermediate support loc a t i n g bolts and lockwashers ( t w o outside of case and one inside). W h e n r e m o v i n g the u n i t , i d e n t i f y 1HM • i 56x612 A 56x614 A Fig. 39—Removal a n d Installation of Output Shaft Fig. 4 1 — R e m o v a l a n d Installation of Intermediate Support Support Locating Screw TORQUEFLITE TRANSMISSION — 37 UNIT N O . 2 56x617A 56x615 A Fig. 42—Removal of Unit No. 2 Fig. 44—Removal and the l o c a t i n g hole i n t h e i n t e r m e d i a t e support to correspond w i t h t h e threaded l o c a t i n g hole inside of case f o r i n s t a l l a t i o n purposes, F i g u r e 41. ( 3 ) Keep u n i t centered as m u c h as possible to prevent b i n d i n g of i n t e r m e d i a t e support and remove assembly f r o m transmisison case, as shown i n F i g ure 4 2 . Remove f r o n t c l u t c h and sun gear t h r u s t washer. 38. REMOVING UNIT N O . 3 (FRONT CLUTCH PISTON RETAINER A N D INPUT SHAFT ASSEMBLIES) — REMOVAL Keep u n i t centered as m u c h as possible and remove f r o m transmission case, as shown i n F i g u r e 4 3 . Use extreme care w h e n r e m o v i n g t o prevent damage to t h e seal r i n g s on i n p u t shaft and sealing surfaces i n the reaction shaft. Installation ©f low-Reverse B a n d sufficiently t o remove t h e low-reverse band s t r u t . ( 2 ) Remove t h e low-reverse band assembly b y r o t a t i n g band ends t h r o u g h rear opening i n transmission case, as shown i n F i g u r e 44, and remove low-reverse band anchor f r o m a d j u s t i n g screw. 40. 1 I C 1 D O W N BAND — REMOVAL (1) M a r k the band f o r reassembly purposes. Compress k i c k d o w n band ends sufficiently to remove the k i c k d o w n band s t r u t , see F i g u r e 45, and remove t h e k i c k d o w n band anchor f r o m a d j u s t i n g screw. ( 2 ) Remove t h e k i c k d o w n band assembly b y r o t a t i n g band ends over center support i n transmission case, as shown i n F i g u r e 46. B o t h bands have bonded l i n i n g and no a t t e m p t should be made to reline t h e m . The k i c k d o w n band is w i d e r and has different l i n i n g m a t e r i a l t h a n the low-reverse band. 39. LOW-REVERSE BAND — REMOVAL ( 1 ) .Mark the low-reverse band assembly f o r i n stallation purposes; t h e n compress ends o f band n r K D O W N BAND STRUT KICKDOWN BAND ADJUSTING SCREW UNIT NO. 3 , 56x616A Fig. 43—Removal a n d Installation of Unit No. 3 A A l A A 56x618 Fig. 4 5 — R e m o v a l a n d Installation of Kickdown Band Strut 38 —TORQUEFLITE TRANSMISSION SNAP RING , TOOL 56x619 A Fig. 46—Removal and Installation of Kickdown Band N O T E : Use extreme care w h e n r e m o v i n g band so as not to damage lining against edges of transmission case. 56x622A Fig. 4 8 — R e m o v a l a n d Installation of Low-Reverse Servo Piston Spring Retainer Snap Ring TOOL SNAP RING \ 41. LOW-REVERSE A N D K I C K D O W N BAND LEVE1 ASSEMBLIES — REMOVAL mm (1) Remove t h e k i c k d o w n and reverse lever shaft stop p l u g at rear o f t r a n s m i s s i o n case. ( 2 ) U s i n g pliers, remove k i c k d o w n reverse shaft lever spacer ( f l a t ) . and lowill ( 3 ) T h r e a d a guide stud, Tool C-3288, i n t o shaft and remove shaft f r o m case, as shown i n F i g u r e 47, and remove the k i c k d o w n and low-reverse servo levers. m 42. LOW-REVERSE SERVO — REMOVAL ( 1 ) I n s t a l l Tool C-3529 or C-3289 (modified) and depress the reverse servo p i s t o n r e t a i n e r t o p e r m i t t h e r e m o v a l o f t h e snap r i n g w i t h a s c r e w d r i v e r (Fig. 48). (2) 56x624A Fig. 49—Removal a n d Installation of Kickdown Piston Rod Guide Snap Ring Remove the tool f r o m the case. L O W A N D REVERSE BAND LEVER KICKDOWN BAND LEVER TOOLACCUMULATOR PISTON ••yS)Bj| l i b GUIDE STUD KICKDOWN AND REVERSE LEVER SHAFT Fig. 47—Removal mm 56x620 a n d Installation of Kickdown a n d Reverse Lever Shaft •I 56x626 A Fig. 50—Removal and installation ©f Accumulator Piston TORQUEFLITE TRANSMISSION — 39 .SPRING SEAT ADJUSTING S C R E W VALVE SLEEVE SPRING RETAINER- 57x236A 57x232A Fig. 51—Removal and Installation of Regulator V a l v e Retainer (3) Remove piston r o d guide, piston s p r i n g and piston assembly. 43. KICKDOWN SEBVO — REMOVAL (1) I n s t a l l Tool C-3529 or C-3289 (modified) and apply sufficient pressure on the k i c k d o w n piston r o d guide to p e r m i t t h e removal of the snap r i n g ( F i g . 49). (2) Remove the tool f r o m the case. ( 3 ) Remove the piston r o d guide, piston s p r i n g and piston r o d . (4) U s i n g pliers, Tool C-484, remove the k i c k d o w n piston f r o m the transmission case. 44. ACCUMULATOR PISTON — REMOVAL U s i n g the same pliers, remove t h e accumulator piston f r o m transmission case, F i g u r e 50. 45. FRONT OIL PUMP — R E M O V A L (1) Remove the f r o n t oil pump drive sleeve. ( 2 ) Remove the f r o n t oil p u m p screws and washers (sealing washers, used under bolts, are made f r o m a l u m i n u m ; discard i f damaged) and replace w i t h a new washer. SPRING CU? t\ Fig. 53—Regulator V a l v e Assembly (Disassembled V i e w ) (3) Remove o i l p u m p housing f r o m transmission case b y t a p p i n g the housing l i g h t l y w i t h a soft hammer ( F i g . 5 4 ) . U s i n g dye, m a r k the pump gears i n r e l a t i o n t o face o f o i l p u m p housing f o r reassembly purposes. DO N O T S C R I B E . 48. REGULATOR V A L V E BODY — REMOVAL (1) Remove the transmission regulator valve s p r i n g retainer, gasket, cup, spring, sleeve and valve ( F i g s . 5 1 , 52 and 5 3 ) . (2) Remove the torque converter valve retainer, gasket, s p r i n g and valve. A mechanical retriever, such as a piece of w e l d i n g rod, w i l l aid i n r e m o v i n g these valves b y i n s e r t i n g i t i n t h e end of the valve. (3) I n s t a l l guide studs, Tool C-3288, and using the t w o threaded holes provided i n t h e regulator valve body, i n s t a l l the guide studs, Tool C-3283, as shown i n F i g u r e 55. (4) P u l l r e g u l a t o r valve body off of torque conv e r t e r reaction shaft and remove gasket. Regulator valve body ( F i g . 56) is made o f a l u m i n u m and requires care i n h a n d l i n g to avoid damage. HQ SLEEVE SPRING EM MM J7x235A FRONT Spring PbVvP HOUSING 56x627 A Fig. 52—Removal a n d Installation of Regulator Valve O'L Fig 54—Removal of Front Oil Pump Housing Assembly 40 —TORQUEFLITE TRANSMISSION REACTION SHAFT / TOOL REGULATOR VALVE BODY 56x628A - Fig. 55—Removing Regulator V a l v e Body 47. TORQUE CONVERTER. REACTION SHAFT — REMOVAL Refer t o "Inspection o f Torque Converter Reaction Shaft," P a r a g r a p h 49. ( 1 ) I f inspection reveals i t is necessary to remove the t o r q u e converter reaction shaft, remove t h e torque converter reaction shaft seal r i n g (neoprene). ( 2 ) Remove transmission case to reaction bolts and washers. shaft ( 3 ) U s i n g Tool C-3531 press t h e reaction shaft o u t of t h e t r a n s m i s s i o n case ( F i g . 5 7 ) . 48. PRECAUTIONS TO OBSERVE DURING DISASSEMBLY, INSPECTION A N D ASSEMBLY OF COMPONENT PARTS The f o l l o w i n g precautions should be observed d u r i n g assembly o f component parts. W h e r e l u b r i c a t i o n is FRONT A N D REAR PUMP CHECK V A L V E TORQUE CONVERTER CONTROL V A L V E I 56x629 57—Removal and Installation « Converter Reaction Shaft required, use A u t o m a t i c Transmission F l u i d (Type " A " — Suffix " A " ) . Do not use sealing materials on any gasket or m a t i n g surface, always use new gaskets. T i g h t e n all bolts and nuts to correct specifications. W h e r e snap r i n g s are used, always make sure t h e y are seated p r o p e r l y . I f m a t i n g parts do n o t go together properly, always check reason. Do not force parts unnecessarily. 49. TORQUE CONVERTER R E A C T I O N SHAFT — INSPECTION Inspect inside of torque converter reaction shaft f o r b u r r s . Inspect splines on shaft f o r b u r r s and wear. Inspect the reaction shaft seal r i n g (neoprene) f o r d e t e r i o r a t i o n and hardness. Inspect t h r u s t surface f o r wear and heavy scoring. Check the inner bronze b u s h i n g f o r excessive scoring. B u s h i n g is serviced w i t h reaction shaft assembly. Do n o t remove the torque converter reaction shaft unless inspection reveals i t is necessary t o do so. 50. TRANSMISSION CASE — INSPECTION Inspect the transmission case f o r cracks, sand holes and stripped threads. Check f o r b u r r s on m a t i n g surfaces. Blow compressed a i r t h r o u g h all passages t o make sure t h e y are open. Check pressure take-off plugs f o r tightness. U s i n g a s t r a i g h t edge, Tool C-3335, inspect valve body m a t i n g surface on transmission case f o r any b u r r s or i r r e g u l a r i t y i n surface. Surfaces should be smooth and flat. 56x651 A REGULATOR V A L V E Fig. 56—Regulator V a l v e Body a n d V a l v e s Inspect the servo and accumulator bores f o r any scores or scratches. L i g h t scratches m a y be removed w i t h crocus cloth. Check r e g u l a t o r valve body m a t i n g surface i n f r o n t on case f o r any i r r e g u l a r i t i e s . D i s r e g a r d any scratches w h i c h m a y have been caused b y torque converter reaction shaft bolt lockwashers. TORQUEFLITE TRANSMISSION — 41 I t is v i t a l l y i m p o r t a n t t h a t t h e band a d j u s t i n g screws fit freely i n t o t h e t r a n s m i s s i o n case. W h e n the lock n u t s are loose, t h e a d j u s t i n g screws m u s t be finger free. I f not, inspect the screws and n u t s f o r pulled threads or f o r e i g n m a t e r i a l i n t h e threads. T h i s Is v e r y i m p o r t a n t i n o b t a i n i n g proper band adjustments. 51. TRANSMISSION EXTENSION HOUSING — INSPECTION Inspect the extension f o r cracks i n t h e casting and remove b u r r s f r o m the gasket surface. Inspect vent ( d r i v e t y p e ) i n top of extension and make sure i t is open and free f r o m d i r t , undercoating, etc. The purpose o f t h i s vent is to f a c i l i t a t e d r a i n i n g and filling. The v e n t also releases fumes and a i r pressure b u i l d up caused b y expansion of o i l due to heat. Clean outp u t shaft r e a r b u s h i n g and d r y w i t h compressed air. Inspect bushing f o r r o u g h spots. D o n o t remove the b u s h i n g f r o m the extension unless inspection reveals i t is necessary t o do so. 52. OUTPUT SHAFT REAR RUSHING — R E M O V A L I f i t is necessary to remove rear bushing, the o u t p u t shaft rear o i l seal should be removed d u r i n g disassembly. Refer to P a r a g r a p h 33. (1) W i t h t h e larger end of the extension housing on a flat surface, use b u s h i n g r e m o v i n g driver, Tool C-3689, and d r i v e b u s h i n g out of housing, as shown i n F i g u r e 26. 53. OUTPUT SHAFT REAR BUSHING 4ND OIL SEAL INSTALLATION (1) Place new b u s h i n g on driver-burnisher, Tool C-3692, w i t h the l u b r i c a t i o n hole i n b u s h i n g t o w a r d the end of the tool. ( 2 ) A l i g n t h e hole i n b u s h i n g w i t h the l u b r i c a t i o n hole i n t h e top side o f t h e extension housing and drive b u s h i n g u n t i l tool bottoms, F i g u r e 27. OUTER WEIGHT SNAP RING ^ ! N N E R W E I G H T SNAP RING VALVE SHAFT VALVE SHAFT SNAP RING — I N N E R WEIGHT WEIGHT S P R I N G - * - v/ OUTER W E I G H ! " — > BODY'---> BODY TO SUPPORT SCREW AND LOCKWASHER (4) • r - SUPPORT-** . V/.'lVE SNAP RING I LOCATING SCREW ^\ -\ \ ^ - ^ o u r v' O R T SEAL S U P P RINGS 56x716A Fig. 58—Governor A s s e m b l y (Disassembled V i e w ) governor secondary w e i g h t and spring. Inspect a l l p a r t s f o r b u r r s and wear. Check secondary w e i g h t for free movement i n p r i m a r y w e i g h t b y placing weight i n p r i m a r y weight w i t h o u t the spring. P r i m a r y w e i g h t should f a l l freely when b o t h parts are clean and d r y . Inspect governor w e i g h t s p r i n g f o r distortion (Fig. 58). ( 2 ) Place secondary w e i g h t and s p r i n g i n p r i m a r y w e i g h t , compress the s p r i n g and i n s t a l l snap r i n g (flat side f a c i n g d o w n w a r d against w e i g h t ) . Make sure the snap r i n g is seated properly. ( 3 ) Remove and inspect t h e t w o governor support seal r i n g s . ( 4 ) Remove t h e governor body to support bolts TOOL •1 ( 3 ) W h i l e h o l d i n g screw of tool w i t h a w r e n c h t o prevent t u r n i n g , use another wrench and t u r n n u t on tool u n t i l b u r n i s h e r of tool is pulled back out of bushing. T h i s operation c o r r e c t l y sizes t h e bushing. Recheck the i n d e x i n g o f t h e l u b r i c a t i o n hole i n bushi n g w i t h t h e housing ( F i g . 2 8 ) . ( 4 ) U s i n g d r i v e r , Tool C-3691, i n s t a l l o u t p u t shaft rear oil seal ( w i t h m e t a l p o r t i o n o f seal f a c i n g down i n housing bore) u n t i l tool bottoms on extension, as shown i n F i g u r e 25. 53x66 54. GOVERNOR DISASSEMBLY A N D INSPECTION ( 1 ) Remove snap r i n g w i t h Tool C-3229. Remove Fig. 59—Checking Clearance Between Rear Pump Body and Gears 42 — T O R Q U E F L I T E TRANSMISSION and separate body f r o m support. (Washers are p a r t of the bolt and serviced as an assembly.) M a t i n g surfaces are machined and can be easily damaged. Inspect oil passages and.make sure t h e y are free f r o m d i r t or f o r e i g n m a t t e r . Clean passages w i t h compressed air. Inspect governor valve and body f o r s l i g h t scores. Valve should t r a v e l freely i n governor body. 55. BEAR OIL PUMP — INSPECTION Inspect o i l p u m p housing machined surfaces f o r nicks and b u r r s and housing p l u g f o r leaks. Inspect o i l pump gears f o r scoring or p i t t i n g . W i t h gears cleaned and installed i n p u m p housing (as m a r k e d ) and using s t r a i g h t edge, Tool C-3335 (and feeler gauge), check clearance between p u m p housing face and face of the gears, as shown i n F i g u r e 59. Clearance l i m i t s are f r o m . 0 0 1 " to .0025". The clearance between t h e outer gear and the p u m p housing should be f r o m .004" to .006". Replace i f clearance exceeds .008". 56. G O V E R N O R A S S E M B L Y — R E A S S E M B L Y (1) with Suffix port. Lubricate Automatic " A " ) , and M a k e sure the t w o governor support seal r i n g s T r a n m i s s i o n F l u i d (Type . " A " — i n s t a l l t h e m on the governor supr i n g s are free to r o t a t e i n grooves. ( 2 ) P o s i t i o n governor body and support and i n stall the f o u r bolts w i t h attached lockwashers. D o not t i g h t e n the bolts at t h i s t i m e . ( 3 ) Slide the governor support and body assembly into position i n rear oil p u m p housing. Compress 56x633 Fig. 61—Removal a n d Installation of Output Shaft Drive Housing Snap Ring the governor support seal r i n g s w i t h fingers as supp o r t enters o i l pump housing. D o not force. 57. O U T P U T SHAFT S U P P O R T — I N S P E C T I O N Inspect a l l oil passages i n o u t p u t shaft support f o r any obstructions. Remove pressure take-off plugs and clean passages w i t h compressed air. Check the rear oil pump m a t i n g surface f o r b u r r s and score m a r k s . Check f o r stripped threads i n the support. Inspect gasket surfaces f o r b u r r s and d i r t . Inspect the inside bearing surface f o r wear and scoring. I n spect o u t p u t shaft to support plate t h r u s t washer f o r tangs being bent or broken. Replace the washer when bronze is w o r n to the extent t h a t grooves i n face of the washer are w o r n off. 58. D I S A S S E M B L Y , I N S P E C T I O N A N D A S S E M B L Y OF POWER TRAIN UNITS, UNIT SHAFT, K I C 1 D O W N AND 1 (OUTPUT PLANET PINION CARRIER NO. INTERMEDIATE SHAFT ASSEMBLIES) a. Disassembly The u n i t can be placed i n the propeller flange and brake d r u m assembly to aid i n disassembly, as shown i n F i g u r e 60. _ \ UNIT /NO. 1 HAND ( 1 ) U s i n g a screwdriver, remove the ouput shaft d r i v e housing snap r i n g ( F i g . 6 1 ) . Refer to F i g ure 62 and complete disassembly o f u n i t as f o l l o w s : ( 2 ) Remove t h e reverse annulus gear ( B ) f r o m t h e o u t p u t shaft assembly ( K ) . ( 3 ) Remove the t h r u s t plate (C) f r o m the k i c k down planet pinion c a r r i e r ( F ) . BRAKE DRUM ( 4 ) Remove the i n t e r m e d i a t e shaft ( D ) and k i c k down planet pinion c a r r i e r assembly ( F ) f r o m o u t p u t shaft assembly ( K ) . \ 56x632 Fig. 60—Using Propeller Shaft Flange a n d Brake Drum A s s e m b l y (as a Holding Fixture for Unit No. 1) ( 5 ) Remove the o u t p u t shaft t h r u s t washer ( E ) located inside housing. ( 6 ) Remove t h e k i c k d o w n planet pinion carrier assembly ( F ) f r o m intermediate shaft assembly ( D ) . T h e k i c k d o w n planet p i n i o n c a r r i e r assembly used i n TORQUEFLITE TRANSMISSION — 43 A — OUTPUT SHAFT DRIVE HOUSING SNAP RING B - R E V E R S E ANNULUS GEAR C — T H R U S T PLATE D—INTERMEDIATE SHAFT E—OUTPUT SHAFT THRUST WASHER F — K I C K D O W N PLANET PINION CARRIER ASSEMBLY G — K I C K D O W N CARRIER THRUST WASHER H — S U N GEAR THRUST WASHER l - K I C K D O W N ANNULUS GEAR SNAP RING J — K I C K D O W N ANNULUS GEAR K - O U T P U T SHAFT ASSEMBLY L—OUTPUT SHAFT SEAL R I N G - S M A L L M — O U T P U T SHAFT SEAL RING —LARGE N —INTERMEDIATE SHAFT SEAL R I N G - S M A L L O-INTERMEDIATE SHAFT SEAL RING —LARGE 56 x 709 A Fig. 62—Unit No. 1 (Disassembled t h i s u n i t is i d e n t i c a l t o t h e low-reverse planet p i n i o n c a r r i e r assembly used i n U n i t N o . 2, b u t should n o t be interchanged due t o wear p a t t e r n s . ( 7 ) Remove bronze k i c k d o w n c a r r i e r t h r u s t w a s h er ( G ) . (8) Remove t h e sun gear roller t y p e t h r u s t washer ( H ) f r o m t h e i n t e r m e d i a t e shaft assembly ( D ) . ( 9 ) W i t h a screwdriver, remove k i c k d o w n annulus gear snap r i n g (1) and separate gear ( J ) f r o m i n t e r m e d i a t e shaft assembly ( D ) . 59. OUTPUT SHAFT — INSPECTION Inspect the speedometer d r i v e gear f o r any nicks or b u r r s . N i c k s or b u r r s on gear surface can be removed w i t h t h e use of a sharp edged stone. Inspect t h r u s t surfaces, j o u r n a l s and inner b u s h i n g f o r scores o r View) excessive wear. Inspect t h e r i v e t i n g and h o u s i n g f o r a n y cracks and i n t e r n a l d r i v i n g splines f o r excessive wear or b r i n n e l l i n g . The housing and o u t p u t shaft are serviced as an assembly. Inspect t h e i n t e r l o c k i n g seal r i n g s ( L - M ) on outp u t shaft ( K ) f o r wear or b r o k e n locks and m a k e sure t h e y t u r n freely i n t h e grooves. D o n o t remove r i n g s unless condition w a r r a n t s . W h e n replacing r i n g s , use extreme care so as n o t to damage i n t e r l o c k i n g p o r t i o n of r i n g . Make sure a l l o i l passages are open b y b l o w i n g out w i t h compressed air. Inspect o u t p u t shaft and k i c k d o w n c a r r i e r t h r u s t washers (E-G) f o r scratches or excessive wear. Inspect t h e sun gear ( r o l l e r t y p e ) t h r u s t washer ( H ) f o r p i t t e d or cracked rollers. 60. INTERMEDIATE SHAFT ASSEMBLY — INSPECTION Inspect a l l b e a r i n g and t h r u s t surfaces f o r scoring or scratches. B l o w compressed a i r t h r o u g h a l l o i l passages; make sure t h e y are open and free o f f o r e i g n m a t t e r . Inspect t h e f o u r large ( 0 ) and t w o small ( N ) i n t e r l o c k i n g seal r i n g s f o r excessive wear, broken ends and make sure t h e y r o t a t e freely i n t h e grooves. The i n t e r m e d i a t e shaft and clutch feed tubes are serviced as an assembly. 6 1 . I 1 C I D O W N PLANET PINION CARRIER A S S E M B L Y — INSPECTION |. 56x634 Fig. 63—Checking Clearance Between Kickdown Annulus G e a r Snap Ring a n d Intermediate Shaft Assembly Inspect planet p i n i o n c a r r i e r f o r cracks and pinions f o r b r o k e n or w o r n gear teeth. U s i n g a feeler gauge, measure the end clearance o n t h e i n d i v i d u a l planet p i n i o n gears. Clearance should be .006" t o .017". I n spect t h e p i n i o n shafts f o r fit i n t h e c a r r i e r and make sure t h e pinions are free to r o t a t e on t h e shafts (.001 i n c h m a x . looseness i n h o l e ) . Make sure t h e p i n i o n shaft lock pins are installed and t i g h t . Do n o t 44 —TORQUEFLITE TRANSMISSION H 1 O P Q A K I T o " U L F k4l'VJ -v. f 1 v E D B H - O V E R - R U N N I N G CLUTCH CAM ROLLER SPRING I — O V E R - R U N N I N G CLUTCH CAM ROLLER J-INTERMEDIATE SUPPORT AND C A M ASSEMBLY K - R E A R CLUTCH SNAP RING L—PRESSURE PLATE 4 Hi M A - S U N GEAR THRUST WASHER (same as output shaft thrust washer) B - S U N GEAR REAR CLUTCH SEAL RING C - S U N GEAR ASSEMBLY D - R E V E R S E BAND SNAP RING E - R E V E R S E PLANET PINION CARRIER ASSEMBLY F—OVER-RUNNING CLUTCH HUB ASSEMBLY G - L O W AND REVERSE BAND DRUM Fig. 64—Unit No. M — D R I V I N G DISC N — C L U T C H PLATE O - P I S T O N RETURN SPRING SNAP RING P —RETURN SPRING RETAINER Q - R E T U R N SPRING R-PISTON S - P I S T O N SEAL R I N G - O U T E R T - P I S T O N SEAL RING—INNER U — P I S T O N RETAINER ASSEMBLY 2 (Disassembled 56 x 710 View) Note: Number of Clutch Plates a n d Discs Dependent Upon Vehicle Model replace the c a r r i e r assembly unless inspection reveals i t is necessary. The planet pinion c a r r i e r and pinions are serviced o n l y as a complete assembly. Scuffing of the c a r r i e r does not affect i t s operation and the c a r r i e r should not be replaced f o r t h i s reason alone. Inspect the k i c k d o w n c a r r i e r t h r u s t washer (G) f o r scratches or excessive wear. 62. REVERSE A N D K I C I D O W N ANNULUS GEAH — INSPECTION Inspect the annulus gears f o r broken gear t e e t h . worn, cracked or 6 3 . UNIT N O . 1 (OUTPUT SHAFT, I I C I D O W N PLANET PINION CARRIER A N D INTERMEDIATE SHAFT ASSEMBLIES) — A S S E M B L Y To aid i n t h e assembly of U n i t No. 1, use the propeller shaft flange and b r a k e d r u m assembly as a stand. (1) W i t h the o u t p u t shaft assembly ( K ) i n t h e u p r i g h t position, lubricate o u t p u t shaft t h r u s t w a s h er ( E ) w i t h A u t o m a t i c T r a n s m i s s i o n F l u i d ( T y p e " A " — Suffix " A " ) and place i n t o position i n the housing. ( 2 ) Place the k i c k d o w n annulus gear ( J ) i n posit i o n on i n t e r m e d i a t e shaft assembly ( D ) and i n s t a l l snap r i n g ( I ) (select fit). U s i n g a feeler gauge, check the clearance under the k i c k d o w n annulus gear snap r i n g ( F i g . 6 3 ) . Clearance l i m i t s are as close to zero as possible. Snap r i n g s are available i n the f o l l o w i n g thicknesses:—.060" to .062" and .064" t o .066". W h e n checking clearance, s u p p o r t annulus gear on the edge of the bench so i n t e r m e d i a t e s h a f t w i l l seat p r o p e r l y i n the gear. Make sure snap r i n g seats properly. ( 3 ) Place the intermediate shaft assembly ( D ) i n the o u t p u t shaft housing ( K ) . ( 4 ) Place the c a r r i e r assembly ( F ) i n position i n k i c k d o w n annulus gear ( J ) . Make sure the t h r u s t washer (G) remains i n position. ( 5 ) Place the t h r u s t plate (C) on the carrier. Be sure the t h r u s t plate pilot enters bore i n the p i n i o n carrier. ( 6 ) Place reverse annulus gear ( B ) i n position i n housing ( K ) and i n s t a l l o u t p u t shaft d r i v e housing snap r i n g . Make sure the snap r i n g seats p r o p e r l y i n the housing. 56x636 Fig. 65—Removing Rear Clutch Piston Retainer A s s e m b l y From Sun G e a r TORQUEFLITE TRANSMISSION — 45 OVERRUNNING CLUTCH HUB INTERMEDIATE SUPPORT AND CAM ASSY ! : SUN GEAR 5£x637 Fig. 66—Removal a n d Installation of Sun G e a r (Reverse Planet Pinion Carrier a n d Overrunning Clutch Assembly) ( 7 ) L u b r i c a t e and install the sun gear (roller t y p e ) , t h r u s t washer ( H ) over i n t e r m e d i a t e shaft and i n t o position at the base o f t h e shaft. 8 4 UNIT N O . 2 — SUN GEAR, REVERSE PLANET PINION CARRIER, OVERRUNNING CLUTCH, A N D REAR CLUTCH PISTON RETAINER ASSEMBLIES — DISASSEMBLY The letters r e f e r r e d to i n the Disassembly, Inspect i o n and Assembly of the u n i t p e r t a i n to F i g u r e 64. (1) W i t h the u n i t s e t t i n g i n t h e u p r i g h t position, remove the sun gear and the f r o n t clutch t h r u s t washer ( A ) . INTERMEDIATE SUPPORT AND CAM ASSY 56x639 Fig. 68—Removal a n d Installation of Intermediate Support a n d C a m Assembly from Overrunning Clutch (2) U s i n g t w o screwdrivers, inserted between clutch and i n t e r m e d i a t e support, remove the rear clutch retainer assembly f r o m the sun gear, as shown i n F i g u r e 65. ( 3 ) Remove t h e t w o rear clutch seal r i n g s (neoprene) f r o m sun gear and remove t h e reverse sun gear f r o m the o v e r r u n n i n g clutch and reverse planet p i n i o n c a r r i e r assembly, F i g u r e 66. ( 4 ) I n s t a l l gauge, Tool C-3527, i n i n t e r m e d i a t e support and cam assembly, as shown i n F i g u r e 67. Remove i n t e r m e d i a t e support and cam assembly f r o m the o v e r r u n n i n g clutch hub, F i g u r e 68. L O W AND REVERSE BAND DRUM ^ OVERRUNNING CLUTCH HUB -TOOL - * -. 56x638 Fig. 67—installation of Tool €=3527 in Intermediate Support a n d C a m A s s e m b l y • 56x640 Fig. 69—Removal a n d Installation of Overrunning Clutch Hub in Low a n d Reverse Band Drum 46 — TORQUEFLITE TRANSMISSION ( 5 ) U s i n g a screwdriver, remove the snap r i n g ( D ) f r o m t h e l o w and reverse band d r u m assembly ( G ) . ( 6 ) Remove the l o w and reverse planet pinion c a r r i e r assembly ( E ) f r o m reverse band d r u m . ( 7 ) Remove the o v e r u n n i n g clutch hub assembly f r o m reverse band d r u m , F i g u r e 69. TOOL\ TOOL ( 8 ) Remove the o v e r r u n n i n g clutch cam roller springs ( H ) and rollers ( I ) ( t e n each) b y r e m o v i n g gauge, Tool C-3527, f r o m the i n t e r m e d i a t e support and cam assembly. Have t h e assembly over bench w h e n r e m o v i n g the tool. 65. BEAU CLUTCH PISTON 1ETAINEH ASSEMBLY — DISASSEMBLY ( 1 ) U s i n g a screwdriver, remove the snap r i n g (large) f r o m rear clutch p i s t o n retainer assembly (Fig. 70). ( 2 ) Remove the rear clutch pressure plate ( L ) f r o m r e t a i n e r assembly. ( 3 ) I n v e r t the c l u t c h p i s t o n retainer assembly and remove t h e clutch plates ( H ) and d r i v i n g discs ( M ) f r o m assembly. ( 4 ) U s i n g the compressor, Tool C-3575, s l i g h t l y compress the r e a r clutch p i s t o n r e t u r n s p r i n g retainer, as shown i n F i g u r e 7 1 . Use extreme care n o t t o damage piston r e t u r n s p r i n g retainer b y compressing the s p r i n g too f a r . ( 5 ) Remove piston r e t u r n s p r i n g r e t a i n e r snap r i n g w i t h parallel j a w e d snap r i n g pliers, Tool C3301. 56x643 Fig. 71—Removal a n d Installation of Rear Clutch Spring Retainer Snap Ring ( 6 ) Release t h e compressor carefully, Tool C-3575, and remove c l u t c h r e t u r n s p r i n g retainer ( P ) and s p r i n g (Q) f r o m clutch piston r e t a i n e r assembly. T h e s p r i n g r e t a i n e r m a y require g u i d i n g past snap r i n g groove as tool is released. ( 7 ) U s i n g a t w i s t i n g motion, remove the clutch piston assembly ( R ) f r o m retainer. Remove the inner and outer (S and T ) seal r i n g s f r o m piston. 66. CLUTCH D11V1NG DISC A N D PLATE — INSPECTION Inspect d r i v i n g disc f o r evidence o f b u r n i n g , glazing and flaking off o f f a c i n g m a t e r i a l . Check the discs b y s c r a t c h i n g facings w i t h finger nail;. i f m a t e r i a l collects under n a i l , replace all of the d r i v i n g discs. Replace t h e d r i v i n g discs i f t h e splines have become damaged. Inspect t h e steel clutch plates and pressure plate surfaces f o r evidence of b u r n i n g , scoring or damaged d r i v i n g l u g s ; replace i f necessary. 67. PISTON A N D SEAL HINGS — INSPECTION Inspect the seal r i n g surfaces i n the piston r e t a i n e r f o r nicks or deep scratches. L i g h t scratches w i l l n o t i n t e r f e r e w i t h sealing of neoprene r i n g s . Inspect t h e i n n e r and outer piston seal r i n g s (neoprene) f o r det e r i o r a t i o n , wear and hardness. Inspect t h e seal r i n g groove i n the piston f o r nicks or b u r r s . Inspect t h e inside bore of t h e p i s t o n f o r score m a r k s ; i f l i g h t , remove w i t h crocus c l o t h ; i f heavy, replace the p i s t o n . Inspect t h e piston s p r i n g , ret a i n e r and snap r i n g f o r d i s t o r t i o n . 56x641 Fig. 70—Removal a n d Installation of Rear Clutch Piston Retainer Snap Ring 68. BEAU CLUTCH PISTON BETAINER ASSEMBLY — INSPECTION N o t e t h e ball check i n the clutch retainer. T h e p u r pose o f t h e ball check is t o relieve c e n t r i f u g a l o i l TORQUEFLITE TRANSMISSION — 47 pressure and to prevent p a r t i a l clutch engagement when the transmission is i n n e u t r a l or o p e r a t i n g i n drive ( b r e a k a w a y ) w h e n t h e engine speeds are i n creased; otherwise, clutch m a y engage. Make sure the ball operates freely. Inspect t h e band contacting surface f o r deep scores and burns, especially i f the band l i n i n g is w o r n to the point where the steel band has been contacting the rear clutch piston retainer. Do n o t machine the piston retainer i n a lathe to remove score m a r k s . Inspect the steel clutch plate c o n t a c t i n g surfaces f o r b u r r s or b r i n e l l i n g . Make sure the clutch d r i v i n g lugs on steel plates t r a v e l freely i n t o retainer. Remove any m e t a l pickup on t h e hub of retainer. 69. REAR CLUTCH PISTON RETAINER — ASSEMBLY ( 1 ) L u b r i c a t e and i n s t a l l inner piston seal r i n g ( T ) on hub o f clutch retainer. M a k e sure t h a t the l i p o f the seal is facing down and the seal Is properly seated i n groove. ( 2 ) L u b r i c a t e and i n s t a l l the outer seal r i n g (S) on clutch p i s t o n ( l i p of seal t o w a r d piston head). ( 3 ) Place the piston assembly ( R ) i n the clutch retainer ( U ) and w i t h a t w i s t i n g motion, seat t h e piston i n b o t t o m of the retainer. ( 4 ) I n s t a l l t h e piston r e t u r n s p r i n g on hub and position s p r i n g retainer and snap r i n g on s p r i n g . ( 5 ) U s i n g a compressor, Tool C-3575, compress the clutch s p r i n g sufficiently to p e r m i t the snap r i n g t o enter the groove i n the hub and snap the r i n g i n place as shown i n F i g u r e 7 1 . The p i s t o n s p r i n g ret a i n e r m a y require g u i d i n g past t h e clutch hub. Make v e r y sure the snap r i n g is p r o p e r l y seated. ( 6 ) Remove t h e compressor, Tool C-3575. ( 7 ) L u b r i c a t e all clutch plates and d r i v e discs w i t h A u t o m a t i c F l u i d (Type " A " — Suffix " A ) . A s semble by p l a c i n g one of t h e rear clutch steel plates i n the clutch retainer followed by a d r i v i n g disc. A l t e r n a t e l y repeat t h i s procedure u n t i l all discs and plates have been installed. , J The number of discs and plates v a r y according t o the engine and transmission equipment. T h e rear c l u t c h pistons are of various thicknesses. Therefore, t h e correct p i s t o n m u s t always be used w i t h t h e n u m b e r o f discs and plates. A s an example, i f a five plate piston is used w i t h a f o u r pack disc and plate combination excessive slippage of t h e clutch w i l l result. (8) I n s t a l l the pressure plate ( L ) and snap r i n g ( K ) . Make sure the r i n g is p r o p e r l y seated. 70. REVERSE SUN GEAR ASSEMBLY — I N S P E C T I O N Inspect the gears f o r cracked or broken teeth. I n spect the steel back bronze type b u s h i n g f o r scoring or excessive wear. B u s h i n g and reverse sun gear are serviced as an assembly. Inspect intermediate support b e a r i n g surface of gear f o r wear and s l i g h t scores. Inspect the rear c l u t c h seal r i n g groove on the gear f o r nicks or b u r r s . Inspect the inner r i n g sealing area i n bore o f sun gear f o r grooves or scratches. Inspect t h e t h r u s t area of sun gear f o r nicks, scratches or b u r r s . Inspect seal r i n g s (neoprene) for d e t e r i o r a t i o n , wear, nicks or hardness. Inspect t h e f r o n t c l u t c h and sun gear t h r u s t washer f o r scratches or excessive wear. 71. INTERMEDIATE SUPPORT AND C A M ASSEMBLY — INSPECTION Inspect the r i v e t i n g of cam to intermediate support. Inspect the cam roller surface f o r b r i n e l l i n g . Inspect t h e roller s p r i n g r e t a i n i n g tabs f o r being bent or distorted. Inspect the bearing surface on hub f o r scoring. Inspect the steel back bronze type b u s h i n g i n hub f o r scratches, scoring or excessive wear. The bushi n g and i n t e r m e d i a t e support are serviced as an assembly. Inspect the o v e r r u n n i n g clutch cam r o l l ers f o r being p i t t e d or scored. Inspect the o v e r r u n n i n g cam r o l l e r springs f o r d i s t o r t i o n . Replace i f necessary. 72. L O W A N D REVERSE PLANET PINION CARRIER ASSEMBLY — INSPECTION Inspect t h e planet pinion carrier f o r cracks and the pinions f o r b r o k e n or w o r n gear teeth. U s i n g a feeler gauge, check t h e end clearance on i n d i v i d u a l planet pinion gears. Clearance should be .006" to .017". Inspect the pinion shafts f o r fit i n c a r r i e r and make sure pinions are free to rotate on the shafts. Make sure shaft lock pins are installed and t i g h t . Do not replace c a r r i e r assembly unless inspection reveals it is necessary. The planet pinion c a r r i e r and pinions are serviced only as a complete assembly. Scuffing of t h e carrier does n o t affect i t s operation and the c a r r i e r should n o t be replaced f o r t h i s reason alone. 73. L O W A N D REVERSE BAND DRUM—INSPECTION Inspect the band contacting surface f o r deep scratches and burns, especially i f band l i n i n g is w o r n t o the p o i n t where steel band has been contacting the d r u m . Do n o t a t t e m p t to machine the d r u m in lathe to remove score m a r k s . Inspect the d r i v i n g splines inside the d r u m f o r excessive wear. 48 — TORQUEFLITE TRANSMISSION assembly ( E ) i n position i n low and reverse band drum (G). ( 3 ) W i t h the d r u m supported, select snap r i n g to give m i n i m u m clearance. Snap r i n g s are available i n three thisknesses: .060-.062, .064-.066 and .068.070 inch. ( 4 ) Place Tool C-3527 i n position i n the i n t e r mediate support and cam assembly and i n s t a l l cam s p r i n g and rollers, as shown i n F i g u r e 72. Make definitely sure t h a t cam springs and rollers are prope r l y seated against c a m ; otherwise, damage to springs w i l l result w h e n o v e r r u n n i n g c l u t c h h u b Is installed. mm # 56x645 Fig. 72—Installation of Overrunning Clutch toilers and Springs in Intermediate Support and Cam Assembly 74. OVERRUNNING CLUTCH HUB ASSEMBLY— INSPECTION Inspect the cam roller c o n t a c t i n g surface f o r b r i n e l l i n g . Inspect the steel back bronze t y p e b u s h i n g i n h u b f o r s c r a t c h i n g or scoring and excessive wear. The b u s h i n g and hub are serviced as an assembly. Inspect the l u b r i c a t i n g hole and make sure i t is free f r o m f o r e i g n m a t t e r b y cleaning w i t h compressed air. Inspect the reverse band d r u m snap r i n g (select fit) f o r being distorted. 75. UNIT N O . 2 — (SUN GEAR. REVERSE PLANET PINION CARRIER, OVERRUNNING CLUTCH A N D REAR CLUTCH RETAINER)—ASSEMBLY (Fig. 84) ( 1 ) I n s t a l l o v e r r u n n i n g c l u t c h hub assembly ( h u b first) I n t o the snap r i n g side o f t h e l o w and t h e reverse band d r u m ( F i g . 6 9 ) . ( 2 ) Place low and reverse planet p i n i o n c a r r i e r O B A C G ( 5 ) W i t h the intermediate support and cam assembly r e s t i n g on bench, lubricate b u s h i n g and i n stall the low and reverse band d r u m assembly over hub. ( 6 ) W h i l e h o l d i n g the t w o assemblies together, remove Tool C-3527. L u b r i c a t e t h e bearing surface on the reverse sun gear and i n s t a l l intermediate supp o r t and planet pinion carrier assembly. ( 7 ) L u b r i c a t e the t w o sun gear rear clutch seal r i n g s (neoprene) and i n s t a l l t h e m on the reverse sun gear. ( 8 ) I n s t a l l the rear c l u t c h piston retainer assembly on the reverse sun gear. To prevent personal i n j u r y , do not place fingers under the clutch retainer assembly w h e n i n s t a l l i n g . ( 9 ) I n s t a l l the f r o n t c l u t c h and sun gear t h r u s t washer ( A ) . L u b r i p l a t e m a y be used to hold the t h r u s t washer i n position. 76. UNIT N O . 3 — (INPUT SHAFT A N D FRONT CLUTCH PISTON RETAINER ASSEMBLIES) — DISASSEMBLY The letters referred to i n disassembly, inspection and reassembly of t h i s u n i t , p e r t a i n to F i g u r e 73. D I K M N Q 58x754 Fig. 73—Front Clutch (Disassembled V i e w ) TORQUEFLITE TRANSMISSION — 49 (1) (A) Remove t h e i n p u t shaft fiber t h r u s t washer ( 2 ) Remove the snap r i n g ( B ) and l i f t the i n p u t shaft (C) f r o m t h e r e t a i n e r ( R ) . LEVER RETAINER \ CUSHION SPRING ' * CLUTCH RETAINER / ( 3 ) I n v e r t the r e t a i n e r ( R ) , remove d r i v i n g discs ( D ) , plates ( E ) , pressure plate ( F ) and h u b ( G ) . (4) I n s t a l l the compressor, Tool C-3575, and compress s p r i n g r e t a i n e r ( I ) . ( 5 ) Use pliers, Tool C-3301, t o remove s p r i n g retainer snap r i n g ( H ) . (6) Slowly release t h e s p r i n g pressure and remove the compressor. ( 7 ) Remove the s p r i n g r e t a i n e r ( I ) , s p r i n g ( J ) , levers ( L ) , lever r e t a i n e r ( K ) , and cushion s p r i n g washer ( M ) and cushion s p r i n g ( N ) f r o m t h e retainer ( R ) . ( 8 ) W i t h a t w i s t i n g m o t i o n , remove the piston (Q) f r o m retainer ( R ) . 77. INPUT SHAFT R E A C T I O N SHAFT AND FRONT C L U T C H — INSPECTION PISTON LEVER 58x753 Fig. 75—Installing Piston Levers should be smooth, free f r o m scratches and excessive wear. D o n o t unlock or remove r i n g s except f o r replacement unless the condition w a r r a n t s . Seal r i n g s should have sharp, unbroken edges and unbroken lock ends. The side clearance should n o t exceed .005 inch. T h e outer surface should show no evidence of wear. Cleaning and Inspection Clean c l u t c h discs w i t h clean, damp w i p i n g cloths. Clean t h e m e t a l p a r t s i n kerosene, m i n e r a l s p i r i t s or s i m i l a r solvents. B l o w t h e solvent t h r o u g h o i l passages w i t h compressed a i r u n t i l clean. (1) Inspect the i n p u t shaft t h r u s t washer ( A ) f o r cracks or excessive wear. Inspect t h e shaft (C) lugs f o r nicks and b u r r s . Splines should be smooth, w i t h o u t scratches, nicks or b u r r s . T h e b u s h i n g ( 2 ) Do n o t remove t h e reaction shaft f o r inspect i o n . Inspect splines f o r nicks, b u r r s and uneven excessive wear. Inspect i n n e r bore. The i n p u t shaft seal r i n g contact area should not be w o r n . T h e t h r u s t washer contact area on end o f shaft should be smooth and u n m a r k e d . (3) Inspect the d r i v i n g discs ( D ) f o r flaking, glazing, b u r n i n g and excessive wear (grooves n o t e v i d e n t ) . Spline teeth should slide freely on d r i v i n g disc hub splines ( G ) . .020"-.040" ( 4 ) T h e steel clutch plates ( E ) and pressure plate ( F ) should be smooth and lugs should slide f r e e l y i n piston retainer ( R ) . (5) Inspect the snap r i n g ( H ) , s p r i n g retainer ( I ) and r e t u r n s p r i n g ( J ) and lever r e t a i n e r ( K ) f o r d i s t o r t i o n , breakage and cracks. ( 6 ) Inspect the levers ( L ) , cushion s p r i n g ( N ) and cushion s p r i n g washer ( M ) f o r wear, d i s t o r t i o n or evidence of scoring. Fig. 74—Cushion Spring Washer Position (7) Inspect the piston (Q) and piston r e t a i n e r ( R ) . Remove any nicks, b u r r s or l i g h t score m a r k s w i t h crocus cloth. Check ball i n r e t a i n e r m u s t operate freely. Inspect the p i s t o n seal r i n g s (S and T ) for d e t e r i o r a t i o n , nicks, d i s t o r t i o n or excessive wear. 50 — T O R Q U E F L I T E T R A N S M I S S I O N 78. INPUT SHAFT A N D FRONT CLUTCH (UNIT N O . 3) —ASSEMBLY (Fig. 73) ( 1 ) L u b r i c a t e and i n s t a l l t h e new rubber seal r i n g ( T ) i n hub groove of retainer ( R ) w i t h l i p of seal t o w a r d rear of retainer. ( 2 ) L u b r i c a t e and i n s t a l l the new outer seal r i n g (S) on piston (Q) w i t h l i p of seal t o w a r d rear of piston. ( 3 ) U s i n g a t w i s t i n g m o t i o n , seat the piston i n the b o t t o m of t h e retainer, ( 4 ) Place the cushion s p r i n g ( N ) on t h e piston w i t h cupped (concave) side t o w a r d piston. ( 5 ) Place cushion s p r i n g washer ( M ) on cushion s p r i n g w i t h chamfer up, t o w a r d f r o n t on assembly (Fig. 74). ( 6 ) Place lever r e t a i n e r ( K ) on piston hub and i n s t a l l levers ( F i g . 7 5 ) . ( 7 ) Position the r e t u r n s p r i n g ( J ) , retainer ( I ) and snap r i n g ( H ) on r e t a i n e r hub. Use Tool C-3575 t o compress s p r i n g sufficiently to seat snap r i n g i n t h e groove w i t h pliers C-3301 and t h e n remove compressor. Be v e r y sure snap r i n g is p r o p e r l y seated. ( 8 ) I n s t a l l the plate ( F ) (smooth side up) i n ret a i n e r and t h e n install discs ( D ) and plates ( E ) alternately. ( 9 ) Check the clutch t r a v e l (free play f o r complete disengagement). U s i n g the t r u c k transmission f r o n t clutch spacer plate, P a r t N u m b e r 1824319, as a special tool, place the spacer against shoulder i n retainer above the top clutch disc. The clearance between tool and top disc should be .020" to .040". Clutch discs are available i n three thicknesses: .060-.063, .073-.076 and .087-.090 inch. Usually, i t w i l l only be necessary t o repla e the top plate to provide clearance w i t h i n t h i s range. W h e n proper clearance is obtained, remove tool. (10) I n s t a l l the clutch hub (G) and i n p u t shaft (C) i n retainer and install snap r i n g ( B ) . (11) I n s t a l l the t h r u s t washer ( A ) over the i n p u t shaft, against the flange of the shaft. SERVOS, BANDS AND M I S C E L L A N E O U S INSPECTION 79. BAND —INSPECTION A l l letters referred to i n the inspection of these parts p e r t a i n to F i g u r e 76. Make visual inspection of bands and l i n i n g f o r wear and bond t o m e t a l . I f the l i n i n g is w o r n to the p o i n t t h a t the grooves are no longer visible, band assemblies m u s t be replaced. The l i n i n g is bonded to the band and no a t t e m p t should be made to reline t h e m . Inspect bands f o r d i s t o r t i o n or cracked ends. The reverse band is n a r r o w e r t h a n the k i c k d o w n band and the l i n i n g is of a different composition. Therefore, i t should be identified to prevent i m p r o p e r i n s t a l l a t i o n . 80. LEVER ASSEMBLIES —INSPECTION (Fig. 76) Inspect the levers ( J and K ) f o r being cracked or w o r n and make sure t h e y are free to t u r n on the shaft and have side clearance when installed. Inspect the lever shaft ( I ) f o r excessive wear. 81. REVERSE SERVO PISTON ASSEMBLY— INSPECTION (Fig. 76) Inspect the lever contacting surface on p l u g ( L ) f o r excessive wear. Remove and inspect reverse servo piston seal r i n g ( Z ) (neoprene) f o r d e t e r i o r a t i o n and hardness. Inspect seal r i n g groove f o r nicks . or b u r r s . Inspect servo piston r e t u r n s p r i n g ( O ) , retainer ( N ) and snap r i n g (Q) f o r being distorted. 82. KICKDOWN PISTON ASSEMBLY — INSPECTION (Fig. 76) Inspect the r i v e t i n g of k i c k d o w n piston r o d ( T ) . Inspect the guide ( R ) contacting surface f o r nicks or burrs. Inspect seal r i n g (CC) on t h e guide f o r wear and make sure i t t u r n s freely i n the groove. Check the fit of the guide ( R ) on the piston rod. I n spect the three r i n g s ( F F , E E , D D ) ( t w o i n t e r locking) on piston f o r wear or broken locks. Make TORQUEFLITE TRANSMISSION — 51 sure t h e y t u r n freely i n t h e groove. I t is n o t necessary to remove the r i n g s unless the condition w a r r a n t s . W h e n replacing new r i n g s , use extreme care so as n o t t o damage the i n t e r l o c k i n g p o r t i o n of the r i n g . Inspect k i c k d o w n piston ( U ) f o r l i g h t scores and wear. Inspect t h e k i c k d o w n p i s t o n s p r i n g (S) and the r o d guide snap r i n g ( M ) f o r being distorted. t o remove r i n g s unless condition w a r r a n t s . W h e n replacing t h e new I n t e r l o c k i n g seal rings, use ext r e m e care so as not to damage the I n t e r l o c k i n g p o r t i o n of t h e r i n g . Inspect the accumulator p i s t o n ( V ) f o r nicks, b u r r s and excessive wear. Inspect the accumulator s p r i n g ( W ) f o r b e i n g distorted. 88. ACCUMULATOR PISTON A N D SPRING — INSPECTION (Fig. 78) 84. DRIVE SLEEVE —INSPECTION Inspect t h e t w o seal r i n g s ( X and Y ) (one i n t e r l o c k i n g ) f o r w e a r or broken locks and make sure t h e y t u r n freely I n t h e grooves. I t Is not necessary Inspect the f r o n t seal r i n g (neoprene) f o r nicks, d e t e r i o r a t i o n and hardness. Inspect t h e i n t e r l o c k i n g seal r i n g f o r wear or broken locks and make sure I t A—LOW AND REVERSE BAND B—REVERSE BAND STRUT C-ANCHOi D—KICKDOWN BAND E—KICKDOWN BAND STRUT F—ANCHOR G —LEVER SHAFT PLUG H-LEVER SHAFT SPACER I —LEVER SHAFT DD "—EE vx- -Z -P -BB ~L flCC- -GG -HH - C J - L O W AND REVERSE BAND LEVER K - KICKDOWN BAND LEVER L - L O W AND REVERSE SERVO PISTON M —PISTON ROD GUIDE SNAP RING N - l O W AND REVERSE SERVO PISTON O - L O W AND REVERSE SERVO PISTON P - L O W AND REVERSE SERVO PISTON Q-SPRING RETAINER SNAP RING R-PISTON ROD GUIDE S-KICKDOWN SERVO PISTON SPRING T-PISTON ROD U-KICKDOWN SERVO PISTON V—ACCUMULATOR PISTON W—ACCUMULATOR SPRING X-PSSTON RING-LARGE Y-PISTON RING-SMALL Z - L O W A N D -REVERSE SERVO PISTON ,4 A L'"-JC A £7 A, s% ' ,* N* G ,! -v "7 — 'PLUG SPRING RETAINER SPRING RING 5 C C - ? ; $ 7 0 N R O D GUOc SEAL R!NG —PISTON' SEAL K'NG—SMALL £ £ - - ? ; S T O N SEAL RiNG MzDiUM r r —PISTON SEAL R I N G — L A R G E S 3 - B A N D ADJUSTING SCREW -ADJUSTING SCREW LOCK NUT \ t — TRANSMISSION CASE DD — F- HHGG- 56 x 708B Fig. 76—Servos a n d Bands (Disassembled V i e w ) 52 — T O R Q U E F L I T E TRANSMISSION t u r n s freely i n groove. I t is n o t necessary t o remove the r i n g s unless t h e conditions w a r r a n t t h e i r replacement. Inspect t h e d r i v i n g lugs f o r excessive wear and the bearing surface on outer diameter f o r nicks, b u r r s or deep scratches. 85. F I O N T O I L PUMP—INSPECTION A N D OIL SEAL REPLACEMENT Inspect f r o n t o i l p u m p housing outer " 0 " r i n g seal (on circumference of the housing) and the f r o n t o i l seal f o r d e t e r i o r a t i o n and hardness. Do n o t remove t h e f r o n t o i l seal f r o m t h e h o u s i n g unless inspection reveals t h a t i t is necessary. To remove o i l seal, use a brass d r i f t and d r i v e t h e seal out o f housing. W i t h new seal l i p t o w a r d s r o t o r bore ( m e t a l p o r t i o n o f t h e seal d o w n ) , use d r i v e r , Tool C-3278, and d r i v e the seal u n t i l tool bottoms on the face o f housing, as shown i n F i g u r e 77. Inspect the d r i v e sleeve seal r i n g contacting surface i n h o u s i n g f o r wear and scratches. Inspect the steel back bronze t y p e b u s h i n g i n bore f o r deep scratches or scoring and excessive wear. ( B u s h i n g and h o u s i n g are serviced as an assembly). Remove the o i l p u m p r o t o r s and inspect the r o t o r contacting surfaces f o r scratches, b u r r s or g r o o v i n g . Inspect the r e g u l a t o r valve body c o n t a c t i n g surface on p u m p housing face f o r nicks or b u r r s . I n spect housing passages and make sure t h e y are free f r o m d i r t and f o r e i g n m a t t e r . Clean and i n s t a l l o i l p u m p gears i n housing. Replace gears, as identified w h e n removed, w i t h counterbore i n t h e p i n i o n gear f a c i n g down. U s i n g s t r a i g h t edge, Tool C-3335, and feeler gauge, measure t h e clearance between t h e p u m p housing face and the face o f the r o t o r s , as .' o - IDOL "RONT O i l PL'.-AP. H O U S I N G ~™ 53x28 Fig. 77—Installing Front Pump Housing O i l Seal •• ' .^^^^^^^m^^^ TOOL 56x650 Fig. 78—Checking Clearance between front Pump Body and Gears shown i n F i g u r e 78. Clearance l i m i t s are f r o m . 0 0 1 " to .0025". A f t e r measuring p u m p gear clearance, lubricate t h e p u m p r o t o r s w i t h A u t o m a t i c T r a n s mission F l u i d (Type " A " — S u f f i x " A " ) . Measure the t i p clearance between t h e r o t o r lobes. The m a n u f a c t u r i n g l i m i t s are .005 t o .010 i n c h . Replace the r o t o r s i f t h i s clearance exceeds ,,012 i n c h . Measure the clearance between the outer r o t o r and p u m p housing bore. The m a n u f a c t u r i n g l i m i t s are .008 i n c h ( m a x i m u m ) . Replace the r o t o r s or p u m p housing i f t h i s clearance exceeds .010 inch. 86. REGULATOR V A L V E BODY A N D VALVES — INSPECTION Place the body and valves i n pan c o n t a i n i n g a clean solvent, w a s h t h o r o u g h l y and d r y w i t h compressed air. Inspect the reaction seal r i n g surface i n bore f o r scratches, nicks or b u r r s . Inspect b o t h valves f o r free movement i n t h i s valve b o d y ; t h e y should f a l l i n and out of bores w h e n b o t h t h e valves and body are d r y . Crocus cloth m a y be used t o polish valves p r o v i d i n g care is exercised not t o r o u n d t h e sharp edge p o r t i o n o f t h e valves. The sharp edge p o r t i o n is v i t a l l y i m p o r t a n t to t h i s t y p e of valve, i t helps t o prevent d i r t and f o r e i g n m a t t e r f r o m g e t t i n g between the valve and body, t h u s r e d u c i n g the possibilities o f s t i c k i n g . Check a l l fluid passages f o r obstructions and i n spect a l l m a t i n g surfaces f o r b u r r s and d i s t o r t i o n . I f t h e r e g u l a t o r valve body should have a s l i g h t n i c k or raised p o r t i o n on m a t i n g surfaces, i t m a y be removed b y u s i n g a surface plate and N o . 400 or finer, g r i t w e t or d r y , sandpaper. Inspect t h e f r o n t and r e a r p u m p check valve f o r proper seating on b o t h surfaces. I f necessary t o remove valve use a p a i r of l o n g nose pliers. TORQUEFLITE TRANSMISSION — 53 Inspect the r e g u l a t o r valve s p r i n g seat (snap r i n g ) . A f t e r the valves and r e g u l a t o r body have been t h o r o u g h l y cleaned and inspected, the valves should be reinstalled i n body ( F i g . 5 6 ) . Place assembly on a clean surface and cover w i t h a paper towel (line free) u n t i l ready f o r i n s t a l l a t i o n . Inspect regu- l a t o r valve and torque converter c o n t r o l valve springs for distortion. Inspect the r e g u l a t o r valve s p r i n g sleeve and cup f o r b u r r s . Inspect the adjusting screw and l o c k n u t i n r e t a i n e r f o r freeness and pulled threads. A S S E M B L Y O F UNITS IN TRANSMISSION C A S E 87. TORQUE CONVERTER REACTION SHAFT — INSTALLATION I f t h e torque converter reaction shaft was removed, r e i n s t a l l i t as f o l l o w s : (1) U s i n g heat lamps, steam or h o t water, heat the f r o n t o f the transmission case to a p p r o x i m a t e l y 170 t o 190 degrees F . ( v e r y h o t w h e n touched b y fingers). I f steam or h o t w a t e r are used, be sure case and passage w a y s are a l l t h o r o u g h l y d r i e d out w i t h compressed air. ( 2 ) I n s t a l l guide studs, Tool C-3283, i n the f r o n t face of reaction shaft flange. L u b r i c a t e p o r t i o n of reaction shaft t h a t presses i n t o case and t h e n posit i o n i n t o f r o n t o f transmission case so t h a t guide studs i n shaft a l i g n w i t h threaded holes i n case. ( 3 ) U s i n g Tool C-3531, press reaction shaft i n t o place, as shown i n F i g u r e 57. Remove t h e guide studs and install the bolts and washers. T i g h t e n the bolts down evenly to prevent any possible m i s a l i g n m e n t o f the shaft i n the case and t i g h t e n 30 t o 35 foot-pounds torque. ( 4 ) L u b r i c a t e t h e torque converter reaction shaft seal (neoprene) and i n s t a l l on shaft. Fig. 80—Installing Front O i l Pump Drive Sleeve 88. REGULATOR V A L V E B O D Y — I N S T A L L A T I O N ( 1 ) I n s t a l l the guide studs, Tool C-3288, as shown i n F i g u r e 55. ( 2 ) I n s t a l l t h e r e g u l a t o r valve body gasket over guide studs i n t o position on transmission case and w i t h a r o t a t i n g m o t i o n i n s t a l l torque converter and regulator valves i n t o the r e g u l a t o r valve body (cent e r i n g tool hole i n ends of valves goes towards outside) . Be sure the f r o n t and rear p u m p check valve is i n proper p o s i t i o n i n r e g u l a t o r valve body ( F i g . 56). ( 3 ) W i t h (neoprene) seal r i n g i n position on t h e reaction shaft, slide t h e r e g u l a t o r valve body over t h e shaft and guide studs i n t o p o s i t i o n against t h e case. G U I D E STUDS 89. FRONT OIL PUMP ASSEMBLY — INSTALLATION (1) W i t h t h e i n n e r and outer seals l u b r i c a t e d and t h e p u m p r o t o r s i n position i n housing ( F i g . 79) (counterbore i n pinion gear f a c i n g down as identified w h e n removed) place the o i l p u m p h o u s i n g over studs and slide i n t o position. 56x652 - MARKS VALVE BODY Fig. 79—Installing Front O i l Pump A s s e m b l y ( 2 ) S t a r t t h e bolts and a l u m i n u m sealing washers and t i g h t e n evenly u n t i l t h e housing is seated i n t o t h e transmission case. Remove the guide studs and 54 —TORQUEFLITE TRANSMISSION TOOL I n s t a l l the r e m a i n i n g bolts and washers and t i g h t e n 14 t o 16 foot-pounds torque. I m p r o p e r t i g h t e n i n g of these bolts m a y cause p u m p gears t o b i n d . ( 3 ) L u b r i c a t e the f r o n t p u m p d r i v e sleeve. W i t h a s l i g h t r o t a t i n g back and f o r t h m o t i o n i n s t a l l sleeve (smooth bearing surface f i r s t ) being sure t h e d r i v e lugs engage i n the o i l p u m p inner r o t o r and can be r o t a t e d freely, F i g u r e 80. T h e m a i n body of the d r i v i n g sleeve should be l u s h w i t h o i l pump housing w h e n p r o p e r l y installed and the neoprene seal r i n g w i l l n o t be visible. I f t h e r o t o r s do n o t t u r n freely, remove t h e pump and check f o r f o r e i g n m a t t e r between t h e p u m p r o t o r s and h o u s i n g ( F i g . 8 1 ) . ( 4 ) I n s t a l l t h e torque converter c o n t r o l valve s p r i n g , r e t a i n e r and gasket and t i g h t e n 35 to 40 f o o t pounds torque. ( 5 ) I n s t a l l the regulator valve s p r i n g , sleeve, cup, gasket and r e t a i n e r ( w i t h a d j u s t i n g screw and lock n u t installed) and t i g h t e n 45 t o 50 foot-pounds torque. 90. K I C K D O W N PISTON — I N S T A L L A T I O N ( 1 ) L u b r i c a t e p i s t o n seal r i n g s and i n s t a l l t h e m on t h e k i c k d o w n piston. (2) Compress outer r i n g and s t a r t assembly i n t o SEAL RING IS KICKDOWN PISTON R O D KfaCDOWN PISTON SPRING —-KICKDOWN PISTON R O D 56x625 A Fig. 82—Removal a n d Installation of Kickdown Piston Rod G u i d e a n d Spring case. W i t h t h e piston p r o p e r l y centered so as not t o damage the rings, tap l i g h t l y u n t i l p i s t o n bottoms i n t h e case. ( 3 ) Place the k i c k d o w n piston r o d assembly i n the piston and slide the piston s p r i n g over k i c k d o w n p i s t o n rod. ( 4 ) I n s t a l l Tool C-3529 or C-3289 (modified) on case and place k i c k d o w n p i s t o n r o d guide over t h e s p r i n g w h i l e g u i d i n g piston r o d guide, as shown i n F i g u r e 82. (5) U s i n g extreme care, compress the k i c k d o w n p i s t o n s p r i n g t o t h e p o i n t t h a t the p i s t o n r o d guide seal r i n g s l i g h t l y binds on t h e case and t h e n w o r k the seal r i n g i n t o position b y g r a d u a l l y compressing t h e spring, i n s t a l l the snap r i n g and loosen the compression p o r t i o n o f the tool. DRIVE SLEEVE mm TOOL mmWm\ DRIVE SLEEVE ; \ L O W - R E V E R S E SERVO' S P R I N G RETAINER Fig. 81—Front Pump Drive Sleeve Installation — Incorrect Installation (Top V i e w ) — Correct Installation (Bottom; View) ' ; 56x623A Fig. 83—Compressing Low a n d Reverse Servo Spring and Retainer TORQUEFLITE TRANSMISSION — 55 9 L LOW-REVERSE SERVO PISTON — INSTALLATION ( 1 ) L u b r i c a t e t h e low-reverse servo p i s t o n seal r i n g and i n s t a l l o n t h e piston ( l i p of seal f a c i n g top end of p i s t o n ) . I n s t a l l the cushion s p r i n g and p l u g i n t o piston and fasten w i t h t h e snap r i n g . ( 2 ) I n s t a l l t h e p i s t o n assembly i n t o t h e transmission case t h e n place reverse servo piston s p r i n g over piston and position s p r i n g r e t a i n e r over s p r i n g . U s i n g compressing tool f o r reverse servo p i s t o n i n stallation, compress s p r i n g sufficiently to i n s t a l l snap r i n g . S p r i n g r e t a i n e r m a y r e q u i r e g u i d i n g i n t o case (Fig. 83). ( 3 ) Remove compressing tool. 92, K I C K D O W N BAND — INSTALLATION (1) I n s t a l l t h e k i c k d o w n band assembly i n same position as m a r k e d upon disassembly, b y r o t a t i n g t h e band ends over center support i n transmission case, as shown i n F i g u r e 46. Use extreme care w h e n i n s t a l l i n g bands t o prevent damage t o t h e l i n i n g on edges o f transmission case. be made a t t h i s t i m e b y selection o f proper i n p u t shaft t h r u s t washer. To accomplish t h i s , use a m i c r o m e t e r and measure t h e thickness of the t h r u s t washer w h i c h was removed. Then, select a t h i c k e r or t h i n n e r washer t o give proper clearance. T h r u s t washers are available i n t h e f o l l o w i n g thicknesses: Thicknesses .115" .097" .078" .059" to to to to .117" .099" .080" .061" Color Natural Red Black Orange ( 1 ) Select t h e proper thickness t h r u s t washer and position i t on the i n p u t shaft. ( 2 ) W i t h t h e i n p u t shaft seal r i n g s lubricated, s t a r t t h e u n i t t h r o u g h t h e r e a r of t h e transmission case, as shown i n F i g u r e 43. B y s u p p o r t i n g and keepi n g t h e u n i t centered as m u c h as possible, guide t h r o u g h bands and reaction shaft i n t o position. 96. UNIT N O . 2 — (SUN GEAR, REVERSE PLANET PINION CARRIER, OVERRUNNING CLUTCH A N D REAR CLUTCH ASSEMBLIES)—INSTALLATION ( 2 ) I n s t a l l the anchor on t h e k i c k d o w n band adj u s t i n g screw. (1) case. 9 3 . LOW-REVERSE BAND — INSTALLATION ( 2 ) A l i g n t h e identified l o c a t i n g hole i n i n t e r m e d i ate support w i t h threaded l o c a t i n g hole inside o f t r a n s m i s s i o n case ( F i g . 8 4 ) . (1) I n s t a l l the anchor on reverse band a d j u s t i n g screw. ( 2 ) I n s t a l l the band b y r o t a t i n g ends t h r o u g h rear opening i n case, i n t h e same p o s i t i o n as m a r k e d upon disassembly, as shown i n F i g u r e 44. 9 4 LOW-REVERSE A N D K I C K D O W N BAND LEVER ASSEMBLIES A N D STRUTS — INSTALLATION (1) Place t h e levers i n p o s i t i o n i n the case, as shown i n F i g u r e 47. S t a r t the u n i t t h r o u g h rear of transmission ( 3 ) B y s u p p o r t i n g and keeping u n i t centered as m u c h as possible, guide i t t h r o u g h t h e bands u n t i l i t contacts t h e hub of the f r o n t clutch. W h i l e p u s h i n g i n on assembly, r o t a t e the sun gear t o engage clutch plates at the rear clutch on hub o f f r o n t clutch. W h i l e r o t a t i n g t h e sun gear, make sure t h e u n i t IDENTIFIED L O C A T I N G ( 2 ) Remove t h e guide stud, Tool C-3288, f r o m the threaded end of shaft and i n s t a l l i n case to hold levers, followed b y spacer (flat) and p l u g . T i g h t e n p l u g securely. ( 3 ) Position the k i c k d o w n band anchor over t h e a d j u s t i n g screw, compress band and i n s t a l l k i c k d o w n band s t r u t . ( 4 ) Position t h e low-reverse band anchor over adj u s t i n g screw, compress band and w i t h the aid o f a screwdriver, i n s t a l l t h e s t r u t . 95. UNIT N O . 3 — FRONT CLUTCH A N D INPUT SHAFT ASSEMBLIES — INSTALLATION I f w h e n transmission was disassembled, the end clearance was found t o be incorrect, correction can Fig. 8 4 - l n s t a l l i n g Unit No. 2 56 —TORQUEFLITE TRANSMISSION does not bind on bands or i n i n t e r m e d i a t e support. B o n o t use excessive force w h e n i n s t a l l i n g t h i s u n i t so as to prevent damage t o clutch discs i n rear c l u t c h . A d r i f t m a y be used to assist i n a l i g n m e n t o f i n t e r mediate l o c a t i n g holes. (4) I n s t a l l the i n t e r m e d i a t e support locating bolts and lockwashers and t i g h t e n 25 to 30 foot-pounds torque. Test t h e i n p u t shaft and sun gear f o r free rotation. 97. UNIT N O . 1 — (OUTPUT SHAFT, K I C I D O W N PLANET PINION GABBIER A N D INTEBMEDIATE SHAFT ASSEMBLIES)—-INSTALLATION Be sure reverse sun gear t h r u s t washer (roller t y p e ) is i n position on the i n t e r m e d i a t e shaft. (1) I n s t a l l the planet p i n i o n c a r r i e r anti-scuff plate i n t o p o s i t i o n ( p i l o t flange goes i n t o the inside bore of the k i c k d o w n planet pinion c a r r i e r ) against planet p i n i o n housing. L u b r i c a t e plate, seal r i n g s and bearing surface on i n t e r m e d i a t e shaft w i t h A u t o m a t i c Transmission F l u i d T y p e " A " , Suffix " A " . ( 2 ) Place t h e i n t e r m e d i a t e shaft i n sun gear, as shown i n F i g u r e 40. K e e p i n g u n i t centered as m u c h as possible and w h i l e slowly t u r n i n g o u t p u t shaft, slide into p o s i t i o n (large seal r i n g on o u t p u t shaft m u s t be flush w i t h rear of transmission case). N O T E : Use e x t r e m e care w h e n i n s t a l l i n g t o p r e v e n t damage t o seal r i n g s on i n t e r m e d i a t e shaft. Fig. 86—Removal a n d Installation of Rear O i l Pump Pinion t a t e the washer to find the location t h a t w i l l provide a m i n i m u m amount of r o t a t i o n ( F i g . 8 5 ) . L u b r i p l a t e should be used to hold t h e washer i n place. ( 2 ) W i t h the guide studs, Tool C-3283, installed i n rear of transmission case, place o u t p u t shaft supp o r t gasket over guide studs and i n t o position on rear of case. ( 3 ) L u b r i c a t e the o u t p u t shaft seal r i n g s . I n s t a l l t h e support over the shaft and guide studs and posit i o n against transmission case ( F i g . 3 9 ) . 9 8 . OUTPUT SHAFT SUPPOBT — INST ALL A T I O N N O T E : Use care w h e n i n s t a l l i n g support so as not to damage r i n g sealing surfaces. (1) Position the o u t p u t shaft support t h r u s t washer w i t h the f o u r tabs spaced between t h e webs on t h e f r o n t side o f t h e o u t p u t shaft support. Ro- ( 4 ) I n s t a l l the one ( s h o r t ) o u t p u t shaft support t o transmission case bolt and lockwasher and t i g h t e n finger t i g h t . THRUST WASHER 99. BEAB O I L PUMP A N D GOVERNOB ASSEMBLIES — INSTALLATION N O T E : T h e o i l p u m p gears were m a r k e d upon disassembly f o r ease of identification and should be reassembled i n t h e same manner. (1) Place the rear o i l p u m p p i n i o n ball i n ball pocket i n o u t p u t shaft. ( 2 ) L u b r i c a t e the r e a r oil p u m p d r i v e pinion. Place over t h e o u t p u t shaft and slide i n t o p o s i t i o n a l i g n i n g t h e k e y w a y i n p i n i o n w i t h ball i n shaft, as shown i n F i g u r e 86. ( 3 ) L u b r i c a t e the r e a r o i l p u m p gear and position i t i n t h e p u m p housing, rounded edge down. Fig 85—Installing Thrust W a s h e r on Output Shaft Support ( 4 ) Slide the rear o i l p u m p and governor assemblies over the o u t p u t shaft and p o s i t i o n i t against t h e support, as shown i n F i g u r e 87. There are t w o e x t r a holes i n the housing w h i c h are used f o r vents. TORQUEFLITE TRANSMISSION — 57 valve b y t u r n i n g t h e o u t p u t shaft. B o t h shall f a l l freely i n governor b o i y . .101. TBANSMISSION EXTENSION — INSTALLATION (1) I n s t a l l t h e new transmission extension gasket over guide studs and i n t o position against o u t p u t shaft support. D o n o t use any sealing m a t e r i a l on gaskets. OUTPUT SHAFT G O V E R N O R A N D REAR O I L PUMP H O U S I N G ASSEMBLIES Fig. 56x611 A 87—Removal and Installation of Governor and Rear Oil Pump Housing Assemblies Make definitely sure t h a t no a t t e m p t is made t o i n s t a l l bolts i n these holes. Check each threaded hole before i n s t a l l i n g bolts. ( 5 ) I n s t a l l the r e a r o i l p u m p h o u s i n g t o o u t p u t shaft support bolts. These special bolts do not require washers. T i g h t e n the bolts d o w n evenly and torque 10 to 12 foot-pounds torque. A f t e r the bolts have been p r o p e r l y torqued, t u r n t h e o u t p u t shaft t o make sure the p u m p gears are free t o rotate. I f not, disassemble the p u m p t o determine cause. ( 2 ) Place t h e extension housing over o u t p u t shaft and guide studs and slide i n t o position against supp o r t being careful n o t to damage rear o i l seal or bushing. I n s t a l l the extension to case bolts and lockwashers and t i g h t e n 25 to 30 foot-pounds t o r q u e . A f t e r these bolts have been p r o p e r l y torqued, t u r n t h e o u t p u t shaft t o make sure i t t u r n s freely. ( 3 ) I n s t a l l the speedometer d r i v e pinion and sleeve assembly i n t h e transmission extension and t i g h t e n 40 t o 45 foot-pounds t o r q u e . 102. P A B I I N G BBA1E — INSTALLATION (1) I n s t a l l brake shoe anchor and anchor p i n i n t h e extension housing. ( 2 ) I n s t a l l the brake support spacer (neoprene) i n p o s i t i o n o n back o f b r a k e support and spacer sleeve i n center o f support. Slide p a r k i n g brake assembly ( i n t a c t ) over rear of extension and anchor p i n . Make sure spacer sleeve remains i n center o f support. G O V E B N O l WEIGHTS A N D V A L V E ASSEMBLY — INSTALLATION ( 3 ) I n s t a l l brake support grease shield on extension housing. ( 1 ) A l i g n t h e l o c a t i n g hole i n o u t p u t shaft t o locating bolt hole i n governor support and i n s t a l l locating bolt, t i g h t e n 60 to 80 i n c h pounds torque. I f the governor body has been removed, t i g h t e n t h e f o u r governor body screws. I n d e n t i n the shield is f o r correct p o s i t i o n i n g on t h e extension. The shield m u s t be located o n t h e extension f a r enough t o p e r m i t i n s t a l l a t i o n of t h e spring. 100. ( 2 ) D r y the governor w e i g h t assembly and valve w i t h compressed air, b u t do not l u b r i c a t e w h e n assembling. Place the governor w e i g h t assembly (secondary w e i g h t snap r i n g facing o u t ) , i n t o governor body ( F i g . 8 8 ) , and using pliers, Tool C-3229, i n s t a l l t h e snap r i n g ( F i g . 3 8 ) , beveled side o u t w a r d . ( 3 ) Place t h e governor valve ( s m a l l end up) on governor shaft, slide assembly i n t o g o v e r n o r body t h r o u g h t h e o u t p u t shaft and governor w e i g h t assembly ( F i g . 3 7 ) ; a t t h e same t i m e p o s i t i o n i n g valve i n body and t h e n i n s t a l l the governor valve shaft snap r i n g ( w e i g h t assembly end), ( F i g . 3 6 ) . M a k e v e r y sure snap r i n g s on b o t h ends of t h e governor valve shaft fit securely. A f t e r snap r i n g i n s t a l l a t i o n , apply sufficient pressure t o b o t h ends of t h e valve shaft t o force snap r i n g s to outer p o r t i o n of snap r i n g grooves. Check operation of governor w e i g h t assembly and 56x610 Fig. 88—Removal a n d Installation of Governor Weight Assembly 58 — TORQUEFLITE TRANSMISSION BRAKE S H O E A N C H O R PIN ^ BRAKE A N C H O R W A S H E R Fig. 89—Internal Expanding Hand Brake (Drum Removed) ( 4 ) I n s t a l l the brake support grease shield s p r i n g (opening i n the s p r i n g t o w a r d a d j u s t i n g sleeve). Make sure t h e s p r i n g is p r o p e r l y seated i n groove. ( 5 ) Slide the brake shoe r e t u r n s p r i n g behind t h e grease shield s p r i n g and hook i n t o position, as shown i n F i g u r e 89. (6) I n s t a l l " C " type brake anchor washer. (7) I n s t a l l propeller shaft flange and d r u m assembly, washer and n u t . W h i l e h o l d i n g flange w i t h Tool C-3281, t i g h t e n t o 175 foot-pounds torque. transmission w i l l have t o be p a r t i a l l y disassembled to allow an i n p u t shaft t h r u s t washer of proper thickness to be installed by the f o l l o w i n g additional steps: ( 4 ) Remove t h e bolts f r o m transmission extension and i n s t a l l guide studs, Tool C-3283. ( 5 ) A s a complete assembly, remove t h e p a r k i n g brake, extension, o u t p u t shaft support and U n i t N o . HAND BRAKE ASSY. 103. HECHECIING FBONT CLUTCH END CLEA1ANCE P r i o r t o i n s t a l l i n g the valve bodies and t r a n s f e r plate assembly, recheck f r o n t c l u t c h end clearance u s i n g dial indicator, Tool C-3339, as shown i n F i g u r e 34. (1) I n s t a l l the dial indicator and p r y the c l u t c h f o r w a r d b y carefully i n s e r t i n g s c r e w d r i v e r between the f r o n t and r e a r c l u t c h . ( 2 ) Remove the s c r e w d r i v e r and w i t h p o i n t of dial i n d i c a t o r contacting edge of f r o n t c l u t c h retainer, set the i n d i c a t o r t o zero. ( 3 ) P r y t h e f r o n t c l u t c h assembly r e a r w a r d against rear c l u t c h and take i n d i c a t o r reading. T h i s clearance should be f r o m .020" t o .050". I f the clearance is n o t w i t h i n these l i m i t s , the OUTPUT SHAFT SUPPORT o6x6.56A Fig. 90—Removal of Output Shaft Support, Extension, H a n d b r a k e Assembly a n d Unit No. 1 a s a n Assembly TORQUEFLITE TRANSMISSION— 59 1, as shown i n F i g u r e 90. Support assemblies as m u c h as possible w h e n r e m o v i n g to prevent damaging the seal r i n g s on t h e i n t e r m e d i a t e shaft. Refer t o "Power T r a i n U n i t s — Removal," U n i t N o . 2 and U n i t N o . 3. ( 6 ) U s i n g a micrometer, measure t h e thickness of the i n p u t shaft t h r u s t washer and select a washer t h a t w i l l provide correct clearance. T h r u s t washers are available i n t h e f o l l o w i n g thicknesses: Thickness .116" .097" .078" .059" to to to to .117" .099" .080" .061" Color Natural Red Black Orange ( 7 ) Reinstall the power t r a i n u n i t s . Refer t o "Power T r a i n U n i t s — I n s t a l l a t i o n ; " U n i t N o . 3 and U n i t N o . 2. ( 8 ) I n s t a l l t h e p a r k i n g b r a k e assembly, extension, o u t p u t shaft support and U n i t N o . 1 i n one assembly as removed, f o l l o w i n g t h e procedure as described i n the i n s t a l l a t i o n of U n i t N o . 1. (9) I n s t a l l the extension housing bolts and washers (remove t h e guide studs and replace the r e m a i n i n g bolts and lockwashers) and t i g h t e n a l l extension housing bolts 25 to 30 pounds torque. lockwith then foot- ( 1 0 ) Rotate the o u t p u t shaft to make sure i t t u r n s freely and t h e n recheck the f r o n t clutch end clearance. 104. BAND ADJUSTMENTS Since b o t h band assemblies have been removed, i t is v e r y i m p o r t a n t t h a t t h e p a r k i n g brake d r u m is t u r n e d i n a clockwise and counter-clockwise direc- Fig. 92—Installing Oil Strainer on V a l v e Body a n d Transfer Plate A s s e m b l y t i o n t o center the bands on t h e d r u m s p r i o r t o m a k i n g band adjustments. Low-Reverse (Rear) Band Refer t o ''Maintenance A d j u s t m e n t s Test," graph 8 ( b ) . Para- Kickdown (Front) Band Refer to "Maintenance, A d j u s t m e n t s Paragraph 8 (a). and Tests," 105. ACCUMULATOR PISTON — INSTALLATION ( 1 ) L u b r i c a t e t h e p i s t o n seal r i n g s and place t h e accumulator i n t o position i n t h e transmission case. Compress t h e outer seal r i n g and tap l i g h t l y i n t o the t r a n s m i s s i o n case and t h e n place t h e accumulator piston s p r i n g down i n t o the accumulator piston. 106. V A L V E BODY A N D TRANSFER PLATE ASSEMBLY — INSTALLATION ( 1 ) Inspect t h e m a t i n g surfaces of the valve body assembly f o r cleanliness. Place t h e manual lever i n t h e reverse position ( a l l t h e w a y i n ) . ( 2 ) U s i n g a suitable guide, such as a piece o f w e l d i n g r o d , inserted t h r o u g h the push b u t t o n cable opening i n t h e transmission case, slide t h e cable adapter over the end o f the guide, as shown i n F i g u r e 91, w i t h t h e adapter a t t a c h i n g s t u d f a c i n g t o w a r d the b o t t o m of t h e transmission case. ( 3 ) Place t h e valve body and t r a n s f e r plate assemb l y i n t o position on the transmission case, and at the same t i m e g u i d i n g t h e cable adapter stud i n t o the hole i n the manual c o n t r o l lever ( F i g . 3 3 ) . •4 Fig. 91—Installing C a b l e A d a p t e r 60x9 (4) I n s t a l l the cable adapter s t u d n u t and t i g h t e n securely. 60 — TORQUEFLITE TRANSMISSION ( 5 ) I n s t a l l the transfer plate bolts (leaving f o u r holes vacant to attach the o i l s t r a i n e r ) , t i g h t e n evenly and torque 14 to 16 foot-pounds. ( 6 ) W i t h the sealing washers on the ends of the s t r a i n e r tubes, place strainer i n position on t h e t r a n s f e r plate. I n s t a l l r e m a i n i n g bolts and torque 14 to 16 foot-pounds ( F i g . 9 2 ) . ( 7 ) I n s t a l l the n e u t r a l s t a r t e r s w i t c h and sealing washer and t i g h t e n 15 to 20 foot-pounds torque. Make sure manual lever contacts the s w i t c h plunger w h e n i n n e u t r a l position. 107. OIL PAN — I N S T A L L A T I O N Use a new gasket, install the oil pan and t i g h t e n bolts 12 to 17 foot-pounds torque. Do not overt i g h t e n , as a leak at the gasket m a y result due t o possible d i s t o r t i o n of the flange of the pan. 108. INSTALLING TRANSMISSION I N VEHICLE ( 1 ) I n s t a l l guide studs, Tool C-3276, i n the t w o transmission m o u n t i n g holes i n t h e r i g h t side o f torque converter housing. ( 2 ) W i t h f r o n t o i l pump d r i v e sleeve lubricated, i n s t a l l i t , m a k i n g sure the d r i v i n g lugs are p r o p e r l y engaged w i t h the oil p u m p pinion. The m a i n p o r t i o n of d r i v e sleeve w i l l be l u s h w i t h the f r o n t o f t h e p u m p housing when p r o p e r l y installed ( F i g . 8 1 ) . ( 3 ) Note the position of the d r i v i n g lugs inside the torque c o n v e r t e r - h u b , t h e n position f r o n t o i l p u m p d r i v e sleeve on the transmission accordingly, to aid i n proper engagement w h e n transmission is installed. ( 4 ) Slide the transmission over the guide studs and i n t o position against the converter housing. M a k e sure d r i v i n g lugs on f r o n t o i l p u m p d r i v e sleeve properly engage the torque converter. To avoid damage t o the f r o n t o i l pump, do not use t r a n s m i s - sion to torque converter housing screws t o force transmission and housing together. I f the o i l pump drive sleeve and i n p u t shaft have been properly aligned, the transmission should slide i n t o position relatively easy. Do not force. ( 5 ) I n s t a l l t w o transmission case to torque converter housing screws and lockwashers i n the left side, do not t i g h t e n . Remove the guide studs and install t h e t w o transmission case to housing screws and lockwashers i n the r i g h t side. T i g h t e n the f o u r down evenly to specifications. (6) Place crossmember i n t o position and i n s t a l l t h e crossmember to torsion bar bracket bolts. T i g h t e n to specifications. L o w e r the engine and at the same t i m e a l i g n m o u n t i n g bolts i n insulator bracket w i t h holes i n rear s p r i n g m o u n t plate. I n s t a l l the nuts and lockwashers, t i g h t e n to specifications. ( 7 ) Remove the support fixture, Tool C-3487, f r o m the side of t h e frame member. (8) I n s t a l l the o i l cooling lines. Connect n e u t r a l s t a r t i n g s w i t c h w i r e to s w i t c h . I n s t a l l o i l pan filler tube n u t and t i g h t e n the n u t to specifications. Connect speedometer cable. Engage ball end of the p a r k i n g brake cable i n operating lever and t i g h t e n cable clamp bolt. I n s t a l l a d j u s t i n g brake screw cover plate on p a r k i n g brake support. Connect t h e f r o n t u n i versal j o i n t and t i g h t e n nuts to 37 foot-pounds torque. I n s t a l l the starter ( i f removed). ( 9 ) Connect t h r o t t l e control linkage to t h r o t t l e lever on the transmission. I n s t a l l push b u t t o n cont r o l cable i n the adapter m a k i n g sure s p r i n g lock engages the cable. A d j u s t t h e manual control cable. Refer to Paragraph 7. T i g h t e n the cable adjustable m o u n t i n g bracket n u t securely. L o w e r the vehicle and connect the b a t t e r y . Refill transmission w i t h A u t o m a t i c Transmission F l u i d (Type " A " , Suffix " A " ) . A d j u s t the t h r o t t l e linkage (Paragraph 1 0 ) . RECONDITION V A L V E BODY AND T R A N S F E R PLATE ASSEMBLIES 109. V A L V E BODY — R E M O V A L FROM TRANSFER PLATE A N D DISASSEMBLY To f a c i l i t a t e t h e reassembly o f t h e valve body i t is suggested t h a t the valves, springs, and plugs removed f r o m one side o f the valve body be k e p t i n separate containers, a p a r t f r o m the parts removed f r o m t h e o t h e r p o r t i o n of the valve body. The parts used i n t h i s new one piece valve body are not interchangeable w i t h those of earlier p r o d u c t i o n models. ( 1 ) Place the valve body and t r a n s f e r plate assemb l y i n stand, Tool C-3528, w i t h the operating lever shafts i n the d o w n w a r d position, as shown i n F i g u r e TORQUEFLITE TRANSMISSION —61 TRANSFER PLATE TOOL VALVE VALVE BODY BODY PLATE 60x7 60x26 Fig. 93—Valve Body a n d Transfer Plate Assembly Fig. 95—Location of Check V a l v e Balls in V a l v e Body in Stand valve s p r i n g ( C ) . Remove the snap r i n g ( J ) and slide out s h u t t l e valve ( I ) . 93. Never clamp a n y p o r t i o n o f any valve body assembly i n a vise or use force w h e n r e m o v i n g or i n s t a l l i n g t h e valves and plugs, ( 6 ) Remove t h e 1-2 r e l a y valve s p r i n g ( D ) and 1-2 relay valve ( E ) . ( 2 ) Remove t h e blocker valve blocker valve and s p r i n g , F i g u r e 94. retainer plate, ( 3 ) Remove t h e cross recess screws t h a t hold t h e t r a n s f e r plate, valve body and valve body cover together. A l l screws are o f equal l e n g t h . W h e n the last screw i s removed, t h e valve body should be held and lowered cautiously t o prevent loss of any o f the six ball check valves. Observe the location o f these balls and t h e n remove t h e balls. A l l check valve balls are of t h e same size ( F i g . 9 5 ) . ( 4 ) Remove t h e s h u t t l e valve and governor p l u g cover plate ( A ) (larger of the t w o covers). (Refer t o F i g . 96.) (5) Remove the s h u t t l e valve p l u g ( B ) and shuttle BLOCKER VALVE BLOCKER VALVE ( 7 ) Remove the 1-2 ( F ) and 2-3 (G) s h i f t valve governor plugs. ( 8 ) Remove t h e s h i f t valve cover plate ( L ) . H o l d t h e cover plate w h i l e releasing the s p r i n g tension to prevent possible loss o f springs w h i l e the cover is removed. (Refer to F i g . 97.) ( 9 ) Remove t h e 1-2 ( M ) and 2-3 ( N ) s h i f t valve springs and valves ( O P ) . (10) Remove t h e (Q) and valve ( R ) . t h r o t t l e compensating spring (11) Remove the t h r o t t l e valve cover plate ( S ) , t h r o t t l e valve ( T ) , t h r o t t l e valve s p r i n g ( U ) , k i c k down valve ( V ) and detent ( W ) . F o r general cleaning purposes i t is n o t usually necessary to disassemble and remove the m a n u a l valve, manual valve lever, t h r o t t l e o p e r a t i n g lever, or t h e manual valve lever detent ball and s p r i n g . However, i f i t is deemed advisable to remove these parts, p e r f o r m the f o l l o w i n g additional steps: SPRING THROTTLE LEVER STOP SCREW ' T H R O T T L E VALVE "OPERATING LEVER MANUAL VALVE OPERATING 60x8 " LEVER Fig. 94—Removal a n d Installation of Blocker V a l v e ( 1 2 ) Remove t h e t h r o t t l e control lever shaft snap r i n g and w h i l e h o l d i n g t h e manual valve o p e r a t i n g lever detent ball against the s p r i n g to prevent loss of the ball and s p r i n g , slide o u t t h r o t t l e and manual valve levers. Remove t h e detent ball and s p r i n g (Fig. 94). (13) Carefully slide the manual valve out of the valve body. (14) Remove blocked valve plate, s p r i n g and valve (Fig. 94). 62 —TORQUEFLITE TRANSMISSION mmmWl ••H -D -A A. B. 60x5 Shuttle Valve and Governor Plug Cover Shuttle Valve Plug Fig. 96—Shuttle a n d Relay V a l v e Side of V a l v e Body C. D. E. Shuttle Valve Spring 1-2 Relay Valve Spring 1-2 Relay Valve F. 1-2 Shift Valve Governor Plug G . 2-3 Shift Valve Governor Plug H. Manual Valve I. J. K. Shuttle Valve Shuttle Valve Snap Ring Valve Body V i 60x6 L. Shift Valve Cover Plate M. 1-2 Shift Valve Spring N. 2-3 Shift Valve Spring u / Fig. 97—Shift a n d Throttle V a l v e Side of V a l v e Body O. 1-2 Shift Valve P. 2-3 Shift Valve Q. Throttle Compensating Valve Spring R. S. T. Throttle Compensating Valve Throttle Valve Cover Throttle Valve U. Throttle Valve Spring V. Kickdown Valve W. Kickdown Vatve Detent TORQUEFLITE TRANSMISSION— 110. V A L V E BODY, V A L V E BODY PLATE AND TRANSFER PLATE — C L E A N I N G AND INSPECTION Place a l l p a r t s i n clean solvent, wash t h o r o u g h l y and d r y w i t h compressed a i r . M a k e definitely sure all passages are free f r o m obstructions. W h e n inspecting, also check f o r porous castings. Inspect a l l m a t i n g surfaces f o r b u r r s , nicks and grooves. The small ones m a y be removed w i t h v e r y fine w e t or d r y sand paper ( 4 0 0 g r i t ) ; otherwise, t h e damaged parts m u s t be replaced w i t h new parts. U s i n g straightedge, Tool C-3335, check a l l m a t i n g surfaces f o r d i s t o r t i o n . U s i n g a pen l i g h t , inspect t h e bores i n t h e valve body f o r score marks, p i t s , and i r r e g u l a r i t i e s . I n spect a l l springs f o r d i s t o r t i o n and collapsed coils. Inspect a l l valves and plugs f o r b u r r s , nicks and scores. The small scratches m a y be removed w i t h crocus cloth p r o v i d i n g e x t r e m e care is used n o t to r o u n d off t h e s h a r p edge p o r t i o n o f v a l v e . The sharp edge p o r t i o n is v i t a l l y i m p o r t a n t to t h i s t y p e valve as i t helps t o prevent d i r t and f o r e i g n m a t t e r f r o m g e t t i n g between valves and body, thus reducing possibilities o f s t i c k i n g . Check t h e valves and plugs f o r free operation i n bores; t h e y m u s t f a l l freely i n bores w h e n clean and d r y . Inspect the valve body plate f o r nicks, scratches, or b u r r s ; and make sure m e t e r i n g holes are open. Inspect the t r a n s f e r plate f o r p o r o s i t y . Inspect t h e machined surfaces f o r nicks and b u r r s . The t h r o t t l e operating lever stop screw should be inspected f o r being loose o r w o r n . Be sure the lock n u t is t i g h t . T h i s screw s h o u l d n e v e r be r e m o v e d o r i t s position changed. I t is pre-set a n d controls the base t h r o t t l e p r e s s u r e s e t t i n g . S h o u l d i t become loose it w i l l r e q u i r e c a r e f u l r e a d j u s t m e n t w i t h a s p e c i a l s e r v i c e tool. R e f e r to P a r a g r a p h 10 ( e ) f o r a d j u s t ment procedure. Inspect the manual and t h r o t t l e valve o p e r a t i n g levers a n d shafts f o r being bent, w o r n , or the levers loose on t h e i r shafts. I f bent or w o r n t h e y should be replaced. I f t h e levers are loose o n shafts, t h e y m a y be silver soldered only, otherwise t h e y m u s t be r e placed w i t h new parts. All valves should be installed d r y and w i t h a r o t a t ing motion. 111. V A L V E BODY, V A L V E BODY PLATE A N D TRANSFER PLATE — ASSEMBLY ( 1 ) W h i l e h o l d i n g the valve body, w i t h t h e o i l passage ways f a c i n g d o w n w a r d , insert the manual valve operating lever detent s p r i n g i n t o t h e valve 63 body recess followed b y t h e detent ball. H o l d t h e b a l l against t h e s p r i n g w i t h t h e fingers t o prevent loss. ( 2 ) Slide the t h r o t t l e lever shaft up t h r o u g h t h e valve body w i t h the smallest cam c o n t a c t i n g the end of t h r o t t l e lever stop screw, as shown i n F i g u r e 94. ( 3 ) W h i l e c o n t i n u i n g t o hold the detent ball against s p r i n g , slide t h e manual o p e r a t i n g lever down over t h e t h r o t t l e valve shaft and at the same t i m e index t h e a r m on the lever i n t o the end groove of the m a n u a l valve. The detent notches i n the lever should slide down against the detent ball. ( 4 ) I n s t a l l t h e snap r i n g over t h e t h r o t t l e lever shaft. R o t a t e the manual lever t o see t h a t detent and valve operate freely. (5) (Refer t o F i g . 97,) Slide the k i c k d o w n detent ( W ) (counterbored end f i r s t ) over t h e machined end of the k i c k d o w n valve ( V ) , and t h e n slide the assembly ( W - V ) , detent end first, i n t o the valve body. I n s t a l l t h e t h r o t t l e valve s p r i n g ( U ) i n t o t h e valve body followed b y the t h r o t t l e valve ( T ) , s p r i n g p i l o t end first. I n s t a l l the t h r o t t l e valve cover plate (S) and t i g h t e n the screw 2 5 t o 3 0 inch-pounds torque. ( 6 ) I n s t a l l the 1-2 and 2-3 s h i f t valves (O-P) w i t h the s p r i n g p i l o t ends pointed o u t w a r d followed b y springs ( M - N ) . ( 7 ) I n s t a l l the t h r o t t l e compensating valve ( R ) w i t h s p r i n g p i l o t end o u t w a r d followed b y the t h r o t t l e compensating pressure s p r i n g ( Q ) . ( 8 ) I n s t a l l t h e s h i f t valve cover plate ( L ) and t i g h t e n the screws 25 t o 30 inch-pounds torque. ( 9 ) T u r n t h e valve body over and refer to F i g u r e 96. I n s t a l l t h e shuttle valve ( I ) , small end first i n t o valve body and i n s t a l l t h e snap r i n g ( J ) . T h e snap r i n g should be replaced i f i t does not f i t securely. ( 1 0 ) I n s t a l l s h u t t l e valve s p r i n g (C) followed b y t h e s h u t t l e valve p l u g ( B ) . ( 1 1 ) I n s e r t t h e 1-2 relay valve ( E ) , s p r i n g p i l o t end o u t w a r d , followed b y relay valve s p r i n g ( D ) i n t o valve body. ( 1 2 ) I n s t a l l the 1-2 and 2-3 s h i f t valve governor plugs ( F - G ) . ( 1 3 ) Place the s h u t t l e valve and governor p l u g plate cover ( A ) on valve body and t i g h t e n screws 2 5 to 30 inch-pounds torque. ( 1 4 ) Place the six ball checks i n t h e i r respective positions i n the valve body, as shown i n F i g u r e 9 5 . ( 1 5 ) Set t h e t r a n s f e r plate cover ( t h i n steel p l a t e ) over the stand pilots, Tool C-3528, as shown i n F i g u r e 64 —TORQUEFLITE TRANSMISSION LINE P R E S S U R E CHART (Ram Manifold Cars O n l y ) Push B u t t o n Position Rear Wheels R N D (Shifted into Direct) 2 1 D Free t o T u r n Free Free Free Free 93, followed by the t r a n s f e r plate so t h a t all screw holes line up. (16) W i t h a l l ball check valves i n place, position the valve body up against the t r a n s f e r plate and cover, a l i g n i n g the screw holes and i n s t a l l the a t t a c h i n g screws and washers. T i g h t e n all screws evenly 25 to 30 inch-pounds torque. (17) I n s e r t the reverse blocker valve s p r i n g into top o f t r a n s f e r plate, as shown i n F i g u r e 94, f o l lowed by t h e blocker valve. The slot i n the lower p o r t i o n of the blocker valve m u s t index w i t h the bar of t r a n s f e r plate cover so t h a t the valve can be depressed flush w i t h the top o f t r a n s f e r plate. (18) Position the blocker valve cover plate over the blocker valve so t h a t a l l openings i n the t r a n s f e r plate are completely covered and t i g h t e n screws 25 to 30 inch-pounds torque. N O T E : I f t h i s plate is i n c o r r e c t l y positioned, governor pressure leakage w i l l result. W h e n c o r r e c t l y installed, the edge of the plate w i l l align up flush w i t h the edge of the valve body t r a n s f e r plate, completely covering the blocker valve bore and governor pressure passage i n the t r a n s f e r plate. 112. SERVICE I N F O R M A T I O N a. TorqueFlite Transmission — Ram Manifold Engines T h e f o l l o w i n g i n f o r m a t i o n w i l l acquaint the service — to Turn to T u r n to T u r n to Turn Engine Speed (rpm) Line Pressure (psi) 1600 1200 1200 1200 1200 3500 235-275 100-110 104-106 100-110 100-110 108-115 technician w i t h the procedures t h a t differ f r o m the standard TorqueFlite transmission and the one used on cars equipped w i t h the r a m manifold. Disassembly, inspection, and assembly procedures are the same. There is a difference, however, i n line pressure, governor pressure, planet pinion carrier, and t h r o t t l e linkage a d j u s t m e n t ; t h e y are as follows: ( 1 ) The line pressure is increased f r o m 90 to 105 psi, (refer to r a m manifold line pressure c h a r t ) . I n order to achieve t h i s change, a heavier regulator valve spring is used. ( 2 ) Governor pressure is also changed. (Refer to r a m m a n i f o l d governor pressure chart.) I n t h i s case, t h e governor w e i g h t assembly incorporates a heavier s p r i n g along w i t h a l i g h t e r outer w e i g h t . ( 3 ) Due to the increased torque provided b y r a m induction, the k i c k d o w n and reverse planet p i n i o n c a r r i e r assemblies differ, they embody a planet pinion c a r r i e r t h a t is made of a different a l u m i n u m alloy. ( 4 ) The t h r o t t l e linkage is designed to conform w i t h the r a m manifold equipped engine. (Refer to Fig. 98). I t is very i m p o r t a n t t h a t the t h r o t t l e linkage be set i n the following order: GOVERNOR P R E S S U R E CHART (Ram M a n i f o l d Cars O n l y ) Push B u t t o n Position Rear Wheels PS-1, PS-3 Car Speed D D D Free to T u r n Free to T u r n Free to T u r n 20-24 35-41 53-60 PC-3, C300F Car Speed 21-24 36-43 55-62 Governor Pressure 15 psi 50 psi 75 psi TORQUEFLITE TRANSMISSION — 65 b. Positioning the Accelerator Shaft ( 1 ) Loosen t h e a d j u s t i n g nuts " A " and " B " (accelerator shaft to transmission r o d and accelerator shaft to t h r o t t l e shaft lever r o d ) . ( 2 ) I n s e r t a piece o f 3/16 inch d r i l l rod, 10 inches long i n t o t h e accelerator shaft bracket and t h r o u g h the hole i n the lever. (3) Move t h e transmission t h r o t t l e control lever f o r w a r d u n t i l i t stops. T i g h t e n t h e locknut " A " securely. T h i s positions t h e accelerator shaft. Co Positioning the Accelerator Pedal ( 1 ) Unsnap t h e accelerator pedal t o shaft r o d . ( 2 ) T u r n the threaded end o f r o d either i n or o u t u n t i l a n angle measurement of 114 degrees is ob- -RIGHT BANK CARBURETOR ROD BELL CRANK ADJUSTING LINK 3/16"x3" PIN (WELDING ROD) (6) LOCKING BOLT A N D NUT TOP VIEW ADJUSTING LINK (D L O C K I N G NUT © LOCKING BOLT AND NUT ACCELERATOR SHAFT TO TRANSMISSION ROD TRANSMISSION THROTTLE CONTROL LEVER KICKDOWN POSITION WIDE OPEN THROTTLE POSITION LEFT BANK CARBURETOR ROD L O C K I N G NUT 0 ANTI-STALL UNIT BELL CRANK IDLE POSITION ACCELERATOR PEDAL TO SHAFT ROD 3/16"xl0" PIN (WELDING ROD) ACCELERATOR SHAFT TO THROTTLESHAFT LEVER ROD ACCELERATOR SHAFT BRACKET ACCELERATOR PEDAL ACCELERATOR PEDAL TO SHAFT ROD ACCELERATOR SHAFT T O TRANSMISSION ROD SIDE VIEW @ L O C K I N G NUT" ADJUSTING LINK Fig. 9 8 — T h r o t t l e L i n k a g e — R a m M a n i f o l d (Schematic V i e w ) 60x191 66 — TORQUEFLITE TRANSMISSION tained between the floor of car and the flat face of the accelerator pedal. and r i g h t bank carburetor r o d s ) . ( 3 ) T h i s angle can be obtained w i t h a p r o t r a c t o r . ( 3 ) Back off t h e anti-stall a d j u s t i n g plunger f a r enough to allow the bellcrank to be pivoted. ( 4 ) A f t e r correct measurement has been obtained, connect the r o d . Remove the locating p i n f r o m accelerator shaft bracket. ( 4 ) P i v o t the bellcrank u n t i l a 3/16 inch piece of d r i l l rod 3 inches long can be inserted t h r o u g h the bellcrank hole and down into the intake manifold. d. Setting the Bellcrank ( 5 ) T i g h t e n locking nuts " C " and " D " securely. Remove the % inch d r i l l r o d f r o m the bellcrank. ( 1 ) Inspect each carburetor to be sure the choke valves are open; t h a t the fast idle cams are released and the t h r o t t l e valves are closed. ( 2 ) Loosen t h e locking nuts " C " and " D " (left 6 ( 6 ) Push r e a r w a r d on the accelerator shaft to t h r o t t l e shaft lever rod a d j u s t i n g l i n k , u n t i l the stop is reached. T i g h t e n locking n u t securely. TORQUE CONVERTER SERVICE PROCEDURES 113. REMOVAL A N D INSTALLATION OF TORQUE C O N V E R T E R A N D HOUSING moved f r o m flanges. a. Removal ( 2 ) Measure the crankshaft flange r u n o u t ( m a x i m u m is . 0 0 2 inch t o t a l indicator reading) b y using dial indicator set, Tool C-3339, at one of the engine block to housing bolt holes. Checking the crankshaft flange r u n o u t w i l l determine w h e t h e r or not the crankshaft flange m a y be c o n t r i b u t i n g to torque converter hub r u n o u t . ( 1 ) Remove the transmission as outlined i n Paragraph 2 6 . ( 2 ) Remove the converter housing dust shield and s t a r t i n g motor. Remove the torque converter housing-to-engine block, (or adapter plate) bolts and washers. A s the housing is doweled to t h e engine block (or adapter p l a t e ) , care m u s t be exercised d u r i n g removal. Do not h a m m e r or p r y between the m a t i n g surfaces t o loosen, as the m e t a l m a y be dist o r t e d w h i c h can result in m i s a l i g n m e n t . ( 3 ) A f t e r r e m o v i n g t h e housing, inspect t h e m a t i n g surfaces of t h e housing and engine block (or adapter p l a t e ) . Remove a l l b u r r s or r o u g h spots w i t h emery cloth. Remove all obstructions, d i r t , etc. f r o m vent hole screens ( w h e n so equipped). ( 4 ) U s i n g wrench, Tool C-589, remove the s t u d nuts and lock washers w h i c h hold the converter u n i t to the c r a n k s h a f t . The torque converter assembly is a welded u n i t and cannot be serviced, except as an assembly. the converter and crankshaft drive I f the crankshaft flange r u n o u t is w i t h i n tolerance, proceed to install the torque converter and housing as f o l l o w s : ( 3 ) Position t h e torque converter u n i t on the crankshaft flange. U s i n g wrench, Tool C-589, t i g h t e n the stud nuts to specifications. Before i n s t a l l i n g the torque converter housing, i t is recommended t h a t the torque converter hub r u n out be checked (and corrected i f necessary) as outlined i n Paragraph 115. I f the torque converter hub r u n o u t is w i t h i n specifications, continue t o i n s t a l l the housing i n the f o l l o w i n g m a n n e r : b. Installation ( 4 ) Position t h e housing over the dowels and against m a t i n g face of the engine block (or adapter p l a t e ) . T i g h t e n the m o u n t i n g bolts j u s t snug enough to r e t a i n the housing i n position. ( 1 ) [ f a new torque converter is being installed, make sure a l l visible f o r e i g n m a t t e r , such as raised metal around studs, b u r r s , chips, etc. have been re- ( 5 ) Check (and correct i f necessary) t h e torque converter housing bore and face r u n o u t as outlined i n Paragraph 4. I f the bore and face r u n o u t are TORQUEFLITE TRANSMISSION — 67 w i t h i n specifications, t i g h t e n h o u s i n g bolts to specifications. I n s t a l l t h e m e t a l dust shield and s t a r t i n g motor. I n s t a l l t h e transmission as outlined i n the t r a n s m i s s i o n Group, P a r a g r a p h 108. 114. REPLACING STARTER RING GEAR Boiling Water Place the r i n g gear i n a shallow container, add water, and heat f o r a p p r o x i m a t e l y e i g h t minutes a f t e r the w a t e r has come to a boil. Steam a. Removing Ring Gear (1) Remove t h e t o r q u e converter and housing as outlined i n P a r a g r a p h — . ( 2 ) Place the converter on t h e bench and carefully remove the s t a k i n g lugs. T h i s can be done b y f i l i n g or b y carefully k n o c k i n g the head off t h e l u g w i t h a hammer and chisel. ( 3 ) Place t h e t o r q u e converter on blocks of wood (for s u p p o r t ) w h i l e r e m o v i n g t h e gear. U s i n g a b l u n t chisel, or d r i f t , t a p around t h e r i n g gear u n t i l i t comes off the t o r q u e converter as shown i n F i g u r e 99. N O T E : A small a m o u n t o f heat, directed on gear, w i l l a i d i n i t s r e m o v a l i f r i n g gear is t o be discarded. b. Installing Ring Gear Remove the b u r r s or raised spots ( l e f t on t h e gear contact surface of t h e torque converter) w i t h a file. Do n o t remove more m e t a l f r o m the torque converter t h a n is required t o remove the b u r r s and r o u g h surfaces. A n y of the f o l l o w i n g methods m a y be used t o heat the s t a r t e r r i n g gear f o r i n s t a l l a t i o n on converter. Place the r i n g gear on a flat surface and d i r e c t the steam flow around t h e gear f o r a p p r o x i m a t e l y t w o minutes. Flame Place the r i n g gear squarely on a flat surface. U s i n g a medium-size t i p , direct a slow flame around the i n n e r r i m of the gear, being careful not to direct t h e flame onto t h e teeth of the r i n g gear. Place a few drops o f w a t e r on t h e face of t h e gear at i n t e r v a l s d u r i n g t h e h e a t i n g process. W h e n t h e gear is h o t enough t o boil the drops of w a t e r , i n s t a l l a t i o n o f the gear to the torque converter can be made. Place the s t a r t e r gear over flange surface of the torque converter, m a k i n g sure t h a t t h e rear face o f gear contacts flange on the torque converter evenly around t h e entire diameter. Reweld t h e r i n g gear t o the torque converter, u s i n g extreme care to place, as nearly as possible, the same amount of m e t a l i n exactly the same locat i o n as on t h e o r i g i n a l assembly. T h i s is necessary i n order to m a i n t a i n proper balance of t h e u n i t . Place t h e welds a l t e r n a t e l y on opposite sides of t h e converter to minimize distortion. Oven Use Oven, C-794, and set t e m p e r a t u r e at 150 degrees F. A l l o w r i n g gear to r e m a i n i n t h e oven f o r a p p r o x i m a t e l y 15 to 20 m i n u t e s . The f o l l o w i n g suggestions are offered as an a i d i n m a k i n g the w e l d : (a) Use a w e l d i n g c u r r e n t of 200 amps. ( b ) Use a D.C. welder t h a t is set s t r a i g h t p o l a r i t y or an A . C . welder. (c) Use 5/32 i n c h diameter, N o . 47 or 5/32 i n c h d i a m e t e r N o . W 2 B w e l d i n g rods ( o r t h e i r equival e n t ) . T o prevent b u r n i n g t h r o u g h the torque converter, t h e arc should be directed at the intersection of t h e gear and t h e housing f r o m an angle o f a p p r o x i m a t e l y 45 degrees f r o m t h e face o f the gear. D O NOT GAS W E L D . Before i n s t a l l i n g t h e torque converter, inspect a l l gear teeth and remove a l l nicks w h e r e m e t a l is raised, w e l d i n g splatter, etc., as these w i l l cause noisy s t a r t e r operation. 53x91 Fig. 99—Removing Starter Ring G e a r I n s t a l l torque converter and housing. P a r a g r a p h 113. Refer to 68 —TORQUEFLITE TRANSMISSION 115. TORQUE CONVERTER HUB RUNOUT a. Checking Hub Runout I t is n o t necessary t o remove t h e torque converter housing t o make t h i s check. ( 1 ) I n s t a l l attachment, Tool C-3613, t o dial i n d i cator set, Tool C-3339, as shown i n F i g u r e 100. i ( 2 ) I n s t a l l dial indicator support r o d i n one o f t h e t r a n s m i s s i o n t o torque converter housing m o u n t i n g bolt holes, as shown i n F i g u r e 100. Disconnect at coil t o d i s t r i b u t o r secondary cable. ( 3 ) W i t h t h e remote c o n t r o l s t a r t e r s w i t c h , Tool C-763, p r o p e r l y installed a t a convenient " h o t " t e r m i n a l , crank t h e engine w h i l e n o t i n g i n d i c a t o r needle deflection. Torque converter h u b r u n o u t m u s t not exceed .004 inch. Fig. b. Correcting Hub Runout I f t h e h u b r u n o u t exceeds .004 i n c h t o t a l i n d i c a t o r reading, correct b y using heat. Before using heat, make definitely sure that the torque converter has been d r a i n e d . ( 1 ) I t is n o t necessary t o remove t h e h o u s i n g t o correct r u n o u t w i t h heat application, as shown i n F i g u r e 101. ( 2 ) M a r k t h e position o f t h e h u b l o w spot as accurately as possible on t h e impeller shell. Rotate t h e converter so t h a t t h i s m a r k is d i r e c t l y down. ( 3 ) U s i n g a piece o f chalk, m a r k t h e f r o n t cover radius d i r e c t l y opposite t h e h u b low spot p r e v i o u s l y m a r k e d on t h e impeller shell. T h e subsequent heati n g operation can now be done a t t h i s location, as shown i n F i g u r e 101. The size o f t h e spot t o be heated is governed b y t h e m a g n i t u d e of hub r u n o u t and is usually about (TOOL) §111111™ ^ ^ ^ ^ ^ ^ • ^ ^ ^ K i f* i^m^^^^ ' i . ' <<^^»^^-Si*|iBiiB^Bi^^^R^ : : :: : ; : IK K i l l (TOOL) lllilw 101J—Heating Torque Converter Showing Heating Operation y i n c h diameter f o r .008 inch t o t a l indicator readi n g . U s i n g an acetylene t o r c h containing a N o . 3 t i p , and set t o m i n i m u m heat, apply i t t o t h e selected spot u n t i l i t becomes a d u l l red. Rapid h e a t i n g o f a local area is essential and i f t h e t o r c h is adjusted properly, t h e spot w i l l become r e d w i t h i n a f e w seconds. I f sparks are noted, i t is an indication t h a t the t o r c h is too close and t h e m e t a l is s t a r t i n g t o b u r n ; move back s l i g h t l y . 2 CAUTION Care should be taken t o remove t h e t o r c h t h e i n s t a n t t h e selected spot becomes a d u l l r e d , t o avoid over correction o r damage t o t h e u n i t . T h e area is t h e n quenched (as r a p i d l y as possible) w i t h cold w a t e r (hose or w e t r a g s ) . I t is suggested t h i s be done b y s t a r t i n g around t h e heated area and w o r k i n g i n t o w a r d t h e spot. T h i s prevents t h e heat f r o m spreading. T h e h u b r u n o u t should n o t be rechecked u n t i l t h e converter has r e t u r n e d t o a u n i f o r m r o o m temperature. I f t h e converter h u b r u n o u t exceeds .016 inch t o t a l i n d i c a t o r reading, remove t h e converter and recheck t h e d r i v e flanges f o r raised metal chips. Check crankshaft flange r u n o u t ( m a x i m u m .002 i n c h ) . I f t h e h u b r u n o u t remains i n excess o f .016 inch t o t a l i n d i c a t o r reading, i n s t a l l a new converter. 116. CHECKING A N D CORRECTING HOUSING FACE A N D BORE RUNOUT Fig. H00—Checking Torque Converter Hub Runouft (Typical) a. Bore Runout T h e torque converter housing bore and face alignment, as well as converter h u b r u n o u t , should be checked a n y t i m e t h a t a P o w e r F l i t e o r T o r q u e F l i t e transmission is removed t o correct leakage a t t h e TORQUEFLITE TRANSMISSION — 69 PUMP DRIVE LUG TORQUE CONVERTER MPELLER HUB Fig. 102—Torque Converter Hub Showing Tool C-3461 Installed f r o n t p u m p o i l seal or f r o n t p u m p f a i l u r e — also whenever a n engine replacement is made. ( 1 ) M o u n t Tool C-3461, shown i n F i g u r e 102, i n side the converter w i t h the ears of the washer beh i n d the converter pump d r i v e lugs. The square end of the bolt can be held w i t h a w r e n c h as t h e n u t is t i g h t e n e d . The dial indicator set, Tool C-3339, can now be attached, as shown i n F i g u r e 103. ( 2 ) Locate the i n d i c a t o r so t h a t i t is b e a r i n g on the transmission p i l o t bore of the converter housing and r o t a t e t h e converter. ( 3 ) The r u n o u t m u s t not exceed .010 i n c h t o t a l indicator reading. To i l l u s t r a t e the recommended correction procedure, assume t h a t the t o t a l i n d i c a t o r r e a d i n g is .016 inch, i n a d i r e c t i o n w h i c h approximates 2 o'clock ^ l«^^^^^^^B f Fig. 104—Eccentric Dowel (Schematic Diagram) on engine block. (Refer to F i g . 104.) I n t h i s case, the housing is off c r a n k s h a f t centerline .008 i n c h (one-half t o t a l i n d i c a t o r reading) w h i c h is .003 i n c h greater t h a n the allowable l i m i t of .005 (one-half total indicator reading). To correct an off-center condition, three dowels are available. W h e n selecting dowels to be used f o r a p a r t i c u l a r job, take t h e dowel closest to one-half the t o t a l i n dicator reading. Refer to c h a r t . I n t h e case, under consideration, use of the i n c h offset dowels ( p a i r ) w i l l b r i n g the r u n o u t w i t h i n the allowable l i m i t o f .005 inch, or .008 m i n u s .007 i n c h (offset dowels) equals .001 inch out. The dowels m u s t be used i n pairs (same number). (TOOL) INDICATOR A Fig. 103—Checking Housing l o r e Runout (Typical) .007 well inch runpart To i n s t a l l the dowell pins ( p a i r ) , remove t h e torque converter h o u s i n g as outlined i n P a r a g r a p h 1 ( a ) . DOWEL 58x1 off-set 57x524 Fig. 105—Removing Dowel Pin 70 —TORQUEFLITE TRANSMISSION E C C E N T R I C DOWEL CHART Total Indicator Reading One-Half Total Indicator Reading Size Dowel To B e Used Dowel P a r t Number .012" to .020" .022" to .034" .036" to .052" .006" to .010" .011" to .017" .018" to .026" .007" .014" .021" 1736347 1736348 1736353 Select the eccentric dowels ( p a i r ) as indicated i n the Eccentric Dowel Chart. i t m a y be necessary to use the n e x t higher step dowels, a d j u s t i n g these dowels w i t h t h e housing installed to b r i n g the housing bore w i t h i n tolerance. B o t h dowels should be inserted i n t o the engine block (or adapter plate) up t o offset shoulder. I n s t a l l b o t h dowels w i t h the slots parallel and aligned i n t h e d i r e c t i o n to correct the bore r u n o u t . (Slot indicates the d i r e c t i o n of m a x i m u m dowel ecc e n t r i c i t y . ) M a j o r i t y o f corrections w i l l be f o r one direction o n l y ; b u t i t is possible t h a t the housing bore m a y be out i n t w o directions. I n the l a t t e r case, I n s t a l l and t i g h t e n the converter housing bolts to specifications. Remount the dial indicator and recheck the bore r u n o u t . Small corrections can be made by loosening the housing m o u n t i n g bolts and t u r n i n g dowels w i t h a screwdriver to s h i f t the housing and b r i n g the bore w i t h i n l i m i t s . Remove the dowel pins f r o m engine block (or adapter plate) as shown i n F i g u r e 105. SHIM T H I C K N E S S - L O C A T I O N T A B L E Location o f H o u s i n g Face L o w P o i n t (a) Near one o f the lower trans, to hsg. bolt holes. Location of Shim (a) Place s h i m on bolt w h i c h w i l l enter t h i s hole. T o t a l I n d i c a t o r Reading Observed on Housing Face Total Shim Thickness (a) 1) 2) 3) .005 to .010" .010 to .015" .015 to .020" (a) 1) 2) 3) .013" .020" .026" (b) Near one o f the upper trans, to hsg. bolt holes. (b) Place s h i m on b o l t w h i c h w i l l enter t h i s hole. (b) 1) 2) 3) .005 to .010" .010 to .015" .015 to .020" (b) 1) 2) 3) .014 .021" .029" (c) Between the t w o lower t r a n s , to hsg. bolt holes (c) Place shims on b o t h bolts t h a t w i l l enter these holes. (c) 1) 2) 3) .005 to .010" .010 to .015" .015 to .020" (c) 1) 2) 3) .010" .015" .020" (d) Between the t w o upper trans, to hsg. bolt holes. (d) Place shims on b o t h bolts w h i c h w i l l enter these holes. (d) 1) 2) 3) .005 to .010" .010 to .015" .015 to .020" (d) 1) 2) 3) .003" .012" .016" (e) 1) .005 to .010" (e) 1) 2) .010 to .015" 2) 3) .015 to .020" 3) (e) Between t h e upper and lower trans. to hsg. bolt holes. (e) Place shims on b o t h bolts w h i c h w i l l enter these holes. u p p e r - -.010" lower— -.014" u p p e r - -.015" lower— -.020" upper— -.020" lower—.027 ; POWERFLITE TRANSMISSION — 71 as shown i n F i g u r e 106. (2) Rotate t h e converter. ( 3 ) I f t h e t o t a l i n d i c a t o r r e a d i n g is greater t h a n .008", note t h e amount of t h e t o t a l i n d i c a t o r reading and t h e location o f the lowest i n d i c a t o r reading (i.e., the p o i n t w h e r e the i n d i c a t o r a r m or follower is extended t h e f u r t h e s t ) . ( 4 ) Place t h e s h i m or shims on one or more o f t h e transmission housing bolts i n position between t r a n s mission and housing. CONSULT T H E " S H I M THICKNESS — LOCAT I O N T A B L E * FOR S E L E C T I O N O F CORRECT S H I M OR S H I M S TO B E U S E D I N C O R R E C T I O N PROCEDURES. 9 INDfCAIoi^ (TOOL) K ' ^B^^ I Fig. 58x2 A 106—Checking Face Runout (Typical) b . Face Runout (1) Relocate the dial i n d i c a t o r set, Tool C-3339, (5) T i g h t e n the housing bolts to specifications. ( 6 ) I n s t a l l the transmission as outlined i n Parag r a p h 108, Transmission Group. P O W E R F L I T E TRANSMISSION CONTENTS A s s e m b l i n g t h e Transmission Paragraph 9 Page 95 I n s t a l l i n g K i c k d o w n B a n d A d j u s t i n g Screw I n s t a l l i n g t h e Torque Converter Reaction Shaft Installing the Kickdown Piston I n s t a l l i n g the Reverse Servo P i s t o n I n s t a l l i n g the Regulator V a l v e B o d y Installing the Front Oil Pump I n s t a l l i n g the K i c k d o w n B a n d and Levers A s s e m b l i n g t h e D i r e c t C l u t c h Piston Retainer I n s t a l l i n g Reverse B a n d and Levers Assembly I n s t a l l i n g t h e Planet P i n i o n Carriers i n H o u s i n g I n s t a l l i n g the O u t p u t Shaft Support, Planet P i n i o n Carriers and H o u s i n g Assembly I n s t a l l i n g the Rear O i l P u m p I n s t a l l i n g t h e Governor on the O u t p u t Shaft I n s t a l l i n g t h e Transmission Extension, O i l Seal and B e a r i n g Checking Transmission E n d Play A d j u s t m e n t of Bands (on bench) Checking f o r O i l Leaks _ Leaks N o t R e q u i r i n g Removal o f Transmission F r o m Vehicle Leaks R e q u i r i n g Removal of Transmission F r o m Vehicle 4 81 72 —POWERFLITE TRANSMISSION Paragraph Page Disassembly and Inspection (Transmission) Checking Transmission E n d Play Removal of H a n d Brake Assembly Removal, Disassembly and Inspection of Transmission Extension Removal, Disassembly and Inspection of Governor Removal, Disassembly and Inspection of Rear O i l P u m p Removal of O u t p u t Shaft Support, Planet P i n i o n Carriers and D i r e c t C l u t c h Assemblies Removal and Inspection of Planet Carriers Disassembly and Inspection o f the D i r e c t Clutch P i s t o n Retainer Removal and Inspection of K i c k d o w n B a n d Removal of t h e Reverse and K i c k d o w n B a n d Levers Removal of the F r o n t O i l P u m p Removal of Regulator Valve Body Removal of Reverse Servo Piston Removal of K i c k d o w n Piston Removal of Torque Converter Reaction Shaft 8 86 E x p l a n a t i o n of Index Items (Trouble Diagnosis C h a r t ) 1 77 H y d r a u l i c C o n t r o l Pressure Checks 3 80 11 105 2 78 7 86 10 101 L i n e Pressure T h r o t t l e Pressure Governor Pressure D i r e c t Clutch Pressure L u b r i c a t i o n Pressure I n s t a l l i n g the Transmission i n Vehicle Operation . _ Torque Converter Gearshift C o n t r o l Push B u t t o n Gearshift C o n t r o l H o u s i n g Neutral Starting Switch S t a r t i n g t h e Engine Push S t a r t i n g H o w t o D r i v e the Vehicle Towing Checking F l u i d L e v e l R e m o v i n g Transmission F r o m Vehicle . Servicing the Valve Body and T r a n s f e r Plate Disassembling the Valve Body and T r a n s f e r Plate Cleaning and Inspecting the Valve Body and T r a n s f e r Plate A s s e m b l i n g t h e Valve Body and T r a n s f e r Plate I n s t a l l i n g the V a l v e Body and T r a n s f e r Plate POWERFLITE TRANSMISSION — 73 Paragraph Page Servicing Gearshift C o n t r o l U n i t Removal of Gearshift Control U n i t I n s t a l l i n g Gearshift Control U n i t R e m o v i n g Gearshift Control Cable I n s t a l l i n g Gearshift Control Cable Replacing Back-Up L i g h t S w i t c h ( i f so equipped) Replacing P u s h B u t t o n U n i t L a m p B u l b Removal and Inspection o f Cable Assembly, Transmission E n d 5 82 Transmission and Controls — A d j u s t m e n t T h r o t t l e Pressure and T h r o t t l e L i n k a g e A d j u s t m e n t Throttle Linkage Adjustments T h r o t t l e Pressure A d j u s t m e n t A d j u s t m e n t o f K i c k d o w n ( F r o n t ) Band Reverse (Rear) B a n d A d j u s t m e n t A d j u s t i n g the Gearshift Control Cable Cable and N e u t r a l S t a r t i n g S w i t c h A d j u s t m e n t Road T e s t i n g 6 83 T r o u b l e Diagnosis C h a r t — 76 P O W E R F L I T E TRANSMISSION DATA AND SPECIFICATIONS Type A u t o m a t i c T w o Speed w i t h Torque Converter Torque Converter D i a m e t e r (inches) 11% Oil Capacity of Transmission and Torque Converter 20 pt. ( A u t o m a t i c Transmission F l u i d — T y p e " A " Suffix " A " ) M e t h o d of Cooling Water Lubrication Pumps ( R o t o r Type) N u m b e r of C l u t c h Plates 6 GEAR RATIOS Low Drive — Breakaway 1.72 to 1 . 1.72 t o 1 Drive — Direct 1 to 1 Reverse 2.39 t o 1 FRONT-REAR PUMPS Type E n d Clearance ( F r o n t P u m p ) E n d Clearance (Rear P u m p ) GOVERNOR (3-STAGE) Type Clearance Between Governor Valve and Body Gear ( R o t a r y ) . .0012 to .0022" .001 t o .003" Centrifugal .002 t o .005" 74 —POWERFLITE TRANSMISSION DATA AND SPECIFICATIONS (Continued) THRUST WASHERS Direct Clutch P i s t o n Retainer ( F i b r e ) .078 to .080" .095 to .097" .112 to .114" K i c k d o w n Planet P i n i o n C a r r i e r _ .062 to .064" K i c k d o w n A n n u l u s Gear .062 to .064" Planet P i n i o n C a r r i e r H o u s i n g .078 t o .080" SNAP RINGS Planet P i n i o n C a r r i e r H o u s i n g .062 t o .064"* .072 to .074"* .082 to .084"* K i c k d o w n Sun Gear .058 to .060" .062 to .064" Reverse A n n u l u s Gear .078 to .080" .082 t o .084" .086 to .088" I f t h i s selection of snap r i n g s fails to provide m i n i m u m clearance, use k i c k d o w n sun gear snap r i n g ( . 0 5 8 - .060"). S P E C I A L TOOLS C-452 Puller C-3288 Pilots C-484 Pliers C-3292 Gauge C-589 Wrench C-3293 Gauge C-748 Puller C-3294 Stand Pilots C-760 Pliers C-3295 C-811 Wrench C-3297 Remover-Installer C-3201A Jack C-3301 Pliers C-3202A Jack C-3335 Straightedge C-3204 Driver C-3339 Set-Dial Indicator C-3205 Driver C-3380 Wrench C-3275 Driver C-3461 Fixture C-3276 Pilots C-3487 Support C-3278 Driver C-3529 Compressor- C-3279A W rench Servo S p r i n g C-3280 Stand C-3575 Compressor C-3281 Wrench C-3583 Adapter-For C-3283 Pilots DD-1150 Tachometer C-3287 Puller C-3380 Torque W r e n c h POWERFLITE TRANSMISSION — 75 TIGHTENING R E F E R E N C E Foot-Pounds Case to Converter H o u s i n g B o l t Case O i l L i n e P l u g Inch-Pounds 45 - 120 - Case to Reaction Shaft B o l t - 15 30 Direct Clutch Shift Valve Plug Bolt E x t e n s i o n to Case B o l t 25 F r o n t O i l P u m p H o u s i n g Bolt — .— . 180 — Governor Body B o l t 90 Governor L o c a t i n g B o l t . 45 Governor O i l Pressure Take Off P l u g 120 K i c k d o w n Band A d j u s t i n g B o l t N u t . 40 K i c k d o w n Band L e v e r Shaft P l u g . 25 180 K i c k d o w n Strainer Support B o l t Manual Control Lever N u t 7 l N e u t r a l Starter S w i t c h — I n i t i a l E l e c t r i c a l Contact Plus / to y T u r n s Oil Pan B o l t and Lockwasher . 7 5 Max. 2 180 .. Oil Pan F i l l e r Tube Bracket B o l t N u t _ 20 Oil Pan F i l l e r Tube N u t 40 O u t p u t Shaft Support B o l t O u t p u t Shaft Support Pipe P l u g Rear O i l P u m p H o u s i n g Bolt 25 . 120 - 180 . Regulator Valve S p r i n g Retainer 50 Reverse Band Lever A d j u s t i n g B o l t N u t 35 Shaft Flange N u t Speedometer P i n i o n Sleeve T h r o t t l e Control Lever N u t 175 45 7 120 T h r o t t l e O i l Pressure Take Off P l u g T h r o t t l e V a l v e A d j u s t i n g Bolt P l u g 25 Torque Converter C o n t r o l Valve S p r i n g Retainer 40 45 T r a n s f e r Plate Cover B o l t — L o n g T r a n s f e r Plate Cover B o l t — S h o r t T r a n s f e r Plate B o l t — L o n g T r a n s f e r Plate B o l t — S h o r t V a l v e Body E n d Cover L o n g B o l t V a l v e Body E n d Cover B o l t V a l v e Body E n d Cover Short B o l t 45 180 180 25 25 25 Cable C o n t r o l Cable Clip to Column Jacket B o l t 70 Push B u t t o n Box to I n s t r u m e n t Panel, Plate or B r a c k e t Assembly N u t 20 Transmission Cable B r a c k e t B o l t 15 76 — POWERFLITE TRANSMISSION S E R V I C E DIAGNOSIS CHART (PowerFlite Transmission) OPERATING STEMS Shift A b n o r m a l i t i e s T O CHICK Miscellaneous Response m A. Oil Level B. Throttle C. Gearshift Control Link Adj. • # Cable Adj. D. Pressure Checks— Line Lube, etc. E. K.D. Band Adj. m * m m m m l 1 # • % • • • • # • o • G. Engine Idle H. Neutral Start SW. I. Handbrake Adj. J. Regulator Valves— Springs I m K. Converter Control Valve L. Breather M. Output Shaft Rear Bushing N. T.C. O. K.D. Servo-Band Linkage P. R. Servo Band Linkage Q. Oil Strainer • • • R. Valve Body-Bolts— Mating Surfaces m • m m m m m S. Speedometer Pinion T. Governor # • • • • • • • • • • • # m • • • • m # i • • • # U. Rear Pump a. Front Pump— Drive Sleeve b. Reg. Valve Body, Gasket, Surfaces m o • m c. Converter-Housing e. Planetary Gear Set f. Seal Rings • m d. Direct Clutch • m • j # # • j | ! m ® • • • • • • • • # m • m 1 • • • • • • • • m m • • • Starter Won't Energize Impossible to Push Start Engine Trans. Overheats Grating, Scraping, Growling Noises Drags or Locks Moves Backward in Neutral • m ® F. Reverse Band Adj. No Drive in Any Range Moves Forward in Neutral • • • • • • • • • m • • • • • Reverse Band Slips No Drive in D-L Slips in All Ranges Slips in Drive Position # Shifts Erratically First No K.D. or Normal Downshift G No Upshift C, and Harsh Upshift and K D. Always Runaway on Upshift and K.D. NOTE: Check Items A , B Delayed N to D ITEM Harsh N to R or N to D INDEX Trans. Hard to FillOil Blows Out Fill Tube Explanation of I n d e x I t e m s Buzzing Noise See DIFFICULTY POWERFLITE TRANSMISSION—77 P O W E R F L I T E TRANSMISSION 1. EXPLANATION OF INDEX ITEMS O N TROUBLE DIAGNOSIS C H A 1 T THROTTLE PRESSURE TAKEOFF PLUG TORQUE CONVERTER CONTROL T h e Trouble Diagnosis C h a r t has t h e o p e r a t i n g difficulties listed i n three groups. A f t e r road t e s t i n g , m a t c h t h e t r o u b l e found to i t s p a r t i c u l a r group and t o t h e specific difficulty under t h a t group. The I n d e x and I t e m i n the " I t e m s to Check" column are n e x t checked against t h e " E x p l a n a t i o n o f I n d e x I t e m s " . C a p i t a l l e t t e r items refer t o those operations w h i c h m a y be performed w i t h o u t r e m o v i n g t h e t r a n s m i s sion. The small l e t t e r items refer to those operations done after the transmission is removed f r o m t h e vehicle. 7/ • VALVE -O;L 6, C. Gearshift c o n t r o l cable—Refer to P a r a g r a p h 6. D . Pressure tap check — H y d r a u l i c pressure taps have been provided to check t h e f o l l o w i n g pressures: FILLER TUBE OPENING KICKDOWN BAND ADJUSTING S C R E W . 56x109 A LUBRICANT PRESSURE TAKEOFF ^ THROTTLE C O N T R O L LEVER S H A F T A . O i l level • Refer t o L u b r i c a t i o n G r o u p o f t h i s Manual. B . T h r o t t l e linkage — Refer t o P a r a g r a p h " T r a n s m i s s i o n and C o n t r o l A d j u s t m e n t s . " TRANSMISSION REGULATOR DIRECT CLUTCH PRESSURE TAKEOFF PLUG Never remove a transmission f r o m a vehicle u n t i l a l l the possible " i n car" causes have been checked f o r the operating difficulty and t h e o i l p a n has been removed t o check f o r d i r t , m e t a l chips, band m a t e r i a l , b r o k e n band ends and burned or scored band contacti n g surfaces. Inspect t h e manual c o n t r o l cable and t h r o t t l e linkage f o r adjustment and wear. LVE 0 NEUTRAL START ; \ G J N E PRESSURE "AKEOFF PLUG CONTROL CABLE ENTRANCE HOLETHROTTLE V A L V E ADJUSTING SCREW- """ ?LUG GOVERNOR 56x110B PRESSURE TAKEOFF PLUG REAR E X T E N S I O N BREATHER Fig, 2—Exterior V i e w s of Transmission line, l u b r i c a t i o n , d i r e c t clutch, governor and t h r o t t l e (Refer t o F i g . 2 ) . These pressures should f a l l w i t h i n specified l i m i t s stated i n H y d r a u l i c C o n t r o l Pressure Check Charts. LATCHED P O S I T I O N LOCK SPRING UNLATCHED POSITION 57x430 Fig. 1—Gearshift Control Unit ( O p e r a t i o n a l Sketch) E . K i c k d o w n band adjustment — The k i c k d o w n band adjustment screw is f o u n d on t h e left side o f transmission case ( F i g . 2 ) . Refer t o P a r a g r a p h 6, "Transmission and C o n t r o l A d j u s t m e n t s . " F . Reverse band adjustment — The o i l p a n m u s t be removed t o m a k e t h i s adjustment. The adjustm e n t is made b y b a c k i n g off a d j u s t i n g screw lock n u t . Torque t h e a d j u s t i n g screw 20 to 25 i n c h pounds torque t h e n back a d j u s t i n g set screw o u t 12 t u r n s . W h i l e h o l d i n g t h e a d j u s t i n g screw a t t h i s position, t i g h t e n lock n u t 30 to 35 foot-pounds torque. 78 — POWERFLITE TRANSMISSION G. Engine idle — A d j u s t to 475 to 500 r . p . m . H . N e u t r a l s t a r t i n g s w i t c h — Check w i r e connections and s w i t c h . N O T E : I f j u m p e r w i r e is used f o r c r a n k i n g engine ( w h e n t a k i n g compression readings, etc.) i t is i m p o r t a n t t h a t j u m p e r leads be connected to b a t t e r y t e r m i n a l s and to s t a r t e r s w i t c h t e r m i n a l (located tow a r d rear of c a r ) of t h e solenoid. I . Handbrake—Check f o r excessive drag. A d j u s t as outlined i n Brakes Group of t h i s manual. J. Regulator valve s p r i n g — may be removed by r e m o v i n g s p r i n g retainer w h i c h is on the mission case ( F i g . 2 ) . Check f o r valve and/or buckled s p r i n g . The regulator valve the r e g u l a t o r valve r i g h t side of t r a n s a stuck or scratched K . Converter c o n t r o l valve, s p r i n g — The conv e r t e r control valve m a y be removed b y r e m o v i n g the converter c o n t r o l valve s p r i n g retainer w h i c h is on r i g h t side of transmission case ( F i g . 2 ) . Check f o r a stuck or scratched valve a n d / o r buckled s p r i n g . face — Check f o r loose bolts, b u r r s or scratches on m a t i n g surfaces. Clean valve body assembly. Check f o r stuck valves, d i r t , scratched valves or body and b u r r s on valves. Torque valve body bolts to specifications. S. Speedometer pinion — Check n y l o n teeth f o r wear, shredding. T. Governor — Clean assembly and check w e i g h t assembly and valve f o r burrs, scratches or s t i c k y operation. E x a m i n e the governor valve shaft, shaft snap r i n g s and seal r i n g s . U . Rear p u m p — Clean and inspect assembly f o r side and d i a m e t r a l clearance. N o t e whether rear o i l p u m p pinion ball is i n place. E x a m i n e o u t p u t shaft support face f o r scoring. a. F r o n t p u m p and d r i v e sleeve — Clean and i n spect assembly f o r side and d i a m e t r a l clearance. E x a m i n e oil p u m p inner and outer r o t o r f o r scoring. Check f r o n t pump d r i v e sleeve seal r i n g . M . O u t p u t shaft rear bearing, snap r i n g — C h e c k f o r r o u g h bearing a n d / o r unseated snap r i n g . Snap r i n g s are available i n t w o sizes. b. Regulator valve body, m a t i n g surfaces, gasket — Clean and inspect valve body f o r scratches and scoring on valve bores and face w h i c h bears against the f r o n t p u m p housing. Examine valve body to determine i f secondary reaction orifice is free of d i r t . Check gasket f o r uniformness of compression by valve body. N . Torque converter housing cooling a i r passages — Check f o r d i r t , m u d or other f o r e i g n m a t e r i a l on screens or torque converter cooling fins. c. Converter — F l u s h out converter and check converter hub runout. (Refer to Torque Converter Page.) O. K i c k d o w n servo, band and linkage — Check f o r broken seal rings, stuck servo piston or broken linkage. d . D i r e c t clutch — Clean and inspect discs, plates, d r i v e hub, r e t u r n s p r i n g and piston. L . B r e a t h e r — Check to determine breather is free of d i r t , undelegating, etc. whether P. Reverse servo, band and linkage — Check f o r t o r n seal, stuck or broken band a n d / o r linkage. Q. O i l strainer and suction tubes — Check f o r possible a i r leakage at f r o n t p u m p suction tube, or rear pump suction tube. R. Valve body a t t a c h i n g bolts and m a t i n g sur- e. Planetary gear set — Clean and inspect gear set f o r w o r n t h r u s t washers, nicked or r o u g h gear teeth and excessive pinion and clearance. f. Seal r i n g s — Check f o r b u r r s , broken ends. N O T E : Refer to F i g u r e 35 f o r i l l u s t r a t i o n showing location of the various drilled passages i n transmission case. SERVICE PROCEDURES 2. O P E H A I i O N P o w e r F l i t e combines a h i g h l y efficient torque conv e r t e r and a simple a u t o m a t i c two-speed transmission w h i c h provides exceptionally smooth performance t h r o u g h o u t the e n t i r e speed range. The transmission is equipped w i t h a n e u t r a l s t a r t i n g safe- t y s w i t c h w h i c h prevents s t a r t i n g the car i n gear. A l l normal d r i v i n g can be done i n the d r i v e ( D ) range, w h i c h accelerates the car i n low range t h e n automatically upshifts t h e transmission i n t o direct d r i v e at the proper t i m e , depending upon the degree of acceleration desired by the d r i v e r . The s h i f t is POWERFLITE TRANSMISSION — 79 f u l l y automatic, allowing t h e d r i v e r t o keep constant pressure on the accelerator a t a l l times. I n stantaneous acceleration, w i t h t h e D ( D r i v e ) push b u t t o n engaged, is accomplished b y pressing the accelerator pedal t o the floor. T h i s action downshifts the transmission to low gear. w i l l move to t h e n e u t r a l position. The d r i v e r is t h e n required t o again select the proper gear range. c. Gearshift Control Housing (Refer to Fig. 1) The L (low) range is provided t o keep the transmission i n low gear regardless of speeds f o r unusual d r i v i n g conditions such as c l i m b i n g o r descending mountains or d r i v i n g t h r o u g h sand. Mechanical connection between the gearshift control housing and t h e transmission manual control valve is obtained t h r o u g h the use of a single push-pull cable. One end o f the w i r e cable is secured to the cable actuator i n the gearshift housing, while the other end enters the transmission case t o engage the manual c o n t r o l valve lever assembly. " R o c k i n g " the car, when m i r e d i n m u d or snow, is easily accomplished by a l t e r n a t e l y engaging t h e R (reverse) and L (low) push buttons. A back-up l i g h t s w i t c h ( w h e n so equipped) is i n corporated i n the g e a r s h i f t control housing and is operated by the R (reverse) push b u t t o n slide. a. Torque Converter d. Neutral Starting Switch The torque converter receives i t s o i l supply at a constant pressure f r o m the f r o n t o i l pump i n t h e transmission. The s t a r t i n g m o t o r is w i r e d i n such a w a y t h a t t h e engine cannot be s t a r t e d unless t h e N ( n e u t r a l ) button is engaged. E n g a g i n g t h e N ( n e u t r a l ) b u t t o n closes the s t a r t i n g m o t o r c i r c u i t at the n e u t r a l s t a r t i n g switch, located on t h e transmission case ( F i g . 2). The u n i t is bolted to and supported by the crankshaft flange. I t consists of three basic p a r t s : an impeller, a t u r b i n e and a stator. The impeller, w h i c h f o r m s the outer sh^ll of the converter u n i t , is d r i v e n by the engine. The t u r b i n e is d r i v e n b y the force o f oil f r o m the impeller vanes. T h e t u r b i n e is splined to the i n p u t shaft of the transmission. The stator, located between the impeller and t u r b i n e , serves to redirect the flow of oil i n t h e u n i t , t h u s m u l t i p l y i n g engine torque. The stator is m o u n t e d on an overr u n n i n g clutch w h i c h permits i t t o r o t a t e only i n the direction of impeller and t u r b i n e r o t a t i o n . e. Starting the Engine (1) A s a safety precaution, apply handbrake foot brake. (2) Push the N ( n e u t r a l ) b u t t o n . (3) Depress accelerator pedal s l i g h t l y . (4) tion. or T u r n i g n i t i o n key t o extreme clockwise posi- T h e torque converter is serviced only as a complete assembly. (5) W h e n engine starts, release pressure on i g n i t i o n key. b. Gearshift Control Push Button 1 Push Starting P o w e r F l i t e Transmission equipped cars have f o u r gearshift control buttons located t o t h e left of t h e steering column on the i n s t r u m e n t panel, as shown i n F i g u r e 1. The buttons, w h i c h control the transmission are identified by the l e t t e r s R (reverse), N ( n e u t r a l ) , D (drive) and L ( l o w ) . T h e buttons are illuminated for night driving. I f t h e engine fails to s t a r t i n the n o r m a l manner, because of a discharged b a t t e r y , i t m a y be started by pushing t h e car. T o w i n g the car to s t a r t is not recommended due to the sudden surge of power w h e n the engine s t a r t s . W h e n operating the gearshift c o n t r o l , the b u t t o n selected must be pushed to the f u l l extent of i t s t r a v e l . T h i s w i l l automatically release a previously selected b u t t o n f o r r e t u r n to i t s n o r m a l position. A hydraulic interlock prevents t h e d r i v e r f r o m i n advertently pushing the R (reverse) b u t t o n t o t h e reverse position when the vehicle is t r a v e l i n g i n t h e D ( d r i v e ) position above 15 m p h . Should the reverse b u t t o n be pushed " i n " a t a speed i n excess of 15 mph., the m a n u a l valve lever T u r n the i g n i t i o n s w i t c h on, then push " i n " on the N ( n e u t r a l ) b u t t o n . A f t e r t h e car has been pushed to a speed of 25 m.p.h. ( a p p r o x i m a t e l y ) , push i n on the L ( l o w ) b u t t o n . T h i s w i l l allow the transmission t o d r i v e the engine by power transm i t t e d f r o m t h e r e a r wheels. g. How to Drive the Vehicle (1) A f t e r t h e engine is started, better fuel econom y and quicker engine w a r m up can be obtained b y s t a r t i n g to d r i v e i m m e d i a t e l y . I f the engine is cold apply the foot brake t o prevent a creep tendency when pushing t h e b u t t o n s i n D (drive) or R (re- 80 —POWERFLITE TRANSMISSION LINE P R E S S U R E CHART Gearshift Position Rear Wheels Engine Speed Line Pressure R* N D* Free to T u r n 1400 R . P . M . 800 R . P . M . 800 R . P . M . 225 to 275 P.S.I. 85 t o 95 P.S.I. 85 to 95 P.S.I. Brakes A p p l i e d * Engine m u s t be at operating temperature. verse) positions and avoid fast acceleration d r i v i n g (regardless of the m i l e a g e ) . (5) K i c k d o w n or forced d o w n s h i f t -— A t speeds between 15 to a p p r o x i m a t e l y 55 m p h i n D ( d r i v e ) , after the transmission has upshifted t o direct, m a x i m u m acceleration can be obtained f o r passing or c l i m b i n g a steep grade by pressing the accelerator wide open. T h i s w i l l cause the transmission to downs h i f t . I t w i l l automatically u p s h i f t to direct i f the accelerator is released or a speed o f about 61 m p h is reached. A n y v a r i a t i o n i n d o w n s h i f t speed l i m i t s m a y be due to permissible o p e r a t i n g fluid leakage w i t h i n t h e transmission, when (2) A l l n o r m a l d r i v i n g w i l l be done i n D ( d r i v e ) range. The vehicle w i l l have a s l i g h t tendency t o creep after p u s h i n g the b u t t o n f r o m N ( n e u t r a l ) to D ( d r i v e ) at idle due to s l i g h t torque o u t p u t f r o m t h e torque converter. T h i s can be prevented b y app l y i n g the foot brake. A s soon as the accelerator is depressed, the vehicle w i l l move f o r w a r d i n the d r i v e ( b r e a k a w a y ) range. A t speed o f between a p p r o x i m a t e l y 15 and 61 mph and the a m o u n t the accelerator is depressed, the transmission w i l l u p s h i f t to direct. W h e n s l o w i n g the car d o w n at t h r o t t l e openings s h o r t , of wide open, the transmission w i l l a u t o m a t i c a l l y d o w n s h i f t f r o m a p p r o x i m a t e l y 9 t o 11 m p h . h. Towing (1) Transmission inoperative — T o w t h e car w i t h a rear end pickup or remove the propeller shaft. ( 2 ) Transmission O p e r a t i n g P r o p e r l y — The car m a y be towed safely i n N ( n e u t r a l ) at moderate speeds. However, f o r long distance t o w i n g (over 100 m i l e s ) , the propeller shaft should be removed. ( 3 ) L ( l o w ) provides d r i v i n g characteristics s i m i l a r to D ( d r i v e ) except the t r a n s m i s s i o n w i l l n o t u p s h i f t ( i n t o d i r e c t ) at any car speed. T h i s position provides excellent h a n d l i n g ease i n m o u n t a i n d r i v i n g and superior p u l l i n g qualities i n sand and snow. I t is possible to push the buttons f r o m L ( l o w ) to D ( d r i v e ) and D ( d r i v e ) to L ( l o w ) at a n y speed below 65 m p h . Damage m a y result i f a s h i f t f r o m D ( d r i v e ) to L ( l o w ) is made above 65 m p h . L Checking Fluid Level Refer to L u b r i c a t i o n Group O o f t h i s manual. 3. HYDRAULIC C O N T I O L PRESSURE CHECKS a. Line Pressure Remove the pipe p l u g f r o m the line pressure takeoff hole located on the f r o n t left side of the t r a n s mission case ( F i g . 2 ) . I n s t a l l pressure gauge, Tool C-3293 (300 p s i ) , at t h i s p o i n t . (4) Reverse — Stop the vehicle and w i t h the foot brake applied, push the R (reverse) b u t t o n t o f u l l l i m i t of t r a v e l . U p o n depressing t h e accelerator, the vehicle w i l l move i n reverse. Do n o t depress the R (reverse) b u t t o n w h e n the car is m o v i n g f o r w a r d at a speed above 5 m p h . b. Throttle Pressure Remove the p l u g f r o m the t h r o t t l e pressure take-off hole located on the r i g h t - h a n d side of the t r a n s m i s - THROTTLE PRESSURE *Do Gearshift Position D D CHART Brakes T h r o t t l e Engine Speed Throttle Pressure A p p l i e d Closed A p p l i e d W i d e Open* Idle 1400 to 1500 R . P . M . 13 t o 15 P.S.I. 80 t o 90 P.S.I. not hold t h r o t t l e wide open f o r longer t h a n a few seconds. POWERFLITE TRANSMISSION— 81 GOVERNOR PRESSURE CHART Gearshift Position Car Speed Wheels Governor Pressure D Free to T u r n I S t o 15 M . P . H . 15 P.S.I. D Free t o T u r n 24 t o 82 M . P . H . 45 P.S.I. D Free to T u r n 51 t o 60 M . P . H . 60 P.S.L sion ease ( F i g . 2 ) . I n s t a l l pressure gauge, Tool C-3292 (100 p s i ) , at t h i s point. W h e n checking t h r o t t l e pressure, always follow up by checking t h r o t t l e linkage adjustment (Parag r a p h 6 ) . I f t h r o t t l e pressure does n o t conform t o specifications, refer to Paragraph 6. c. Governor Pressure Remove the pipe p l u g f r o m the governor pressure take-off hole located on the lower l e f t side of the output s h a f t support ( F i g . 2 ) . I n s t a l l pressure gauge, Tool C-3292 (100 p s i ) , at t h i s p o i n t . d. Direct Clutch Pressure Remove t h e pipe p l u g f i t t i n g f r o m t h e pressure takeoff hole tapped i n the k i c k d o w n servo ( F i g . 2) and install pressure gauge, Tool C-3292 (100 p s i ) . W i t h the rear wheels free to t u r n , accelerate t h e engine slowly u n t i l an u p s h i f t occurs. D u r i n g the upshift, the pressure gauge attached to the k i c k d o w n servo should show a v e r y r a p i d pressure rise f r o m 0 to final c l u t c h or line pressure. T h i s rise should n o t take more t h a n l / to 2 seconds. l 2 W i t h an engine speed o f n o t less t h a n 650 r p m (transmission upshifted) the direct clutch pressure should read not lower t h a n 10 psi below line pressure. Should a slow rise i n clutch pressure be observed, or a clutch pressure of more t h a n 10 psi lower t h a n line pressure be obtained, i t is an i n d i c a t i o n o f abn o r m a l leakage. e. Lubrication Pressure Remove the oil cooler f i t t i n g f r o m the l u b r i c a t i o n pressure take-off hole located on the l e f t side of t h e transmission case ( F i g . 2 ) . I n s t a l l gauge, Tool C3292 (100 p s i ) . W i t h engine r u n n i n g at 800 r p m I n neutral, l u b r i c a t i o n pressure should read not below 10 psi m i n i m u m . I f t h e pressure Is Incorrect, check line pressure and T r o u b l e Diagnosis Chart, 4. CHECKING F O R O I L LEAKS I f the transmission Is leaking oil, check the f o l l o w i n g points: a. Leaks Not Requiring Removal of Transmission from Vehicle (1) Transmission o u t p u t shaft rear oil seal. (2) Speedometer pinion assembly. (3) O i l filler tube to oil pan connector. (4) O i l pan to transmission case. (5) Regulator valve and torque converter control valve retainers. (6) Test pressure hole plugs. ( 7 ) I f oil is found inside converter housing, check torque converter d r a i n plug. Leaks at these locations should be corrected regardless of how s l i g h t . b. Leaks Requiring Removal of Transmission from Vehicle (1) Sand hole i n transmission case. (2) Sand hole i n f r o n t oil p u m p housing. (3) F r o n t o i l pump housing bolts loose or sealing washers damaged. (4) Torque converter impeller hub seal (located on f o r w a r d end of f r o n t o i l p u m p h o u s i n g ) . W h e n correcting, make sure torque converter hub r u n o u t is w i t h i n l i m i t s . (Refer to Torque Converter, Page —). (5) F r o n t oil pump housing o i l seal (located on outside diameter o f f r o n t o i l p u m p h o u s i n g ) . W h e n replacement of the f r o n t o i l p u m p housing is made or whenever i t is necessary t o correct a leak due to t h i s " O " seal r i n g , the f o l l o w i n g precautions should be t a k e n : ( a ) I n s t a l l a new " O " r i n g seal i n i t s groove i n the f r o n t oil pump housing. ( b ) Make sure t h a t the seal has n o t been t w i s t e d d u r i n g t h i s i n s t a l l a t i o n , as t h i s alone w i l l cause a leak. (c) Measure the amount t h e seal protrudes above 82 — POWERFLITE TRANSMISSION t h e f r o n t o i l p u m p housing completely around t h e O.D. I f , a t any point, the seal protrudes less t h a n .010 inch, or i f considerable v a r i a t i o n exists i n t h e amount t h e seal protrudes, a new f r o n t pump housing should be selected. Leaks at these points m a y be remedied b y t i g h t e n i n g loose bolts or replacing damaged or f a u l t y parts. (2) Remove gearshift c o n t r o l housing and cable as outlined under " S e r v i c i n g Gearshift Control U n i t , " Removal, Paragraph 5. ( 3 ) F r o m inside of vehicle, pull cable assembly t h r o u g h rubber g r o m m e t (or remove g r o m m e t ) i n dash panel. 5. SERVICING GEARSHIFT CONTROL UNIT a. Removing Gearshift Control Unit (1) mission assembly, as outlined under "Removal and Inspection o f Cable Assembly—Transmission E n d , " Paragraph 5 " G " , steps 1 and 2. d. Disconnect one b a t t e r y cable. ( 2 ) Disconnect back-up l i g h t s w i t c h ( i f so equipped) and i l l u m i n a t i n g lamp lead wires, a t the rear of the i n s t r u m e n t panel. ( 3 ) Remove the push b u t t o n face plate screws, t h e n remove t h e push b u t t o n s b y p u l l i n g t h e m off the push b u t t o n slide. Remove lamp bolt. ( 4 ) Remove t h e c o n t r o l housing stud n u t s t h a t are now accessible and remove c o n t r o l and cable f r o m r e a r of i n s t r u m e n t panel. ( 5 ) Remove h a i r p i n securing c o n t r o l cable to actuator and the screws h o l d i n g the cable bracket to t h e c o n t r o l housing. b. Installing Gearshift Control Unit Installing Gearshift Control Cable (1) F r o m inside of vehicle, i n s t a l l transmission end of cable t h r o u g h rubber g r o m m e t i n dash panel. (2) I n s t a l l cable at g e a r s h i f control housing as outlined i n "Servicing Gearshift C o n t r o l U n i t , " I n stallation, Paragraph 5. ( 3 ) I n s t a l l cable assembly i n t o transmission case. (Refer to P a r a g r a p h 5, " A d j u s t i n g the Gearshift Control Cable.) e. Replacing the Back-Up Light Switch (when so equipped) ( 1 ) Remove gearshift c o n t r o l housing and plate assembly as outlined under " S e r v i c i n g Gearshift Control U n i t , " Removal, Paragraph 5. ( 1 ) I n s e r t end o f cable o n actuator and reassemble h a i r p i n clip. Place cable bracket on control u n i t and i n s t a l l screws securely ( F i g . 3 ) . ( 2 ) Back-up l i g h t s w i t c h is fastened to the cont r o l u n i t b y four tabs. S t r a i g h t e n tabs to remove switch. (2) Carefully guide the u n i t i n t o position f r o m the r e a r of the i n s t r u m e n t panel and i n s t a l l t h e att a c h i n g s t u d nuts f r o m the f r o n t side of the i n s t r u m e n t panel. ( 3 ) I n s t a l l repaired or replacement s w i t c h and bend tabs to secure s w i t c h to gearshift control housing. ( 3 ) I n s t a l l l a m p bulb i n push b u t t o n c o n t r o l and r e i n s t a l l push b u t t o n s onto c o n t r o l actuator slides. Replace face plate. (4) I n s t a l l gearshift control housing assembly. f. Replacing Push Button Unit Lamp Bulb (1) Remove the face plate r e t a i n i n g screws. (4) Connect back-up s w i t c h and push b u t t o n i l l u m i n a t i n g l a m p wires. (2) ance. c. Removing Gearshift Control Cable (3) Replace defective or burned out bulb, using Tool C-3399. (1) Remove g e a r s h i f t c o n t r o l cable f r o m trans- (4) CABLE i BRACKET . / / CABLE ASSY. ^ ^ ^ ^ ACTUATOR^ Fig. HAiRP^CLIP 56x55 A 3—Exterior V i e w of Gearshift Control Housing (Typical) Remove one or more push buttons f o r clear- Replace face plate. Test operation of u n i t . g. Removal and Inspection of Cable Assembly (Transmission End) (1) Push i n the R (reverse) push b u t t o n to posit i o n cable adapter f o r removal of cable lock s p r i n g , and placing cable adapter i n close p r o x i m i t y to cable entrance hole i n transmission case ( f o r r e i n s t a l l a t i o n of cable). Raise car on hoist and remove n e u t r a l s t a r t i n g s w i t c h f r o m transmission case. Some fluid w i l l d r a i n out. Transmission fluid m a y be h o t ! I POWERFLITE TRANSMISSION — 8 3 ( 2 ) Loosen cable to transmission adjustable m o u n t i n g bracket screw. Place screwdriver blade t h r o u g h n e u t r a l s t a r t i n g s w i t c h hole, and push against cable lock s p r i n g . W i t h the other hand, w i t h d r a w cable assembly f r o m transmission case. (3) E x a m i n e " 0 " r i n g seal on cable f e r r u l e . Replace seal i f i t shows signs o f roughness, shredding or d e t e r i o r a t i o n . Inspect f i t of bracket slot and cable f e r r u l e groove. The bracket should f i t j u s t freely i n t o f e r r u l e groove t o f u l l depth o f bracket slot. I f cable bracket slotted section does not meet t h i s requirement, remove excess m e t a l w i t h a file. 6. TRANSMISSION AND CONTROLS — ADJUSTMENTS a. Throttle Pressure and Throttle Linkage Adjustment A c c u r a t e adjustment of the transmission t h r o t t l e linkage and s e t t i n g of the t h r o t t l e o i l pressure is v e r y i m p o r t a n t f o r proper operation of t h e PowerF l i t e transmission. Therefore, t h e f o l l o w i n g procedures should be v e r y carefully p e r f o r m e d : b. Throttle Linkage Adjustments (Refer to Fig. 4) ( 1 ) W i t h the engine at o p e r a t i n g temperature, c a r b u r e t o r off the fast idle cam and t r a n s m i s s i o n i n n e u t r a l , adjust idle speed to 475-500 r . p . m . (use tachometer). ( 2 ) Loosen the t h r o t t l e linkage a d j u s t m e n t lock nuts on b o t h the carburetor r o d and the transmission throttle rod. ( 3 ) I n s e r t a 3 / 1 6 " r o d or d r i l l b i t i n the hole and open slot of the accelerator shaft bracket and i n t o the elongated hole of the t h r o t t l e lever. ( 4 ) W i t h the r o d i n position, hold the t r a n s m i s sion t h r o t t l e valve lever all the w a y f o r w a r d (closed p o s i t i o n ) , and t i g h t e n transmission to accelerator lever assembly rod a d j u s t i n g lock n u t " A " , F i g u r e 4. ( 5 ) Remove r o d f r o m accelerator lever, shaft and b r a c k e t assembly. ( 6 ) W i t h the carburetor t h r o t t l e lever off t h e idle cam and against the idle stop screw, move r e a r h a l f of the c a r b u r e t o r r o d r e a r w a r d u n t i l stop i n the transmission is felt, t i g h t e n lock " B " , F i g u r e 4. fast the the nut ( 7 ) The accelerator pedal should be at an angle of 113 t o 114 degrees to the h o r i z o n t a l . I f necessary to correct, adjust pedal angle by r e m o v i n g the accelerat o r pedal end of the bellcrank to pedal rod, and s h o r t e n i n g or l e n g t h e n i n g the r o d by loosening t h e lock n u t at t h e swivel end and r o t a t i n g the swivel. R e i n s t a l l the r o d and t i g h t e n the lock n u t . Be sure the rod is properly aligned to prevent binding. Poor engine performance due to carburetor throttle not opening fully or lack of kickdown may result if accelerator pedal angle is incorrect. c. Throttle Pressure Adjustment ( 1 ) W i t h t h r o t t l e linkage properly adjusted and tachometer attached, s t a r t engine and recheck idle s e t t i n g (475-500 r p m ) w i t h transmission i n n e u t r a l and h a n d brake set. Raise vehicle on hoist. ( 2 ) Remove the t h r o t t l e oil pressure take off p l u g located between reverse and k i c k d o w n servos on r i g h t side of transmission. (Refer to F i g . 2.) Connect 100 psi pressure gauge, Tool C-3292. (3) Push i n the D ( D r i v e ) push b u t t o n . ( W h e n the manual c o n t r o l lever is moved i n t o d r i v e range, engine speed w i l l drop a p p r o x i m a t e l y 50 r p m ) . Check t h r o t t l e pressure. Oil pressure should read 13 t o 15 psi. I f t h e pressure is not w i t h i n specifications, adjust as f o l l o w s : ( 4 ) Remove the t h r o t t l e valve a d j u s t i n g screw p l u g ( F i g . 2 ) . A b o u t 1 q u a r t of transmission fluid w i l l d r a i n out. ( 5 ) I n s e r t a d j u s t i n g screw wrench, Tool C-3279A, and adjust t h r o t t l e pressure to 13-15 psi, as shown i n F i g u r e 5. T u r n screw O U T to increase pressure and I N to decrease pressure. ( 6 ) Replace the t h r o t t l e valve a d j u s t i n g p l u g and torque f r o m 20 to 25 foot-pounds. ADJUSTMENT LOCK NUT " A " Fig. 4—Throttle Linkage Adjustment 60x171 screw ( 7 ) W i t h the accelerator pedal f u l l y released, and engine at 475 to 500 r p m , the pressure should read 13 to 15 psi. 84 — POWERFLITE TRANSMISSION N E U T R A L STARTER SWITCH C A M Fig. 7—Neutral S t o r t i n g Switch C a m Centered i n Switch M o u n t i n g Fig. 5—Adjusting T h r o t t l e Pressure (Typical) ( 8 ) Move t h e accelerator pedal or lever f r o m u n derneath, v e r y slowly. W i t h t h r o t t l e pressure and l i n k a g e p r o p e r l y adj u s t e d , t h e t h r o t t l e pressure w i l l rise ( a p p r o x i m a t e l y 6-8 psi) the i n s t a n t engine r p m Is increased. Do not use t h r o t t l e r o d . W h e n m a k i n g t h i s check, use accele r a t o r pedal lever located on underside of floor pan. ( 9 ) Remove oil pressure gauge and i n s t a l l p l u g . Torque f r o m 10 to 12 foot-pounds. ( 1 0 ) I f t h e t h r o t t l e pressure was adjusted, replace the fluid t h a t drained out, w i t h A u t o m a t i c T r a n s m i s s i o n F l u i d ( T y p e " A " , Suffix " A " ) . ( 1 1 ) Check accelerator pedal h e i g h t at wide open t h r o t t l e . There should be sufficient clearance between t h e t i p o f the pedal and t h e floor m a t . A d j u s t pedal t o accelerator shaft r o d assembly. d. Adjustment of Kickdown (Front) B a n d ( 1 ) U s i n g a % i n c h open-end w r e n c h loosen t h e Hole locknut ( F i g . 2 ) . Check the freeness of the a d j u s t i n g screw i n t h e transmission case. I f free, use i n c h pound torque wrench, Tool C-3380 ( w i t h extension C-3583), and t i g h t e n t h e a d j u s t i n g screw f r o m 40-43 inch-pounds* torque. D i s r e g a r d m u l t i p l i c a t i o n f a c t o r on Extension, C-3583. Use a reference m a r k of chalk or colored pencil on t h e corner of the a d j u s t i n g screw square and t h e transmission case. U s i n g extreme care, back the a d j u s t i n g sc^ew out exactly 2 % t u r n s . N o w , hold t h e a d j u s t i n g screw s t a t i o n a r y w i t h wrench and t i g h t e n the l o c k n u t securely. E x t r e m e care m u s t be exercised i n perf o r m i n g t h i s operation to insure correct a d j u s t m e n t otherwise serious damage w i l l occur w h e n t r a n s m i s sion is operated. * I f Tool C-3380 ( w i t h extension C-3583) Is n o t used, t h e n , use wrench, Tool C-3380, and t i g h t e n a d j u s t i n g screw t o 72 inch-pounds torque. e e R e v e r s e (Bear) B a n d A d j u s t m e n t ( 1 ) D r a i n transmission and remove transmission oil pan. ( 2 ) Loosen reverse band a d j u s t i n g screw l o c k n u t and t i g h t e n a d j u s t i n g screw f r o m 20 to 25 i n c h pounds, as shown i n F i g u r e 6. Rack o u t a d j u s t i n g screw 12 t u r n s . H o l d i n g a d j u s t i n g screw i n t h i s locat i o n , t i g h t e n l o c k n u t securely (30-35 foot-pounds torque). ( 3 ) Replace the transmission o i l pan, u s i n g a new gasket and refill transmission w i t h A u t o m a t i c T r a n s mission F l u i d , Type " A " , Suffix " A " . f. Adjusting the Gearshift Control Cable Fig. 6—Adjusting the Reverse l a n d (Typical) Push i n L ( l o w ) push b u t t o n . Place t r a n s m i s s i o n manual valve lever i n reverse detent b y m o v i n g n e u t r a l s w i t c h contact p a r t of lever f u l l t r a v e l t o w a r d s rear of car manually, b y u s i n g screwdriver (or other suitable tool) i n n e u t r a l s t a r t i n g s w i t c h hole. W i t h L ( l o w ) push b u t t o n held t i g h t l y i n ( f u l l POWERFLITE TRANSMISSION — 85 t r a v e l ) , i n s e r t cable assembly i n t o t r a n s m i s s i o n case engaging cable f e r r u l e groove w i t h lock s p r i n g i n cable adapter. P u s h and p u l l the cable, using l i g h t pressure, to be sure groove i n cable f e r r u l e has engaged lock s p r i n g . Replace adjustable m o u n t i n g bracket and t i g h t e n cap screw finger t i g h t . g. Cable and Neutral Starting Switch Adjustment Move the cable and bracket assembly ( m a n u a l l y ) at the transmission, as required, t o position the manual valve lever i n t o n e u t r a l detent. H o l d the N ( n e u t r a l ) b u t t o n t i g h t l y " i n " a t f u l l t r a v e l . The n e u t r a l s t a r t i n g s w i t c h cam should t h e n be centered i n the n e u t r a l s t a r t i n g s w i t c h hole, as shown i n F i g u r e 7. Use a f r e e - f i t t i n g flat-faced shaft, inserted t h r o u g h the n e u t r a l s w i t c h m o u n t i n g hole ( F i g . 8 ) , and apply l i g h t pressure against t h e m a n u a l valve lever to m a i n t a i n t h e n e u t r a l detent position of the manual lever. I f tool is not available, lever m a y be held by finger pressure. Carefully move cable assembly " i n " and " o u t " w i t h o u t m o v i n g t h e manual lever, t o determine t o t a l free play t r a v e l o f cable. Locate the cable i n m i d position o f the free play, release the pressure against the manual lever and t i g h t e n the m o u n t i n g bracket securely. Do not allow the cable to move when tightening the bracket. N O T E : Excessive tightening may damage case and interfere with push button control. Check transmission fluid level L u b r i c a t i o n Group of t h i s M a n u a l . l s 2 Frp J&a outlined i n h. Road Testing W h e n f a u l t y operation of the t r a n s m i s s i o n is reported, t r a n s m i s s i o n fluid level and engine idle should be checked before a n y t h i n g else. Good transmission operation also depends on good engine operation. Therefore, before b l a m i n g any r o u g h s h i f t i n g on the transmission, i t is necessary to make sure t h e engine is o p e r a t i n g at f u l l efficiency. If, when tuning the engine, the throttle linkage between the carburetor and the transmission is disturbed, it will be necessary to readjust the linkage. Refer to "Throttle Pressure and Throttle Linkage Adjustment," Paragraph 6. A f t e r all t h e adjustments and pressure checks are completed, road test the car under v a r y i n g road conditions. The t r a n s m i s s i o n should respond according to t h e f o l l o w i n g s h i f t p a t t e r n s : A l l shift speeds may vary somewhat due to production tolerances, however, the quality of the shifts should be smooth, responsive, and without noticeable engine runaway. Replace the n e u t r a l s t a r t i n g s w i t c h . I n s t a l l the concave (cupped) s p r i n g washer over t h e threads of the n e u t r a l s t a r t i n g s w i t c h so t h a t the concave (cupped) side of the washer is t o w a r d t h e t r a n s m i s sion case. I n s t a l l the " 0 " r i n g seal over the threads of the n e u t r a l s t a r t i n g s w i t c h and u p against the washer. W i t h proper cable adjustment assured and N (neut r a l ) b u t t o n depressed, make c e r t a i n t h a t s w i t c h is properly aligned i n center of n e u t r a l s t a r t i n g s w i t c h hole. W i t h test leads connected t o b a t t e r y c u r r e n t and t e r m i n a l of t h e s w i t c h , screw s w i t c h i n t o transmission case u n t i l test l i g h t l i g h t s , t h e n t u r n s w i t c h an additional / t o y t u r n . Do n o t exceed 75 footpounds torque. as • • PS l g C A B l £ RETAINER FERRULE x 56 x ",54A Fig. N E U T R A L STARTER SWITCH C A M 8—"Locking" M a n u a l V a l v e Lever in Neutral Position (Oil Pan Removed fro Show Operation) p g m ^ i aaa I3M sate tJsi CJU B Upshift Downshift Light Throttle Wide Open Throttle Light Throttle Wide Open Throttle Kickdown Limit 14 t o 19 51 to 61 9 t o 11 9 to 17 41 to 57 86 —POWERFLITE TRANSMISSION ? 0 REMOVING TRANSMISSION F R O M VEHICLE ( 1 ) D r a i n transmission b y disconnecting o i l filler tube connector at o i l pan. Remove torque converter housing cover. Then, remove the torque converter d r a i n plug. A f t e r d r a i n i n g , replace p l u g and t i g h t e n securely. Replace torque converter housing cover. Remove oil cooler lines f r o m t h e transmission. ( 2 ) Disconnect f r o n t propeller shaft j o i n t and secure shaft to frame. universal ( 3 ) Remove brake a d j u s t i n g screw cover plate and loosen cable clamp bolt on hand brake cable support. Disengage ball end of handbrake cable f r o m operati n g lever and remove cable f r o m handbrake cable support. ( 4 ) Disconnect speedometer cable and housing. To avoid damage to neutral starting switch, remove switch from transmission case before removing transmission from vehicle. ( 5 ) Disconnect t h r o t t l e linkage f r o m lever transmission. Remove g e a r s h i f t control cable. at ( 6 ) Remove engine rear support insulator bolts f r o m crossmember. ( 7 ) I n s t a l l engine support f i x t u r e , Tool C-3487. A d j u s t f i x t u r e to support w e i g h t o f engine and raise engine s l i g h t l y . ( 8 ) Remove crossmember to t o r s i o n bar support bracket bolts. Remove t h e rear m o t o r support i n sulator bolts to support bracket, t h e n remove t h e complete support assembly f r o m t h e crossmember. W h e n using F i x t u r e , Tool C-3487, do not lower engine more t h a n three inches f r o m floor pan to avoid dist u r b i n g the set position of w a t e r hoses and other engine attachments. ( 9 ) Support transmission w i t h a suitable j a c k . Remove the t w o upper transmission case to conv e r t e r housing screws and lockwasher. I n s t a l l guide studs, Tool C-3276. i Fig. 10—Checking Transmission End Clearance (10) Remove t h e t w o lower transmission case to converter housing screws and lockwashers. Slide j a c k and transmission s t r a i g h t back to avoid damagi n g the f r o n t pump d r i v e sleeve. A f t e r r e m o v i n g transmission f r o m the vehicle, attach fixture, Tool C-3280, and i n v e r t transmission assembly, as shown i n F i g u r e 9. 8. DISASSEMBLY AND INSPECTION ( 1 ) Remove the f r o n t o i l pump d r i v e sleeve and inspect. Check the d r i v e lugs and machined surfaces for b u r r s and wear. Inspect seal r i n g f o r brittleness and shredding. ( 2 ) Remove the bolts and lockwashers w h i c h hold the engine rear support adapter t o extension housing. ( 3 ) Loosen the t h r o t t l e control lever assembly locking screw. Slide the t h r o t t l e control lever assemb l y off the shaft and remove the f e l t retainer and felt. Inspect t h r o t t l e control lever f o r wear. ( 4 ) Remove the oil pan bolts, o i l pan, and gasket. ( 5 ) Remove the o i l strainer support bolts and washers. Inspect seal r i n g s located at b o t h outlets of strainer. ( 6 ) Remove the five t r a n s f e r plate bolts and lockwashers. Remove the valve body and t r a n s f e r plate assembly f r o m transmission case. Remove t h r o t t l e valve camshaft sleeve " 0 " r i n g seal. Discard seal i f t o r n or shredded. The valve body m a t i n g surfaces are machined. W o r k carefully to avoid damaging these surfaces. Place valve body i n stand, Tool C3294. a. Checking Transmission End Play Fig. 9—Transmission Inverted in Repair Stand P r i o r to removal of propeller shaft flange and d r u m POWERFLITE TRANSMISSION — 87 assembly, check end clearance of f r o n t clutch piston r e t a i n e r assembly using dial indicator, Tool C-3339, as shown i n F i g u r e 10. ( 1 ) P r y f r o n t clutch f o r w a r d b y i n s e r t i n g screwd r i v e r between the direct c l u t c h assembly and pinion c a r r i e r housing. ( 2 ) Remove s c r e w d r i v e r ; and w i t h dial indicator point c o n t a c t i n g edge of direct clutch retainer, set dial i n d i c a t o r to zero. P r y direct clutch assembly r e a r w a r d against p i n i o n c a r r i e r housing, remove screwdriver, and take i n d i c a t o r reading. Clearance should be f r o m .026 to .052 inch. I f t h i s clearance exceeds the specified l i m i t , p a r t i c u l a r a t t e n t i o n should be shown to t h e condition of the direct clutch r e t a i n e r t h r u s t washer w h e n disassembling transmission. Record the a m o u n t o f end clearance so t h a t t h e proper thickness fiber t h r u s t washer can be i n stalled a t assembly. ' I f clearance exceeds .052 inch, i n s t a l l a t h i c k e r direct c l u t c h p i s t o n r e t a i n e r t h r u s t washer ( f i b e r ) . I f clearance is less t h a n .026 inch, i n s t a l l a t h i n n e r washer. The t h r u s t washer is selectively fit and is available i n the f o l l o w i n g thicknesses: .078-.080, .095-.097, .112-.114 inch. b. Removal of Hand Brake Assembly ( 1 ) U s i n g w r e n c h , Tool C-3281, t o hold the m a i n shaft, as shown i n F i g u r e 1 1 , remove t h e t r a n s m i s sion flange n u t and washer. ( 2 ) I n s t a l l puller, Tool C-452, to remove brake d r u m and flange assembly. ( 3 ) U s i n g a suitable d r i f t , remove p i n w h i c h secures the brake shoe anchor i n extension. Remove t h e brake support grease shield s p r i n g and remove shield. I f a screwdriver or sharp i n s t r u m e n t is used i n r e m o v i n g shield, care m u s t be exercised to avoid d a m a g i n g t h e neoprene sealing surface at t h e b o t t o m of t h e shield. ^ 53x60 Fig. 12—Removal a n d Installation of Speedometer Drive Pinion ( 4 ) Slide t h e hand brake assembly i n t a c t f r o m extension housing. c. Removal, Disassembly and Inspection of Transmission Extension ( 1 ) Remove t h e speedometer drive p i n i o n and sleeve assembly, as shown i n F i g u r e 12. The nylon gear can be easily damaged if extension housing is removed without first removing the speedometer drive pinion. ( 2 ) Inspect the o u t p u t shaft rear b e a r i n g o i l seal and remove, i f necessary, b y using puller, Tool C-748. Remove any b u r r s f r o m counter-bore o f extension housing. ( 3 ) Remove the seven t r a n s m i s s i o n extension to case screws and lockwashers. ( 4 ) I n s t a l l guide studs, Tool C-3283, and remove O J TP J T SHATT SUPPORT PCT/*-N N'G SCRfcv. GOVERNOR ; •f BODY GOVERNOR LOCATING SCREW TOOL G O V E R N O R VALVE SHA-T ~ _—-r.* GOVERNOR V A L V E — — ^ Fig. 11—Holding Output Shaft While Removing . Fig. 13—Removal a n d Installation of 57v98 Nut Governor V a l v e a n d Shaft 53 13A X 88 —POWERFLITE TRANSMISSION OUTPUT SHAFT SUPPORT GOVERNOR B O D Y REAR OIL PUMP HOUSING G O V E R N O R BODY SUPPORT GOVERNOR BODY GOVERNOR ^-WEIGHT ASSEMBLY GOVERNOR SUPPORT PISTON RINGS 53x73 53x14 Fig. 14—Removal and Installation of Governor Weight Assembly Fig. 16—Removal and Installation of Governor Body and Support extension assembly b y carefully t a p p i n g assembly r e a r w a r d , using a soft hammer. Remove t r a n s m i s sion extension gasket and discard. w e i g h t assembly snap r i n g (large one), and remove the governor w e i g h t assembly f r o m the governor body ( F i g . 1 4 ) . Remove governor secondary w e i g h t snap r i n g ( F i g . 15) using pliers, Tool C-3229. (4) Remove governor secondary w e i g h t and s p r i n g and the intermediate w e i g h t . Inspect all parts ( F i g . 15) f o r b u r r s and wear. Check intermediate w e i g h t for free movement i n p r i m a r y w e i g h t b y placing intermediate w e i g h t i n p r i m a r y w e i g h t . I n t e r m e d i ate w e i g h t should f a l l freely w h e n b o t h parts are clean and d r y . Inspect s p r i n g f o r d i s t o r t i o n and i n spect secondary w e i g h t . ( 5 ) Remove governor locating screw f r o m the governor body and output shaft. ( 6 ) Slide governor body and support f r o m o u t p u t shaft ( F i g . 1 6 ) . Remove and inspect the t w o governor support piston rings. (7) Remove the f o u r governor body to support OUTPUT SHAFT S U P P O R T 'PUMP PINION (5) Do not remove extension bearing unless i n spection reveals i t is necessary. Never reuse a beari n g w h i c h has been removed. I f necessary to remove bearing, remove the o u t p u t shaft rear bearing snap r i n g . Inspect r i n g f o r d i s t o r t i o n . Use driver, Tool C-3275, and drive b e a r i n g out o f extension housing. d. Removal, Disassembly and Inspection of Governor (1) Loosen governor body t o support screws t o aid i n removal o f governor assembly. (2) U s i n g a s h a r p i n s t r u m e n t , such as an ice pick, remove the governor valve shaft snap r i n g ( w e i g h t end) and remove the governor valve shaft and valve f r o m governor valve body assembly ( F i g . 1 3 ) . (3) U s i n g pliers, Tool C-760, remove the governor R (CUTER) WEIGHT INTERMEDIATE f c A R Q J L /OUTPUT SHAFT REAR OIL PUMP. HOUSING WEIG.-T S?.*ING SECONDARY (INNER) WEIGHT • SNAP I v G .56x26 Fig. 15—Governor Weight Assembly (Exploded View) wvm ' 'C-3283 GUIDE STUDS Fig. 17—Removal and Installation of Rear Oil Pump Housing POWERFLITE TRANSMISSION — 89 TOOL ^ 53x66 Fig. 18—Checking Clearance Between _ Pump Body and Gears screws and lockwashers and separate body f r o m supp o r t . M a t i n g surfaces are machined and can be easily damaged. Inspect o i l passages. Clean passages t h o r oughly w i t h compressed air. Inspect valve and governor body f o r scores. Check ball p l u g i n face o f governor. e. Removal, Disassembly and Inspection of Rear O i l Pump ( 1 ) Remove the five rear oil p u m p housing to outp u t shaft support screws and lockwashers. Remove rear o i l pump housing, as shown i n F i g u r e 17. Use dye to m a r k f r o n t side o f gear i n housing. B o not use scribe. Inspect machined surfaces f o r nicks and b u r r s , the o i l p u m p gear and housing f o r scoring or p i t t i n g and p u m p housing plugs f o r leaks. ( 2 ) Remove rear oil p u m p p i n i o n f r o m o u t p u t shaft and m a r k f r o n t side w i t h dye. The o i l p u m p p i n i o n is keyed to o u t p u t shaft b y a small ball. W h e n r e m o v i n g p i n i o n , do n o t lose t h e ball. Inspect k e y w a y i n pinion and ball pocket i n o u t p u t shaft f o r ' w e a r , and also the gear f o r p i t t i n g 56 x "156 Fig. 20—Removing or installing Reverse Band or scoring. ( 3 ) U s i n g straightedge, Tool C-3335, and feeler gauge, check clearance between p u m p housing face and face of gears as shown i n F i g u r e 18. Clearance l i m i t s are f r o m .001 to .003 inch. f. Removal of Output Shaft Support, Planet Pinion Carriers, and Direct Clutch Assemblies ( 1 ) Remove o u t p u t shaft support t o transmission case screw and washer ( F i g . 1 3 ) . Loosen reverse band a d j u s t i n g screw and l o c k n u t to release any tension of reverse band on c a r r i e r housing. Grasping o u t p u t shaft i n b o t h hands, carefully w o r k shaft, planet p i n i o n carrier assemblies, housing and supp o r t , out o f transmission case, as shown i n F i g u r e 19. I f support is stuck to transmission case and cannot be removed as described, l i g h t l y t a p support w i t h a soft hammer. •K GUIDE STUDS 56x171 Fig. 19—Removing Output Shaft, Carrier Housing and Input Shaft Assemblies 56x157 Fig. 21—Removing ©r Installing Direct Clutch Assembly 90 —POWERFLITE TRANSMISSION r PLANET PINION CARRiHR HOUSING THRUST WASH.!? 4 . KICKDOWN PLANET PINION CARRIER THRUST WASHER 56x343A Fig. 22—Transmission G e a r Train (Exploded V i e w ) ( 2 ) Remove t h e large (tabbed) k i c k d o w n planet p i n i o n c a r r i e r t h r u s t washer f r o m direct c l u t c h p i s t o n r e t a i n e r assembly ( i f n o t removed w i t h gear t r a i n ) . Inspect f o r cracks, b u r r s and wear. (3) Because the diameter of t h e direct clutch ret a i n e r is greater t h a n the diameter of the reverse band, i t is necessary to first remove t h e reverse band before t h e direct clutch assembly can be w i t h d r a w n f r o m t h e t r a n s m i s s i o n case. To remove t h e reverse band, loosen the band adj u s t i n g screw and l o c k n u t and compress band suffic i e n t l y to remove band s t r u t . U n h o o k reverse band f r o m l i n k assembly. Remove band b y r o t a t i n g i t t h r o u g h t h e relieved area i n t r a n s m i s s i o n case, as shown i n F i g u r e 20. (4) To remove the direct c l u t c h assembly, loosen k i c k d o w n band a d j u s t i n g screw l o c k n u t and back off a d j u s t i n g screw sufficiently to provide clearance f o r r e m o v a l o f c l u t c h retainer. Remove t h e direct c l u t c h assembly f r o m t h e reaction shaft, as shown i n F i g u r e 2 1 . W r a p towel around sun gear t o protect hands. Re sure to remove direct c l u t c h r e t a i n e r t h r u s t washer (fiber) f r o m reaction shaft. g. Removal and Inspection of Planet Carriers (Refer to Fig. 22) Fig. 23—Removing Kickdown Planet Pinion Carrier Housing Snap Ring - • ' 57x42 Fig. 24—Removing or Installing Input Shaft a n d Kickdown Planet Pinion Carrier Assembly (1) U s i n g a feeler gauge, check clearance between t h e planet pinion c a r r i e r housing snap r i n g and k i c k d o w n planet c a r r i e r assembly. T h i s clearance should be f r o m .010 to .021 inch. Snap r i n g s are available i n t h e f o l l o w i n g thicknesses: .062-.064, .072-.074, and .082-.084 inch. I f t h i s selection of snap r i n g s fails to p r o v i d e the necessary clearance, use one of the k i c k d o w n sun gear snap r i n g s ( p a r t number 1327729) w h i c h w i l l p e r m i t a m i n i m u m of .058-.060 inch. ( 2 ) U s i n g a screwdriver, remove the planet pinion c a r r i e r housing snap r i n g ( F i g . 2 3 ) . I d e n t i f y snap r i n g t o aid i n reassembly. ( 3 ) Remove the i n p u t shaft, k i c k d o w n planet p i n i o n c a r r i e r assembly and k i c k d o w n annulus gear f r o m c a r r i e r housing, as shown i n F i g u r e 24. (4) Remove the k i c k d o w n annulus gear after rem o v i n g snap r i n g ( F i g . 25) f r o m i n p u t shaft. Inspect gear f o r w o r n , cracked, and b r o k e n teeth. Remove Fig. 25—Removing or Installing Kickdown Annulus G e a r Snap Ring POWERFLITE TRANSMISSION — 91 4 INPUT SHAFT KICKDOWN P L A N E T / PINION CARRIER ASSY 53xl6B K I C K D O W N ANNULUS GEAR Fig. 26—Input Shaft, Kickdown Planet Pinion Carrier and Annulus Gear (Disassembled View) the small (tabbed) t h r u s t washer and inspect f o r cracks, b u r r s and wear. ( 5 ) Remove k i c k d o w n planet pinion c a r r i e r assembly f r o m i n p u t shaft. Check all o i l passages i n b o t h the gear and shaft f o r obstructions. Inspect splines and b e a r i n g surface on i n p u t shaft f o r b u r r s and wear. Inspect snap r i n g groove ( F i g . 2 6 ) . Inspect k i c k d o w n planet pinion c a r r i e r f o r scores on t h r u s t surfaces and broken and w o r n gear teeth. U s i n g a feeler gauge, check end clearance on i n d i vidual planet p i n i o n gears. Clearance should be .006 to .017 inch. Inspect pinion shafts f o r fit i n the carr i e r and make sure pinions are free to rotate. Inspect r e t a i n i n g pins i n p i n i o n shaft. Inspect planet pinion washers f o r scoring. Do not replace c a r r i e r unless inspection reveals i t is necessary. The k i c k d o w n planet pinion c a r r i e r assembly is serviced only as a complete assembly. 53x56A Fig. 28—Removing Kickdown Sun G e a r Snap Ring ( 6 ) Remove the reverse planet pinion c a r r i e r f r o m the c a r r i e r housing, as shown i n F i g u r e 27. Remove the o u t p u t shaft and reverse annulus gear assembly and fiber t h r u s t washer f r o m the c a r r i e r housing. U s i n g pliers, Tool C-3301, remove the reverse annulus gear snap r i n g and remove annulus gear f r o m output shaft. Inspect annulus gear f o r w o r n or broken teeth. Inspect o u t p u t shaft r i n g grooves (seal and snap) f o r b u r r s and inspect r i n g s f o r b r o k e n ends. Inspect splines on b o t h shaft and annulus gear f o r b u r r s and wear. Check speedometer gear f o r b u r r s . Check outp u t shaft bronze pilot b u s h i n g f o r wear, scoring. The o u t p u t shaft is serviced only as an assembly. N O T E : O u t p u t shaft b u s h i n g I . D . ( a f t e r m a c h i n i n g ) should be .752 to .753" w i t h m a x i m u m service l i m i t of .0065" greater. Inspect reverse planet pinion c a r r i e r housing fiber t h r u s t washer f o r cracks and wear. Inspect planet ''mm mm 57x40A Fig. 27—Removal a n d installation of Reverse Fig. 29—Removal a n d Installation of Planet Pinion Carrier Assembly Kickdown Sun G e a r 92 — POWERFLITE TRANSMISSION p i n i o n c a r r i e r housing and d r i v i n g l u g slots inside housing f o r wear. Closely inspect band c o n t a c t i n g surface f o r burned spots and scoring, especially i f reverse band l i n i n g has become excessively w o r n . Inspect reverse planet pinion c a r r i e r assembly i n same manner as k i c k d o w n planet pinion c a r r i e r assembly. Inspect all oil passages i n o u t p u t shaft support f o r obstructions. Check rear o i l p u m p m a t i n g surface for b u r r s and score m a r k s . Check f o r s t r i p p e d threads i n support. Inspect gasket surfaces f o r b u r r s and d i r t . Inspect b o t h inside and outside bearing surfaces f o r wear and scoring. h. Disassembly and Inspection of the Direct Clutch Piston Retainer (1) U s i n g a screwdriver, remove the k i c k d o w n sun gear snap r i n g , as shown i n F i g u r e 28. The r i n g is a select fit. I d e n t i f y to aid i n reassembly. (2) L i f t out k i c k d o w n sun gear assembly ( F i g . 29). O i l passages i n f r o n t are to lubricate the k i c k down planet pinion c a r r i e r t h r u s t washer. Inspect f o r clutch m a t e r i a l o b s t r u c t i n g o i l passages. Remove foreign m a t e r i a l w h i c h m a y have accumulated on f r o n t side. Inspect d r i v i n g disc contact surface f o r evidence of b u r n i n g or scoring. Inspect sun gear f o r cracked or b r o k e n t e e t h . L i f t out direct clutch hub f r o m center of direct c l u t c h piston retainer. O i l passages i n h u b are t o l u b r i c a t e the clutch plates and d r i v i n g discs w h e n clutch is i n released position. Inspect clutch h u b d r i v i n g lugs f o r wear and remove m e t a l pickup w h i c h m a y have accum u l a t e d on e i t h e r side of t h e hub. Inspect h u b splines f o r b u r r s and wear. (3) I n v e r t t h e direct clutch p i s t o n r e t a i n e r and . DIRECT CLUTCH SPRING ' ^ . : DIRECT CLUTCH SPRING R L T A I N E ? SNAP RING DIRECT CLUTCH PISTON RETAINER A S S Y DIRECT CLUTCH SPRING RETAINER OOI. 53x121 A Fig. 30—Removed arid Installation of Direct Clutch Spring Retainer Snap Ring remove t h e clutch plates (steel) and d r i v i n g disc assemblies. Inspect d r i v i n g discs f o r evidence of b u r n ing, glazing, and flaking off of facing m a t e r i a l . Check discs b y s c r a t c h i n g facings w i t h finger n a i l ; i f mater i a l collects under nail, replace a l l d r i v i n g discs. Replace d r i v i n g discs i f splines have become damaged. Inspect t h e steel clutch plates f o r evidence of b u r n ing, scoring, and damaged splines. (4) U s i n g compressor, Tool C-3575 (or C-3533), compress the direct clutch s p r i n g sufficiently t o u n seat the direct clutch s p r i n g r e t a i n e r snap r i n g w i t h pliers, Tool C-3301, as shown i n F i g u r e 30. Release compressor, Tool C-3575 (or C-3533), and remove the direct clutch s p r i n g retainer snap r i n g , s p r i n g retainer and s p r i n g f r o m the clutch retainer. Check spring, r e t a i n e r and snap r i n g f o r d i s t o r t i o n . ( 5 ) U s i n g a t w i s t i n g m o t i o n , remove t h e direct clutch p i s t o n f r o m retainer. N o t e the ball check i n clutch retainer housing. The ball check relieves c e n t r i f u g a l o i l pressure w h e n transmission is i n n e u t r a l and prevents clutch engagement w h e n engine speeds are increased. M a k e sure ball operates freely and seals properly. The bronze b u s h i n g used i n t h e direct clutch piston r e t a i n e r is not replaceable. N O T E : Particular attention should be paid to the inside diameter of the direct clutch retainer bushing. Excessive clearance between the direct clutch retainer bushing and the reaction shaft, can permit the retainer to wobble and reduce the effectiveness of the reaction shaft seal. Accordingly, if this seal is ineffective, clutch slippage may result due to loss of clutch application pressure. Normal direct clutch bushing inside diameter dimensions (after machining) are 1.8125 inches to 1.8135 inches. Maximum useable service limit is .004 greater. Inspect reaction shaft seal r i n g c o n t a c t i n g areas, on retainer, f o r g r o o v i n g . Inspect the band contacti n g surface f o r deep scores and burns, especially i f t h e k i c k d o w n band l i n i n g is w o r n to the p o i n t w h e r e the steel band has been contacting the direct clutch piston retainer. Do not turn the direct clutch piston retainer in a lathe to remove score marks. ( 6 ) Inspect steel clutch plate contacting surfaces f o r deep scores and b u r r s . Make sure clutch d r i v i n g lugs w i l l slide freely i n t o retainer. Remove any m e t a l pickup on h u b o f retainer. Inspect bore of t h e p i s t o n for score m a r k s . I f score m a r k s are l i g h t , remove w i t h crocus cloth. I f t h e y are heavy, replace the piston. Remove t h e direct clutch p i s t o n r e t a i n e r seal r i n g ( l i p type neoprene) f r o m r e t a i n e r hub, u s i n g a suitable piece of w i r e . Remove t h e direct c l u t c h p i s t o n seal r i n g (neoprene) f r o m outer circumference o f piston. POWERFLITE TRANSMISSION — 93 i. Removal and Inspection of Kickdown Band ( 1 ) Compress k i c k d o w n band ends sufficiently t o remove the k i c k d o w n band s t r u t . Note t h a t s t r u t is grooved to act as a guide to the k i c k d o w n band s t r u t pin on band end. Remove a d j u s t i n g screw blade. (2) Remove the k i c k d o w n band assembly b y r o t a t i n g band ends t h r o u g h rear opening i n t r a n s m i s sion case. B o t h reverse and k i c k d o w n bands have bonded l i n i n g and no a t t e m p t should be made t o reline t h e m . The k i c k d o w n band is n a r r o w e r , l a r g e r i n diameter, and has a different l i n i n g m a t e r i a l . Make visual inspection of l i n i n g f o r wear and bond. I f l i n i n g is w o r n so t h a t grooves are no longer visible, the band assembly m u s t be replaced. Inspect band for d i s t o r t i o n and cracked ends. j. Removal of the Reverse and Kickdown Band Levers Inspect reverse band l i n k assembly f o r wear and r i v e t i n g of assembly. Inspect levers f o r cracks and wear. Make sure t h e y have side clearance and are free to t u r n on shafts. Do not remove these assemblies unless inspection reveals i t is necessary to do so. ( 1 ) I n s e r t fingers i n back of reverse band and l i n k assembly lever shaft. H o l d i n g the reverse band lever and l i n k assembly w i t h the other hand, push shaft out of rear opening i n case. ( 2 ) Remove k i c k d o w n band lever shaft p l u g i n f r o n t of transmission case. Remove k i c k d o w n lever b y i n s e r t i n g finger i n back o f k i c k d o w n lever shaft and, holding the band lever w i t h the other hand, push shaft out f r o n t of transmission case. k. Removal of the Front Oil Pump ( 1 ) Remove the transmission r e g u l a t o r s p r i n g retainer, gasket and "spring. WmW mmW' ( 2 ) Remove t h e torque converter control valve s p r i n g retainer, gasket and s p r i n g . Do not remove valves. To remove these valves w h e n transmission is installed i n vehicle, use a mechanical r e t r i e v e r or a piece of w e l d i n g r o d inserted i n end of valve. Valves are so constructed t h a t t h e y w i l l not drop i n t o f r o n t housing w h e n r e m o v i n g . ( 3 ) Remove the f r o n t o i l p u m p housing to transmission case bolts and washers. ( 4 ) U s i n g a soft hammer, tap on the circumference of the housing t o loosen. P u l l oil p u m p housing assembly and gears f r o m the transmission case ( F i g . 3 1 ) . U s i n g dye, m a r k f r o n t side of gears. Do not use scribe m a r k s . ( 5 ) Remove o i l p u m p gear f r o m f r o n t oil p u m p housing. Remove the f r o n t o i l pump housing seal (large neoprene) f r o m circumference o f housing. ( 6 ) U s i n g a brass d r i f t , d r i v e the f r o n t oil pump housing oil seal f r o m f r o n t of housing. Inspect f r o n t oil pump housing b u s h i n g f o r scores ( b u s h i n g is n o t replaceable). B u s h i n g I . D . (after m a c h i n i n g ) should be 1.878 t o 1.879 inches w i t h m a x i m u m service l i m i t of .002 inch greater. T h i s bushing supports the f r o n t oil p u m p d r i v e sleeve. S l i g h t scores m a y be removed w i t h crocus cloth. Inspect p u m p housing and gears f o r scores and wear. ( 7 ) U s i n g straightedge, Tool C-3335, and feeler gauge, check clearance between pump housing face and face o f gears. Clearance l i m i t s are .0012 to .0022 inch. Make sure a l l o i l passages are open b y b l o w i n g t h e m out w i t h compressed air. valve L Removal of the Regulator Valve Body ( 1 ) I f r e g u l a t o r valve body cannot be removed b y i n s t a l l i n g guide studs, Tool C-3283, i n tapped holes i n body (and p u l l i n g o u t w a r d w i t h the hands, as shown i n F i g u r e 32) use the t w o threaded holes provided i n the r e g u l a t o r valve body to attach puller, Tool C3287, and i n s t a l l ( i f removed) guide studs, Tool C3288 ( F i g . 3 2 ) . 0mm?. ( 2 ) P u l l r e g u l a t o r valve body f r o m torque conv e r t e r reaction shaft and discard the gasket. Handle the r e g u l a t o r valve body carefully. FRONT O i l PLMP HOUSING .56x627 Fig. 31—Removal of Front Oil Pump Housing (Typical V i e w ) A ( 3 ) Place body and b o t h valves i n pan c o n t a i n i n g a clean solvent, wash t h o r o u g h l y , and d r y w i t h compressed air. Inspect b o t h valves for free movement i n valve body. T h e y should f a l l i n and o u t of bores w h e n b o t h t h e valves and body are d r y . Crocus cloth m a y be used to polish valves, p r o v i d i n g care is exercised n o t t o r o u n d the sharp edge p o r t i o n of the 94 —POWERFLITE TRANSMISSION t a i n e r may require g u i d i n g out of transmission case. ( 3 ) Remove the s p r i n g retainer, s p r i n g and servo piston and p l u g assembly. ( 4 ) Remove the servo piston seal ( l i p type neoprene) f r o m piston. ( 5 ) Remove reverse servo piston p l u g snap r i n g . 6 mi ""' Using Guide Studs (Top View) ( 6 ) Remove p l u g and cushion s p r i n g f r o m piston. Inspect servo bore f o r scoring. L i g h t scores m a y be removed w i t h crocus cloth. Check p l u g f o r scoring and wear at lever contact point. Check p l u g snap r i n g and groove f o r burrs, wear. n. Removal of Kickdown Piston ( 1 ) U s i n g compressor, Tool C-3289 or C-3529, apply sufficient pressure on the k i c k d o w n piston r o d guide to remove the p i s t o n r o d guide r e t a i n i n g snap ring. ( 2 ) Loosen compressing p o r t i o n of tool and remove tool f r o m transmission case. Remove p i s t o n r o d guide, piston spring, and k i c k d o w n piston rod assembly. Inspect r i v e t i n g of the k i c k d o w n p i s t o n r o d to k i c k d o w n s p r i n g retainer. ( 3 ) Remove seal r i n g f r o m guide. Inspect f o r l i g h t scores and wear on piston r o d and guide. TORQUE CONVERTER REACTION SHAFT Fig. 32—Removing Regulator Valve B o d y Using Puller Tool (Bottom View) valves. The sharp edge p o r t i o n prevents d i r t and f o r e i g n m a t t e r f r o m g e t t i n g between the valve and body, reducing the p o s s i b i l i t y of s t i c k i n g . Check all fluid passages f o r obstructions and inspect all m a t i n g surfaces f o r b u r r s and d i s t o r t i o n . I f r e g u l a t o r valve body should have a s l i g h t nick or raised p o r t i o n on m a t i n g surfaces, i t m a y be removed b y u s i n g a surface plate and crocus cloth. ( 4 ) U s i n g lock r i n g pliers, Tool C-484, remove the k i c k d o w n piston f r o m the transmission case. ( 5 ) Remove the three cast i r o n seal r i n g s f r o m the k i c k d o w n piston. Inspect piston f o r l i g h t scores and wear. Inspect r i n g s f o r broken ends. o. Removal of Torque Converter Reaction Shaft Inspect torque converter reaction shaft steel seal r i n g s ( i n t e r l o c k i n g type) f o r broken ends. Make sure ( 4 ) Check r e g u l a t o r valve s p r i n g seat (snap r i n g ) . A f t e r b o t h valves and r e g u l a t o r valve body have been t h o r o u g h l y cleaned and inspected, place t h e m on clean paper and cover w i t h clean paper u n t i l ready f o r i n s t a l l a t i o n . Leave valves i n r e g u l a t o r body bores. m. Removal of Reverse Servo Piston ( 1 ) I n s t a l l compressor, Tool C-3289 or C-3529, on t r a n s m i s s i o n case (use o i l pan screws) and compress reverse servo p i s t o n s p r i n g retainer. ( 2 ) U s i n g a screwdriver, remove the reverse servo piston s p r i n g r e t a i n e r snap r i n g , as shown i n F i g u r e 33. Loosen compressing p o r t i o n of tool. S p r i n g re- REVERSE ASSY SERVO RETAINER SNAP RING 53x40 Fig. 33—Removal a n d Installation of Reverse Servo Assembly Retainer Snap Ring POWERFLITE TRANSMISSION — 95 t h e y are free t o r o t a t e I n t h e lands. Inspect neoprene seal r i n g f o r brittleness. Inspect splines on shaft f o r b u r r s and wear. Inspect t h r u s t surfaces f o r wear and s l i g h t scores. Remove t h e reaction shaft seal (neoprene). Do not remove the torque converter reaction shaft unless inspection reveals i t is necessary to do so. REAR PUMP S U C T I O N REVERSE PRESSURE \ OTTLE K I C K D O W N O N PRESSURE ' / \ PRESSURE \ i K I C K D O W N O F F PRESSURE / / • •' ' ' / PRESSURE TO / REGULATOR VALVE / FRONT PUMP ,' /SUCTION 7 - FRONT PUMP ,' / / /CHECK VALVE I f necessary to remove reaction shaft, follow these steps: ( 1 ) Remove neoprene seal r i n g . ( 2 ) Remove the t h r e e t r a n s m i s s i o n case to reaction shaft screws and washers. ( 3 ) U s i n g Tool C-3297 or C-3521 press reaction shaft out o f t r a n s m i s s i o n case, as shown i n F i g u r e 34. ( 4 ) Remove the t w o torque converter shaft seal r i n g s ( i n t e r l o c k i n g ) . reaction \ UPSET PRESSURE TO REGULATOR VALVE \ DIRECT CLUTCH PRESSURE \ ; I GOVERNOR PRESSURE TO PRESSURE GAUGE (FOR SERVICE) REAR PUMP CHECK VALVE 57x161 Fig. 35—Transmission Oil Passages N O T E : Reaction shaft b u s h i n g I . D . ( a f t e r machini n g ) should be 1.063 t o 1.064 inches w i t h a m a x i m u m of .0035 greater. p. Removal of Kickdown, Band Adjusting Screw Loosen l o c k i n g n u t and remove k i c k d o w n band adj u s t m e n t screw and l o c k n u t . W h e n l o c k n u t is loosened, the a d j u s t i n g screw m u s t be finger free. I f i t is not, inspect screw and n u t f o r pulled threads or f o r e i g n m a t e r i a l i n threads. T h e transmission and i t s components have been disasembled f o r inspection, cleaning and t h e replacem e n t o f w o r n or damaged parts. Inspect t r a n s m i s s i o n case f o r cracks, sand holes, and stripped threads. Check f o r b u r r s on m a t i n g surfaces. B l o w compressed a i r t h r o u g h a l l passages (refer t o F i g . 35) to make sure t h e y are open. Check oil pressure take-off plugs f o r tightness. Check d r i v e t y p e b r e a t h e r i n extension housing f o r being plugged (under coating) and looseness. 9. ASSEMBLING THE TRANSMISSION Before assembling the transmission, l u b r i c a t e each p a r t w i t h clean A u t o m a t i c Transmission F l u i d , T y p e " A " , Suffix " A " . a. Installing Kickdown Band Adjusting Screw I t is v i t a l l y i m p o r t a n t t h a t the a d j u s t i n g screw f i t freely i n t o the t r a n s m i s s i o n case. I n s t a l l a d j u s t i n g screw, w i t h l o c k i n g n u t attached, i n t o transmission case u n t i l there is a p p r o x i m a t e l y 1 i n c h o f screw l e f t on outside o f case. Do n o t lock screw i n t o p o s i t i o n at this time. b. Installing the Torque Converter Reaction Shaft ( 1 ) Coat the t w o steel torque converter reaction shaft seal r i n g s w i t h t r a n s m i s s i o n fluid. _,:y •. ( 2 ) I n s t a l l r i n g s on shaft. M a k e sure t h e y interlocked and r o t a t e freely i n the r i n g lands. are ( 3 ) Coat p o r t i o n o f reaction shaft ( t h a t presses i n t o case) w i t h t r a n s m i s s i o n fluid. P o s i t i o n t o r q u e converter reaction shaft i n t o t r a n s m i s s i o n case so t h a t holes i n shaft a l i g n w i t h bolt holes i n case. I n stall Tool C-3297 ( o r Tool C-3531). / TOOL C-3297 TORQUE CONVERTER R E A C T I O N SHAFT Fig. 34—Removal o f T o r q u e C o n v e r t e r Reaction Shaft ( 4 ) Place t w o f r o n t o i l p u m p to t r a n s m i s s i o n case screws (coarse t h r e a d ) t h r o u g h reaction s h a f t screw holes i n transmission case u n t i l threads contact the machine threads of r e a c t i o n shaft flange screw holes 96 — POWERFLITE TRANSMISSION ! ! ; compress the k i c k d o w n piston s p r i n g to the p o i n t t h a t piston guide seal r i n g s l i g h t l y binds on case. U s i n g a piece of brass r o d flattened on end, w o r k seal r i n g i n t o position, gradually compressing s p r i n g u n t i l seal r i n g enters case. REGULATOR V A L V E I TORQUE CONVERTER CONTROL V A L V E / ( 6 ) I n s t a l l the k i c k d o w n piston r o d guide r e t a i n i n g snap r i n g . Make sure snap r i n g is properly seated. d. Installing the Reverse Servo Piston (1) ton. I n s t a l l cushion s p r i n g and p l u g i n servo pis- GUIDE STUDS ( 2 ) I n s t a l l t h e reverse servo piston p l u g snap r i n g . Make sure snap r i n g is properly seated. J 56x159 Fig. 36—Installing Regulator Waive Body (fine t h r e a d ) . Use v e r y l i g h t finger pressure t i g h t e n ( a p p r o x i m a t e l y one t u r n ) . to I n t h i s position, the bolts w i l l serve as guides i n a l i g n i n g the reaction shaft flange dowel hole w i t h the dowel i n the t r a n s m i s s i o n case. ( 5 ) Press reaction shaft i n t o transmission case. Eemove Tool C-3297 ( o r Tool C-3531). ( 6 ) Remove the t w o f r o n t p u m p screws ( g u i d e ) . S t a r t the three t r a n s m i s s i o n case to reaction shaft bolts and washers and t i g h t e n f r o m 10 to 15 footpounds torque. Coat new t o r q u e converter reaction shaft seal r i n g (neoprene) w i t h transmission fluid and install on shaft. c. Installing the Kickdown Piston ( 3 ) Coat a new reverse servo piston r i n g (neoprene) w i t h transmission fluid and install ( l i p f a c i n g down) on piston. I n s e r t reverse servo piston and p l u g assembly i n t o transmission case i n a cocked position. Then, b y r o t a t i n g piston, t h e piston r i n g w i l l enter case w i t h o u t being damaged. ( 4 ) Place reverse servo piston s p r i n g over piston and position s p r i n g retainer over s p r i n g . Compress s p r i n g w i t h compressor, Tool C-3289 (or Tool C3529), sufficiently t o i n s t a l l snap r i n g . The s p r i n g retainer m a y require g u i d i n g i n t o case. Make sure snap r i n g seats properly. Remove i n s t a l l i n g tool f r o m transmission case. e. Installing the Regulator Valve Body Inspect r e g u l a t o r valve body and valves to make sure t h a t no damage has occurred since first inspection and cleaning. Blow out passages w i t h compressed a i r . ( 1 ) Coat the three k i c k d o w n piston r i n g s w i t h transmission fluid ( t w o l o c k i n g and one open t y p e ) and install on piston. I n t e r l o c k the r i n g s and m a k e sure t h e y are free t o r o t a t e i n lands. ( 2 ) Place k i c k d o w n p i s t o n assembly i n t o t r a n s mission case. Compress b o t t o m r i n g (large) w i t h a piece of brass r o d . A f t e r b o t t o m r i n g has entered, piston w i l l seem to h a n g at t w o different locations w h i l e being pushed i n t o case. T h i s is due to r i n g s e n t e r i n g cylinder. DO N O T H A M M E R . ( 3 ) Place k i c k d o w n p i s t o n r o d i n p i s t o n and slide s p r i n g over k i c k d o w n p i s t o n r o d . ( 4 ) Coat a new k i c k d o w n p i s t o n r o d guide seal r i n g w i t h transmission fluid and i n s t a l l on k i c k d o w n piston r o d guide. M a k e sure r i n g rotates f r e e l y i n land. ( 5 ) I n s t a l l compressor, Tool C-3289 (or Tool C3529), on t r a n s m i s s i o n case. U s i n g extreme care, I ^ — T O O L IF Wfcfef' ' FRONT OIL ' PUMP H O U S I N G 53x28 Fig. 37—Installing Front Pump O i l Seal POWERFLITE TRANSMISSION — 97 M a k e sure torque converter reaction shaft seal (neoprene) is coated w i t h transmission fluid. ( 1 ) Place the transmission r e g u l a t o r valve and torque converter c o n t r o l valve i n the regulator valve body. (Refer to F i g . 36.) ( 2 ) I n s t a l l guide studs, Tool C-3288 ( i f r e m o v e d ) , i n f r o n t of transmission case, position new r e g u l a t o r valve body gasket and valve body assembly ( w i t h o i l passages to r e a r ) over torque converter reaction shaft. -Seat firmly against gasket on f r o n t o f t r a n s mission case. Use extreme care w h e n placing r e g u l a t o r body i n position to prevent reaction shaft screws f r o m damaging passages i n r e g u l a t o r body. I . Installing the Front Oil Pump ( 1 ) P o s i t i o n f r o n t o i l p u m p housing o i l seal i n f r o n t of oil p u m p housing ( m e t a l p o r t i o n o f seal d o w n ) . U s i n g d r i v e r , Tool C-3278, b o t t o m seal i n t o housing, as shown i n F i g u r e 37, ( 7 ) U s i n g a new gasket, i n s t a l l t h e t r a n s m i s s i o n r e g u l a t o r valve s p r i n g and retainer. T i g h t e n f r o m 45 to 50 foot-pounds torque. g. Installing the Kickdown Band and Levers ( 1 ) Place k i c k d o w n band lever assembly i n t o t r a n s m i s s i o n case and slide the k i c k d o w n band lever shaft i n t o position f r o m f r o n t of transmission case. The lever should operate freely on shaft. ( 2 ) I n s t a l l k i c k d o w n band lever shaft p l u g i n f r o n t of t r a n s m i s s i o n case and t i g h t e n 30 t o 35 foot-pounds torque. ( 3 ) Place k i c k d o w n band assembly i n t o t r a n s m i s sion case b y r o t a t i n g ends of band t h r o u g h rear openi n g i n case. F i t either end o f t h e k i c k d o w n band over a d j u s t i n g screw blade and compress t h e band lever. Make sure the kickdown band strut slot engages with k i c k d o w n strut pin i n the band end. h . Assembling the Direct Clutch Piston Retainer ( 2 ) Coat new f r o n t o i l p u m p housing seal (neoprene) w i t h transmission fluid and i n s t a l l on housi n g . M a k e sure seal is p r o p e r l y seated i n groove ( l i p f a c i n g down) and t h a t i t protrudes .010 inch above circumference o f housing. ( 3 ) Place transmission f r o n t o i l p u m p gear and p i n i o n ( d r i v i n g lugs of p i n i o n f a c i n g up) i n ' o i l p u m p h o u s i n g and' check t h e m a r k i n g . Unless o i l p u m p pinion is installed correctly, considerable damage w i l l r e s u l t w h e n transmission is installed i n vehicle. L u b r i c a t e o i l p u m p gears w t h A u t o m a t i c T r a n s m i s sion F l u i d , Type " A " , Suffix " A " . ( 4 ) Place f r o n t o i l p u m p housing assembly ( w i t h oil d r a i n f a c i n g u p ) over torque converter reaction s h a f t and slide i n t o position over guide studs and up against r e g u l a t o r valve body. S t a r t five o f t h e bolts and d r a w housing down evenly u n t i l i t is seated i n t o t r a n s m i s s i o n case. ( 5 ) Remove guide studs and i n s t a l l the t w o rem a i n i n g bolts and washers. T i g h t e n to 17 footpounds torque. A f t e r a l l bolts have been installed and p r o p e r l y torqued, engage the d r i v i n g lugs o f t h e oil p u m p p i n i o n t o determine i f o i l p u m p p i n i o n t u r n s freely. Use the o i l p u m p d r i v e sleeve f o r t h i s check. I f p i n i o n does not t u r n freely, remove p u m p and check f o r f o r e i g n m a t t e r between p u m p gears and housing. L u g s o f d r i v e sleeve should extend n o t m o r e t h a n f r o m y t o % i n c h beyond face o f o i l p u m p housing. ( 1 ) Coat a new direct c l u t c h p i s t o n seal r i n g w i t h transmission fluid and i n s t a l l on piston, w i t h l i p o f seal f a c i n g away f r o m the flange. ( 2 ) Coat a new d i r e c t clutch p i s t o n retainer seal r i n g w i t h transmission fluid and i n s t a l l ( l i p of seal down) on retainer h u b . ( 3 ) Place piston assembly i n t h e d i r e c t c l u t c h ret a i n e r and, w i t h a t w i s t i n g m o t i o n , seat p i s t o n i n b o t t o m of retainer. W o r k carefully t o avoid damagi n g l i p of seals. ( 4 ) Seat the direct c l u t c h spring- i n t o the d i r e c t c l u t c h piston retainer. Place s p r i n g r e t a i n e r on s p r i n g and snap r i n g on s p r i n g retainer. ( 5 ) U s i n g compressor, Tool C-3575 ( o r Tool C3533), compress t h e direct clutch s p r i n g sufficiently to seat the snap r i n g i n i t s groove. M a k e sure snap r i n g is p r o p e r l y seated. ( 6 ) Remove compressor, Tool C-3575 (or Tool C3533). Place the d i r e c t clutch h u b i n the center o f t h e d i r e c t clutch piston retainer. ( 7 ) L u b r i c a t e t h e c l u t c h plates and d r i v i n g discs w i t h A u t o m a t i c Transmission F l u i d ( T y p e " A " , Suffix " A " ) . Place one o f t h e c l u t c h plates (steel) i n t h e direct clutch piston retainer, followed b y a d r i v i n g disc. 2 ( 8 ) U s i n g a new gasket, i n s t a l l t h e torque conv e r t e r c o n t r o l valve s p r i n g and retainer. T i g h t e n 35 t o 40 foot-pounds torque. ( 8 ) Place t h e k i c k d o w n sun gear assembly i n t h e direct clutch piston retainer. ( 9 ) U s i n g a feeler gauge, check the clearance under the k i c k d o w n mn gear snap r i n g . Select a 98 —POWERFLITE TRANSMISSION snap r i n g t o give m i n i m u m clearance (close t o zero as possible). M a k e sure snap r i n g seats p r o p e r l y . Snap r i n g s are available i n the f o l l o w i n g t w o t h i c k nesses: .058 to .060 inch and .062 to .064 i n c h . ( 1 0 ) Place fiber t h r u s t washer (select fit, see "Checking Transmission E n d P l a y , " P a r a g r a p h 9) on reaction shaft and i n s t a l l direct c l u t c h assembly i n transmission case, as shown i n F i g u r e 2 1 . sonably tight on output shaft. E n d clearance is controlled by various snap rings which are available in the following thicknesses: .078 to .080 i n c h ; .082 to .084 inch, and .086 to .088 inch. Make sure snap r i n g seats p r o p e r l y . ( 3 ) Coat o u t p u t shaft seal r i n g w i t h transmission fluid and i n s t a l l on shaft. I n t e r l o c k the seal r i n g i n t o position and make sure r i n g rotates freely i n land. i. Installing Reverse Band and Levers Assembly ( 1 ) Place t h e reverse band lever assembly i n t h e reverse band l i n k assembly and place i n t r a n s m i s s i o n case. (2) A l i g n blies to shaft reverse band transmission t h e holes i n the lever and l i n k assemhole i n t h e transmission case. Slide t h e lever shaft i n t o position f r o m r e a r o f case. ( 3 ) Place reverse band assembly i n t o t r a n s m i s sion case b y r o t a t i n g ends of band t h r o u g h relieved area i n t r a n s m i s s i o n case ( F i g . 2 0 ) . H o o k end o f band i n l i n k assembly. Compress band sufficiently t o i n s t a l l the s t r u t i n the slots of t h e band and lever assembly. ( F i g u r e 38 illustrates assembly of reverse band linkage a f t e r i n s t a l l a t i o n i n t r a n s m i s s i o n case.) j . Installing the Panet Pinion Carriers in Housing (Refer to Fig. 22) ( 1 ) L u b r i c a t e b e a r i n g surface o f planet p i n i o n c a r r i e r housing, and place bearing surface o f h o u s i n g over o u t p u t shaft support bearing surface. ( 2 ) Place t h e reverse annulus gear on t h e o u t p u t shaft and i n s t a l l snap r i n g . O u t p u t s h a f t m a y be placed i n a vise, p r o v i d i n g i t is clean and equipped w i t h soft j a w s . Reverse annulus gear must fit rea- REVERSE BAND LEVER ADJUSTING SCREW -REVERSE BAND LEVER REVERSE BAND ASSY y REVERSE BAND LEVER SHAFT • REVERSE BAND LEVER ADJUSTING SCREW NUT i" Fig. 38—Reverse Band Linkage ( 5 ) Place o u t p u t shaft and reverse annulus gear i n t o position i n the planet c a r r i e r housing. Be careful not t o damage the o u t p u t shaft seal r i n g as i t enters the o u t p u t shaft support. Make sure t h e fiber t h r u s t washer seats properly between the reverse annulus gear and t h e planet p i n i o n c a r r i e r housing. ( 6 ) Coat reverse annulus gear teeth w i t h transmission fluid. ( 7 ) L u b r i c a t e t h r u s t surfaces and gear teeth of the reverse planet pinion gears and c a r r i e r assembly. Place c a r r i e r assembly*(Fig. 27) i n t h e reverse annulus gear. Make sure d r i v i n g lugs on c a r r i e r assembly p r o p e r l y engage t h e slots i n t h e planet pinion c a r r i e r housing. ( 8 ) Coat i n p u t shaft bearing surfaces and gear teeth on the k i c k d o w n planet p i n i o n gears and carrier assembly w i t h transmission fluid. Slide k i c k down planet pinion carrier assembly carefully d o w n on rear end of i n p u t shaft. ( 9 ) L u b r i c a t e teeth and t h r u s t surfaces, t h e n slide k i c k d o w n annulus gear over i n p u t shaft. I n s t a l l k i c k d o w n annulus gear snap r i n g and make sure i t is seated p r o p e r l y ( F i g . 2 5 ) . I n p u t shaft m a y be placed i n a vise, p r o v i d i n g vise is clean and equipped w i t h soft j a w s . ( 1 0 ) L u b r i c a t e t h e large k i c k d o w n planet p i n i o n c a r r i e r t h r u s t washer (tabbed) w i t h l u b r i p l a t e and i n s t a l l on k i c k d o w n planet p i n i o n carrier assembly. ( 1 1 ) Place the k i c k d o w n planet p i n i o n c a r r i e r assembly, k i c k d o w n annulus gear and i n p u t shaft i n t o position i n planet p i n i o n c a r r i e r housing. M a k e sure lugs on k i c k d o w n c a r r i e r assembly p r o p e r l y engage t h e slots i n t h e planet p i n i o n c a r r i e r housing. 17)' REVERSE B A N G , LINK ASSY ( 4 ) Coat the planet pinion c a r r i e r housing fiber t h r u s t washer w i t h lubriplate, slide washer over outp u t shaft and against t h r u s t surface on reverse annulus gear. 53x50 ( 1 2 ) I n s t a l l planet p i n i o n c a r r i e r housing snap r i n g (raise housing s l i g h t l y t o a i d i n i n s t a l l i n g snap POWERFLITE TRANSMISSION — 99 r i n g ) . Make sure snap r i n g is positioned and seated properly. and i n s t a l l the f o u r screws and lockwashers. tighten screws at this time. ( 1 3 ) U s i n g feeler gauge, check the clearance bet w e e n the k i c k d o w n planet c a r r i e r h o u s i n g snap r i n g and t h e k i c k d o w n planet p i n i o n c a r r i e r assembly. L i m i t s are .010 to .021 inch. I f t h e clearance is n o t w i t h i n these l i m i t s , select a new snap r i n g . Snapr i n g s are available i n the f o l l o w i n g thicknesses: .062 to .064 i n c h ; .072 to .074 inch, and .082 t o .084 inch. I f t h i s selection o f snap r i n g s f a i l s to provide sufficient clearance, use a k i c k d o w n sun gear snap r i n g ( p a r t n u m b e r 1327729) w h i c h w i l l p e r m i t a m i n i m u m o f .058-.060 i n c h . ( 2 ) Slide governor support and body assembly over o u t p u t shaft, as shown i n F i g u r e 16, and i n t o posit i o n i n r e a r oil p u m p housing. Compress governor support p i s t o n r i n g s w i t h fingers as support enters o i l p u m p housing. k. Installing the Output Shaft Support, Planet Pinion Carriers and Housing Assembly ( 1 ) I n s t a l l guide studs, Tool C-3283, i n r e a r of t r a n s m i s s i o n case. Position new o u t p u t shaft supp o r t gasket over guide studs and against case. ( 2 ) I n s e r t i n p u t shaft, planet p i n i o n c a r r i e r housi n g , o u t p u t shaft support and o u t p u t shaft t h r o u g h t h e r e a r o f t r a n s m i s s i o n case. M a k e sure large k i c k d o w n planet p i n i o n c a r r i e r t h r u s t washer (tabbed) is positioned c o r r e c t l y against t h r u s t surface o f d i rect c l u t c h r e t a i n e r assembly. ( 3 ) I n s t a l l t h e one o u t p u t shaft support t o t r a n s mission case screw and lockwasher and t i g h t e n finger tight. 1. Installing the Rear O i l Pump ( 1 ) Coat t r a n s m i s s i o n rear o i l p u m p p i n i o n b a l l w i t h t r a n s m i s s i o n fluid and i n s e r t i n b a l l pocket i n o u t p u t shaft. ( 2 ) L u b r i c a t e rear o i l p u m p d r i v e p i n i o n w i t h t r a n s m i s s i o n fluid, place over o u t p u t shaft and slide i n t o position. A l i g n k e y w a y i n p i n i o n w i t h ball shaft. P i n i o n was m a r k e d w h e n removed i n disassembly, so make sure i t is installed correctly. Check t h e m a r k ing. ( 3 ) Slide r e a r o i l p u m p h o u s i n g assembly over o u t p u t shaft support bolts and lockwashers. D r a w d o w n evenly and t i g h t e n f r o m 10 t o 12 foot-pounds t o r q u e . After bolts have been properly tightened, turn output shaft to make sure pump gears are free to rotate. I f they are not, remove pump to determine cause. Do not ( 3 ) A l i g n l o c a t i n g hole i n o u t p u t shaft t o l o c a t i n g screw hole i n governor body and i n s t a l l governor l o c a t i n g screw. T i g h t e n 3 / t o 4 foot-pounds torque. Holes can be easily aligned b y t u r n i n g o u t p u t shaft and h o l d i n g governor body. l 2 ( 4 ) T i g h t e n t h e f o u r governor body screws f r o m 5 to 10 foot-pounds torque. ( 5 ) D r y governor p a r t s w i t h compressed a i r , b u t do n o t lubricate w h e n assembling. Place governor intermediate weight i n p r i m a r y weight. ( 6 ) I n s t a l l t h e secondary w e i g h t s p r i n g and w e i g h t . Compress s p r i n g sufficiently t o i n s t a l l snap r i n g . M a k e sure t h e s p r i n g seats properly and t h a t snap r i n g is seated p r o p e r l y . ( 7 ) Place t h e governor w e i g h t assembly (seconda r y w e i g h t snap r i n g up) i n t o governor body ( F i g . 14) and i n s t a l l snap r i n g . M a k e sure t h e snap r i n g seats p r o p e r l y . ( 8 ) Slide t h e governor valve shaft i n t o t h e governor body ( F i g . 13) t h r o u g h t h e o u t p u t shaft and governor w e i g h t assembly. A t t h e same t i m e , posit i o n valve i n t o body. ( 9 ) I n s t a l l t h e governor valve shaft snap r i n g . M a k e sure snap r i n g is positioned at outer end of groove. (Refer t o F i g . 39.) I f positioned a t inner end o f groove i t m a y l i m i t t r a v e l of governor valve. Make sure r i n g is p r o p e r l y locked to shaft. ( 1 0 ) Check operation of governor w e i g h t assemb l y and valve b y t u r n i n g o u t p u t shaft. B o t h should f a l l freely i n body. n. Installing the Transmission Extension, O i l Seal and Bearing SNAP RINGS m. Installing the Governor on the Output Shaft ( 1 ) Coat t h e t w o governor support p i s t o n r i n g s w i t h t r a n s m i s s i o n fluid and i n s t a l l on t h e governor support. Stagger r i n g gaps and make sure t h e y are free t o r o t a t e i n lands. P o s i t i o n governor on s u p p o r t 57x37 Fig. 39—Positioning Governor V a l v e Snap Ring 100 —POWERFLITE TRANSMISSION i § If C-3205 DRIVER-:- OUTPUT SHAFT REAR BEARING -<>• OIL SEAL REAR EXTENSION HOUSING t i Fig. 41—Removal of Output Shaft Support, Extension, Handbrake Assembly and Pinion Carrier Housing as an Assembly -• t 57x38 w i t h A u t o m a t i c Transmission F l u i d , Type " A " , Suffix "A". 53x25 Fig. 40—Installation of Output Shaft Rear Bearing Oil Seal ( 2 ) I n s t a l l o u t p u t shaft rear b e a r i n g snap r i n g . Snap r i n g s are available i n t w o sizes. Select one to eliminate all end play at bearing. ( 1 ) I n s t a l l the new o u t p u t shaft rear b e a r i n g i n extension housing w i t h d r i v e r , Tool C-3204. M a k e sure b e a r i n g is properly seated and t h e n lubricate ( 3 ) I n s t a l l extension oil seal w i t h d r i v e r , Tool O-3205, as shown i n F i g u r e 40. ( 4 ) Place new transmission extension gasket over SCREW (25 • S C P P A ' (4) LOC.C LOCK WASHER (2) ^ W A S H LP s LO" 0)-—*" WASHER 1 (4) TRANSFER PLATE COVER SCREW (3) AND LOCK WASHER (3) SCREW ~ SERVO RESTRICTOR VALVE -TRANSFER PLATE ^ PUMP CHECK VALVE SPRING - PUMP CHECK VALVE V A L V E BODY PLATE /m liiJ T H R O T T L E CONTROL CAM THROTTLE PRESSURE CHECK SERVO BLEED VALVE . SCREW—LONG CONTROL CABLE RETAINER , LOCK SCREW-SHORT (1) ! 3) it / \ SHAFT BALL SHUTTLE SPRING M A N U A L VALVE LEVER VAiVF + CABLE RETAINER -CLIP ASSEMBL*' - DRIVE SCREW > mtSm • REVERSE BLOCKER VALVE AND SPRING , SHIFT VALVE A N D SPRING SCREW—-SHORT 1 PLUG END COVER PLATE END COVER ^ K I C K D O W N ROD, BALL AND SPRING ^ - JJ i ^ l f e . ^J^f^^jK^m ' "^Ttrf^ l VALVE BODY COTTER P I N /' SLEEVE AND R N O / MANUAL VALVE . w T \ " \ • x A?'UAL \ " O " RING SEAL ^EiAfNSNG PING View) \ y t : * '* x \\ I H . ' O n - L f VAiV= AMD SPP'NG Fig. 42—Valve Body and Transfer Plate Assembly (Exploded SCREW (2) T H R O T T L E VALVE — O P E R A T I N G LEVER ArjEMBLY POWERFLITE TRANSMISSION—101 guide studs, Tool C-3283, and i n t o position against o u t p u t shaft support. Do not use sealing m a t e r i a l on gasket. A v o i d d a m a g i n g the governor housing w h e n placing t h e rear extension h o u s i n g over t h e o u t p u t shaft and onto the guide studs. ( 5 ) Position housing b y t a p p i n g w i t h soft h a m mer. Remove guide studs and i n s t a l l t h e seven transmission extension to case bolts and lockwashers. D r a w d o w n evenly and t i g h t e n 25 t o 30 foot-pounds torque. TRANSFER PLATE ASSCAABLY PUMP CHECK VALVE GUIDE o. Checking Transmission End Play Before transmission end play is checked, i t is necessary t h a t t h e hand brake d r u m be installed and t i g h t ened to r e q u i r e d torque specifications (175 footpounds) . T h i s operation is necessary to a i d i n proper seating on the extension rear b e a r i n g . I f end p l a y does n o t f a l l w i t h i n specifications, t h e t r a n s m i s s i o n will have t o be partially disassembled t o allow a direct c l u t c h r e t a i n e r t h r u s t washer (fiber) o f proper thickness to be installed. T h r u s t washers are available i n the f o l l o w i n g t h r e e thicknesses: .078-.080 i n c h ; .095-.097 inch, and .112-.114 i n c h . STUD ' SERVO -RESTR1CTOR VALVE OPERATING PLUG • • 1 ( 6 ) L i g h t e n t h e o u t p u t s h a f t support t o ease bolt 25 t o 30 foot-pounds torque. T u r n o u t p u t shaft t o make sure i t t u r n s freely. ( 7 ) Coat n y l o n gear and threads on speedometer d r i v e p i n i o n w i t h transmission fluid and i n s t a l l i n t r a n s m i s s i o n extension, as s h o w n i n F i g u r e 12. T i g h t e n 40 to, 45 foot-pounds torque. ^ VALVE BODY PLATE Pig. 44—Removing Transfer Plate Assembly ( 1 ) Remove the screws and lockwashers f r o m the t r a n s m i s s i o n extension and i n s t a l l guide studs, Tool C-3283. ( 2 ) Remove the o u t p u t shaft support t o case screw and washer and remove the extension housing ( w i t h brake assembly), o u t p u t shaft support and planet p i n i o n c a r r i e r housing as one assembly as shown i n Figure 41. ( 3 ) Slide t h e direct c l u t c h piston retainer f r o m torque converter reaction shaft ( i t is unnecessary t o remove i t f r o m t r a n s m i s s i o n case) and remove t h e direct c l u t c h r e t a i n e r t h r u s t washer. ( 4 ) U s i n g a micrometer, measure t h e thickness of t h e washer and select washer to give correct clearance. Assemble as previously i n s t r u c t e d . p. Adjustment of Bands (Bench) Kickdown (Front Band) GUIDE STUDS ( 1 ) U s i n g a % i n c h open end wrench, loosen the locknut. ( 2 ) Check t h e freeness o f t h e a d j u s t i n g screw i n t h e t r a n s m i s s i o n . Refer to "Transmission and Cont r o l s — A d j u s t m e n t s , " P a r a g r a p h 6. Reverse (Rear B a n d ) ( 1 ) Loosen reverse band a d j u s t i n g screw l o c k n u t and t i g h t e n a d j u s t i n g screw f r o m 20 to 25 i n c h pounds torque. •••I ( 2 ) Back o u t a d j u s t i n g screw 12 t u r n s . ( 3 ) H o l d i n g t h e a d j u s t i n g screw i n t h i s location, t i g h t e n t h e a d j u s t i n g screw l o c k n u t 30 t o 35 footpounds torque. STAND _ (TOO; ) 10. SERVICING THE V A L V E BODY A N D TRANSFER PLATE 56x160 Fig. 43—Valve . ' <zns 2H Si a I i d rie Assembly a. Disassembling the Valve Body and Transfer Plate To disassemble t h e valve body and t r a n s f e r plate f o r 102 —POWERFLITE TRANSMISSION CONTROL CABLE ADAPTER CLIP / THROTTLE VALVE ( 8 ) Check the distance f r o m valve body to end of t h r o t t l e valve operating a d j u s t i n g screw. Using wrench, Tool C-3279B, remove the t h r o t t l e valve adj u s t i n g screw lever assembly. N o r m a l l y , i t is not necessary t o remove t h i s assembly unless damaged p a r t s are t o be replaced. ( 9 ) H o l d i n g the manual valve lever detent plate and sleeve securely, remove small retainer r i n g w h i c h locks t h r o t t l e camshaft i n sleeve ( F i g . 4 7 ) . W h i l e m a i n t a i n i n g constant t h u m b pressure on detent plate, carefully w i t h d r a w sleeve f r o m valve body. Remove t h r o t t l e valve cam assembly and manual valve lever assembly. D e t e n t plate ball is s p r i n g loaded. Do not lose the detent ball. Fig. 45—Valve Body Assembly (Volve Body Plate Removed) cleaning, inspection, and overhaul, refer to F i g u r e 42, and proceed as f o l l o w s : ( 1 ) Place valve body and t r a n s f e r plate assembly i n stand, Tool C-3294 ( i f not previously done so) ( F i g . 4 3 ) . Do n o t use vise t o h o l d valve body and t r a n s f e r plate. ( 1 0 ) Remove detent ball and s p r i n g f r o m valve body. Remove the manual valve b y slowly r o t a t i n g i t out of i t s bore. ( 1 1 ) Remove reverse blocker valve cotter p i n , s p r i n g and valve. Remove valve b y r o t a t i n g i t out of the bore. Do n o t remove push b u t t o n u n i t control cable adapter, lock^ s p r i n g or cable adapter clip, u n less inspection reveals i t is necessary to do so ( F i g . 45). ( 2 ) Remove t w o of the l o n g t r a n s f e r plate cover bolts and lockwashers and i n s t a l l guide studs, Tool C-3295. (12) Remove the f o u r (three long and one s h o r t ) valve body and cover plate bolts and lockwashers and remove valve body and cover plate. ( 3 ) K e e p i n g finger pressure against t r a n s f e r plate, remove t h e r e m a i n i n g t h r e e (2 l o n g and 1 s h o r t ) t r a n s f e r plate cover bolts, and remove t r a n s f e r plate cover, as shown i n F i g u r e 43. ( 1 3 ) Remove valve body end cover screw and lockwasher (oval f i l l i s t e r ) . Keep pressure against valve body and cover w h e n r e m o v i n g screws as t h e r e are t h r e e springs behind cover. Do not disturb the setting. Do n o t lose t h e servo r e s t r i c t o r valve o p e r a t i n g p l u g f r o m t r a n s f e r plate w h e n r e m o v i n g t r a n s f e r plate f r o m valve body plate ( F i g . 4 4 ) . ( 4 ) Remove valve body plate f r o m valve body. T h e servo pressure bleed valve m a y s t i c k t o valve body plate w h e n i t is removed. N o t e position of servo pressure bleed valve and pressure check valve b a l l . (Refer to F i g . 45.) b. Cleaning and Inspecting the Valve Body and Transfer Plate A f t e r each p a r t has been t h o r o u g h l y cleaned and i n - ( 5 ) Remove valve body f r o m stand, Tool C-3294, and remove guide studs. Remove servo pressure bleed valve and pressure check valve ball, and place i n clean container. ( 6 ) Remove t h e t h r o t t l e valve cam r e t u r n s p r i n g f r o m cam and t h r o t t l e o p e r a t i n g lever. ( 7 ) Compressing t h e t h r o t t l e valve o p e r a t i n g lever assembly against t h r o t t l e valve s p r i n g , as shown i n F i g u r e 46, r o t a t e t h e t h r o t t l e valve o p e r a t i n g assemb l y o u t w a r d f r o m the t h r o t t l e valve cam. S w i n g t h r o t t l e valve o p e r a t i n g lever out o f the w a y and remove t h e t h r o t t l e valve s p r i n g f r o m t h r o t t l e valve. Remove t h e t h r o t t l e valve f r o m t h e valve bore. 56x161 Fig. 46—Compressing Throttle V a l v e Operating Lever POWERFLITE TRANSMISSION—103 RETAINER RING Fig. 47—Removing Throttle Camshaft Retaining Ring spected, place on clean paper u n t i l ready f o r assembly. Make sure all p a r t s are free f r o m obstructions, and inspect a l l m a t i n g surfaces f o r b u r r s , nicks and grooves. Small nicks, etc. m a y be removed w i t h crocus c l o t h ; otherwise, damaged p a r t s m u s t be replaced. U s i n g straightedge, Tool C-3335, check all m a t i n g surfaces f o r d i s t o r t i o n . Inspect bores i n valve body f o r score m a r k s , p i t s and i r r e g u l a r i t i e s . Inspect all springs f o r d i s t o r t i o n and collapsed coils. Inspect a l l valves and plugs f o r b u r r s , nicks and scores. Small b u r r s , nicks, etc., m a y be removed w i t h crocus cloth, p r o v i d i n g extreme care is t a k e n to avoid r o u n d i n g off the s h a r p edge p o r t i o n of t h e valve w h i c h helps to prevent d i r t and f o r e i g n m a t t e r f r o m g e t t i n g between valves and body, r e d u c i n g t h e poss i b i l i t y of s t i c k i n g . Check valves and plugs ( d r y ) f o r free operation i n bores. A l l m u s t f a l l freely i n t h e bores w h e n the valves, plugs and bores are clean and d r y . Inspect detent portions on m a n u a l valve lever assembly f o r wear. Inspect detent ball f o r wear and make sure i t slides freely i n t o valve body. Fig. 49—Holding M a n u a l Valve Lever Detent Ball Inspect s t a k i n g of c o n t r o l cable adapter t o detent plate and cable adapter clip t o valve body. Inspect t h e .staking of valve lever and t h r o t t l e valve cam t o t h e i r respective shafts. Inspect the t h r o t t l e valve o p e r a t i n g lever roller t o make sure i t rolls freely. Inspect t h r o t t l e valve o p e r a t i n g lever a d j u s t i n g screw and p i n f o r wear. Make sure a d j u s t i n g screw rotates f r e e l y i n the t h r o t t l e valve operating lever. Inspect k i c k d o w n valve r o d f o r w e a r and scoring and also inspect f o r wear at e n t e r i n g p o i n t i n valve body. Inspect servo r e s t r i c t o r valve ( F i g . 48) i n t h e t r a n s f e r plate to make sure valve is seating p r o p e r l y . I f valve is d i s t o r t e d , carefully remove t h e d r i v e screw. I n s t a l l new valve and new d r i v e screw. Make sure t h e d r i v e screw is t i g h t . A v o i d d i s t o r t i n g t r a n s f e r plate w h e n p e r f o r m i n g t h i s operation. I n spect valve body plate f o r b u r r s and make sure t h e five small m e t e r i n g holes are open. V i s u a l l y i n spect p u m p check valve springs i n the t r a n s f e r plate. Make sure r a d i a l grooves i n check valves are free of obstructions. c. Assembling the Valve Body and Transfer Plate DETENT Fig. 48—Servo Restrictor Valve Fig. 50—Aligning M a n u a l V a l v e Lever A s s e m b l y 104 —POWERFLITE TRANSMISSION . N O T E : Three steel balls are used I n t h e valve body and each m u s t be installed i n i t s correct position. Each is i d e n t i i e i b y i t s size as f o l l o w s : Tf K i c k d o w n r o d ball—large M a n u a l valve lever detent b a l l — m e d i u m 0 : T h r o t t l e pressure check ball—-small (1) I n s t a l l reverse blocker valve and s p r i n g . new cotter p i n . (2) Use Place manual valve i n i t s bore. ( 3 ) I n s t a l l s h i f t valve. I n s t a l l s h i f t valve p l u g and t i g h t e n screws securely. ( 4 ) Place m a n u a l valve lever detent s p r i n g and ball i n valve body and hold i n position, as shown i n F i g u r e 49. W h i l e h o l d i n g the detent ball, position the m a n u a l valve lever assembly so t h a t t h e lever a r m engages t h e manual valve (manual valve m a y be positioned t o -assist i n t h i s a l i g n m e n t ) and the push b u t t o n c o n t r o l cable adapter i n d i r e c t a l i g n m e n t w i t h t h e c o n t r o l cable adapter clip. (Eefer t o F i g . 50.) A t t h e same t i m e , a l i g n t h e shoulder on the m a n u a l valve lever w i t h the sleeve bore i n t h e valve body so t h a t t h e detent b a l l w i l l engage t h e detent plate w h e n finger pressure on .detent ball is released. ( 5 ) W i t h finger pressure h o l d i n g m a n u a l valve shoulder i n bore, i n s e r t sleeve ( s h o r t end) i n bore (up to stop r i n g ) . ( 6 ) Position t h r o t t l e valve cam in. sleeve, as shown i n F i g u r e 5 1 , and lock i n place w i t h retainer. I f ret a i n e r is not placed i n p o s i t i o n a t t h i s t i m e , t h e 56x163 Fig. 52—Indexing Throttle Valve Cam Shaft w i t h Throttle Valve Operating lever detent plate m a y move out o f position, a l l o w i n g the detent ball to escape f r o m i t s bore. (7) Place valve body i n stand, Tool C-3294. ( 8 ) Place k i c k d o w n r o d i n t o position i n valve body. (9) I n s t a l l the s h i f t valve s p r i n g i n valve body. (10) I n s t a l l t h e s h u t t l e valve i n valve body. Coat stop r i n g l i g h t l y w i t h transmission f l u i d and place i n t o recess i n valve body. (11) Place shuttle valve s p r i n g i n valve body. (12) Place k i c k d o w n valve ball i n t o valve body. (13) Place valve body and cover plate on end cover. I n s t a l l the one short screw and lockwasher and t i g h t e n snugly. (14) Place adjustable s h u t t l e valve p l u g i n t o posiS E R V O RESTRICTOR V A L V E O P E R A T I N G P L U G / TRANSFER PLATE . ; y ^ mm Sg||| MM mm 56x176 Fig. 51—Placing Throttle Valve Cam Shaft in Sleeve Fig. 53—Installing Servo Restrictor Plug POWERFLITE TRANSMISSION—105 t i o n i n valve body end cover. P l u g m u s t fit to f u l l depth of bore. (15) I n s t a l l the k i c k d o w n valve s p r i n g i n place i n end cover. (16) I n s t a l l valve body end cover to valve body. Make sure t h e s h i f t valve, s h u t t l e valve and k i c k down valve springs are p r o p e r l y seated i n position w h e n cover is being installed. (17) I n s t a l l t h e valve body end cover screw and lockwasher b u t do n o t torque. (18) I n s t a l l the three (long) valve body end cover plate screws and lockwashers. D r a w down evenly and t i g h t e n to 24 to 30 inch-pounds torque. (19) Remove valve body f r o m r e p a i r stand. U s i n g wrench, Tool C-32798, i n s t a l l t h r o t t l e valve a d j u s t i n g screw and t h r o t t l e valve o p e r a t i n g lever assembly. A d j u s t to a p p r o x i m a t e l y 1-11/16" distance between t h e valve body and end of t h r o t t l e valve a d j u s t i n g screw. (20) I n s t a l l t h r o t t l e valve ( p o i n t o u t w a r d ) i n valve body. Place t h r o t t l e valve s p r i n g over t h r o t t l e valve. S w i n g t h r o t t l e valve o p e r a t i n g lever over spring. Compressing t h e t h r o t t l e operating lever assembly against t h e t h r o t t l e valve s p r i n g , slide t h e t h r o t t l e valve cam assembly i n t o t h r o t t l e valve opera t i n g lever, i n d e x i n g t h e cam p o r t i o n i n slot o f o p e r a t i n g lever, as shown i n F i g u r e 52. Replace t h r o t t l e valve cam assembly r e t u r n s p r i n g and replace valve body i n stand. (21) I n s t a l l servo bleed valve and t h r o t t l e pressure check valve ball i n t o p o s i t i o n i n valve body and i n s t a l l guide studs, Tool C-3295. (22) I n s t a l l t h e servo r e s t r i c t o r valve o p e r a t i n g p l u g (long end f i r s t ) i n t o t r a n s f e r plate ( F i g . 5 3 ) . M a k e sure the pump check valves and springs are p r o p e r l y positioned i n t r a n s f e r plate. The p u m p check valve w i t h the m e t e r i n g hole should be positioned i n end of t r a n s f e r plate t h a t lies n e x t t o t h e m a n u a l valve. (23) Place the valve body plate flush i n t o p o s i t i o n on valve plate b y compressing p u m p check "valve springs. M a k e sure p u m p check valves enter t r a n s fer p l a t e ; otherwise, t h e valve body plate w i l l be damaged w h e n assembly is d r a w n d o w n onto valve body. (24) Keep sufficient pressure on t r a n s f e r plate and valve body plate t o hold t h e m together. Place t h e m over t h e guide studs and i n t o position on v a l v e body. (25) Place t r a n s f e r plate cover i n t o position and i n s t a l l t w o of t h e t r a n s f e r plate cover screws and lockwashers (one each side) finger t i g h t . M a k e sure p u m p check valves r e m a i n i n position i n body plate. (26) Remove guide studs and i n s t a l l the r e m a i n i n g t r a n s f e r plate cover bolts and lockwashers. T i g h t en t h e bolts 45 t o 50 inch-pounds torque. A v o i d overt i g h t e n i n g as t h i s w i l l d i s t o r t valve body, r e s u l t i n g i n s t i c k y valves. Operate p u m p check valves t o make sure t h e y can be unseated before final t i g h t e n i n g . d. Installing the Valve Body and Transfer Plate ( 1 ) Place " 0 " r i n g seal on t h r o t t l e camshaft sleeve, t h e n place valve body and t r a n s f e r plate i n t o position on transmission case. I n s t a l l the five t r a n s fer plate bolts and lockwashers. T w o bolts are 1 % inches l o n g and go t h r o u g h the t r a n s f e r plate cover on valve body. T h e other three are 1 % inches long. D r a w bolts d o w n evenly and t i g h t e n 12 to 17 footpounds torque. ( 2 ) M a k e sure the t w o o i l s t r a i n e r tube seals are i n position on o i l s t r a i n e r and place o i l s t r a i n e r assembly i n t o p o s i t i o n on valve body. I n s t a l l the t w o oil s t r a i n e r support bolts ( 1 % inches long) and lockwashers.' T i g h t e n 12 t o 17 foot-pounds torque. ( 3 ) Replace o i l pan and gasket ( n e w ) . T i g h t e n oil pan bolts 12 t o 17 foot-pounds torque. ( 4 ) Replace f e l t and felt r e t a i n e r on t h r o t t l e camshaft, t h e n i n s t a l l t h r o t t l e control lever assembly. T i g h t e n lock screw securely. ( 5 ) Place engine rear support adapter i n t o posit i o n on extension h o u s i n g and i n s t a l l bolts and lockwashers. T i g h t e n t o 50 foot-pounds torque. ( 6 ) Remove t r a n s m i s s i o n assembly f r o m Tool C-3280. stand, 11. INSTALLING THE TRANSMISSION I N VEHICLE' N O T E : Before installing transmission in vehicle, check torque converter hub runout and housing a l i g n m e n t a s outlined i n the T o r q u e C o n v e r t e r Group 2 1 . (1) I n s t a l l guide studs, Tool C-3276, i n t h e t w o upper transmission case to converter housing bolt holes. ( 2 ) L u b r i c a t e f r o n t o i l p u m p drive sleeve seal r i n g and bearing surface w i t h transmission fluid. ( 3 ) I n s t a l l d r i v e sleeve i n f r o n t o i l p u m p housing ( i f n o t previously installed) making sure driving lugs are properly engaged i n front oil pump pinion gear. N o t e position of d r i v i n g lugs on f r o n t o i l pump d r i v e sleeve and position accordingly, to aid i n proper 106 — POWERFLITE TRANSMISSION engagement w i t h torque converter hub w h e n transmission is installed. ( 4 ) M o u n t transmission i n suitable j a c k . Raise and a l i g n transmission w i t h pilot bore i n t o r q u e converter housing. Slide transmission over guide studs and i n t o position against torque converter housing. To avoid damage to f r o n t o i l pump, t h e transmission m u s t be p r o p e r l y aligned. Do n o t a t t e m p t to use transmission t o converter housing bolts to b r i n g t r a n s m i s s i o n and converter h o u s i n g together. I f oil p u m p d r i v e sleeve and i n p u t shaft have been p r o p e r l y aligned, transmission should slide i n t o position r e l a t i v e l y easy. Do n o t force i t i n t o position. ( 5 ) I n s t a l l t h e t w o lower transmission case to converter housing bolts and lockwashers, b u t do not t i g h t e n . Remove guide studs and i n s t a l l the t w o upper t r a n s m i s s i o n case to converter h o u s i n g bolts and lockwashers. D r a w a l l bolts down evenly and t i g h t e n 45 t o 50 foot-pounds torque. ( 6 ) Place crossmember i n t o position and i n s t a l l crossmember to t o r s i o n bar s p r i n g bracket bolts. T i g h t e n bolts securely. ( 7 ) I n s t a l l the r e a r engine m o u n t to the trans- mission and t i g h t e n bolts to 35 foot-pounds torque. I n s t a l l rear engine crossmember t o frame and t i g h t en bolts to 75 foot-pounds torque. Remove the transmission 'jack. I n s t a l l the rear engine m o u n t t o crossmember bolts and t i g h t e n to 35 foot-pounds torque. L o w e r the ear and remove h o l d i n g fixture Tool C3487. ( 8 ) Connect t h r o t t l e linkage to t h r o t t l e lever, i n sert gearshift control cable i n t o transmission and adjust as outlined i n "Transmission and Controls — A d j u s t m e n t s , " Paragraph 6. I n s t a l l n e u t r a l s t a r t i n g s w i t c h . Connect speedometer cable housing to drive pinion. Engage ball end o f brake cable w i t h brake opera t i n g lever, secure to support and t i g h t e n support screw securely (refer t o Brakes, Group 4) of t h i s manual f o r method o f a d j u s t i n g p a r k i n g b r a k e ) . Connect propeller shaft and t i g h t e n nuts 33 to 37 footpounds torque. Connect oil pan filler tube and refill transmission to proper level (refer to L u b r i c a t i o n , Group 0 of t h i s m a n u a l ) . Connect b a t t e r y and make a l l necessary adjustments and tests, as outlined i n "Transmission and Controls — A d j u s t m e n t s / ' Paragraph 6. WHEELS, BEARINGS AND TIRES — 1 Group 22 W H E E L S , BEARINGS AND T I R E S CONTENTS Page Paragraph Care of Tires Wheel Balance 12 5 15 8 8 4 13 6 14 7 1 2 10 5 9 4 11 5 DATA AND SPECIFICATIONS MODELS D E S O T O (PS-1, PS-3) W I N D S O R (PC-1) WHEELS Type _ Steel Disc Rim D r o p Center—Safety Wheel Size 14 x 5 i / K 14 x 5 y K 2 2 14 x GK ( T o w n and C o u n t r y ) N u m b e r of Wheel N u t s 5 S t u d Hole Circle W S t u d Size y "-20 2 TIRES Type Super Cushion Tubeless Size 8 x 14 8.00 x 14 8.50 x 14 Optional 8.50 x 14 ( T o w n and C o u n t r y ) Ply 4 Standard Tread Twin Grip TIRE PRESSURES-COLD Pounds—Rear Rear Front 24—Town and C o u n t r y * 22 24 22 * W i t h T o w n & C o u n t r y f u l l y loaded, increase rear t i r e cold pressure to 28 pounds. C a p t i v e - A i r tires are optional equipment on T o w n & C o u n t r y Wagons 3-seat Models only. (8.50 x 14 on Model PC-1 and 9.00 x 14 on Model PC-3.)
