TORQUE SPECIFICATIONS

V.1 N. CODE

1&V
Exhaust Pipe To Manifold
Bolts . . . . . . . . . . . . .
Nuts

. . . . . . . . . . . . .

U-H-L

19 N-m
(14 ft. lb.)
21 N*m
(1 5 ft . lb .)

19 N*m
(14ft.lb.)

R&K

(Exc. Toro.)

K
Toronado

30 N=m
(22ft.lb.)

19 N*m
(14ft.lb.)

21 N*m
(15 ft. lb.)
4

Crossover Pipe To Manifold

Bolts . . . . . . . . . . . . .
Nuts

19 N*m
(14ft.lb.)

. . . . . . . . . . . . .

19 N-m
(14ft.lb.)

19 N*m
(14ft.lb.)

19 N-m
(14ft.lb.)

21 N-m
(15ft.lb.)

Exhaust Pipe To Converter

U-Bolt
. . . . . . . . . . . .
Intermediate Pipe To Converter
Bolts . . . . . . . . . . . . .
Intermediate Pipe To Muffler
U -Bolt
. . . . . . . . . . . .

STARFIRE

OMEGA

CUTLASS

28 N-m
(21 ft.1b.)

28 N-m
(21 ft. Ib.)

47 N*m
(3.5ft.lb.)

23 N*m
(17 ft. lb.)

28 N*m
(21 ft. lb.)

41 N-m
(30 ft . lb .)

31 N-m
(23 ft . lb .)

'

88-98

TORONADO

54 Nom
(40ft.lb.)

41 Nom
(30 ft. Ib.)

20 N-m
(15 ft. Ib.)

27 N*m
(20 ft. lb.)
29 N*m
(21 ft.1b.)

41 N-m
(30 ft. lb.)

Muffler Hanger
Right U -301t

. . . . . . . . . .

Left U-Bolt

. . . . . . . . . .

Right Screw
Left Screw

. . . . . . . . . .
. . . . . . . . . .

Pipe and Resonator Hanger

Screw . . . . . . .
Tail Pipe To Muffler
U-Bolt
. . .

17 N*m
(13 ft. lb.)

41 N-m
(30 ft . lb .)
Fully Driven
14 N*m
(10 ft. lb.)
14 N*m
(10 ft . Ib.)

. . . . . .

. . . . . . . . .

41 N=m
(30 ft. lb .)

31 N*m
(23 ft . lb .)

Tail Pipe To Frame Hanger

Screw . . . . . . . . . . . . .
*

10 N-m
(7 ft. Ib.)

TORQUE SPECIFICATIONS
I

V.1 N. CODE

1&V
Exhaust Pipe To Manifold
Bolts . . . . . . . . . . . . .
Nuts

. . . . . . . . . . . . .

U-H-L

19 N-m
(14 ft. lb.)
21 N*m
(1 5 ft . lb .)

19 N*m
(14ft.lb.)

R&K

(Exc. Toro.)

K
Toronado

30 N=m
(22ft.lb.)

19 N*m
(14ft.lb.)

21 N*m
(15 ft. lb.)
4

Crossover Pipe To Manifold

Bolts . . . . . . . . . . . . .
Nuts

19 N*m
(14ft.lb.)

. . . . . . . . . . . . .

19 N-m
(14ft.lb.)

19 N*m
(14ft.lb.)

19 N-m
(14ft.lb.)

21 N-m
(15ft.lb.)

Exhaust Pipe To Converter

U-Bolt
. . . . . . . . . . . .
Intermediate Pipe To Converter
Bolts . . . . . . . . . . . . .
Intermediate Pipe To Muffler
U -Bolt
. . . . . . . . . . . .

STARFIRE

OMEGA

CUTLASS

28 N-m
(21 ft.1b.)

28 N-m
(21 ft. Ib.)

47 N*m
(3.5ft.lb.)

23 N*m
(17 ft. lb.)

28 N*m
(21 ft. lb.)

41 N-m
(30 ft . lb .)

31 N-m
(23 ft . lb .)

'

88-98

TORONADO

54 Nom
(40ft.lb.)

41 Nom
(30 ft. Ib.)

20 N-m
(15 ft. Ib.)

27 N*m
(20 ft. lb.)
29 N*m
(21 ft.1b.)

41 N-m
(30 ft. lb.)

Muffler Hanger
Right U -301t

. . . . . . . . . .

Left U-Bolt

. . . . . . . . . .

Right Screw
Left Screw

. . . . . . . . . .
. . . . . . . . . .

Pipe and Resonator Hanger

Screw . . . . . . .
Tail Pipe To Muffler
U-Bolt
. . .

17 N*m
(13 ft. lb.)

41 N-m
(30 ft . lb .)
Fully Driven
14 N*m
(10 ft. lb.)
14 N*m
(10 ft . Ib.)

. . . . . .

. . . . . . . . .

41 N=m
(30 ft. lb .)

31 N*m
(23 ft . lb .)

Tail Pipe To Frame Hanger

Screw . . . . . . . . . . . . .
*

10 N-m
(7 ft. Ib.)

TORQUE CONVERTER (ALL TURBO HYDRA-MATICS) 7A1-1

TRANSMISSIONS AND CLUTCH

.....................
T
~ HYDRA-MATIC
~
~
O 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURBO HYDRA-MATIC 350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURBOHYDRA-MATIC 400
425.. ...............................
MANUAL TRANSMISSIONS 3S, 45, 5 s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH - (ALL SERIES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ~ ~ Q CONVERTER
U E
ALL TURBO HYDRA-MATICS

7AI-1
7A1-7
7A3-1
7A4-1
70-1
7C-1

TORQUE CONVERTER
ALL TURBO HYDRA-MATICS
GENERALDESCRIPTION
The torque converter couples the engine to the planetary
gears t h r o u g h oil and provides hydraulic torque
multiplication when required. The compound planetary gear
set produces three forward speeds and reverse.
The 3element torque converter consists of a pump or
driving member, a turbine or driven member, and a stator
assembly. The stator is mounted on a one-way roller clutch
which will allow the stator to turn clockwise but not
counterclockwise.
The torque converter housing is filled with oil and is
attached to the engine crankshaft by a flex plate and always
rotates at engine speed. The converter pump is an integral
part of the converter housing, therefore the pump blades,
rotating at engine speed, set the oil within the converter into
motion and direct it to the turbine, causing the turbine to
rotate.
As the oil passes through the turbine it is traveling in
such a direction that if it were not redirected by the stator it
would hit the rear of the converter pump blades and impede
its pumping action. So at low turbine speeds, the oil is
redirected by the stator to the converter pump in such a
manner that it actually assists the converter pump to deliver
power or multiply engine torque.
AS turbine speed increases, the direction of the oil
leaving the turbine changes and flows against the rear side of
the stator vanes in a clockwise direction. Since the stator is
now impeding the smooth flow of oil, its roller clutch
releases and it revolves freely on its shaft. Once the stator
becomes inactive, there is no further multiplication of engine
torque within the converter. At this point, the converter is
merely acting as a fluid coupling as both the converter pump
and turbine are being driven at approximately the same
Speed, or at one-to-one ratio.
A hydraulic system pressurized by a gear type pump
Provides the working pressure required to operate the
ffiction elements and automatic controls.

Stator Assembly Freewheels

If the stator roller clutch becomes ineffective, the stator
assembly freewheels at all times in both directions. With this
condition, the car will tend to have poor acceleration from a
standstill. At speeds above 48 to 56 kmlh (30-3 5 mph), the
car may act normal. If poor acceleration problems are noted,
it should first be determined that the exhaust system is not
blocked, the engine is in good tune and the transmission is in
first (1st) gear when starting out.
If the engine will freely accelerate t o high rpm in Neutral
(N), it can be assumed that the engine and exhaust system
are normal.
Stator Assembly Remains Locked Up
If the stator assembly remains locked up at all times, the
engine rpm and car speed will tend to be limited or restricted
at high speeds. The car performance when accelerating from
a standstill will be normal. Engine overheating may be noted.
Visual examination of the converter may reveal a blue color
from the overheating that will result.
Under conditions above, if the converter has been
removed from the transmission, the stator roller clutch can
be checked by inserting a finger into the splined inner race of
the roller clutch and trying to turn the race in both
directions. The inner race should turn freely in the clockwise
direction, but not turn or be very difficult to turn in the
counterclockwise direction.

(NOTE: Do not use such items as the pump cover or stator

shaft to turn the race as the results may be misleading.)
CONVERTER ASSEMBLY

C A U T I O N : After

C O N V E R T E R T R O U B L E DIAGNOSIS

leak testing,
pressurized a i r from
J-2 1369-2 before removing from
converter.

O
w STATOR
~
~OPERATION
~
~ DIAGNOSIS
~
The torque converter stator assembly and its related
clutch can possible have one of two different type
malfunctions.
1. The stator assembly freewheels in both directions.
2. The stator assembly remains locked up at all times.

Checking Converter
1. Check converter for leaks as follows:
a. Install J-21369-2 and J-213694 and tighten hex
nut on 5-21369-2. (Fig. 7A1-1)
b. Fill converter with air; 55 1 kilopascals (80 psi).
c. Submerge in water and check for leaks.

bleed

d. Bleed air pressure from 5-21369-2 and remove

wear.
3 . Check converter end clearance as follows:
a. Fully release collet end of tool 5-25020.
b. Install collet end of tool 5-25020 into converter
hub until it bottoms; then tighten cap nut to 6.7 N*m (5
ft. lbs.). (Fig. 7A1-2)
c. Install tool J-2 137 1-3 and tighten hex nut to 4.0
N - m (3 ft. lbs.). (Fig. 7A1-3)
d. Install dial indicator and set it at zero while its
plunger rests on the cap nut of tool 5-25020. (Fig.
7A 1-3)
e. Loosen hex nut while holQng cap nut
stationary. With hex nut loose and holding tool
5-2 1371-3 firmly against the converter hub, the reading
obtained on the dial indicator will be the converter end
clearance. End should be less than 0-1.27 mm (0-.05OU).
If the end clearance is greater, the converter must be
replaced. (Fig. 7A 1-3)

(NOTE: The converter will be properly installed if the

distance is 25.4mm (1.00") minimum between the engine
mounting face of the case and the front face of the converte,
cover drive straps.)

5 . Retain converter with 5-2 1366. (Fig. 7Al-3 1)

(NOTE: See additional Converter Diagnosis, Fig. 7A 1-10.)

Fig. 7A 1-3-Installing Tool 5-2137 1-3

Fig. 7Al-1 -Installing Tool 5-21369

CHECKING FOR CONVERTER VIBRATION

1. Inspect for missing or loose converter-to-flywheel
bolts. Tighten or replace as necessary.
2. Inspect converter for damage or missing balance
weights. If the converter is damaged or balance weights are
missing, replace the converter.
3 . Change position of converter-to-flywheel 120
.degrees at a time to cancel out engine and converter
unbalance. Recheck in each position for vibration
improvements.
4. If the unbalanced condition still exists, leave the
converter-to-flywheel in the best balanced position. Instau
longer flywheel-toconverter bolts adding and removing
washers until the best balance is achieved.

C A U T I O N : Longer bolts are

required only when washers are
added. Be sure the bolts are not
bottoming in the holes. Always
rotate the converter by hand after
adding washers to check for
clearance.
CONVERTER FLUSHING PROCEDURE
1 . Drill a 118" hole in the converter at the flywheel
attaching lug bulge. (Fig. 7A 14)

Fig. 7A 1-2-Installing Tool 5-25020

CAUTION: To prevent converter

damage, coat drill bit with grease to
hold the metal chips. Drill at the
high part o f the bulge. Keep the
drill at right angles to the surface.
Install a sleeve on the drill bit so it
can enter no deeper than 7/4".

TORQUE CONVERTER

2. Remove any burrs on the edge of the drilled hole

d t h a flat file.
3. Drain fluid by propping converter in a drain pan
the drilled hole at the bottom. (Fig. 7AI -5) Drain
15 minutes.
4. Charge converter hub with air to remove as much
transmission fluid as possible. Set converter
hub face up in the parts cleaner basket and insert Tool
J-26261 into the converter hub. Insert until spline is engaged
into stator roller clutch race. (Fig. 7A 1 -6)
5 . Connect nozzle of parts cleaner to 5-26261 and turn
on the parts cleaner. Flush converter for approximately
twenty to thirty minutes, redrain and charge converter hub
with air to remove solvent. If parts cleaner is not equipped
with filtration system, clean solvent must be used for each
repair.
6. Apply gasket sealer such as Loctite No. 271,
permatex No. 1 or equivalent on a 1/8" closed end pop rivet.
-

(Fig. 7A1-7) Install rivet in the drilled hole. (Fig. 7A1-8)

Brush sealer over head of rivet.

(NOTE: A special closedend pop rivet MUST be used in t h s

repair. Use of any other type of rivet may result in converter
leaks and transmission failure .)

7 . Pressure test the converter for leaks at 80 psi air

pressure using Tool 3-2 1369. (Fig. 7A1-9) Put liquid soap or
leakdetecting solution on the pop rivet and watch for
bubbles. If the pop rivet leaks, the converter must be
replaced. The rivet cannot be drilled out, as part of it would
remain inside and damage the converter.

CONNECT NOZZLE
TO PARTS CLEANER

Fig. 7A1-6-Tool 3-26261 Installed

Fig. 7Al.4-Location of Hole to be Drilled

CLOSED-END POP RIVET

(USE ONLY A CLOSED-END
POP RlVET FOR THIS F I X )

OPEN END POP RIVET

(DONUT USE THIS TYPE)

Fig. 7A 1 -7-Pop Rivets

OSED-END POP

Fig. 7A 1 -5 -Draining Converter

Fig. 7A 1 -8-Pop Rivet Installed

CONDITION : Contaminated O i l

CONDITION: Noisy o r Slips

CONDITION: Vibration

1. I f oil in the converter is

discolored b u t does n o t contain metal
particles, the converter is n o t damaged
internally and need n o t be replaced.
Remove as much o f the discolored oil
as possible b y draining through the
hub.
2. I f o i l i n the converter
contains metal particles the converter
is damaged internally and must be
replaced. The o i l may have an
"aluminum paint" appearance.
3.If
t h e cause o f o i l
contamination was due t o burned
d u t c h plates, overheated o i l o r engine
coolant (cooler leak), the converter
must be flushed.
4. I f the pump gears o r cover
show signs o f damage or are broken,
the converter w i l l contain metal
particles and must be replaced.

(NOTE: Most converter noise occurs

under light throttle i n "Drive" range
w i t h brakes applied.)

1. Isolate the cause of vibration

by disconnecting other engine driven
parts one a t a time. I f the converter is
d e t e r m i n e d t o be the cause of
vibration, check f o r loss o f balance
w e i g h t s a n d replace converter if
weights are missing. If weights are not
missing, r e - i n d e x converter 120
degrees a t a time t o cancel o u t engine
and converter unbalance conditions.
Washers may be used o n the converter
t o flywheel bolts t o isolate area of
unbalance.

(NOTE: After failure that generates

sludge, metal particles o r converter
replacement, it is recommended that
the transmission be properly cleaned
and the cooler lines be flushed. Refer
t o the Cooler and Cooler Lines
Flushing Procedure.)
r

CON D IT I ON : Stripped Converter

Bolt Holes
1. inspect for cause, such as
d a m a g e d b o l t threads. T o repair
stripped b o l t holes, use heli-coils or
equivalent.

1. Check f o r loose o r missing

flywheel t o converter bolts, a cracked
flywheel, a broken converter pilot, o r
o t h e r engine parts that may be
vibrating. If any of these conditions
are found, correct as required.
2. I n s p e c t the converter for
damage t o the roller bearing, thrust
races and roller clutch. The thrust
roller bearing and thrust races can be
c h e c k e d b y viewing them when
looking i n t o the converter neck or
feeling through the opening t o make
sure they are n o t cracked, broken or
mispositioned.
The stator roller clutch can be
checked by inserting a finger into the
splined inner race o f the roller clutch
and trying t o t u r n the race in b o t h
directions. The inner race should turn
freely i n the clockwise direction, b u t
n o t turn o r b e very difficult t o t u r n i n
the counterclockwise direction.
(NOTE: D o n o t use such itemsasthe
pump cover or stator shaft t o t u r n the
race as the results may be misleading.)
The converter must be replaced if
the roller bearing, thrust races or
roller clutch are damaged.
3. I n s p e c t for excessive end
play. (Refer t o Procedure) Replace
the converter i f turbine end play
clearance exceeds .050".

CONDITION: Leaks

1. Inspect converter hub surface

for roughness, scoring o r wear that
could damage seal o r bushing. If
roughness can be felt w i t h a fingernail,
front seal could be damaged. Repair
the converter h u b w i t h crocus cloth if
possible and replace the front seal.
2. Inspect the inside of the bell
h o u s i n g . If covered w i t h oil, a
converter leak is indicated and the ,
c o n v e r t e r should be leak tested.
(Refer t o Procedure) Replace the
converter ifleaks are found.
4

T.V. CABLE SY TEM THM 200

me T.V. cable used with the Turbo Hydra-matic 200

transmission

should not be thought of as a THM 350

downshift cable. The T.V. cable used on the THM 200
controls line pressure, shift points, shift feel, part throttle
and detent downshifts. The function of the cable
is similar to the combined functions of the vacuum
modulator and the downshift cable used in cars which use
fie THM 350 transmission. The cable operates the throttle
bly . (Figs. 7Al-11 and 7A1-12)
r and Bracket Assembly serves two (2)
1. The primary function of this assembly is to transfer

he carburetor throttle plate movement to the T.V. plunger

in the control valve assembly as related by the T.V. cable and
linkage. (Fig. 7A1-11) This causes T.V. pressure and line
pressure to increase according to throttle opening and also
controls part throttle and detent downshifts. The proper

THROTTLE L E V E R &
BRACKET ASSEMBLY

Fig. 7A 1 -1 1 - T h o t tle Valve (T .V.) Cable and Linkages

Fig-7A 1-12-~hrottle Lever and Bracket Assembly

adjustment of the T.V. cable is based on the T.V. plunger

being fully depressed to flush with the T.V. bushing at wide
open throttle.
2. The second function of the assembly involves the
T.V. exhaust valve lifter rod, spring and the T.V. exhaust
ball. The function of this system is to prevent the
transmission from operating at low (idle position) pressures,
if the T.V. cable should become broken or disconnected. If
the cable is connected, not broken or stretched, the T.V.
lifter rod will not move from its normal, spring loaded, up
position which holds the T.V. exhaust check ball off its seat.
The T.V. lifter rod will drop down to allow the T.V. exhaust
ball to seat only if the cable is broken, disconnected or
extremely out of adjustment. With the transmission pan
removed, it should be possible to pull down on the T.V.
exhaust valve lifter rod and the spring should return the rod
to its normal up position. If the throttle lever and bracket
assembly or lifter rod binds or sticks so that the T.V. lifter
rod cannot lift the exhaust ball off its seat, high line
pressures and delayed upshifts will result. The normal shape
of the T.V. lifter rod is shown in Fig. 7A1-13. The right angle
leg must not be bent to any other angle or it will not
function properly.
If the T.V. cable is broken, sticky, misadjusted or
incorrect part for the model, the car may exhibit various
malfunctions.
Sticking or binding T.V. linkage can result in delayed or
full throttle shifts. The T.V. cable must be free to travel to
the full throttle position and return to the closed throttle
position without binding or sticking.
Some binding or sticking of the T.V. cable and
associated parts may only occur with the engine running and
will not be noted or obtained with the engine off.
Inspection of the T.V. linkage for sticking or binding
should be made with the engine running at idle speed, with
the transmission selector in Neutral and the parking brakes
set. Pull the T.V. cable full travel beyond the carburetor lever
pin that it attaches to and then release the cable; it should
return to the closed throttle position against the carburetor
lever pin. (Fig. 7A1-14) If the T.V. cable sticks and remains
ahead of the carburetor lever pin, (Fig. 7A1-15) it may be
caused by one or more of the following:
1. Sharp bends or a damaged T.V. cable housing.
Correct by re-routing the cable or replace it if required.
2. Sharp end or burr on the T.V. link, dragging in the
T.V. cable housing. Correct by making end smooth, using a
fiIe or stone.

Fig. 7Al-13-Throttle Valve Lifter Rod

7A1-6 T.V.CA3

3 . Bent T.V. link. Correct by straightening or replace as

downshifts.

Fig. 7Al-16-Alignment of Throttle Lever

and Bracket Assembly

Fig. 7A 1-14-T .V. Cable at Carburetor Lever

Fig. 7Al-IS-Sticking T.V. Cable

DIAGNOSIS PROCEDURE
1. Check transmission oil level and correct as requir
2. Be sure engine is operating properly and brakes
not dragging.
3 . Check for correct T.V. cable, according to the par
catalog.
4. Check that the T.V. cable is connected at both end
5 . Adjust the T.V, cable as follows:
a. Unlock the "snap lock" on the T.V. cable.
b. Rotate the carburetor lever to the wide o
position. (Engine Off)
c. While holding the carburetor lever at wide o
throttle, push the "snap lock" flush to secure the c
housing.
d. Return the carburetor lever to the clo
posit ion.
6. Check T.V. cable for sticking and binding.
7. When the T.V. cable adjustment is made and lot
the cable housing will extend t h r o u p the cable snap
assembly about 1.57 - 7.95 mm (1116 -5116"). (Fig. 7A1

Fig. 7A1-17 -Snap Lock Assembly

TURBO HYDRA-MATIC 200 7A1-7

delayed or only full throttle shifts still

8. Road - test.
. , If
"
I

idle
speed.
.
b. Record or1 pressures m Neutral and YarK.
4

down as the lifter does. Also, be sure lifter spring holds the
lifter rod up against the bottom of the controI valve
assembly. Make sure T.V. plunger is not stuck. Inspect
transmission for correct throttle lever t o cable link. (Fig.
7A 1-18)

TE: Neutral

pressure should be equal to, or n o more

69 kPa (1 0 psi) above Park pressu[re.)

pressure is 69 kPa (10 psi) or more

1 .0 below.
b a n Park pressure, proceed to, Stel
.
........r
! 10. Remove the oil pan ana .lnspect
,
, tne tnrottle leve
,-.
bracket assembly on tne control valve assemtxy . (rig.
-16) Check that the T.V. exhaust valve lifter rod is not
'
'distorted and not blniling in the con1trol valve assembly or
inneer ~ l a t e The
.
T.V. exnaust cnecK oall must move up aria
C.

-,.

a T -

11 NeULliiJ

.+

'

11

Fig. 7Al-18-Throttle Lever t o Cable Link

TURBO HYDRA-MATIC 200

SUBJECT

PAGE

Assembly of Transmission . . . . . . . . . . 7A 1-31

Bushing Service
. . . . . . . . . . . . . . 7A 1-65
Capacity . . . . . . . . . . . . . . . . . . 7Al-9
Case and Porositv R e ~ a i r . . . . . . . . . . 7A1-11
Checking and ~ d d i n i ~ l u i d . . . .
Clutch Plate Usage . . . . . . . .

. . . . . . . . . . .

V 1 I . \

. . . . . . . .
. . . .

&termediate ServcI Usage .

latemediate Band Apply Pin

. . .

SUBJECT

PAGE

Maintenance
. . . . . . . . . . . . . . . .7A18
Manual Linkage
. . . . . . . . . . . . . . 7A 1- 18
. . . . . . . . . . . . . 7A 1-9
Oil Cooler Servicing
Oil Cooler Pipes . . . . . . . . . . . . . . 7A1-10
Oil Pan and Screen . . . . . . . . . . . . . 7A 1-23
Oil Passages . . . . . . . . . . . . . . . . 7A 1-3 1
Oil Pressure Checks
. . . . . . . . . . . . 7A1-11
OilPump . . . . . . . . . . . . . . . . .7A1-150
Oil Sea1,Rear . . . . . . . . . . . . . . . 7A1-18
. . . . . . . . . . 7A1-19
Pressure Regulator Valve
Selective Spacer/Washer/Pin
Front Unit Washer . . . . . . . . . . . . 7A1-53
. . . . . . . 7A 1-55
Intermediate Band Apply Pin
Rear Unit Spacer . . . . . . . . . . . . . 7A1-43
Service Precautions . . . . . . . . . . . . . 7A1- 17
Shift Rod and Cable Adjustment . . . 7A1-18 & 7A1-20
Speedometer Driven Gear . . . . . . . . . . 7A1-18
Tools
Hand Tools . . . . . . . . . . . . . . . 7A1-63
. . . . . . . . . . . . . . 7A1-63
Special Tools
Torque Converters . . . . . . . . . . . . . . 7A1-1
Torque Specifications
. . . . . . . . . . . 7A1-62
Transmission Mounts . . . . . . . . . . . . 7A1-18
Transmission Removal
. . . . . . . . . . . 7A1-20
T.V.CableAdjustment
. . . . . . . 7A1-6&7A1-20
ValveBody . . . . . . . . . . . .7A1-56-7A1-61

(
I

'

7A1-8 TURBO HYDRA-MATIC 200 MAINTENANCE

GENERAL DESCRIPTION
The Turbo Hydra-Matic 200 transmission is a fully
automatic unit consisting primarily of a 3element hydraulic
torque converter and a compound planetary gear set. Three

multiple-disc clutches, a roller clutch and a band provide the

friction elements required to obtain the desired function
the compound planetary gear set.

MAINTENANCE
MAINTENANCE SCHEDULE

CHECKING AND ADDING FLUID (Transmission at

Operating Temperature) (Fig. 7A 1-20)
The automatic transmission is designed to operate at the
"FULL HOT" mark on the dipstick at normal operating
temperature of 88" t o 93' C. (190' to 200' F.) and should
be checked under these conditions. The normal operating
temperature is obtained only after at least 15 miles of
highway type driving or the equivalent of city driving.
To determine proper level, proceed as follows:
1. Apply parhng brake and block car wheels.
2. With the selector lever in the PARK position, start
engine. DO NOT RACE ENGINE. Move selector lever
through each range.
3 , Immediately check fluid with the selector lever in
PARK, engine running at SLOW IDLE and the car on a
LEVEL surface. The fluid level on the dipstick should be at
the "FULL HOT" mark.

NOTE: DO NOT OVERF ILL I T TAKES

ONLY ONE P I N T TO R A I S E
LEVEL F R O M ADD TO FULL
W I T H A HOT T R A N S M I S S ION.
Fig. 7A 1 -20-Transmission Dipstick

CONVERTER

Fig. 7Al-19-Cutaway View - THM 200 Transmission

TURBO HYDRA-MATIC 200 MAINTENANCE 7A1-9

IF

bfjng '0

to the "FULL

nu 1 mark on the dipstick.

,,

CHECKINGAND A D v m G FkUID (Transmission at Room

Temperature 18" to 29 C , 65 to 85 F.) (Fig. 7Al-20)
Automatic transmlsslons are frequently overfilled
the fluid level is checked when the fluid is cold and
be dipstick indicates fluid should be added. However, the
low reading is normal since the level will rise as the fluid
tcmvrature increases. A level change of over 19.05 mm
/ ? / A ) will occur as fluid temperature rises from 16" to 82O
to 180" F .).
n~e~fillina
can cause foaming and loss of fluid through
slippage
and transmission failure can result.
the
Fluid level too low can cause slipping, particularly, when
be transmissionis cold or the car is on a hill.
Check the transmission fluid level with the engine
mnjng,the shift lever in park, and the car level.

use

(NOTE: If the car has recently been operated for an

ended period at high speed or in city traffic in hot

weather or the car is being used to pull a trailer, an accurate
fluid level cannot be determined until the fluid has cooled
down-usually about 30 minutes after the car has been
parked.)

Remove the dipstick and touch the transmission end of

the dipstick cautiously to find out if the fluid is cool, warm
or hot.
Wipe it clean and re-insert until cap seats. Remove
*stick and note reading.
1. If the fluid feels cool, about room temperature, (1 8"
to 29' C. or 65" to 85" F .) the level should be between the
two dimples below the "ADD" mark.
2. If it feels warm the level should be close to the
"ADD" mark (either above or below).
3. If it feels hot (cannot be held comfortably) the level
ihould be between the "ADD" and "FULL" marks.

FLUID DRAIN INTERVALS

The transmission operating temperature resulting from

the type of driving conditions under which the car is used is

tbc main consideration in establishing the proper frequency

of transmission fluid changes.
Change the transmission fluid and clean the screen every
24,135 km (15,000 miles) if the car is usually driven under
04M or more of the following conditions which are
considered severe transmission service.
1. In heavy city traffic.
2 . Where the outside temperature regularly reaches 32O

C8(9O0 F.').

'
t

3. In very hilly or mountainous areas.

4. Frequent trailer pulling.
5 . Commercial use, such as taxi, police car, or delivery
ervice .
If you do not use your car under any of these
mditions, change the fluid and clean the screen every
96540km (60,000 miles).

~ T E DO
: NOT OVERFILL. It takes only one pint to
"iie level from "ADD" to "FULL" with a hot transmission.)

zey~
-

TURBO HYDRA-MATIC (200)

Pan Removal . . . . . . . . .
Overhaul . . . . . . . . . . .

. . . 2.8 litres (3 qts.)

. . . 8.4 litres (9 qts.)

1. Raise car.
2. With drain pan placed under transmission oil pan,
remove oil pan attaching bolts from front and side of pan.
3. Loosen rear pan attaching bolts approximately four
(4) turns,
4. Carefully pry transmission oil pan loose with
screwdriver, allowing fluid to drain.
5. Remove remaining bolts and remove oil pan and
gasket. Discard gasket.
6. Drain fluid from oil pan. Clean pan with solvent and
dry thoroughly with clean compressed air.
7. Remove two (2) screen-to-valve body bolts, screen
and gasket . Discard gasket.
8 . Thoroughly clean screen assembly in solvent and dry
thoroughly with clean compressed air.
9. Install new gasket on screen and two (2) bolts.
Tighten bolt to 8 to 14 N*m (6 to 10 ft . lbs.)
10. Install new gasket on oil pan and install oil pan.
Tighten attaching bolt and washer assemblies to 14 .O-18.0
N*m (10-1 3 ft. lbs.).
1 1. Lower car, add approximately 2.8 litres (3 quarts) of
DEXRO@-11 automatic transmission fluid or its equivalent
through filler tube.
12. With selector lever in PARK position, apply hand
brake, start engine and let idle (carburetor off fast idle step).
DO NOT RACE ENGINE.
13. Move selector lever through each range and, with
selector lever in PARK range, check fluid level.
14. Add additional fluid to bring level between the
dimples on the dipstick.
ADDING FLUID TO FILL DRY TRANSMISSION AND
CONVERTER
In cases of transmission overhaul, when a complete fill is
required, including converter, proceed as follows:
1 . Add 6.6 litres (7 quarts) of transmission fluid
through filler tube.
2. With manual control lever in park (P) position, start
engine and place on cold idle cam. DO NOT RACE ENGINE.
Move manual control lever through each range.
3. Immediately check fluid level with selector lever in
park (P), engine running and car on LEVEL surface and add
additional fluid to bring level to a point between the two
dimples on the dipstick. Do not overfill.
TRANSMISSION FLUID
FLUID LEVEL AND CAPACITY
The transmission dipstick is located in a filler tube at
right rear of the engine. To bring fluid level from ADD mark
to FULL mark requires .5 litres (one pint) of fluid. Fluid
level should be checked at every engine oil change.
Fluid level should be to FULL mark with transmission
fluid at normal operating temperature 93' C. (200' F .). With
warm fluid room temperature 2 1" C. (70" F.) level will be
between the two dimples on the dipstick. The normal
operating temperature is obtained only after at least 24 km
(15 miles) of highway type driving or equivalent of city
driving.

AND ADDING FLUID (after Transmission

If ,Work has been performed on the transmission, add the

z , m 8 quantity of fluid, then check fluid as outlined

SERVICING THE OIL COOLER

The oil cooler is located in the side tank of the radiator
and its purpose is to cool the oil in the event excessive
temperature tends to develop. The oil cooler is a sealed

7A 1 -10 TURBO HY DRA-MATIC 200 DIAGNOSIS

In a major transmission failure, where particles of metal

have been carried with the oil throughout the units of the
transmission, it will be necessary to flush out the oil cooler
and connecting lines. To flush the oil cooler and lines, use
the following procedure :
1 . Disconnect both cooler lines from the transmission.

empty container.
3 . Flush clean oleum solvent or equivalent through the
return line (from the bottom of the cooler) using an oil
suction gun until clean solvent comes out of the hose. This
will "back flush" the cooler.
4. Remove the hose from the inlet cooler line and place
it on the return line.
5. Flush clean oleum solvent or equivalent through the
inlet line until clean solvent comes out the return line.
Remove remaining solvent from cooler with compressed air
applied to the return line and flush with transmission fluid.
6. Reconnect oil cooler lines and torque nuts to 12 ft.
Approximately 2.8 litres (3 quarts) of fluid are required
to refill transmission after the oil pan has been drained; The
fluid capacity of the Turbo Hydra-Matic 200 transmission
and converter assembly is approximately 8.4 litres (9 quarts)
but correct level is determined by mark on the dipstick
rather than by amount added. Use only DEXRON@-11
automatic transmission fluid or its equivalent (with a " D
prefix to the numbers on top of the can).

(NOTE : If the oil changes to a darker color at an early st age,

from the usualredcolor and/or t o a s t r o n g o d o r , t h t s i s
normal even though it is usually associated with overheated
transmission fluid. It is not a positive sign of required
maintenance or transmission failure .)
SEQUENCE FOR DIAGNOSIS
I . Check and correct oil level.
2. Check and adjust T.V. cable.
3. Check and correct manual linkage.
I

ENG INE MOUNTING

OF ENG lNE
MOUNTING BRACKET

FRONT OF CAR

Fig. 7A 1-21 -Transmission Oil Cooler Lines

4. Install oil pressure gauge.

5. Road test car.
a. Road test using all selective ranges, noting
differences in operation or oil pressure occur.
b. At tempt to isolate the unit or circuit involved
the malfunction.
c. If engine performance indicates an engine
up is required, t h s should be performed before
t e sting is completed or transmission
attempted. Poor engine performance can result in ro
shifting or other malfunctions.

,,,,,

DIAGNOSIS
OIL LEAKS
The suspected area should be wiped clean of al
before inspecting for the source of the leak. Red dye is
in the transmission oil at the assembly plant and will
if the oil leak is from the transmission.
When an oil leak is found the following procedure
assist in locating the leak.
1. Clean the area with solvent to remove all traces
oil.
2. Remove the flywheel lower cover, if leak
suspected at rear of engine or front of the transmission,
3. Spray suspected leak areas with a pressurized
powder (to aid in detection).
4. Start engine and run at high idle.
5 . Repair any leaks which are detected and rechea
necessav. Reinstall previously removed Parts.
The use of a "black light" to identify the oil at'
source of the leak is also helpful. Comparing the oil from
leak to that on the engine or Wmsmission dipstick
dewedb~blacklight)willdeterminethesourceofth
Oil leaks around the engine and
generally carried toward the rear of the car
For example, a transmission "oil filler tube
sometimes appear as a leak at the rear of th
determining the source of an oil leak, it i
keep the engine running.
A "black light" testing unit such as 5-6640 rn
obtained from service tool suppliers.
6. Degrease underside of transmission.
7. Road test to get unit at operating temperatu
C . (180" F.).
8. Inspect for leak with engine running.
9. With engine off, check for oil leaks due to the r
oil level caused by drain back.
POSSIBLE POINTS OF OIL LEAK
I . Transmission Oil Pan Leak
a. Attaching bolts not correctly torqued.
b. Improperly installed or damaged pan gasket*
c. Oil pan gasket mounting face not flat.
2. Case Leak
a. Filler pipe "0" ring seal damaged or
misposition of filler pipe bracket to engine "1
one side of "0" ring.
b. T.V. cable "0" ring seal missing, dam8
improperly installed.
c. Rear seal assembly damaged or imPf
installed.
d. Governor cover and "0"rings dama
missing.
e. Speedometer driven gear "0" ring damage
f. Manual shaft lip seal damaged or impr
installed.
g. Line pressure tap plug.

TURBO HYDRA-MATIC 200 DIAGNOSIS 7A1-11

h. Porous casting.
i, Intermediate servo "0" ring damaged.
3. Leak at Front of Transmission.
Front pump seal leaks.
1. Seal lip cut. Check converter hub for nicks,

,,

2. Bushing moved forward and damaged.

3. Garter spring missing from seal.
c. Front pump housing "0"ring damaged or cut.
d. Converter leak in weld area.
e, Porous casting (pump or case).
4. Oil comes out vent
a. Transmission over-filled .
b. Water in oil.
c. Incorrect dipstick.
d. Gasket missing.

CASE POROSITY REPAIR

External leaks caused by case porosity have successfully

hen repaired with the transmission in the car by using the

following recommended procedures :
. I . Road test and bring the transmission to operating
mperature, approximately 93O C. (200 F.).
2. Raise car on a hoist or jack stand, engine running
a d locate source of oil leak. Check for leak in all operating
pcQitions.A mirror may be helpful in finding leaks.
3, Shut engine off and thoroughly clean area to be
paired with a cleaning solvent and air dry.
4. Using instructions of the manufacturer, mix a
nt amount of epoxy, No. 1360016, or equivalent t o
bserve cautions of manufacturer in handling.
the transmission case is still HOT apply the
area to be repaired. A clean, dry soldering acid
used to clean the area and also to apply the
t. Make certain the area to be repaired is fully

. Allow cement to cure for three hours before starting

7. Road test and check for leaks.
PRESSURE CHECKS (Figs. 7A 1-22 and 71\3-23)
1. Connect an oil pressure gage t o the line pressure tap.
2 . Connect a tachometer to the engine.

0 DRIVE IN DRIVE RANGE (Check Oil Pressures)

1. LOWOil Level.
Incorrect level.
b. External leaks.
a.

b. Forward clutch oil seal rings missing or damaged

on turbine shaft; leak in feed circuits; pump to case
gasket mis-positioned or damaged.
c. Clutch housing check ball stuck or missing.
d. Cup plug leaking or missing in the rear of the
turbine shaft in the clutch apply passage.
e. Wrong forward clutch apply ring or wrong
number of clutch plates.
f . Feed orifice plugged in turbine shaft.
g. Turbine shaft not welded to housing.
h. Feed passage in turbine shaft intersecting lube
passage.
6. Roller Clutch Assembly
a. Springs missing in the roller clutch.
b. Rollers galled or missing.
7. Converter
a. Turbine hub broken loose from turbine.

HIGH OR LOW OIL PRESSURES

1. Throttle Valve Assembly
a. Misadjusted, binding, unhooked or broken.
b. Wrong throttle lever to cable link.
c. Wrong T.V. cable.
2. Manual Valve
a. Not connected to inside detent lever pin.
3. Throttle Lever and Bracket Assembly
a. Bindingunhooked ormis-positioned.
4. T.V. Exhaust Valve Lifter Rod (Causes high line
pressure)
a. Bent or binding.
5 . Pressure Regulator Valve and Spring
a. Valve binding.
b . Wrong spring.
c. Pressure regulator bore plug leaking.
6. Control Valve Assembly
a. Throttle valve or throttle valve plunger binding.
b . Shift T .V. valve binding.
c. Intermediate boost valve binding. Pressures will
be incorrect in Intermediate and Low ranges only.
d. Reverse boost valve binding. Pressures will be
incorrect in Reverse range only.
7. Valve Body Spacer Plate
a. "Intermediate Boost" orifice plugged in spacer
plate.
b. "Reverse Boost" orifice plugged in the spacer
plate.
8. Pump Assembly
a. Low oil pressure.
b. Damaged gears and damaged pump gear pocket.
c. Cup plugs missing.
d. Mismatched pump cover/pump body.
e. Oil pressure control orifice in pump cover
plugged, causing high line pressure.
9. Forward Clutch Assembly
a. Cup plug missing from turbine shaft.
1-2 AND 2-3 SHlFTS-FULL THROTTLE ONLY
1 . Throttle Valve Cable
a. Binding, unhooked or broken.
b . Misadjusted .
c. Wrong T.V. cable.
2. Throttle Lever and Bracket Assembly
a. Bindingorunhooked.
b. Wrong throttle lever to cable link.
3. T.V. Exhaust Valve Lifter Rod (high line pressure)
a. Binding, rnis-positioned or unhooked.
(NOTE: Allowing No. 5 ball to seat causes full T.V. pressure
regardless of throttle valve position.)

TURBO HYDRA-MATIC 200 DIAGNOSIS 7A 1-1 3

control valve assembly gaskets or spacer plate,

damaged, incorrectly installed.
b. Throttle valve and throttle valve plunger
a.

kmg,

(NOTE. If the outer governor cover " 0 ring seal leaks, an

cxternai leak will be present along with no upshifts .)

d t

d. Governor shaft seal worn, missing or damaged.

e . Governor driven gear stripped.
f. Governor weights binding on pin.
g. Distorted or misaligned governor spring(s).
h. Governor cover shaft bore worn or damaged.
i. Governor weight tangs must seat check balls
when weights are extended completely outward.
3. Intermediate Servo Assembly
a. Servo t o cover oil seal ring missing or damaged.
b. Porosity in servo cover or piston.
c. Wrong intermediate band apply pin.
d, Incorrect usage of cover and piston.
4. Throttle Lever and Bracket Assembly
a. Binding or unhooked.
b. Wrong throttle lever to cable link.
5. Control Valve Assembly
a. 1-2 shift valve or 1-2 throttle valve stuck in
downshift position.
b. Wrong spacer plate gaskets or in wrong position.
6. Valve Body Spacer
a. Plugged "Governor to Valve Body" orifice in
spacer plate -- feeds governor oil to shift valves.
b. Plugged "Drive to Governor" orifice in spacer
plate.
7. Case
a. Porosity in case channels or undrilled 2nd speed
feed holes.
b. Excessive leakage between case bore and
intermediate band apply pin.
C. Intermediate band anchor pin missing or
unhooked from band.
d. Broken or missing band.

ST AND SECOND SPEEDS ONLY, NO 2-3 SHIFT

1. Throttle Valve Cable
a. Misadjusted.
b. Binding, disconnected or broken.
c . Wrong T .V . cable.
2. Governor Assembly and Governor Cover
a. Governor shaft oil seal missing, damaged or
worn.
b. Check balls missing.
c. Governor cover seal damaged.
3. Intermediate Servo Assembly (Direct Clutch
Accumulat~
r Oil Passages)
a. Servo to case oil seal ring broken or missing on
:
intermediate servo piston.

b. Exhaust hole in case between servo piston seal

rings plugged or undrilled .
c. Orifice plug missing from case in the
intermediate servo bore area.
4. Throttle Lever and Bracket Assembly
a. Binding or unhooked.
b. Wrong throttle lever to cable link.
5. Control Valve Assembly and Spacer Plate
a. 2-3 shift valve or 2-3 throttle valve stuck in the
downshift position.
b. "Direct Clutch Feed" orifice in spacer plate
plugged.
c, Valve body spacer plate or gaskets leaking,
damaged or incorrectly installed.
d . Wrong spacer plate to valve body gaskets.
6. Case
a . Porosity in case channels.
b. Orifice cup plug in intermediate servo bore area
in case missing.
7. Pump Assembly
a. Channels in pump plugged or leaking.
b. Check ball missing or m'islocated.
c. Pump to case gasket off location.
d. Rear oil seal ring on pump cover leaking or
missing.
e . Cup plug missing.
8. Direct Clutch
a. Oil seals rnissing or damaged on piston.
b. Direct clutch piston or housing cracked.
c. Direct clutch plates damaged or missing.
d . Direct clutch backing plate snap ring out of
groove.
e. Wrong piston apply ring.
f. Check ball in housing and/or piston missing or
damaged.
g. Direct clutch release spring guide mislocated,
preventing check ball in the piston from seating, causing
plates t o burn.

DRNE IN NEUTRAL
1 . Manual Linkage
a. Misadjusted or disconnected.
2. Forward Clutch
a. Clutch does not release. Exhaust check ball
sticking. Plates burned together.
3. Pump
a. Cross leakage in pump passages.
4. Case
a. Cross leakage to forward clutch passages.
NO DRIVE IN REVERSE OR SLIPS IN REVERSE (Refer
to Oil Pressure Checks)
1. Throttle Valve Cable
a. Binding or misadjusted.
2. Manual Linkage
a. Misadjusted.
3. Pump Assembly
a. Pressure regulator valve binding or stuck with
chips.
b . Check ball missing or mislocated.
c. Pump to case gasket mislocated or damaged.
d. Direct clutch feed holes leaking, cross-feeding or
not drilled.
e . Cup plugs missing.
f. Oil rings damaged or missing.
4. Control Valve Assembly
a. Throttle valve binding.
b. Shift T.V. valve binding.
c. Reverse boost valve binding.

d. Lo overrun clutch valve binding. (Line pressure

readings will be norrnal.)
5. Valve Body Spacer Plate and Gaskets
a. Orifices plugged.
b. Control valve assembly gaskets in reverse order.
6. Case Assembly
a. Lo and reverse clutch housing case seal or cup
plug missing, damaged or no feed hole in cup plug. Also,
seal may not be seated against the housing.
b. Porosity in case passages -- direct clutch feed.
7. Direct Clutch Assembly
a. Piston or housing cracked.
b. Piston seals cut or missing.
c. Check ball in housing and/or piston stuck,
leaking or missing.
d. Plates burned.
e. Incorrect piston.
f. Clutch release spring guide mislocated,
preventing check ball in the piston from seating, causing
plates to burn.
8, Lo and Reverse Clutch Assembly
a. Piston cracked, broken or missing seals. Clutch
plates burned.
b. Wrong selective spacer ring.

SLIPS ON 1-2 SHIFT

1. Low Oil Level
a. Oil will aerate. Correct oil level.
2. Throttle Valve Cable
a. Not adjusted properly.
3 . Intermediate Servo Piston and Cover Assembly
a. Incorrect usage of piston and cover.
b. Wrong band apply pin.
c. Porosity in piston.
d. Seals damaged or missing.
e. Excessive leakage between band apply pin and
case.
4. Control Valve Assembly
a. Throttle valve binding.
b . Shift T.V .valve binding.
c. 1-2 accumulator valve sticking, causing low 1-2
accumulator pressure.
5. 1-2 Accumulator Piston and Spring
a. Piston seal cut or missing.
b. Leak between piston and pin in control valve
c. Spring broken or missing.

sleeye does not line up with "Drive" oil in the pump

cover casting.
8. Intermediate Band
a. Worn or burned.
9. Forward Clutch Assembly
a. Forward clutch feed passage intersects with lube
passage in the turbine shaft.

ROUGH 1-2 SHIFT

1 . Throttle Valve Cable
a. Not adjusted properly.
b. Binding.
c . Wrong or damaged cable.
2. Intermediate Servo Assembly
a. Wrong band apply pin.
b. Servo piston to case oil seal ring damaged or
missing.

3 . Control Valve Assembly

a. T.V. plunger binding.
b. Throttle valve binding.
c. Shift T.V. valve binding.
d . 1-2 accumulator valve binding.
4. 1-2 Accumulator Piston and Spring
a. Oil ring damaged.
b. Piston stuck.
c. Broken or missing spring.
d. Bore damaged.

SLIPS 2-3 SHIFT

1. Oil Level Low
a. Correct oil level.
2. Throttle Valve Cable
a. Not adjusted properly.
b. Binding.
3 . Intermediate Servo Assembly
a. Servo to case oil seal ring damaged.
4. Control Valve Assembly
a. Throttle valve binding.
5. Spacer Plate and Gaskets
a. Direct clutch orifice partially blocked in rp
b. Gaskets mispositioned or damaged.
6. Case Assembly
a. Porosity in direct clutch feed channels in
b. Orifice cup plug missing from case in
intermediate servo bore area.
7. Pump Assembly
a. Pump to case gasket mispositioned or dam
b. Pump channels cross-feeding, leaking
restricted.
c . Pump cover oil seal rings damaged or missin
d. Pump cover sleeve loose.
8. Direct Clutch Assembly
a. Direct clutch piston or housing cracked.
b. Piston seals cut or missing.
c. Direct clutch plates burned.
missing.
d. Check ball in housing and/or piston dam

ROUGH 2-3 SHIFT

1. Throttle Valve Cable
a. Not adjusted properly.
b. Binding.
c. Wrong or damaged cable.
2. Intermediate Servo Assembly
a. Exhaust hole undrilled or plugged be
intermediate servo piston seals, not afl
intermediate servo piston to complete its stroke.
3. Control Valve Assembly
a. T.V. plunger binding.
b. Throttle valve binding.
c. Shift T.V. valve binding.
d. Direct clutch check ball NO. 4 missin
mislocated.
NO ENGINE BRAKING-INTERMEDIATE RANGEGEAR (Check Oil Pressures)
1. Intermediate Servo Assembly
a. Small oil seal on piston cut or missing.
2. Control Valve Assembly
a. Intermediate - rev. check ball No. 3 misled
or missing.
b. Shift T.V. check ball No. 1 mislocated:
missing.
c. Intermediate boost valve binding.

TURBO HYDRA-MATIC 200 DIAGNOSIS 7A1-15

8. Case
a. Porosity.

m ~ ~ N BRAKING
E
IN LOW RANGE-1ST GEAR
colltrol Valve Assembly
LOW overrun clutch valve binding.

. NO reverse should also be a complaint with any of

FoTE

thrkfollowing conditions.)

2. LO and Reverse Clutch Assembly

Piston seals broken or missing.

b, Porosity in piston or housing.
,. Clutch housing snap ring out of case.
3. Case
a. LO and reverse clutch housing-tocase seal or cup
plug missing, damaged or no feed hole in cup plug. Also,
real may not be seated against the housing.

NO PARTTHROTTLE OR DETENT DOWNSHIFTS (Check

01~essures)
1. Throttle Valve Cable
a. Improperly adjusted.
b. Wrong or damaged cable.
2, Throttle Lever and Bracket Assembly
a. Wrong throttle lever to cable link.
3. Control Valve Assembly
a. Passages not open in 2-3 T.V.bushing.
b. Throttle vlave bushing passages not open.
c. Shift T .V. valve binding.
d. Throttle valve binding.
4. Control Valve Assembly Gaskets
a. Mispositioned, damaged or wrong gaskets.
5. Valve Bady Spacer Plate
a. Hole plugged or undrdled.

LOW OR HIGH SHIFT POINTS (Check Oil Pressures)

1. Throttle Valve Cable
a. Binding, disconnected or misadjusted.
b. Wrong or damaged cable.
2. Throttle Lever and Bracket Assembly
a. Binding, unhooked or loose at mounting valve

b. Not positioned at the throttle valve plunger

a. Broken or missing.
4. Governor Cover "0" Rings

a. Broken or missing.

WON'T HOLD IN PARK

1. Manual Linkage
a. Misadjusted
2. Manual Detent Roller and Spring Assembly
a. Bolt loose that holds roller assembly to control
valve assembly .
b. Pin or roller damaged or mispositioned or
missing.
3. Inside Detent Lever and Pin Assembly
a. Nut loose.
b. Hole in lever worn or damaged.
4. Parking Lock
a. Park pawl binding in case.
b. Actuator rod or plunger damaged.
c. Parking pawl broken.
d. Parking bracket loose or damaged.
CLUTCH PLATE DIAGNOSIS
Lined Drive Plates
1. Dry plates and inspect for:
a. pitting and flaking
b. wear
c. glazing
d. cracking
e. charring
f . chips or metal particles imbedded in lining.
If a lined drive plate shows any of the above conditions,
replacement is required.

(NOTE: Do not diagnose drive plates by color.)

Steel Driven Plates
Wipe plates dry and check for heat discoloration. If the
surface is smooth and an even color smear is indicated, the
plate should be reused. If severe heat spot discoloration or
surface scuffing is indicated, the plate must be replaced.
Clutch Release Spring
Evidence of extreme heat or burning in the area of the
clutch may have caused the springs to take a heat set and
would require replacement of the springs.

CAUSES OF BURNED CLUTCH PLATES

1. Forward Clutch
a. Check ball in clutch housing damaged, stuck or
missing.
b. Clutch piston cracked, seals damaged or missing.
c. Low line pressure.
d. Pump cover oil seal rings missing, broken or
undersize; ring groove oversize.
e. Case valve body face not flat or porosity
between channels.
ntermediate clutch piston seals damaged or
b. Low line pressure.
c. Case valve body face not flat or porosity
between channels.
3. Direct Clutch
a. Restriction in vacuum line to modulator (poor
vacuum response).
b. Clutch piston seals damaged or missing.
c. Case valve body face not flat or porosity
between channels.

a. Damaged or wrong gaskets.

(NOTE: Burned clutch plates can be caused by incorrect

TURBO HY DRA-MATIC 200 7A 1- 17

of clutch plates. Also, engine coolant in transmission

can cause severe damage, such as large pieces of
,sition clutch plate material peeling off.)

(;mECOOLANTIN TRANSMISSION

the transmission oil cooler, located in the radiator

bly, has developed a leak allowing engine coolant to
the transmission, use the following procedure :
1. Remove transmission from car.
2. Disassemble transmission and replace all rubber type
(The coolant will attach the seal material causing

~f

,,

w
a
g
e .I

3, Replace the composition-faced clutch plate

ipernblies. (The facing material may become separated from
,tee1 center portion .)
4, Replace the nylon washers, speedometer gears and
p m o r gear. (The nylon can swell and become damaged.)
5. lush the converter.
6. Thoroughly clean and rebuild transmission, using

new gaskets and oil filter.

7 . Flush the cooler lines after the transmission cooler
has been properly repaired or replaced.
TRANSMISSION NOISY
1. Pump Noise
a. Oil level setting low.
b. Cavitation due to plugged screen, porosity in
intake circuit, water in oil.
c. Pump gears damaged.
2 . Gear Noise
a. Transmission grounded to body.
b. Roller bearings worn or damaged.
THUMPING OR CLUNKING SOUND AT 1-5 MPH IN
DRIVE OR INTERMEDIATE RANGE
3 . Governor Assembly
a. Governor spring(s) damaged, mispositioned or
tilted.

TURBO HYDRA-MATIC (200)

Ir

THE TURBO HYDRA-MATIC

200

TRANSMISSION

MODEL CODE AND TRANSMISSION IDENTIFICATION

NUMBERSARE STAMPED ON A PLATE ATTACHED TO
THE RIGHT SIDE OF THE TRANSMISSION. PLEASE
REFER TO SECTION 0 FOR THE MODEL USAGE.
11
On all Turbo Hydra-matic 200 transmissions, the car
serial number is stamped on a pad located above the bottom
'pan face on the left hand side of the transmission below the
kfng pawl area, or on a pad above this location, or on the
K
4er right hand side of the case bellhousing.
The following parts can be serviced with the transmission
h the car. For part removal and installation procedures not
heed in this section, refer to the disassembly and reassembly
Ections.
:
1. Governor Cover and Seals; Governor Assembly.
2. Intermediate Servo Cover and Seal; Intermediate
h
o
Piston Assembly.
'
3. Oil Pan; Oil Screen Assembly.
4. Pressure Regulator Parts.
5. Control ~ d v eAssembly; Spacer Plate; Gaskets;
amual Detent Roller and Spring Assembly; Throttle Lever
ad Bracket Assembly; Manual Valve; Check Balls; 1-2
Accumulator Valve and Spring; Intermediate Band Anchor
LOW and Reverse Clutch Cup Plug and Seal. (Fig.
7A1-24)
6 . Inside Detent Lever and Parking Pawl Actuator Rod;
Mmual Shaft; Manual Shaft to Case Seal; Parking Pawl;
Puking Bracket .
7. Rear Seal.
8. Vent Assembly.
9. Cooler ~ i t t i n i s .
lo. T.V. Cable
l1. Speedometer Driven Gear Assembly.
l2. Oil Filler Pipe and "0" Ring Seal.

THIS IS A METRIC DESIGNED TRANSMISSION, METRIC

IS STAMPED ON THE BOTTOM OF THE OIL PAN. FOR
YOUR CONVENIENCE, A LIST OF STANDARD HAND
TOOLS IS LOCATED AT THE END OF THIS SECTION.

GENERAL SERVICE PRECAUTIONS

i
i

servicing the transmission, it is recommended that

IWn disassembly of a unit, all parts should be cleaned and

PISTON

Fig. 7A1-24-Valve Body Fifth Ball Location

inspected as outlined under CLEANING AND INSPECTION.
The unit should be reassembled before disassembly of other
units to avoid confusion and interchanging of parts.
1. Before disassembly of the unit, thoroughly clean the
exterior.
2. Disassembly and reassembly of the unit and the

7A1-18 TURBO HYDRA-MATIC 200

subassemblies must be made on a clean work bench. As in

repairing any hydraulically operated unit, cleanliness is of the
utmost importance; therefore, the bench, tools, and parts
must be kept clean at all times.
3 . Before installing cap screws into aluminum parts,
ALWAYS DIP SCREWS INTO OIL to prevent cap screws
from galling the aluminum threads and also to prevent the
screws from seizing,
4. Always use a torque wrench when installing cap
screws into aluminum parts to prevent the possibility of
stripping the threads.
5. If tapped, threads in aluminum parts are stripped or
damaged, the part can be made serviceable by the use of
Helitoils or equivalent.
6. Seal protecting tools must be used when assembling
the units to prevent damage to the seals. The slightest flaw in
the sealing surface of the seal can cause an oil leak.
7. The aluminum castings and the valve parts are very
susceptible to nicks, burrs, etc., and care should be exercised
when handling them.
8. The internal snap rings should be expanded and the
external snap rings compressed if they are to be reused. This
will insure proper seating when installed.
9 , Replace all "0"rings, gaskets and oil seals that are

7. Remove intermediate servo cover and discard

ring, seal ring may be located in case.
8. Remove intermediate servo piston and band a
pin assembly.
9. Refer to Overhaul operations for inspec
procedure.
To install, reverse removal procedure.

SPEEDOMETER DRIVEN GEAR

Removal and Installation
1. Disconnect speedometer cable.
2. Remove retainer bolt, retainer, speedometer
gear and "0" ring seal.
To install, reverse removal procedure, using new
ring seal (if required) and adjust fluid level.

'6

REAR HOUSING OIL SEAL

Removal
1. Remove propeller shaft.
2. Pry out lip oil seal with screwdriver or small chi
Installation
5-21426.
2. Install propeller shaft and adjust fluid level.

10. During assembly of each unit, all internal parts must

be lubricated with oil.

PARTS CLEANING AND INSPECTION

After complete disassembly of a unit, all metal parts
should be washed in a clean solvent and dried with
oil passages should be blown out and
air.
checked to make sure that they are not obstructed. Small
passages should be checked with tag wire. All parts should be
inspected to determine which parts are to be replaced.
The various inspections of parts are as follows:
1. Inspect linkage and pivot points for excessive wear.
2. Bearing and thrust surfaces of all parts should be
check for excessive wear and scoring.
3. Check for broken seal rings, damaged ring lands and
damaged threads.
4. Inspect seals and "0"rings.
5. Mating surfaces of castings and end plates should be
checked for burrs and irregularities may be removed by
lapping the surface with crocus cloth. The crocus cloth
should be laid on a flat surface, such as a piece of plate glass,

MANUAL LINKAGE
Manual linkage adjustment and the associated neu
start switch are important from a safety standpoint.
The neutral start switch should be adjusted so that
engine will start in the Park and Neutral positions only.
With the selector lever in the Park position, the p
engage and prevent the car from
pawl
The pointer on the indicator quadrant should lin
properly with the range indicators in all ranges.
If the linkage is not adjusted properly, an internal
which "'ld
cause a
Occur at the
or band failure,

EVER IN THE

POSITION,
~
~THE

(NOTE: Steps 3 , 4 and 5 apply to Starfire models only.)

CHECKING TRANSMISSION MOUNT

Raise car on a hoist, Push up and pull
transmission tailshaft while observing transmission
rubber separates from metal plate of mount or i
moves up but not down (mount bottomed ou
mount. If there is relative movement between a met
of mount and its attaching point, tighten screws or
attaching mount to transmission or crossmember.

3. Place jack stand under transmission for support and

remove rear transmission support.
4. Let transmission drop down slightly and position a
two inch block on the right side of the transmission.
5. Position transmission to the left of the car.
6. Remove the intermediate servo cover retaining ring.

OIL COOLER PIPES

If replacement of transmission steel tubing c
required, use only double wrapped and brazed
meeting GM Specification 123M or equivalent.
condition use copper or aluminum tubing to rep
tubing. Those materials do not have satisfactory

INTERMEDIATE SERVO ASSEMBLY

Removal and Installation
1. Before raising the car, disconnect the negative
battery cable and release the parking brake.
2 . Raise car on hoist.

TURBO HY DRA-MATIC 200 7A1-19

PRESSURE REGULATOR VALVE

Removal
1. Referring to draining procedures, drain transmission
fluid from oil pan.
2. Remove oil pan and screen. Discard gasket.
3 . Pushing on pressure regulator valve bore plug,
compress pressure regulator spring with small screwdriver or
Tool 5-24684 as shown in Fig. 7A1-26.
4 . Remove retaining ring, withdraw screwdriver or tool
slowly to release spring tension.
5. Remove pressure regulator bore plug, valve, spring
and guide. Refer to overhaul portion of this section for the
inspection procedure.

hwability
to withstand normal car vibrations.
" Steel tubing should be flared using the double flare
i

method.
'r

*y?%
1

GOVERNOR

Removal
1. Before raising the car, disconnect the negative
battery cable and remove the air cleaner.

'.

(NOTE:Steps 2, 3 , 4 and 5 apply to Starfire models only.)

ti

2. Raise car on hoist and remove the exhaust to

converter bolts. Let the catalytic converter and exhaust pipe
k
g down.
3. Place jack stand under transmission for support and
remove rear transmission support bolts.
4. Remove the drive shaft as outlined in Section 4A.
S.Let transmission drop down until sufficient
dearance is obtained to remove the governor.
6. Remove the governor retainer ring and cover.
k d the two seal rings, then remove governor assembly
from case.
c

ot

W T E : If the governor to case washer falls off the

IOVemor, use a small magnet to remove the washer from the
Q@,)

8. For inspection of the governor, refer to the overhaul

Portion of this section.
bation
To install, reverse removal procedure.
CAUTION: Do not useany type of
hammer t o i n s t a l l governor
assembly and cover into case.
Damage to case, governor or cover
could result.

Fig. 7Al-26-Removing Pressure Regulator Valve

Installation
1. Install pressure regulator spring first, guide and then
valve, stem end out and bore plug hole side out.
2 . Pushing with screwdriver or Tool 5-24684 as shown
in Fig. 7A1-26 push bore plug past retaining ring groove by
tompressing pressure regulator valve spring.
3 . Install retaining ring.
4 . Refer to Refill Section for correct fluid level.
VALVE BODY ASSEMBLY
Removal
1. Referring to draining procedures, drain transmission
fluid from oil pan.
2. Remove oil pan and screen. Discard gasket.
3 . Remove screw and washer securing cable to
transmission and disconnect T .V . cable.
4. Remove throttle lever and bracket assembly. Do not
bend throttle lever link.
5. Remove manual detent roller and spring assembly.
6. Support valve assembly and remove retaining bolts.
7. Holding manual valve with fingers, remove valve
assembly spacer plate and gaskets together to prevent
dropping of four (4) check balls located in control valve
body and fifth (5th) check ball located on spacer plate.
(NOTE : After removing valve body assembly, the
intermediate band anchor pin and reverse clutch cup plug
may come out .)
8 . Lay control valve assembly down with spacer plate
side up and remove fifth check ball off spacer plate.

7A1-20 TURBO HY DRA-MATIC 200

9. Refer

to

overhaul

operations

for

inspection

Installation of valve body is the reverse of removal.

Torque all valve body bolts to 10 N-m (8 ft. lbs.).

CA U T I O N : I n termediate band
anchor p i n must locate on
intermediate band or damage to
transmission will result.
Refer to Refilling of Transmission portion of this section
for correct fluid level.

T.V. CABLE
1. Remove air cleaner.
2. Push up on bottom of snap-lock and release lock and

2. (ENGINE OFF) MOVE

CARBURETOR LEVER AND
HOLD I N W l DE OPEN
THROTTLE POS ITION.
3. PUSH "SNAP-LOCK"
DOWNWARD UNTIL FLUSH
W I T H REST OF CABLE.
4. RELEASE CARBURETOR LEVER.

4 . Disconnect cable from carburetor lever.

5. Remove clamp around filler tube, (if used) remove
screw and washer securing cable to transmission and
disconnect T.V. cable.
1. Install new seal on T.V. cable, Lubricate seal with
transmission fluid.
2. Connect transmission end of T.V. cable and secure
to transmission case with bolt and washer tightened to 10
N*m (8 ft. lbs.).
3. Route cable in front of filler tube and clamp to filler
tube at the filler tube bracket.
4 . Pass cable through bracket and engage locking tube
of snap-lock on bracket.
5. Connect cable to carburetor lever.
6. Install air cleaner.
Adjustment (Fig. 7 A1 -27)
1. Disengage "Snap Lock" (Cable should be free to
slide thru "Snap Lock").
2. With cable installed in support and attached to
transmission and carburetor lever, move carburetor lever to
wide open throttle position.
3 . Push "Snap Lock" flush and return carburetor lever
to closed position.

SHIFT RODISHIFT CABLE ADJUSTMENT

Refer to Figs. 7A1-28 through 7A1-30.

6. Remove flywheel cover pan and three bolts hol

the converter to the flywheel. Support engine.
(NOTE: Mark flywheel and converter for reassembly in
same manner .)
7. Disconnect speedometer cable.
8. Remove cotter pin and manual shift linkage.
9. Remove propeller shaft.
10. Remove transmission support to transmission mo
bolts and transmission support to frame bolts.
11. Raise transmission with a jack and remove sup
12. Lower transmission slightly and remove transmi
to engine bolts,
13. Lower transmission being careful not to dam
cooler lines, T.V. cable, and shift linkage.
14. If transmission is to be moved, install conve
holding Tool 5-21366.
(NOTE: To hold the torque converter from falling d
transmission removal, secure converter by drilling ho
5-21366 tool on the 90mm (3.112") step side to line up
converter lug bolt hole and retain with bolt. (Fig. 7A1-3

SHIFT INDICATOR NEEDLE ADJUSTMENT

Refer to Sections 3 and 8.
TRANSMISSION
1. Remove transmission oil level dipstick and upper
bolt on dipstick tube (from above).
2. Hoist car.
3 . Remove retaining bolt for T.V. cable. Remove T.V.
cable from link. Plug hole. (If console equipped, remove shift
control cable .)
4. Disconnect transmission cooler lines at transmission.
5. Remove catalytic converter support bracket.

Installation
1. Place transmission on locating pilots. I
downshift cable in clip on transmission, insert oil
dipstick tube and bolt tube in place. Install transmissio
engine bolts and torque to 54 N-m (40 ft. lbs.).
(NOTE: Rotate converter to permit coupling of
and converter in the original position by aligning t
made before removal.)
2. Install transmission support and torque sUPP
frame nuts to 34 N*m (25 ft . lbs.). Torque sUPP
transmission mount bolts to 61 N*m (45 ft. lbs.). Re

TURBO HYDRA-MATIC 200 7A1-21

StllFT ROD ADJUSl/dENT

1. lil T t i SWIFT ROD CiAA'IP SCREit LOOSENED

SET TRANShllSS lOh OdRR LEVER lh NEUTRAL

POS ITION.

2. H O L D UPPER ShlFT EVER AGAINST NLUTRAl

POS I T I O k 5T0P IN UPPER STEERIbiG COCUR1R.
(DO h O T R A I SF IFVFR)

TRANS. OUTER

TIGHTEV SCRF\:' I N CLAh'lP ON LOlVER END OF

SHIFT ROD TO S M C I F I E D TORQUE.
CHECK OPERATION .

HlNG
A

Y31TH KEY IN "KUh" ['(?ilTlON 4R10

T R A N 5 h l l 5 S ION I N "RFVtRSt " BE 't URE
TIiAT KEY CANNOT f3r RIh1OVED AND THAT
s ~ r i i ~ ~ r , i r ; i t1s~ r~r i~ oto(
i KFI)

VilTII K t Y li\i"iO(,K' 1'0SITiONAhi~

~ H I F I TI V F K I N ~ P A ~~t ~ j ~l i "~ lt t i ~ i
Kt Y ( AN b t Kf hlOlit IJ THAT j l k f K I N G
I Y t i F T i f 5 [(ICKFII AN0 T t l A ? IHF TRAP45
RSi55 IOPJ R! M A I N 5 I N P A R K 1?liifN THt
S R t R I V G [ OiLJAlN 15 lO(,Kt 1)

B RACKET

WASHER
(SEEVIEW)

I \
27 N. m
120 FT. LBS.

'1 f li<iC\l \ AI'I'L II D

( lit( k
hliili \!!AT {lit 5 i A R i f t i i Z I I I
N0Tl"lOKK i N ANY 5 i i l f T l t V f K f ) O ~ l ION
l

i 3 'VVITti i:KAtci

ro hlAiif

i X(,f ['I N1 I J l l t A l AND /'ARK

Fig. 7A1-28-Column Shift Controls

S H IFT CABLE ADJUSTMENT

1. LOOSEN SHIFT ROD CLAMP SCREW, LOOSEN P I N I N TRANSM I S S ION MANUAL LEVER.
SHIFTER ASSEMBLY

2. PLACE SHIFT LEVER I N "PARK" POS ITION. PLACE TRANSM I S S I O N MANUAL LEVER I N "PARK" POS I T I O N AND I G N I T I O N
KEY I N LOCK POSITION.
3. T I GHTEN CABLE P I N NUT TO 20 FT. LBS.
4. ROTATE THE TRANSMISSION MANUAL LEVER FULLY AGAINST
THE "PARK" STOP. THEN RELEASE THE LEVER.
5. PULL SHIFT ROD DOWN AGAINST LOCK STOP TO ELIMINATE
LASH AND T I GHTEN CLAMP SCREW TO 20 FT. LBS.

SHIFT ROD

6. CHECK OPERATION:
TRANSMISS ION

CABU
PIN

c LAMP

CLAMP SCREW

A. MOVE SHIFT HANDLE INTO EACH GEAR POSITION AND SEE

THAT TRANSMISSION MANUAL LEVER I S ALSO I N DETENT
POS ITION.
B. W l T H KEY I N "RUN" POSITION AND TRANSMISSION I N
"REVERSE", BE SURE THAT KEY CANNOT BE REMOVED AND
THAT STEERING WHEEL I S NOT LOCKED.
C. W I T H KEY I N "LOCK" POSITION AND TRANSMISSION I N
"PARK". BE SURE THAT KEY CAN BE REMOVED AND THAT
STEERING WHEEL I S LOCKED.
D. ENGINE MUST START I N PARK AND NEUTRAL
E. W l T H BRAKES F I R M L Y APPLIED. CHECK TO MAKE SURE
THAT THE STARTER W I L L NOT WORK I N A N Y SHIFT LEVER
POSITION EXCEPT NEUTRAL AND PARK.

Fig. 7A 1 -29-Console Shift Cable

TURBO HYDRA-MATIC 200 7A1-23

7 ~ 1 - 3 2 Also,
)
make sure rings are seated in the grooves
iFFrevent damage to the rings during reassembly of mating
over rings. Retain with petrolatum.
4. New angle cut or full circle teflon seal rings may
to be distorted after being installed. Once exposed to
oil temperatures, the new seal rings will
return to their normal shape and fit freely in their bores.
5. The teflon Seal rings allow for a free fit in their bores
after erati ti on. The free fit of the rings in their bores does
not indicate leakage during operation.

,,,

assembly attaching bolts, and they

are not interchangeable.
3. Control Valve Assembly:
a. Remove throttle lever and bracket assembly.
(Fig. 7A 1-34)Do not bend throttle lever link.
(NOTE: T.V. exhaust valve lifter and spring may separate
from throttle lever and bracket assembly.)
b. Remove manual detent roller and spring
assembly . (Fig. 7 A 1-35 )
c. Remove remaining control valve assembly
attaching bolts.

CAUTION: Do not drop manual

valve.
d. Holding manual valve with finger, remove
control valve assembly, spacer plate, and gaskets
together, t o prevent the dropping of 4 check balls,
located in the control valve assembly. (Fig. 7A1-36).
e . Lay control valve assembly down with spacer
plate side up and discard gaskets.

RIGHT

(NOTE: Some spacer plates may be of a rubberized type

which do not require gaskets and are re-used if not damaged.)

WRONG
I

Fig. 7A1-32-Teflon Oil Seal Rings

SNAP RINGS
Do not over expand snap rings when removing or
installing.

THRUST WASHER SURFACES

The thrust washers and thrust bearings will polish the
surfaces they protect. This is not to be considered a damaged
part because of this condition.

EXTERNAL PARTS

Removal
1. Remove oil pan and discard gasket.
2. Remove oil screen and discard gasket. (Fig. 7A1-33)

CAUTION: The two oil screen

attaching bolts are about 7Omm
{3/8")longer than the control valve

Fig. 7 A l - 3 3 - ~ e m o v i nOil
~ Screen

Fig. 7Al-36-Removing Control Valve

Assembly From Case

Fig. 7Al-34-Removing Throttle

Fig. 7A 1 -35--Removing Manual Detent
Valve and Bracket Assembly
Roller and Spring Assembly

TURBO HYDRA-MATIC 200 7A1-25

8. Check for proper intermediate band apply pin as

follows:
a. lnstall 11-25014-2 in intermediate servo bore and
retain with intermediate servo cover retaining ring,
aligning ring with gap at case slot. (Fig. 7A1-46)
b. Install pin 5-25014-1 into 5-25014-2. (Fig.
7~1-46)

CA U TION: Make sure the tapered.

pin end is properly located against
the band apply lug. Also, make sure
the band anchor pin is properly
located in the case and band anchor
lug.

d . Align stepped side of pin 5-25014-1 with

torquing arm of 5-25014-2. Arm must stop against step
of pin 5-25014-1.

(NOTE: If band selection pin does not register between the

h g h and low limits, look for possible problem with the
intermediate band, direct clutch or case .)
e . Apply 12 N*m (100 in. Ibs.) of torque to hex
nut on side of gage. Slide dial indicator over pin
5-25014-1. (Fig. 7Al-47) Read dial indicator and see
chart for proper size. (Fig. 7A1-48)

c. Install dial indicator J-8001 and position dial

indicator point (Fig. 7A1-46) on top of 5-25014-2 zero
post and set dial indicator to zero.

(NOTE: Dial indicator travel is reversed, malung the

indicator readings backwards. On an indicator that ranges
from 0-100, a .5mm (.02OV) travel will read 2mm (.08OV),a
1.5mm (.060") travel will read 1mm (.04OU). The
identification ring is located on the band end of the pin.)

VOTE: Seat J -2501 4-2 squarely against the servo retaining

f.

Remove tools 5-25014-2 and 5-25014-1.

snap ring.)

Fig. 7AI-44-Direct Clutch

Accumulator Port

Fig. 7A1-45-Apply Air Pressure to

Remove Intermediate Servo

Fig. 7A 1-46-Intermediate Band

Apply Pin Tools

INTERMEDIATE BAND
APPLY PIN SELECTION CHART

APPLY PIN
DIAL INDICATOR TRAVEL

IDENTIFICATION

0 mm-2.16mm
2.16mm-2.88rnm

(.00OV-.086")
(.086" -.I 14")

2 Rings
Wide Band

Fig. 7Al-47-Checking For Proper

Intermediate Band
Apply Pin

Fig. 7Al-48-Intermediate Band Apply Pin Selection Chart

FRONT UNIT PARTS

1. Check front unit end play as follows: (Fig. 7A1-50)
a . Install 5-25013-1 sleeve on output shaft first;
then bolt 5-25013-5 on end of case. (Fig. 7A 149)
c. Remove pump to case bolt and washer and
install 278mrn (1 1") long bolt and locking nut as shown.

Fig. 7A 1-49-Installing Tools on Rear End of case

washers; discard washers.

c. Using 5-24773 tool, remove pump assembly,
pump to case gasket and discard gasket. (Fig. 7A1-53)
3. Forward and Direct Clutch:

Fig. 7A 1 -51 -Front Unit End Play Washer Thickness C

4. Remove intermediate band assembly. (Fig. 7A1-

Fig. 7A 1-52-Removing Pump Seal

Fig. 7Al-53-Removing Pump ~ s s e m b

-.

TURBO HYDRA-MATIC 200 7A1-27

ERMEDIATE BAND

1-54-Removing Forward and

Direct Clutch Assemblies

Fig. 7Al-55-Removing Intermediate

Band Assembly

Fig. 7Al-56-Removing Intermediate

Band Anchor Pin

REAR UNIT END PLAY

WASHER THICKNESS CHART
I

THICKNESS

er may be stuck to the end of the turbine

IDENTIFICATION
Number and/or Color

2. Check Rear Unit end play as follows:

a. Loosen 5-25013-5 adjusting screw on output
output shaft downward. (Fig. 7A1-58)
gage clamp on case as shown. (Fig.
c. Install dial indicator 5-8001 and plunger
extension 5-7057. Position extension against end of
output shaft and set dial indicator to zero. (Fig. 7A1-59)
d. Move output shaft upward by turning adjusting
screw on 5-25013-5 until the white or scribed line on
sleeve J-25013 begins to disappear; then read end play.
end play should be 0.10-0.64mm

@OTE: Selective washer controlling this end play is located

between the front internal gear thrust washer and output

Fig. 7Al-57-Location of Front

Selective Washer

2.463-2.59Omm
290-3.01mm
3.08-3.19mm
326-3.37mm
3.44-355mrn
3.62-3.73rnm
3.80-391mm
3.984.09mm
4.164.27mrn
4.344.45rnm

(0.097"0.102")
(0.1 14" 0 . 1 19")
(0.121" 0.126")
(0.128" 0.133")
(0.135" 0.140")
(0.143" 0.147")
(0.150" 0.154")
(0,157" 0 . 1 61 ")
(0.164" 0.168")
(0.171"-0.175")

0
1
2
3
4
5
6
7
8
9

- Orange

White
Yellow

Blue
Red

Brown

- Green

- Black
- Purple

Fig. 7A1-60-Rear Unit End Play Washer Thickness Chart

shaft snap ring. If more or less washer thickness is required to
bring end play within specifications, select proper washer
from the Rear Unit End Play Washer Thickness Chart, Fig.
7A1-60.)

Fig. 7Al-58-Installing Tools on

Rear End of Case

Fig. 7Al-59-Checking Rear Unlr

End Play

F-------,. Using 5-25012, remove low and reverse clutch

housing assembly by moving 3-25012 back and forth.
( ~ i g7~
. 1-67)
d. Remove low and reverse clutch housing to case
,pacer ring. (Fig. 7A 1-68)

TURBO HYDRA-MATIC 200 7A1-29

REAR GEAR PARTS

Removal
(NOTE: Make sure governor has been removed at this time.)
1. Grasp output shaft and lift out rear unit parts and
lay down in a horizontal position. (Fig. 7A1-69)
2 . Roller clutch and rear carrier assembly:
a. Remove roller clutch and rear carrier assembly
off output shaft.
b . Remove the 4 tanged rear carrier t o rear internal
gear thrust washers off the end of the rear carrier, or
inside the rear internal gear. (Fig. 7A1-70)
3 . Remove low and reverse clutch plates off output
shaft.
4. Rear internal gear:
a. Remove rear internal gear to rear sun gear thrust
bearing assembly off rear internal gear.
b. Remove rear internal gear off output shaft. (Fig.
7A1-71)
5 . Turn transmission to horizontal position and remove
5-25013-5 and 5-25013-1 tools from case. Turn transmission
to vertical position with rear end up.
6. If necessary, remove rear oil seal. (Fig. 7A1-72)

Fig. 7Al-67-Removing Low and Reverse Clutch Housing

Fig. 7A 1-68-Proper Location of Low and Reverse

Housing to Case Spacer

Fig. 7Al-72-Removing Rear Oil Seal

OUTPUT SHAFT

Fig. 7Al-69 - ~ e m o v i nRear

~ Unit Parts

Fig. 7A 1-70-Removing Thrust Washer

Fig. 7A 1-71-Removing Rear Internal Gear

TURBO HYDRA-MATIC 200 7A1-31

Fig. 7A 140-Removing Parking Pawl Shaft From Case

TRANSMISSION INSPECTION AND REASSEMBLY
7A 1-81 and
INSPECTION OF CASE ASSEMBLY (Figs.
y.ir82)
1. Inspect case assembly for damage, cracks, porosity

Fig. 7A182-Oil Passages - Front of Case

or interconnected oil passages. If case is porous, refer to
porosity repair.

Fig. 7A1-81 -Oil Passages - Bottom of Case

P I N (MANUAL SHAFT TO CASE)

MANUAL DETENT
ROLLER AND S PRl NG
BOLT (BRACKET TO CASE)
PARKING BRACKET
PARKING PAWL
PARKING PAWL
RETURN S PR ING

PARKING PAWL SHAFT

4
SLOTTED SPRING PIN
PARKING
PAWL CUP PLUG

TURBO HYDRA-MATIC 200 7 ~ 1 - 3 3

CAUTION: File any burrs or raised

edges off the manual shaft that
could damage the seal during
installation of the shaft.
11, Install manual shaft, small identification ring groove

mt,through case. Install manual shaft to case retaining pin,

indexing with larger groove on manual shaft. (Fig. 7A1-89)
12. Aligning inside detent lever with flats on manual
b f t , install inside detent lever on shaft.

Fig. 7A 1 -86-Installing Parking Pawl

13. Install hex nut on manual shaft and torque to
27.0-34.0 N*m (20-25 ft. lbs.).

E4ik

7 $a RETAINING

IDENTIFICATION
GROOVE
T P I N GROOVE

MANUAL
SHAFT

Fig. 7A 1 -87-Installing Parking Pawl

Cup Plug

Fig. 7A 1-88-Installing Parking

Actuator Rod

Fig. 7A 1-89-Installing Manual Shaft

Into Case

REAR GEAR PARTS

h p u t Shaft (Fig. 7A 1-90)

(NOTE: The service output shaft has one speedometer drive

gear clip hole at the front speedometer gear location which is
about 6.3 mm (114") diameter and opposite this hole is
mother clip hole which is about 4.0 mm (5132"). The shaft
has the same size holes at the rear speedometer gear
lof~tion.)

1 . Inspect journals and snap ring grooves for wear or

damage.
2. Inspect lubrication passages for being plugged or
damaged.
3 . Inspect splines for damage.
4 . Inspect governor drive gear for rough or damaged
teeth.
5 . Inspect speedometer drive gear for rough or
damaged teeth and also the clip for damage.

SPEEDOMETER
DRIVE GEAR CLIP

\
\Y

SNAP R I N G

SPEEDOMETER
DRIVE GEAR

OUTPUT SHAFT

Fig. 7A1-90

tput Shaft

I
I

7A 1-34 TURBO HYDRA-MATIC 200

6. If necessary to replace speedometer drive gear,

proceed as follows:
a. Depress speedometer drive gear clip.
b. Remove gear and clip, tapping gear lightly with
plastic hammer.

c. Place speedometer drive gear clip with

tanged end in the correct hole in the output shaft,(
7~ 1- 9)~
d . Align the slot of the speedometer drive
with the clip and install the gear.

Fig. 7A 1-91 -Installing Speedometer Driven Gear and Clip

STEEL SPEEDOMETER DRIVE GEAR
(Models PA, CO, CR, CS AND CY)

2. Position speedometer gear, larger chamfered insi

diameter first over rear end of output shaft.

Removal

Inst allation
1. Place front end of output shaft on block of wood to
prevent damaging the front end.

SPEEDOMETER
DRIVE GEAR

SPEEDOMETER
CIRIVE GEAR

Fig. 7Al-92-Removing Steel Speedometer Drive Gear

Fig. 7Al-93-Installing Steel Speedometer Drive Gear

TURBO HYDRA-MATIC 200 7 A l - 3 5

4. Thoroughly clean, air dry and inspect closely, the

rear internal gear to rear sun gear thrust bearing assembly for
pitted or rough conditions.
5. Install rear internal gear to rear sun gear thrust
bearing assembly by placing the small diameter race over the
output shaft. (Fig. 7A1-95)

REAR INTERNAL GEA

OUTPUT SHAFT

Fig. 7A 1-94-Installing Rear Internal Gear

onto Output Shaft

Fig. 7A 1 -95-Installing Thrust Bearing Assembly

Roller Clutch and Rear Carrier Assembly

[~pection
1. Remove roller clutch race. Inspect race and spline
for scoring or wear. (Fig. 7A1-96)
2. Remove roller clutch assembly and inspect roller
bearings, cage and springs for damage or wear. (Fig, 7 A 1-96)
3. Remove and inspect rear carrier to clutch thrust
washer for signs of scoring or excessive wear. (Fig. 7A1-96)
4. Inspect 4 tanged rear carrier to rear internal gear
thrust washers for being scored or distorted tangs. (Fig.
7A1-96)
5. Inspect rear carrier for damage. (Fig. 7A 1-96)
6. Inspect roller clutch cam ramps for damage.
7. Inspect bushing for damage or scoring.
8 . Inspect planet :pinions for damage, rough bearings or
tilt.
9. Check pinion end play. Pinion end play should be
0.24-0.69mm (0.009" -0.027"). (Fig. 7A 1-97)
Reassembly
1. Install roller clutch to rear carrier thrust washer.
(Fig. 7A1-98)

THRUST WASH
REAR CARRIER

Fig. 7Al-98-Installing Thrust Washer Into Rear Carrier

REAR C A R R I E R

Fig. 7A1-96-Roller Clutch and Rear Carrier - Exploded View

Fig. 7A 1-97-Checking Rear Carrier

Pinion End Play

7A1-36 TURBO HYDRA-MATIC 200

11 f

I
/

2. lnstall rollers that may have come out o f roller

clutch cage, by compressing the energizing spring with
forefingerBnd inserting roller from outer edge. (Fig. 7A 1-99)
3. Install roller clutch assembly into roller clutch cam.
(Fig. 7A1-100)
4. Install roller clutch race, spline side out and r otate
clutch race counterclockwise into pisition. (Fig. 7A1-101)
5. lnstall 4 tanged rear cairier to rkar- internal gear
thrust washer. Align tangs into slots of rear carrier and retain
with petrolatum. p i g . 7i1-102)
6. Inst all roller clutch and rear carrier assembly into
rear internal gear. (Fig. 7A1-103)
7. ~ n s t d lJ-25013-1, open end first, into rear er
case. Bolt J-25013-5 on end of case. (Fig. 7A1-104)
8. Turn case to vertical ~ o s i t i o nD. U ~ Dend UD.

I
I

L
ROLLER

Fig. 7 A 1-99-Installing Roller Into Cage

Fig. 7A1-100-Installing Roller Clutch

Into Rear Camer

Fig. 7A 1-101-Installing Roller

utch Race

17:- 7 A 1 1 n3
1.1s.
I nl-luL

T-~+~II:-,.

a-r.-+
Urnohfir

OUTPUT SHAFT
RRlER

REAR INTERNAL GEAR

Fig. 7Al-103-Installing Rear Carrier Into Rear Internal Gear

Fig. 7A1-1.04-Installing Tools on

Rear End of Case

TURBO HYDRA-MATIC 200 7A1-37

POJOTE:Make sure speedometer drive gear is visible through

speedometer gear bore. If drive gear is not visible, it may be
located on wrong journal of shaft.)
OUTPUT SHAFT
LO & REVERSE
CLUTCH HOUSING

PARKlNG PAWL
LUGS

Fig. 7Al-107-Removing Low and Reverse Clutch

Spring Retaining Snap Ring

Fig. 7A 1-105 -Installing Rear Unit Parts

LOW AND REVERSE CLUTCH

Inspection
Inspect low and reverse clutch composition-faced and
steel clutch plates for signs of wear or burning.

Low and Reverse Clutch Housing Assembly (Fig. 7A1-106)

Disassembly
1. Compress low and reverse clutch spring retainer,
remove snap ring and retainer and inspect for damage or
distortion. (Fig. 7A1-107)
2. Remove waved spring. (Fig. 7A 1-108)
3. Remove low and reverse clutch piston.
LO & REVERSE
CLUTCH
HOUSING
LO & REVERSE
ASSEMBLY
PISTON SEALS

RlNG
(HOUSING
TO CASE)

HOUSING
TO CASE
SPACER

Fig. 7Al-108-Removing Low and Reverse Clutch

Wave Release Spring

LO & REVERSE
LO & REVERSE CLUTCH
LO&REVERSE
CLUTCH APPLY SPRING
STEEL CLUTCH
RING
RETAINER
PLATE

LO & REVERSE
PISTON
ASSEMBLY

WAVE
RELEASE
SPRING

SNAP
RING

LO & REVERSE
COMPOSITIONFACED PLATE

Fig. 7A1-106-Low and Reverse Clutch Assembly - Exploded View

TURBO HY'DRA-MATIC 200

1'

4. Remove outer and inner piston seals. (Figs. 7A1-109

and 7A1-110)
5. Remove clutch apply ring.

Inspection
1 . Inspect low and reverse clutch housing for d
plugged feed hole.
2. Inspect low and reverse clutch housing bushino c,damage or scoring.
3. Inspect low and reverse clutch splines and
groove for damage or burrs. Remove any burrs on
snap ring groove.
4. Inspect low and reverse clutch piston a
apply ring assembly for distortion, cracks or damage.
--ubba'

(NOTE: The apply ring is identified by a number 1

the ring. Refer to the 200 clutch plate and apply
chart for apply ring identification, Fig. 7A1-115 .)

5. Inspect low and reverse clutch spring retainer for

damage.
6. Inspect waved spring for damage.
7. Inspect low and reverse clutch housing to case spacer
ring for damage.

ig. 7A1-109--Removing or Installing

Low and Reverse Clutnh nmm4n*

b11 V U L b L

Cnql

LJbUL

ir

i'

Reassembly
1 . Install clutch apply ring on low and rev
piston.
2. Install new outer and inner seals on piston with lips
facing away from clutch apply ring side. (Figs. 7A 1-109 and
7A1-110)
3. Install seal protector 5-2501 1 .

(NOTE: Apply transmission fluid to all clutch seals before

reassembly .)
4. Using flat edged small screwdriver or piston
installing tool (Fig. 7Al-142), install low and reverse clutch
piston, while rotating and pushing down into place. (Fig.
7A1-111)

C A U T I O N : F l a t screwdriver
surface area must be smooth to
prevent damaging outer sea/.

Fig. 7A 1-110-Removing or Installing

Low and Reverse Clutch Inner Seal

LO & REVERSE
CLUTCH HOUSING

J-25011

5. Remove seal protector 5-2501 1 .

6. Install waved release spring. (Fig. 7Al-112)
7. Install retainer, cupped faced down. (Fig. 7A1-113)
8. Compress retainer and install snap ring. (Fig.
7A1-113)

LO & R E V

Fig. 7Al-111 -Installing Low and

Reverse Clutch Piston

CLUTCH HOUSING

Fig. 7Al-112-Installing Low and Reverse Fig. 7Al-113-Installing Low and Reverse
Clutch Retaining Snap Ring
Clutch Wave Release Spring

I-

.-

E
E r

E
E z

E
E r

E
E^

$ $ 3% 29 9 : $g
8 9 $5 $ 2 R 2 $0

->.
2 2 :m
r

E
E-

*
*

7A 1-40 TURBO HY DRA-MATIC 200

five (5) flat steel and four (4) composition-faced clutch

plates, starting with a flat steel plate and alternating
composition-faced and flat steel clutch plates.
b. On Models CS, BZ, OR and OW, oil and install
six (6) flat steel and five (5) composition-faced clutch
plates, starting with a flat steel plate and alternating
composition-faced and flat steel clutch plates.
c. On Models PC, PH, CO, CR, CY, BA, OS, OT
and OX, oil and install seven (7) flat steel and six (6)
composition-faced clutch plates, starting with a flat steel
plate and alternating composition-faced and flat steel
clutch plates.
2, Install low and reverse clutch housing t o case spacer
ring in case. (Fig. 7A1-114)
3. Install low and reverse clutch housing assembly

and Reverse Housing to Case Spacer

a. Remove toolJ-25012.
b. Using rear sun gear and input drum as twl
install input drum and rear sun gear in case.
c. Rotate rear sun gear back and forth, tapp
lightly with input drum, to align roller clutch race
low and reverse clutch hub splines. (Fig. 7A1-117)
d . Remove tool (input drum and rear sun gear),

(NOTE: It may be necessary to loosen adjusting screw

5-25013-5 on output shaft to instau snap ring.)
e. Repeat the above steps if low and reverse clutc
housing is not fully seated past case snap ring groove,
4. Install low and reverse clutch housing to case sna
ring, flat side against housing (beveled side up). Position sna
ring gap on opposite side of parking pawl rod.

Reverse Clutch Housing

I

and Rear Sun Gear

FRONT GEAR PARTS

Rear Sun Gear and Input Drum (Fig. 7A1-118)

INPUT DRUM

SNAP RING
(INPUT DRUM TO
REAR SUN GEAR)

REAR SUN GEAR

THRUST WASHER
(DRUM TO HOUSING)

Fig. 7Al-118-Rear Sun Gear and Input Drum

Inspection
1 . Inspect rear sun gear for cracks, splits, d
spline, worn gear or journals and plugged lubrication
(Fig. 7Al-118)
2. Inspect rear sun gear bushing for damage or scar
3. If necessary, remove input drum to rear sun
snap ring and remove sun gear from input drum.
4. Inspect input drum for damage. (Fig. 7A1-118)
5 . Inspect 4 tanged input drum to low and re
clutch housing thrust washer for scoring or distorted t
(Fig. 7A1-118)
6. If damaged, replace rear sun gear to input drum
ring.
Reassembly
1 . Install rear sun gear into input drum, spline si
first, and retain with snap ring. (Fig. 7A1-118)
2. Install 4 tanged thrust washer on input drum
sun gear end; align tangs into input drum and retain
petrolatum. (Figs. 7A1-118 and 7A1-119)
3. Install rear sun gear and input drum assembly (
7A1-117)

R E A R SUN
GEAR

I .

Fig. 7Al-121 -Installing Front Sun Gear

s
Fig. 7Al-119-Installing Thrust Washer

Front Sun Gear

I . Inspect front sun gear splines and teeth for damage

or wear.

2. Inspect machined face for pitting, scoring or

damage.
3. Install front sun gear face with the identification
mark (a drill spot or groove) against input drum to rear sun
p r snap ring. (Fig. 7A1-121) See Fig. 7A1-120 for
identification marks.
4. Thoroughly clean, air dry and inspect front sun gear
to front carrier thrust race and thrust bearing for pitted or
rough conditions.
5 , Install front sun gear t o front carrier thrust bearing
and race assembly with thrust bearing against the front sun
gear. (Fig. 7A1-122)

(NOTE: This thrust bearing requires only 1 thrust race. An

optional thrust bearing and race could be used. Install this
type of thrust bearing and race as follows:)
a. Place thrust bearing on sun gear.
b. Place 0 .D. flanged thrust race on bearing with
cupped side over bearing.

Fig. 7Al-120-Front Sun Gear Identification

RACE ASSEMBLY
NEEDLE BEARfNGS
GAINST GEAR)

Fig. 7Al-122-Installing Thrust Bearing Assembly

Against Front Sun Gear
Front Carrier Assembly
Inspection
1. Inspect front carrier for damage. (Fig. 7A1-123)
2. Inspect pinions for damage, rough bearings or tilt.
3 . Check pinion end play. Pinion end play should be
0.24mm-0.69mm (0.009" -.(I27"). (Fig. 7A1-123)
4. Thoroughly clean, air dry and inspect closely, front
carrier to front internal gear thrust bearing assembly for
pitted or rough conditions.

Fig. 7A 1 -1 23-Checking Front Carrier Pinion End Play

Reassembly
1 . Install front carrier to front internal gear thrust
bearing assembly by placing the smaller diameter race against
carrier. Retain with petrolatum. (Fig. 7A1-124)
Install front carrier and thrust bearing assembly.
(Fig. 7A1-125)

;i

Front Internal Gear and Selective Thrust washer

7A1-126)
1. Inspect forward clutch hub for worn splines and - 1
lubrication holes.
2. Inspect internal gear for cracks or damage.
1
3. Inspect gear teeth for excessive wear or damage, 1
4. Inspect bushing for damage or scoring.
1
1
5 , Insoect thrust washer. front internal near
washer for Loring or damage.
6. Install thrust washer on front intern21 --retain with petrolatum. (Fig. 7A1-126)
7 . Install front internal gear.
+-

--I

Rear Selective Thrust Washer

I
1 . Inspect selective washer for scoring or damage.(FY
7A 1-126)
3

CA U T I 0 N : The rear
thrust washer must be
with the iden tification
t o w a r d the front
transmission.

I'I1'1r

Fig. 7A 1-124 -Installing Thrust Bearing Assembly

Onto Front Carrier

'I

selective
installed
number
o f the

r i
, ,

f
I!

2. Install rear selective washer. (Fig. 7A 1-126)

3. Inspect output shaft to selective thrust washer sna
ring for damage or distortion.

(NOTE: It may be necessary to move output shaft imurnra

by turning the adjusting screw on 1-25013-5 to install outpu
shaft to selective washer snap ring.)
4. Install snap ring on output shaft. (Fig. 7A1-126)

"

CAUTION: Make sure snap ring is

fully seated in output shaft groove.
Check Rear Unit End Play
1 . Loosen J-25013-5 adjusting screw on output
and push output shaft downward. (Fig. 7A1-127)

Slfi

CAUTION: Do not install clamp

assembly on any machined case
surfaces.

4
9

/ /I

Fig. 7A 1-125-Installing Front Carrier

and Roller Thrust Bearing

Fig. 7A 1 -126-Installing Output Shaft

to Selective Washer Snap Ring

2. Install gage clamp on case as shown in Fig. 7A1-128!

3. Install dial indicator J-8001 and plunger extension
3-7057. Position extension against end of' output shaft.
dial indicator t o zero. (Fig. 7Al-128)

Fig. 7A1-127-Installing Tools on

Rear End of Case

Fig. 7Al-128-Checking Rear Unit

End Play
!

--

TURBO HY DRA-MATIC 200 7 A 1-43

by turning the adjusting

or scribed line on sleeve
7A 1-127), and read end
ould be 0.1 0-0.64mm

E: selective washer controlling this end play is located

the front internal gear thrust washer and output
snap ring. If more or less washer thickness is required to
bring end play within specifications, select proper washer
from the chart, Fig. 7A1-129.)

5. Remove dial indicator and clamp assembly. (Fig.

7~1-128)
6 . Loosen 5-25013-5 adjusting screw on output shaft.
7. Inspect output shaft to turbine shaft front selective
wust washer for damage oi scoring.
8.
- - ~nstalloutput shaft to turbine shaft, front selective
b u s t washer, locating in output shaft and retain with
(Fig. 7A 1-130)

Fig. 7Al-130-Location of Front Selective Washer

FRONT UNIT PARTS

REAR UNIT END PLAY

WASHER THICKNESS CHART .(
f

THICKNESS

Direct Clutch Assembly (Fig. 7A1-131)

1. Remove snap ring. (Fig. 7A1-132)
2. Remove the clutch backing plate from the direct
clutch housing.

IDENTIFICATION
Number and/or Color

2.463-2.59Omm
290-3.Olmm
308-3.19mrn
326-3.37mm
3.44-35 5 mm
3.62 -3.73mm
380-39 1 mrn
3984.09rnm
4.16427mm
4.344.45 mm

0
I
2
3
4
5
6
7
8
9

Orange
Whte
Yellow

Blue
Red

Brown
Green
Black

Purple

Fig. 7A 1-129 -Rear Unit End Play Washer Thickness Chart

Fig. 7Al-132-Removing Direct Clutch Snap Ring

.
D lR ECT
CLUTCH
PISTON

DIRECT
CLUTCH
HOUSING

DIRECT
CLUTCH
APPLY

DIRECT CLUTCH
PISTON ASSEMBLY

DIRECT
CLUTCH
RETAINER

SPRING
GUIDE

RING

FLAT
STEEL
PLATE

FACED PLATE

Fig. 7A 1-13 1-Direct Clutch Assembly - Exploded View

DIRECT
CLUTCH
BACKING

RING

7A1-44 TURBO HYDRA-MATIC 200

3. Remove the clutch plates from the direct clutch

housing and keep them separated from the forward clutch
plates. (See Clutch Plate Usage Chart, Fig. 7A1-115)
4. Inspect composition-faced plates and steel clutch
plates for wear or burning.
5. Inspect clutch backing plate for scoring or other

6. Using J-23327, compress retainer and spring

assembly (Fig. 7A1-133), remove snap ring and inspect for
damage or distortion.
7. Remove J-23327.
8. Remove retainer and spring assembly from housing.
9 . Inspect release spring retainer for being collapsed.
10. Inspect release springs for being collapsed.
11. Remove release spring guide and inspect for damage.
12. Remove direct clutch piston.
13. Remove outer and inner seals from direct clutch
piston and discard. (Figs. 7A1-134 and 7A1-135)
14. Do not remove the clutch apply ring from the piston
unless the piston or apply ring requires replacement.

IS. Inspect direct clutch piston assembly for &torti

cracks, damage and check ball for free operation.
16. Remove center seal from direct clutch housing
discard. (Fig. 7A1-136)
17. Inspect direct clutch housing for cracks, wear
open oil passages.
18. Check for free operation of check balls.
19. Inspect direct clutch housing snap ring grooves fo
damage.
20. Inspect direct clutch bushngs for darnage or scoring
Reassembly
1. Install clutch apply ring on piston.
2 . Install new inner and outer seals on piston with
facing away from clutch apply ring side. ( ~ i ~7s~ .1 - 1 3 7
7A 1-138)
3 . Install new center seal on direct clutch housing wi
lip facing up. (Fig. 7A 1-139)
4. Install seal protector 5-25010. (Fig. 7A1-140)

(NOTE: The apply ring is identified by a number on the

ring. Refer to the 200 clutch plate and apply ring usage chart
for apply ring identification, Fig. 7A 1-1 15.)

CAU TION: Use extreme care when

installing direct clutch piston past
larger direct clutch snap ring
groove. Groove could cut outer seal
on piston.

Inner Snap Ring

PISTON

Piston Outer Se

(LIP UP)

TURBO HYDRA-MATIC 200 7A1-45

5 , oil the seals and install direct clutch piston. (Fig.

TE:
CLeen

TO make the piston easier to install, insert tool

~ e a and
l housing, rotate tool around the housing to
the lip of the seal, while pushng down slightly on
&e piston. See tool, Fig. 7Al-142, and tool being used on a
piston, Fig. 7A 1-155 .)

9 . Using 5-23327 tool, compress retainer and spring

assembly past the snap ring groove. Install the snap ring. (Fig.
7A1-143) An arbor press and 5-23327 can be used t o
compress the retainer and spring assembly.

6 . Remove seal protector 5-2.5010.

7, jnstall release spring guide with the omitted rib over
the check ball in the piston as shown in Fig. 7A 1-14 1 .
8, Install retainer and spring assembly.

VOTE: ~ o d e l sBR, CX, PA and PY use a direct clutch

ntainer and spring assembly which contains (16) release
All other models use a retainer and spring assembly
with (10) release springs.)
DIRECT

CAUTION: Retainer could locate

in snap ring groove. Forcing the
retainer to compress the springs
while in this groove could damage
the retainer plate.

-- CLUTCI-%
HOUSING
SNAP ./
W BNG

Fig. 7A1-143-Installing Direct Clutch Inner Snap Ring

Fig. 7A1-139-Installing Center Seal on

Direct Clutch Housing

Fig. 7Al-140-Installing Direct Clutch

Piston

Fig. 7Al-141 -Installing Release Spring

Guide

L 1.5-3 mm R. (.06*-.12'')
Fig. 7A 1-142-Piston Installing Tool

10, Remove 5-23327 and/or J B 129.

11. Oil and install the direct clutch plates into the direct
clutch housing, starting with a flat steel and alternating
composition-faced and flat steel clutch plates. (See Fig.
7A1-144 and Clutch Plate Usage Chart, Fig. 7Al-115.)
12. Install backing plate, cl~arnferedside up.
13. Install snap ring. (Fig. 7A 1-145)

(NOTE: Make sure composition clutch plates turn freely.)

14. Set direct clutch assembly aside.

Fig. 7Al-144-Installing Clutch Plates Into

Direct Clutch Housing

Forward Clutch Housing Assembly (Fig. 7A 1-1 46)

Inspection
1. Inspect teflon oil seals on turbine shaft for dam
and free fit in grooves. Do not remove unless replacing.
2. Remove and inspect forward clutch to direct clu
thrust washer for damage. (Fig. 7A1-147)
3. Place forward clutch down with turbine sh
through hole in work bench.
4 . Remove snap ring and inspect for damage, (Fi
7Al-148)
5. Remove backing plate from the forward clut
housing.
6, Remove the clutch plates from the forward elut
housing and keep them separated from the direct elut
plates. (See Clutch Plate Usage Chart. Fig. 7A1-115.)
7. Inspect composition-faced and steel clutch plates
signs of wear or burning.
8, Inspect backing plate for scratches or damage.
9 . Using tools 5-25018, 5-25024 and 3-233
compress retainer and spring assembly and remove snap
(Fig. 7A1-149) An arbor press and tools 5-25018
3-23327-1 can be used to compress the retainer and sp
assembly.
10. Remove J-23327-1,J-25024 and 5-25018.
11. Remove retainer and spring assembly from housh
12, Inspect release spring retainer for distortion.
13. Inspect release springs for being collapsed,
14. Remove forward clutch piston.
15. Remove forward clutch outer and inner piston se
and discard. (Figs. 7A1-150 and 7A1-15 1)
16. Do not remove the clutch apply ring from the pist
unless the piston or apply ring requires replacement.
17, Inspect the forward clutch piston and clutch a
ring assembly for cracks or damage.

(NOTE: The apply ring is identified by a number locate

the apply ring. Refer to the 200 clutch plate and apply
usage chart for apply ring identification, Fig. 7A 1-115.)
18. Inspect forward clutch housing for cracks, ope
oil passages or other damage.
19. Check for free operation of check ball.
20. Inspect forward clutch housing snap ring groove
damage or burrs.
21. Inspect turbine shaft for open oil passages on
ends of shaft and journals for damage.
Fig. 7A1-145 -Installing Direct Clutch Housing
Outer Snap Ring
FORWARD

FORWARD
CLUTCH

CLUTCH
RETAINER & STEEL

HOUSING

Fig. 7Al-146-Forward Clutch Assembly - Exploded View

FORWARD CLUTCH PISTON

UTCH PISTON
O R W A R D CLUTCH
FEED HOLE

CLUTCH OUTER SEAL

(LIP UP)

Fig. 7Al-150-Removing and Installing

Outer Piston Seal

Fig. 7Al-151 -Removing and Installing

Inner Piston Seal

Fig. 7Al-152-Forward Clutch Housing

22. Inspect cup plug for damage. (Fig. 7A1-152) If cup

+)lug is damaged or missing, proceed as follows:
a. Use 4mm (No. 3) easy out (grind t o fit) and
remove cup plug.
b. Install new cup plug to 1 .Omm (.039") below
surface.

bsembly

1 . Install clutch apply ring on piston.

#'

with lips
_ 2. Install new outer and inner seals on piston
f a h g away from clutch apply ring side. ( F ~ G 7A1-150
.
and

%I-15 1)
k
f

1
E

'

CAU TION: Use extreme care when

installing forward clutch piston past
large forward clutch snap ring
groove. Groove could cut outer seal
on piston.

3. Lubricate seals and install forward clutch piston.

@8.7~1-153)

'On:

To make the piston easier t o install, insert to01

between
the
inner seal and shaft; rotate tool around the shaft
to
the lip of the seal, while pushng down slightly
nthe piston. Use the same procedure between the outer seal
IWthehousing. Refer to Figs. 7A1-154 and 7A1-155.)

FORWARD CLUTC

Fig. 7Al-153-Installing Forward Clutch Piston

Fig. 7~1-159-Installing Fonvard Clutch

to Direct Clutch Thrust Washer

Fig. 7A 1-1 60-Teflon Oil Seal Rings

Fig. 7Al-161 -Installing Intermediate

Band Assembly

2. Install forward clutch assembly turbine, shaft first,

into direct clutch. Hold direct clutch housing and rotate
forward clutch back and forth until the forward clutch is
seated. (Fig. 7A 1- 162)

WOTE: When the forward clutch is seated, it will be

approximately 15.8mm (518") from the tang end of the
direct clutch housing to the end of the forward clutch drum,

Fig. 761-163.)
3. Grasp direct and forward clutch assemblies to
prevent their separation and position on bench, with the
turbine shaft up.
4. Install 5-2502 1 as shown in Fig. 7Al-164.
5. Install direct and forward clutch assemblies, using
J-25021,and rotate into position. (Fig. 7A1-164)
r

(NOTE: The direct clutch housing will be approximately

33.34mm (1-5116") from the pump face in case when
correctly seated . See Fig. 7A 1-165 .)

Fig. 7A 1-162-Installing Forward Clutch Assembly

6. Remove 5-2502 1.

Fig.7A1-163-~orward Clutch Properly Fig. 7Al-164-Installing Direct and

Seated in Direct Clutch
Forward Clutch Assemblies

Fig. 7A 1-165 -Direct and Forward

Clutch Assemblies Properly Installed

HY DRA-MATIC 200

PUMP ASSEMBLY (Fig. 7A1-166)

PUMP BODY

3. Remove pump to direct clutch thrust washer and

inspect for damage or wear. (Fig. 7A 1- 167)
4. Inspect 3 teflon oil ring seals for damage and free fit
in grooves. Do not remove unless replacing.

control valve assembly.

2. Remove drive and driven gear from pump
(Fig. 7A1-169)
3. Inspect drive and driven gears for scoring, g&
damage.

(NOTE: Driven gear identification marks should ha"

against the pump body gear pocket. See Fig. 7 ~ 1 - 1
identification. The drive gear has 1 identification m
each drive tang, Fig. 7A1-169. This side should be
away from the pump body gear pocket.)
4. Inspect drive and driven gear pocket and crescent
scoring or damage.
5. Inspect pump body face for nicks and

PRESSURE REGULATOR

7. Remove pump cover to pump body attaching bolts

and separate pump cover from pump body.

12. Install drive gear with identification marks on d

tangs up. (Fig. 7A1-169)
13. Pump body face to fear face clearance shod
0.020-0.055mm (.0007"-.0021 '). (Fig. 7A1-174)
14. Place the check ball into the check ball pocket in
pump body and retain it with petrolatum. (See Fig. 7A1
for ball location .)

REGULATOR GUIDE
GULATOR VALVE

Fig. 7A1-166-Pump Assembly

- Exploded View

Fig. 7A 1-167 -Removing Thrust

Washer From Pump

Fig. 7A 1-1 68-Removing Pressure

Regulator Valve

d'

F&

QQ ;
&

j%

7~ 1-169-Removing Pump
Drive Gear

Fig. 7Al-172-Installing Pump

Driven Gear

Fig. 7A1-170-Pump Body Assembly

Fig. 7A 1-1 7 1-Installing Seal Into

Pump Body

Fig. 7A 1- 173-Pump Driven Gear

Identification

PUMP COVER
Inspection
1. Inspect for open oil passages. (Figs. 7A1-174A and

Fig. 7Al-174-Checking Pump Body

to Gear Face Clearance

ORIFICE
CONVERTER
TO COOLER

CONVERTER

lA1-175)
2. inspect seven (7) cup plugs. If a plug is missing, drive
'new cup plug to .79mm (1132") below top of hole, using a
7e14mm (9132 I) diameter rod on the two smaller plugs and a
?92mm (51 16") diameter rod on the four larger plugs. Stake
@ofhole two places, directly opposite each other, to retain

plug.

3. Inspect pump cover face for nicks and overall

htness.

4. Inspect for chips in pressure regulator bore.

5. Inspect stator shaft for damaged splines or damaged

b,.

6; Inspect orifice plug. (Fig. 7A1-174A) If the plug

wires replacement. place new plug, orifice end first, into
hole from the rough casting side. Drive the plug flush to
me(.O10") below top of hole, rough casting side. Stake
of hole two places to retain the plug.

PUMP COVER

Fig. 7A 1-174A-Pump Cover Assembly

HYDRA-MATIC 200

4. Torque pump cover attaching bolts to 20.0-2~,

N - m (15-20 ft. lbs.).
5. Remove 5-25015.
6. Install pressure regulator sprlng gulae ana sph
valve stem end out, and bore plug, hole side out. (F.8
'0.
7A1-177)
7 . Compress pressure regulator valve SprIIlg ~y pu
on bore plug with small screwdriver and install retaining rm
a

UVCl Wll m

retain with
(Fig. 7A1-180)
1 1. Remove holding bolt or screwdriver. (Fig. 7Al-180)
12. Install new pump t o case gasket on pump 2lnd retain
with petrolatunl.
. . .
f3. Install 2 pump to case alignment plns ln case as
shown in Fig. 7A1-18 1.

U W U ~ W "

Bit
Reassembly
1 . Place pump body over hole in bench.
2. Assemble pump cover to pump body with attaching
bolts, finger tight.
3. ~ l ;n
i, l pump ,cover and pump body using J-25015
-'t or screwdriver through pump
(Fig. 7A1-176) ana place- 'DUL
t o case bolt hole and bench.

(NOTE: Before installing pump, make sure intermediate

band anchor pin lug is aligned with band anchor pin hole in
case .)

PUMP
ASSY.
PUMP COVER

THRUS: WASHER

PRESSURE REGULATOR SPRING

PRESSURE REGULATOR GUIDE
PRESSURE REGULATOR V A L V E
RETAINER R I N G

Fig. 7 A

RIGHT

HOLDING BOL:
.\

PUMP O I L

em

TURBO HYDRA-MATIC 200 7A1-53

14. ~nstallpump assembly and finger start pump to case

bolts and new washers, except one bolt hole (Fig. 7A1-182)
w ~ c hill be used to make the front unit end play check.

(NOTE: If turbine shaft cannot be rotated as pump is being

into place, the forward or direct clutch housings have
not been installed properly to index with all the clutch
This condition must be corrected before pump is
pulled fully into place.)

THICKNESS
I

1.66-1.77 mm
1.79-1 9 0 mm
192-2.03 mm
2,05-2.16 mm
2.18-2.29mm
2.31-2.42mm
2.44-2.55 mm
2.57-2.68 mm
2.70-2.81 mm
2.83-294mm
296-3.07 mm
3.09-3.20 mm
3.22-3.33 mm
3.35-3.46 rnrn
3.48-3.59 mm

15. ~ e p l a c e2 alignment pins with 2 bolts and new

washers.
16. Torque pump t o case bolts to 20.0-27.0 N*m (1 5-20
ft. lbs.).

(NOTE: Make sure turbine shaft rotates freely.)

Front Unit End Play (Fig. 7A1-182)
1. Install 278mm (1 1") bolt and locking nut as shown
in Fig. 7Al-182.
2. Push turbine shaft downward.
3. Install 5-25022 on 5-24773 tool and locate on end of
turbine shaft. (Fig. 7A1-182)
4. Mount dial indicator on bolt and position indicator
point against cap nut of J-24773.
5, Move output shaft forward by turning the adjusting
screw on 5-25013-5 until the white or scribed line on sleeve
5-25013-1 begins t o disappear, then set dial indicator to zero.
6. Pull turbine shaft upward, and read end play. Front
unit end play should be 0.56mm-1.30mm (.022 " -.05 1" ) .

FRONT UNIT END PLAY

WASHER THICKNESS CHART

(he&

IDENTIFICATION
Number and/or Color

1
(0.065 "-0.070")
2
(0.070" -0.075")
(0.076" 4.080")
3
(0.081~'-0.085")
4
(0.086"-0.090")
5
(0.091~~-0.095~~) 6
(0.096"-0.100")
7
(0.101"-0.106")
8
(0.106"-0.111")
9
(0.111"-0.116")
10
(0.1 17"-0.12 1") 11
(0.122"-0.126")
12
(0.127"-0.13lV)
13
(0.132"-0.136")
14
(0.137t1-0.141") 15

- Black

Light Green
Scarlet
Purple
Cocoa Brown
Orange
Yellow
LightBlue

Pink

- Green
- Gray

Fig. 7A1-183-Front Unit End Play Washer Thickness Chart

(NOTE: Selective washer controlling this end play is located

between the output shaft and turbine shaft. If more or less
washer thckness is required t o bring end play within
specifications, select proper washer from Front Unit End
Play Washer Thickness Chart, Fig. 7A1-183 .)
7. Remove front unit end play checking tools.
8. Install remaining pump t o case bolt and new washer,
torquing bolt to 20.0-27.0 N-m (15-20 ft. lbs.).
9. Remove 5-25013-5 and 5-25013-1 from rear end of
transmission. (Fig. 7A 1-184)
10. Turn transmission t o horizontal position, oil pan
side up.

Fig. 7Al-184-Removing Tools on Rear End of Case

EXTERNAL PARTS
Governor Assembly
Inspection
1. Inspect governor cover for damage, scored or worn
bore, or plugged oil passage.
2. Wash in cleaning solvent and blow out oil passage.
3. Inspect governor driven gear for nicks or damage.
4. Inspect governor shaft seal ring for cuts, damage and
free fit in groove.
5. Inspect for free operation of governor weights.
6. Inspect for damage, mispositioned, or tilted springs.
(NOTE: Governor in models BR and CX use 1 spring. Other
models use 2 springs.)
7.
8.
9.
10.

Fig. 7A 1-182-Checking Front Unit End Play

Inspect for presence of 2 check balls.

Inspect shaft for damage.
Inspect governor washer for damage.
If seal is damaged, cut seal ring off governor shaft.

CAUTION: Do not damage seal

ring when removing seal.

e . Apply 12 Nmm (100 in. lbs.) of torque to hex

nut on side of gage. Slide dial indicator over gage pin
J-25014-1. (Fig. 7A1-189) Read dial indicator and see
chart for proper size. (Fig. 7A1-190)
(NOTE: Dial indicator travel is reversed, malung the
indicator readings backwards. On an indicator that ranges
from 0-100, a .5mm (.02OU) travel will read 2mm (.080f1),a
1.5mrn (.06OU) travel will read l m m (.04OV). The
identification ring is located on the band end of the pin.)
t

INTERMEDIATE BAND
APPLY PIN SELECTION CHART
I

APPLY PIN
DJAL INDICATOR TRAVEL

IDENTIFICATION

Fig. 7Al-188-Intermediate Servo Cover

and Piston Usage Chart

5, Check for proper intermediate band apply pin as

a. Install 5-25014-2 in intermediate servo bore and
*etain with intermediate servo cover retaining ring,
aligning ring with gap at case slot. (Fig. 7A1-189)
b. Install pin 5-25014-1 into 5-25014-2. (Fig.

CAUTION: Make sure the tapered

pin end is properly located against
the band apply lug. Also, make sure
the band anchor pin is properly
located in the case and band anchor
c. Install dial indicator 5-8001 and position dial
indicator point (Fig, 7Al-189) on top of 5-25014-2 zero
post and set dial indicator to zero.
d. Align stepped side of pin 5-25014-1 with
torquing arm of 5-25014-2. Arm must stop against step
of pin 5-25014-1,

(NOTE: If band selection pin does not register between the

high and low limits, look for possible problem with the
intermediate band, direct clutch or case.)

Fig. 7Al-189-Intermediate Band Apply Gages

0 mm-2.16mm
2.16mm-2.88mm

(.000" -.086")
(.086" -.I 14")

2 Rings
Wide Band

Fig. 7Al-190-Intermediate Band Apply Pin

Selection Chart
f . Remove retaining ring and band apply gages. If
new apply pin or replacement of piston is required,
proceed as follows:

Disassembly
1. Using 5-22269-01 , compress intermediate servo
piston spring. (Fig. 7A1-19 1)
2 . Using small flat edge screwdriver, remove
intermediate pin to piston snap ring.
3. Remove J-22269-01 and separate band apply pin,
spring and washer from intermediate servo piston.
Reassembly
1 . Install washer on snap ring end of band apply pin.
(Fig.7Al-187)
2. Install spring on washer.
3. Install band apply pin, spring end first through
intermediate servo piston.
4 . Using 5-22269-01, compress intermediate servo
piston spring. (Fig. 7A1-191)
5. Using small pliers, install intermediate servo pin t o
piston snap ring. Remove 5-22269-01.

Fig. 7Al-191-Removing Intermediate Servo Piston

From Apply Pin

7141-56 TURBO HY DRA-MATIC 200

II

6 . If removed, install new intermediate servo piston,

inner and outer seal rings. Make sure cut ends are assembled

:
, +La
111 1.I I G

o n m o

aalllc

r ~ l ~ + ; n n a h ;OnP

I C I I U L I U I I J I U ~ UJ

pll+

CIUL.

/Kin
7 A 1,197) Make
\A 15. t A x z r / r I "'""'

nlrp
"UI"

ring;S art: seated in the grooves t o prevent damage to the ings .

Re t ain 1with petrolatum.
7 . Lubricate with petrolatum and install rlew sea ring
on j nter,mediate servo cover.

CAU T I 0N: The in termediate ser'VO

cover seal rings must be w,ell
I u bricated with petrolatum to
prevent damage or cutting of ri/79.
8. Install intermediate servo piston ass;embly into
int e rme diate servo cover. (Fig. 7A1-193)
9 . Install intermediate servo assembly into case,
tap1k g lightly with non-metal or plastic harnm :r if
neccS S S ~:yI . (Fig. 7A1-194)

CA U TION: Make sure the tapered

end of the band apply pin is
properly located against the band
apply lug.
10. Install servo retaining ring. Align ring gap with an
end showing in case slot.

Fig. 7A 1-194 -Installing Intermediate Servo Piston

and Cover Assembly
Low and Reverse Clutch Housing to Case Cup Plug and Seal
(Fig.
. - 7A1-195)
1 . Install new seal, making sure it seats against the
housing.
2 . Place cup plug, with smaller hole end first, into hole
in case. Using a 10mm (318") diameter by 150mm (6") metal
rod and hammer, drive plug until it seats against the seal.

3
-

RIGHT

WRONG

Fig. 7A1-192-Teflon Oil Seal Rings

Fig. 7Al-195-Installing Low and Reverse Clutch Housing
to Case Cup Plug and Seal
Control Valve Assembly (Fig. 7A 1-196)
Disassembly

(NOTE: As each valve train is removed, place the individual

valve train in the order that it is removed and in a separate
location relative to its position in the valve body. None of
the valves, bushings or springs are interchangeable; some roll
pins are interchangeable.
Remove all roll pins by pushing through from the rough cast
surface side of the control valve assembly, except the 2 pins
which retain the throttle valve and throttle valve plunger.)
I

y 1I
I:

Fig. 7A 1-193-Installing Intermediate Servo Pist on

Intn r n v ~ r

1 . Remove the 4 check balls.

2. Position control valve assembly as shown in Fig.
7A1-196.
3 . Remove 1-2 accumulator piston.

1
4

TURBO HYDRA-MATIC 200 7A1-57

42

43 44 45

1. MANUAL VALVE

16. 1 - 2 THROTTLE VALVE BUSH ING

31. ROLL P I N

2. ROLL P I N

17. ROLL P I N

32. SH IFT T. V. PLUG

3. INTERMEDIATE BOOST SPRING

18. ROLL P I N

33. THROTTLE VALVE

4. INTERMEDIATE BOOST VALVE

19. D l RECT CLUTCH EXHAUST SPRING

34.

5. 2 - 3 SHIFT VALVE

20. D I RECT CLUTCH EXHAUST VALVE

35. THROTTLE VALVE S PR ING

6. 2 - 3 THROTTLE VALVE

21.

REVERSE BOOST VALVE

36. THROTTLE VALVE PLUNGER

7. 2 - 3 THROTTLE SPRING

22.

REVERSE BOOST SPRING

37. THROTTLEVALVE BUSHING

INNER ROLL P I N

8. 2 - 3 THROTTLE VALVE BUSHING 23. BORE PLUG

38. OUTER ROLL P I N

9. ROLL P I N

24. ROLL P I N

39. 1 - 2 ACCUMULATOR SPRING

10. ROLL P I N

25. ROLL P I N

40. 1 - 2 ACCUMULATOR SEAL

11. LOW OVERRUN CLUTCH SPRING 26. VALVE BORE PLUG

41. 1 - 2 ACCUMULATOR P I STON

12. LOW OVERRUN CLUTCH VALVE

27. 1 - 2 ACCUMULATOR

42. CHECK BALL#4

13. 1 - 2 SHIFT VALVE

28. 1 - 2 ACCUMULATOR VALVE SPRING

43. CHECK BALL #3

14. 1 - 2 THROTTLE VALVE

29. SHIFT T. V. VALVE

44. CHECK BALL #2

15. 1-2THROTTLEVALVESPRlNG

30. SHIFTT. V. SPRING

45. CHECK BALL #1

Fig. 7Al-196-Control Valve Assembly - Exploded View

4. Remove manual valve from upper bore.

CAUTION: Some of the roll pins

in the control valve assembly have
pressure against them. Therefore,
hold a shop towel over the bore
while removing the pin, to prevent
possibly losing a bore plug, spring,
etc.
5. Remove roll pin from upper, right bore. Remove 2-3
Ulrottle valve bushing, 2-3 throttle valve spring, 2-3 throttle
valve and 2-3 shift valve.

~ T E The
: 2-3 throttle valve spring and 2-3 throttle valve
may be inside the 2 -3 throttle valve bushing.)

6. From next bore down, remove roll pin. Remove 1-2

throttle valve bushing, 1-2 throttle valve spring, 1-2 throttle
valve and 1-2 shift valve.

(NOTE: The 1-2 throttle valve spring and the 1-2 throttle
valve may be inside the 1-2 throttle valve bushing.)
7. From next bore down, remove roll pin and bore
plug. Remove reverse boost spring and reverse boost valve.
8. Check the operation of the shift T.V. valve in the
next bore down, by moving the valve against the spring. If it
is necessary to remove the valve, proceed as follows: (Figs.
7A1-197 and 7A1-198)
a. Remove roll pin and place valve body on shop
towel with rough casting surface up.
b. Using needle nose pliers, compress the shift T.V.

spring by pushing on the shift T .V. valve; hold valve with

small screwdriver. (Fig. 7Al-197)
c. Place 6.3mm (114") rod, 9.5mm (318") long,
against the end of the shift T.V. valve.
d. Prying on end of the rod with a large
screwdriver, remove small screwdriver 2nd remove shift

9 . From next bore down, remove outer roll pin.

Remove the throttle valve plunger, bushing and throttle valve
'spring. Using a 1.5mm (1116 ) allen wrench with ground
sides t o fit inside the pin, remove the inner roll pin. (Fig.
7A 1-199) Remove the throttle valve.
10. From upper left bore, remove roll pin, intermediate
boost spring and intermediate boost valve.
I I . From next bore down, remove roll pin, low overrun
clutch spring and low overrun clutch valve.
12. From next bore down, remove roll pin, direct clutch
exhaust spring and direct clutch exhaust valve.
13. From next bore down, remove roll pin, valve bore
plug, 1-2 accumulator valve and 1-2 accumulator valve spring.

Inspection
1 . Wash control valve body, valves, springs, and ot
parts in clean solvent and air dry.
2 . Inspect 1-2 accumulator piston for damage.
3 . Inspect 1-2 accumulator piston seal for damage
free fitting groove. Do not remove seal unless replacing.
4. Inspect valves for scoring, cracks and free rnovemrn
in their bores.
5. Inspect bushings for cracks or scored bores,
6. Inspect valve body for cracks darnage or sco
bores.
7. Inspect springs for distortion or collapsed coils.
8. Inspect bore plugs for damage,
Reassembly

(NOTE: Install all flared coiled pins (zinc coated) flare

out, and from the r~achined face of the control v
assembly. Install the two tapered coiled pins (black fin
that retain the throttle valve and throttle valve bushin
tapered end first. Coiled pins do not fit flush on ro
casting face. Make sure that all coiled pins are flus
machined face.)
1 . Position control valve body as shown in F

4. In next bore up, install low overrun clutch

longer stem end out, low overrun clutch spring
5. In next bore up, install intermediate

Fig. 7A 1-197-Holding Shift T.V. Valve

Fig. 7Al-198-Removing Shift T.V. Plug

Fig. 7Al-199-Removing Inner Roll Retaining Pin

TURBO HY DRA-MATIC 200 7 A1 -59

8 In next bore up, install rwerse boost valve, stem end

boost spring. Install bore plug, hole side out and

12. If removed, install new seal ring on 1-2 accumulator

piston.
13. Oil and install 1-2 accumulator piston, spring pocket
side out, into 1-2 accumulator piston bore of valve body.

CONTROL VALVE ASSEMBLY

Installation
1. Inspect 1-2 accumulator spring for damage.
2. Install 1-2 accumulator spring into case. (Fig.
7A1-202)
3. Inspect control valve assembly and spacer plate for
damage. (Fig. 7A 1-203)

(NOTE: The size of the 5 check balls used in the case and
control valve assembly is 6.35 mm (-250"). The size of the
check ball used in the pump is 7.14 mm (.281ff). Do not
interchange.)
4 . Install 5th check ball in case as shown. (Fig.
7A 1-204)

Fig. 7A1-200-Installing 1-2 Throttle

Valve Bushing

Fig. 7Al-201 -Installing 2-3 Throttle

Valve Bushing

Fig. 7A 1 -202--Installing 1-2

Accumulator Spring

FOR I D E N T I F I C A T I O Q

5th CHECK
{T.V. EXHA

Fig. 7A1-203-Typical Valve Body Spacer Plate

Fig. 7A1-204-Installing Fifth Check Ball

TURBO HYDRA-MATIC 200 7A1-61

5 lnsta.Il 2 guides as shown in Fig. 7A1-206.

(5: Install 4 check balls into ball seat pockets in control

~ O T E :Make sure check balls, 1-2 accumulator piston and

mmual valve do not fall out.)
11. Start control valve assembly to case attaching bolts,
except the throttle lever and bracket assembly and the oil
screen attaching bolts.

C A U T I O N : The 2 'oii screen

attaching bolts are about 7Omm
(3/8"/ longer than the control valve
assembly attaching bolts, and they
are not interchangeable.

12. Inspect inside manual detent roller and spring

assembly for damage.
13. Remove guide pins and replace with bolts and inside
manual detent roller and spring assembly, locating the tang in
the control valve assembly, and the roller on the inside
detent lever. (Fig. 7A1-207)
14. Throttle lever and bracket assembly.
a. Inspect throttle lever and bracket assembly for
damage. (Fig. 7A 1-208)
b . If removed, install spring on top of lifter then
lifter spring first into throttle bracket. (Fig. 7A1-208)
c. Install link on throttle lever making sure link is
hooked as shown. (Fig. 7A1-209)
d. Install throttle lever and bracket assembly,
location slot in bracket with roll pin, aligning lifter
through valve body hole and link through T.V. linkage
case bore. Retain with bolt. (Fig. 7A1-209)
15. Torque all control valve assembly t o case attaching
bolts to 17.0 N*m (12 f t . lbs.).

Oil Screen
1. Thoroughly clean, air dry and inspect oil screen
assembly.
2. Install new oil screen gasket on screen and retain
with petrolatum.
3 . Install oil screen assembly and attaching bolts. (Fig.
7Al-210) Torque bolts to 17.0 N-m (12 ft. Ibs.).

%
-'

IV EXHAUST

Fig. 7Al-206-Installing Control Valve

Fig. 7A1-207-Insta ~g Manual Detent
Assembly Using Guide Pins
Rolle ~ n dSpring Assembly

Fig. 7A1-208-Throttle Lever and

Bracket Assembly

OIL SCREEN

Fig. 7 A1 -209-Installing Throttle Valve

and Bracket Assembly

Fig. 7 A 1-210-Installing Oil Screen

Oil Pan and Torque Converter

1. Clean and inspect oil pan for damage.
2. Install new oil pan t o case gasket on case.
3. Install oil pan and retaining bolts. Torque bolts t o
14.0-18.0 N - m (10-13 ft. lbs.).
4. Install torque converter.
Speedometer Driven Gear (Fig. 7A 1-21 1 )

inspect gear for damage.

2. Inspect housing for damage and "0" ring for damage

2. Install speedometer driven gear into housing.

3 . Install speedometer driven gear assembly into case.

TORQUE SPECIFICATIONS
DESCRIPTION OF USAGE

QUANTITY

Pump Body to Pump Cover

M8 x 1.25 x 4 5

20.0-27.0 N-m

M8 x 1.25 x 35

Pump Assembly to Case

Parking Lock Bracket to Case

TORQUE ASSEMB

M8 x 1.25 x 20

20.0-27.0 N*m

M8x 1 . 2 5 16
~

Transmission Oil Pan to Case

Manual Shaft to Inside Detent Lever
Cooler Connect or - Steel

1/4-18NPSF

35.04 1.0 Nam

(26-30 ft. Ibs.)

Cooler Connector - Brass

1/4-18 NPSF

20.0-27.0 Nmm
(15-20 ft. lbs.)

Line Pressure Take-Off

1/8-27 NPTF

7.0-14.0 N-m
(5-10 ft. lbs.)

Throttle Lever, Link and Bracket to Case

M6.3 x 1.O x 45

13.0-17.0N*m
(9-12 ft. lbs.)

Control Valve Assembly to Case

M6.3 x 1.O x 45

13.0-17.0N*m
(9-12 ft. lbs.)

Oil Screen to Case

M6.3x 1 . 0 ~ 5 5

13.0-17.0 N*m
(9-12 ft . lbs.)

Speedometer Driven Gear Retainer t o Case

M6.3 x 1 . 0 16
~

8.0-14.0 N*m
(6-10 ft . lbs.)

(NOTE: All critical torque specifications are listed in each section, where appropriate.)

REQUIRED SPECIAL TOOLS

NAME
Transmission Holding Fixture
Transmission Holding Fixture Base
Servo Piston Remover
Plunger Extension (For Rear Unit End Play Check)
Oil Pump Puller and Front End Play Checking Fixture
Front End Play Gage Adapter
Oil Pump Sealer Installer
Low and Reverse Clutch Selective Spacer Gage
Oil Pump Body and Cover Alignment Band
Direct Clutch Seal Protector
Low and Reverse Clutch Seal Protector
Low and Reverse Clutch Housing Installer
Intermediate Band Apply Pin Gage
Forward Clutch Spring Compresser
Forward Clutch Compresser Adapter Plate
Converter End Play Checking Fixture
Turbine Shaft and Direct Clutch Installer
Output Shaft Support and Sleeve
Direct Clutch Spring Compresser
$21369
3-21426
$001
1.24684
5-21366
3.21427-01
J8433
J-28578

Converter L e a k - ~ e s~i i x t i r e
Rear Seal Installer
Dial Indicator Set
Pressure Regulator Valve Remover
Converter Holding Tool
Speedometer Drive Gear Remover
Puller (Use with 5-2142741)
Speedometer Drive Gear Installer

REQUIRED STANDARD TOOLS

Speed Handle Wrench, 318" Drive.

13rnm and lOmm Sockets, 318" Drive and 15mm and

17mm Open End Wrenches.

Alignment Pins: Two (2) M6.3 x 1.0 Thread (Control

Valve Assembly) and Two (2) M8 x 1.25 Size Thread
(Pump Assembly), Both 75rnrn (3") Long.
Needle Nose Pliers.

Small Flat Edge

Screwdriver.

Screwdriver and Long Flat Edge

Newton Meter (Inch Pound and Foot Pound) Torque
Wrench.

Small Plastic or Rubber Hammer.

No. 14 Sheet Metal Screw.

Bolt or Rod 300 mm (12") Long with M8 x 1.25 Size

Threads.

7.14rnrn(9132") and 7 9 3 m m (51 16") Drills.

1.5mm (1116") Allen Wrench with Two (2) Ground Edges.

Feeler- Gage From 0.04 mm - 2.40 mm (.0015") Range

4mm (No. 3) and 6.3mm (No. 4) Easy Outs-Also, 6.7mm

Tru Arc Type Pliers with Adjustable Points.

Pliers.

lhrn (318") x 150mm (6") Rod.

Medium Chisel.

TURBO HYDRA-MATIC 200

BUSHING SERVICE
~ ~ d disassembly
n g
and inspection of the transmission, if
bushing is galled, scored or excessively worn, the bushing
be replaced, using the following procedure:
replacement bushings used for field service are of
with close tolerances to fit, and do not require
reaming
after installation.
,*ring Or

tw

Rear Bushing
1 . Using Tool 5-25019 -14 with Slide Hammer 5-7004-1,
remove bushing. (Fig. 7A1-215)
2. Using Tool 5-250 19-6 with Driver Handle 5-8092,
drive or press new bushing until tool bottoms. (Fig.
7A1-216)

PUMP COVER BUSHING

Fig. 7Al-215-Removing Pump Cover Bushing - Rear

Fig. 7Al-213-Removing Pump Cover Bushing - Front

Fig. 7A 1-216-Installing Pump Cover Bushing - Rear

Fig*7Al-214-~nstalling Pump Cover Bushing - Front

Pump Body Bushing

1. Place pump body with the machined face down, on
two blocks of wood, t o prevent damaging the machined
surface. (Fig. 7A 1-217)
2. Using Tool 5-250194 with Drive Handle 5-8092,
remove bushing. (Fig. 7A 1-217)
3 . Using Tool 5-25019-12 with Driver Handle 5 8 0 9 2 ,
drive or press new bushing into place until tool bottoms.
(Fig. 7A1-2 18)

BUSHINGS - TURBO HYDRA-MATIC 200 7A1-67

Rear Sun Gear

1. Using Tool 5-25019-14with ~ l i h eHammer 5-7004-1,
remove bushing. (Fig. 7A 1-225)
2. Place rear sun gear with gear side down on block of
wood t o prevent damaging the gear. (Fig. 7A1-226)
3. Using Tool J-25019-2 with Driver Handle J-8092,
drive or press new bushing into place until tool bottoms.
(Fig. 7A1-226)

,
,
3-250
- 1 9-14

REAR SUN GEAR

Fig. 7A1-222-InstalIing Direct Clutch Housing

Bushing - Rear
Front Internal Gear Bushing
1. Using Tool 5-25019-3 with Driver Handle 58092,
remove bushing. (Fig. 7A1-223)
2. Using Tool 5-25019-9 with Driver Handle 5-8092,
drive or press new bushing into place until tool bottoms.
(Fig. 7Al-224)

Fig. 7Al-225-Removing Rear Sun Gear Bushing

R E A R SUN GEAR

Fig. 7A 1-226-Installing Rear Sun Gear Bushing

Fig. 7A1-223-Removing Front Internal Gear Bushing

Fig. 7A1-224-~nstalling Front Internal Gear Bushing

Lo and Reverse Clutch Housing Bushing

1. Using Tool 5-25019-16with Slide Hammer J-7004-1,
remove bushing. (Fig. 7A1-227)
2. Place lo and reverse clutch housing with splined hub
between two blocks of wood to prevent damaging the
splines. (Fig. 7A1-228)
3. Using Tool 5-25019-8 with Driver Handle 5-8092,
drive or press new bushing into place until tool bottoms.
(Fig. 7A1-228)

Fig. 7A1-227-Removing Low and Reverse Clutch

Housing Bushing

TURBO HYDRA-MATIC 3 5 0
INDEX
PAGE
sity

. . . . . . . . . . . . . . . 7A3-52
. . . . . . . . . . . . . . . . .7A3-2
. . . . . . . . . . . . . . . . . .7A3-2

. .
. . . . .
. . . .
. . . .

Clutch

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

7A3-37
7A340
7A3-15
7A3-15

h Accumulator

SUBJECT

PAGE

. . . . . .
Oil Leak Diagnosis
. . . . . . . . . .
Oil Pump
. . . . .
Periodic Maintenance
Sun Gear and Sun Gear Drive Shell
Teflon Seal Replacement . . . .
Tools . . . . . . . . . . . .
. . . . .
Torque Specifications
. . . .
Transmission Assembly
. . .
Transmission Disassembly
Transmission Removal . . . . .
Turbo Hydra-Matic 350 Inf. Chart
. . . . . . . . .
Valve Body

.
.
.
.
.
.
.
.
.
.

.
.
.
.
.
.
.
.
.
.

. . . . . . 7A3-2
. . . . . 7A3-34
. . . . . . 7A3-1
. . . . . 7A342
. . . . . 7A340
. . . 7A3-59 & 60
. . . . . 7A3-52
. . . . . 7A344
. . . . . 7A3-23
. . . . . 7A3-17

. . . . . . . 7A3-16

. . . . . . .

7A3-33

PERIODIC MAINTENANCE
(NOTE: Many of the bolts in the exterior of the

transmission case will be metric. See the torque specifications

at the end of this section for the locations and torque.)

WINTENANCE SCHEDULE
The fluid level should be checked at each oil change see
below). When adding or changing fluid, use DEXRON -11
with a "D" prefix and about five numbers on the top of the
can, or equivalent automatic transmission fluid. Under
normal driving conditions, change transmission fluid every

&

CHECKING AND ADDING FLUID (Transmission at

Overfilling can cause foaming and loss of fluid through

the vent. Slippage and transmission failure can result.
Fluid level too low can cause slipping, particularly, when
the transmission is cold or the car is on a hill.
Check the transmission fluid level with the engine
running, the shift lever in Park, and the car level.
(NOTE: If the car has recently been operated for an
extended period at high speed or in city traffic in hot
weather or the car is being used to pull a trailer, an accurate
fluid level cannot be determined until the fluid has cooled
down-usually about 3 0 minutes after the car has been
parked.)

Nerating Temperature) (Fig. 7A3-1)

The automatic transmission is designed to operate at the
"FULL HOT" mark on the dip stick at normal operating
temperature, 88' to 93' C. (1 90' to 200F.), and should be
decked under these conditions. The normal operating

0 IL LEVEL RANGE AT 18-30" C

(65-85 OF) WARM

CAR MUST BE ON A LEVEL SURFACE,

ENGINE IDLING, I N PARK OR NEUTRAL
RANGE. WHEN CORRECT1NG LEVEL AND
RECHECK ING.

Fig. 7A3-1-Transmission Dipstick

Check for leaks in low, drive, and reverse.

rE:Use of a mirror is helpful in finding leaks.)

shut engine off and thoroughly clean area to be
,ith a suitable solvent and a brush, let air dry.
A clean, dry soldering acid brush can be used to
area and also to apply the epoxy cement.)
4. Using instructions of the manufacturer, mix a
ent amount of epoxy, No. 1360016, or equivalent, to

Fig. 7A3-2-Checking Modulator

5 . m l e the transmission case is still HOT, apply the
vxy to the area to be repaired.

3. Holdng the modulators in a horizontal position,

this amount, the modulator should be replaced.

modulators are of the same type. The part numbers are
stamped on the end of the modulator.)

VACUUM MODULATOR DIAGNOSIS

A defective vacuum modulator can cause one or more of

the following complaints :

1. Harsh upshifts and downshifts.

2. Delayed upshifts.
3. Soft upshifts and downshifts.
4. Slips in low, drive and reverse.
f 5. Transmission overheating.
6. Engine burning transmisiion oil.
If any one of the above complaints are encountered, the
modulator must be checked as outlined below:
r

Vacuum Diaphragm Check

Insert a pipe cleaner as far as possible into the vacuum
connector pipe and check for the presence of transmission
fluid. If transmission fluid is found, the modulator should be
replaced.

(NOTE: Gasoline or water vapor may settle in the vacuum

side of the modulator. If this is found without the presence
of oil, proceed to the next check.)
Atmospheric Leak Check
1. Apply a liberal coating of soap bubble solution to
the vacuum connector pipe seam and the crimped upper to
lower housing seam.
2. Using a short piece of rubber hose, apply air pressure
to the vacuum pipe by blowing into the tube; look for
bubbles, if bubbles appear, replace the modulator.

TORQUE CONVERTER DIAGNOSIS

Refer To Section 7A1.
CLUTCH PLATE DIAGNOSIS
Lined Drive Plates
1. Dry plates and inspect for:
a. pitting and flaking
b. wear
c. glazing
d. cracking
e. charring
f. chips or metal particles imbedded in lining.
If a lined drive plate shows any of the above conditions,
replacement is required.
(NOTE: Do not diagnose drive plates by color .)

Load Comparison Check

Steel Driven Plates

Wipe plates dry and check for heat discoloration. If the
surface is smooth and an even color smear is indicated, the
plate should be reused. If severe heat spot discoloration or
surface scuffing is indicated, the plate must be replaced.
Clutch Release Springs
Evidence of extreme heat or burning in the area of the
clutch may have caused the springs to take a heat set and
would require replacement of the springs.

%S
check is made using an available tool, BT-6733. The
@ge Compares the load of a known good modulator with a
"dulator being checked.
1. Install the modulator that is known to be acceptable
On either end of the gage.
2. Install the modulator in question on the opposite
end of the gage. (Fig. 7A3-2)

CAUSES OF BURNED CLUTCH PLATES

1. Forward Clutch
a. Check ball in clutch housing damaged, stuck or
missing.
b . Clutch piston cracked, seals damaged or missing.
c. Low line pressure.

(NOTE: Do

not use any method other than human lung

Pnver for applying air pressure, as pressures over 6 psi may
the modulator .)

Sleeve Alignment Check

Roll the main body of the modulator on a flat surface
and observe the sleeve for concentricity to the can. If the
sleeve is concentric and the plunger is free, the modulator is
acceptable.
If the vacuum modulator assembly passes all of the
above checks, it is an acceptable part and should be reused.

between channels.
2. Intermediate Clutch
b . Low line pressure.

between channels.
3 . Direct Clutch
a, Restriction in vacuum line to modulator (poor
vacuum response).
b . Clutch piston seals damaged or missing.
c. Case valve body face not flat or porosity
between channels.

(NOTE: Burned clutch plates can be caused by incorrect

usage of clutch plates. Also, engine coolant in transmission
fluid can cause severe damage, such as large pieces of
composition clutch plate material peeling off.)

"PARK" POSITION, THE

LY ENGAGE AND PRE

2. Connect a vacuum gage in series with the "ac

hose at the vacuum modulator by using a "T".
3. Connect a tachometer to the engine.
4. Refer to the following pages for oil

the steel center portion.)

4. Replace the nylon washers, speedometer gears and
governor gear. (The nylon can swell and become damaged .)
5. Flush the converter assembly.
6. Thoroughly clean and rebuild transmission, using
new gaskets and oil filter.
7 . Flush the cooler lines after the transmission cooler
has been properly repaired or replaced.

MANUAL LINKAGE ADJUSTMENT

The transmission manual linkage must be adjusted so
that the pointer on the indicator quadrant and linkage

Fig. 7A3-3-Pressure Checking Taps

CLUTCH, BAND, INTERMEDIATE A N D LOW & REVERSE ROLLER CLUT

APPLlCATlON CHART (RANGE REFERENCE CHART)
INT.
RANGE

GEAR

PARK-NEUT.
FIRST

REV.

DIRECT

CLUTCH CLUTCH

OFF

OFF

OFF

OFF

OFF

ON

FORWARD

REVERSE

ROLLER

ROLLER

CLUTCH

CLUTCH

CLUTCH

CLUTCH

OFF

OFF

INEFFECTIVE

INEFFECTIVE

OFF

INEFFECTIVE

LOCKED UP

OFF

INEFFECTIVE

LOCKED UP

OFF

ON

INEFFECTIVE

INEFFECTIVE

OFF

OFF

OVERRUN
BAND

T U R B O HYDRA-MATIC 350
DIAGNOSIS CHART

Fig. 7A3-4-Turbo Hydra-Matic 350 Diagnosis Chart

TURBO HYDRA-MATIC 350 DIAGNOSIS GUIDE

Dependability of this Diagnosis Guide depends upon:
1. Careful analysis of symptoms so that proper malfunction o n the
charts will be.used.
2. Accurate o i l pressure check with a known good gage is made
as indicated o n the chart and these readings recorded so that
they can be compared with the following diagnosis charts.
3. Oil pressure readings must be made with transmission oil at
normal operating temperatures.
4. Refer to detailed diagnosis charts for additional diagnosis on 1-2
and 2-3 shift malfunction diagnosis.
5. Engine must be properly tuned to specifications.
DIAGNOSIS
PRELIMINARY CHECKING PROCEDURES
1. Check transmission oil level.
Check vacuum hoses under hood (connections - cracks - leaks - pinch).
Connect tachometer to engine.
Install vicuum pump at modulator -apply 15-20"vacuum and check for leakdown.
Install oil pressure gage.

2.
3.
4.
5.

6. Check oil pressure using the chart on the,next page.

** CAUTION:

Total test running time for these four (4) tests not to exceed two (2) minutes.

0" vacuum
to modulator

15 20" vacuum applied to modulator

L

**Brakes
Drive
Applied
1OOORPM

#=# Reverse
Brakes
Applied
1OOORPM

** Super or

Neutral
Brakes
Applied
1000RPM

Lo Brakes
Applied
1000RPM

Brakes on
Detent*

Drive
Idle

(11 Drive
30MPH
Closed
Throttle

Drive-from
1000 to
3000 RPM
Wheels free

55-70

Pressure
drop of 10
PSI or more

Activated

**1000
Drive
RPM

Pressure Test
Conditions

to move
I

60-90

85-150

85-110

55-70

90-110

60-85

DROP
r

Normal Results
Note (2)
Malfunction in Control
Valve Assembly
I

NO DROP

Malfunction in
Governor or
Goyernor Feed System

ALL PRESSURES HlGH WlTH LESS THAN 35 PSI BETWEEN PRESSURE READINGS

ALL PRESSURES HlGH WlTH MORE THAN 35 PSI BETWEEN PRESSURE READINGS

Malfunction in
Modulator

Low
---

--

Low

Low to
Normal

Oil Leak in Feed

System to the
Direct Clutch

Low to
Normal

Oil Leak in Feed

System to the
Forward Clutch

-. -- - ---

Low to
Normal

Low to
Normal

Low

Detent System
I

A blank space = Normal pressure

A dash (
) in space = Pressure reading has no meaning
(11 Coast from 30 mph - read before reaching 20 mph
(2)I f high line pressures are experienced see "High Line Pressures" note.
* Cable pulled or blocked thru detent position

_I

Malfunction in
Detent System

--

TURBO HYDRA-MATIC 350 DIAGNOSIS 7A3-7

HIGH LINE PRESSURES

vacuum to lower transmission line pressure within

specifications. The newer engines with emission controls
characteristically have lower engine vacuum than older past
model engines. To obtain line pressures suitable for
evaluation, it is recommended that vacuum be applied to
the modulator, using an external vacuum source such as
5-23738 hand operated vacuum device or its equivalent.
The unit allows definite amounts of vacuum to be applied
t o the modulator so that consistent line pressures may be
obtained for evaluation as follows:
1. Disconnect the vacuum hose to the modulator at
the modulator and plug the vacuum hose.
2 . Attach the hand operated vacuum device and apply
20" of vacuum.
3. R e c h e c k l i n e pressures according to the
Preliminary Checking Procedure Chart. (Fig. 7A3-5)
4. If line pressures are still hgh, proceed t o the
specific diagnosis chart that applies to the malfunction
encountered.
5. If line pressures are normal with external vacuum
applied, check engine vacuum and vacuum systems for
leaks

ENGINES wlTH HIGH

PRESSURES, WHEN THE
EGR VACUUM LINE IS PLUGGED
jf high line pressures are experienced with the EGR line
plugged, it may be that the engine is not producing enough

1 2 PART THROTlil

=
-

3 7 PhRT T H R O T I L t

DEltNl RlGUlAlOR e-LZf

M A N U A l VALVE

D I T I N I VALVE

RAL-ENGINE

RUNNING

Fig. 7A3-6-Transmission Oil Circuit - Neutral

, 7n

A
-

TURBO HYDRA-MATIC 350 DIAGNOSIS 7A3-9

COOLER O U T

'RAL
-4 D 1

EXHAUST

--

EXHAUST

DIRECT CLUTCH
DIRECT C L U T C H
F O R W A R D CLUTCH

PUMP PRESSURE

CObIVERTER FEED

Fig. 7A3-12-Pump Cover

INTERMED IATE CLUTCH
DIRECT CLUTCH ( INNER
FORWARD CLUTCH
CONVERTER FEEDL-,

Fig. 7A3-9-Case Passages

COOLER O U T
( F R O M RADIATOR )
COOLER IN
( TO RADIATOR ) 7

INTERMEDIATE CLUTCH

CONVERTER FEED

COOLER OUT
( FROM RADIATOR

INTERMEDIATE

PRIMING VALVE

Fig. 7A3-10-Pump Cover and Stator Shaft

PRIMING VALVE LOCATION

Fig. 7A3-13-Case Pump Face

FROM RADIATOR

TO RADIATOR )

MP LIP SEAL D R A I N

Fig. 7A3-11-Pump Body Passages

- CHART C -

- CHART D -

CONTROL V A L V E ASSEMBLY-GOVERNOR LINE

PRESSURE CHECK

CAUSES OF IMPROPER VACUUM

AT M O D U L A T O R

1. INSTALL LINE PRESSURE GAGE

2. DISCONNECT VACUUM L l N E TO MODULATOR.
3. WITH CAR ON HOIST (REAR WHEELS, OFF GROUND), FOOT OFF
BRAKE, I N DRIVE, CHECK LINE PRESSURE A T 1000 RPM.
4. SLOWLY INCREASE ENGINE RPM TO 3000 RPM AND DETERMINE
I F A PRESSURE DROP OCCURS, (7 PSI OR MORE)
5. I F PRESSURE DROP OCCURS, DISASSEMBLE, CLEAN A N D INSPECT
CONTROL VALVE ASSEMBLY.
6. I F NO PRESSURE DROP OCCURS:
A. INSPECT GOVERNOR
B. GOVERNOR FEED SYSTEM
1. STUCK VALVE.
1. CHECK SCREEN I N CASE
2. WEIGHT FREENESS.
VALVE ASSEMBLY.
3. RESTRICTED ORIFICE I N
2. SCORED GOVERNOR
GOVERNOR VALVE.
BORE.

1. ENGINE
A. TUNE UP
B. LOOSE VACUUM FITTINGS
C. VACUUM OPERATED UNIT LEAK
(HOSES, VACUUM ADVANCE, ETC.)
2. VACUUM LINE TO MODULATOR
A. LEAK
B. LOOSE FITTING
C. CARBON BUILD UP A T MOD. VAC.
FITTING
D. PINCHED LlNE
E. GREASE I N PIPE (NO OR DELAYED
UPSHIF T-COLD)
C

TURBO HYDRA-MATIC 350 DIAGNOSIS 7A3-1

SUB-STANDARD 1-2 SHIFT FEEL

1. Record o i l pressures as directed in preliminary checking

CHECK MOD.

- CHART A

CAUSE OF LOW L I N E PRESSURE

1. LOWTransmission o i l level.

2. Modulator Assembty - See Checking Procedure.

3. Filter Assembly
a. Blocked o r restricted.
b. Gasket b e t w e e n f i l t e r a n d valve b o d y o m i t t e d o r damaged.

drive gear is installed backwards, o r if converter p i l o t does n o t

enter crankshaft freely 1.
b. Pump t o case gasket mispositioned.
C- Defective p u m p b o d y and/or cover.

6. Internal C i r c u i t Leaks.
a. Forward c l u t c h leak (pressure n o r m a l i n neutral a n d reverse-pressure
l o w in drive.
(1) Check p u m p rings.
(2) Check f o r w a r d c l u t c h seals.
b- Direct c l u t c h leak (pressure n o r m a l i n neutral, l o w , i n t . a n d drivePressure l o w i n reverse).
(1) Check direct c l u t c h outer seal f o r damage.
(2) Check 1-2 accumulator a n d 2-3 accumulator pistons a n d rings
f o r damage o r missing.

CHART B -

CAUSE OF H I G H L I N E PRESSURE
1. V a c u u m Leak
a. F u l l leak-vacuum line disconnected.
b. Partial leak i n line f r o m engine t o modulator.
c. I m p r o p e r engine vacuum
d. V a c u u m operated u n i t leak, (hoses, vacuum
advance, etc.)
2. Damaged M o d u l a t o r
a. S t u c k valve
b. Water in m o d u l a t o r
c. N o t operating properly.

3. P u m p
a.

I n c o r r e c t pressure reg. spring

4. C o n t r o l Valve Assembly
a. Pressure reg. and/or boost valve stuck.
b. Pressure boost valve sleeve b r o k e n o r otherwise
defective.

I 1ST

& 2ND SPEEDS ONLY, NO 2-3

STUCK 2-3 VALVE,

GASKETS MlSPOSlTlONED OR

-DIRECT CLUTCH BURNEDCHECK CAUSE

-IMPROPER VACUUM-

TURBO HYDRA-MATIC 350 DIAGNOSIS 7A3-13

IMPORTANT: BEFORE CHECKING TRANSMISSION FOR WHAT I S BELIEVED TO BE

"TRANS. NOISE" M A K E CERTAIN THE NO1 SE I S NOT FROM THE WATER PUMP,
ALTERNATOR, A I R COND ITIONER. POWER STEERING. ETC. THESE COMPONENTS
CAN BE ISOLATED B Y REMOVING THE PROPER BELT AND RUNNING THE ENGINE
NOT MORE THAN TWO MINUTES AT ONE TIME.

-1

WON'T HOLD IN PARK

IPARK.

I CHECK OUTS IDE MANUAL LINKAGE & CORRECT 1

--

---

NEUTRAL & ALL D R l V ING RANGES

TRANSMISSION NOISY (

PUMP CAVITATION

0 IL L N EL LOW
PLUGGED OR RESTRICTED SCREEN
WRONG F ILTER
POROS ITY I N P U M P INTAKE CASE
PASSAGE
WATER I N O I L
POROS I T Y OR VOIDS AT TRANS. CASE
( PUMP FACE) INTAKE PORT.
PUMP TO CASE GASKET OFF LOCATION

INTERNAL LINKAGE

1. PARKING BRAKE ROD ASSY.

2. PARKING PAWL BROKEN.
3. PARKING BRAKE BRACKET LOOSE, BURR OR ROUGH
EDGES, OR l NCORRECTLY INSTALLED.
4. PARKING PAWL RETURN SPRING M I S S ING, BROKEN
OR lNCORRECTLY HOOKED.

PUhIP ASSEMBLY

NO ENGINE BREAKING-LO

GEARS DAMAGED, OR DEFECTIVE

D R I V I N G GEAR ASSEMBLED BACKWARDS
CRESCENT INTERFERENCE
SEAL RINGS DAMAGED OR WORN

L_T__I
CASE ASSEMBLY

I MANUAL LOW CONTROL I

CONVERTER

VALVE STUCK

LOOSE BOLTS (CONVERTER TO FLEXPLATE)

CONVERTER DAMAGED
WATER I N O I L

-1

INNER SEAL ON LOW

REVERSE PISTON CUT

I
NO ENGINE BREAKING SUPER
RANGE-SECOND GEAR

PLANElARY GEAR SET

GEARS OR THRUST BEARINGS DAMAGED
I N PUT OR OUTPUT RING GEAR DAMAGED

2-3 ACCUMULATOR O I L RINGS

AND/OR BORES LEAKING OR

INTERMEDIATE OVERRUN BAND

BROKEN. BURNED (CHECK FOR CAUSE),

LNOTENGAGED ON SERVO P I N

TRANSMISS ION OR COOLER LINES

GROUNDED TO UNDERBODY. MOTOR

SQUEAL AT LOW
CAR SPEEDS
I

I
SPEEDOMETER DRIVEN GEAR SHAFT SEAL
1

THE MODEL IDENTIFICATION AND CODE NUMBER

FOR THE TURBO HYDRA-MATIC 350 IS STAMPED ON
THE GOVERNOR COVER FOR ALL MODELS EXCEPT
THE WC MODEL. THE MODEL AND CODE NUMBER
FOR THE WC MODEL CAN BE FOUND ON THE RIGHT
VERTICAL SURFACE OF THE OIL PAN. FOR MODEL
USAGE, REFER TO SECTION "0" AND THE TURBO
HYDRA-MATIC 35 0 INFORMATION CHART. (FIG.
7A3-15)

GENERAL DESCRIPTION (Fig. 7A3-14)

The Hydra-Matic (350) is a fully automatic unit
consisting primarily of a 3 element hydraulic torque
converter and two planetary gear sets. Four multiple-disc
dutches, two roller clutches, and an intermediate overrun
band provide the friction elements required to obtain the
desired function of the two planetary gear sets.
Changing of the gear ratios is fully automatic in relation
to car speed and engine vacuum. Car speed and engine
vacuum signals are constantly fed to the transmission to
provide the proper gear ratio for maximum efficiency and
performance at all throttle openings.
External control connections to the transmission are:
1. Manual Linkage - To select the desired operating
mge .
2. Engine Vacuum - T o operate the vacuum modulator.
3. Downshift Cable - To operate the deten't valve.

UNITS OR PARTS THAT CAN BE SERVICED WITHOUT

=MOVING TRANSMISSION
Some of the parts and/or units can be removed from the
hansmissidn without removing the transmission assembly
&om the car. The procedures for some of the operations are
not specifically outlined; however, the basic procedure and
lpecifications as outlined under DISASSEMBLY OF THE

%;

T R A N S M I S S I O N a n d ASSEMBLY O F THE
TRANSMISSION will apply.
Oil pan and gasket.
Oil filter
Valve body assembly.
Direct clutch accumulator and servo (requires valve body
removal).
Manual control linkage and parking pawl.
Extension housing and seal.
Vacuum modulator.
Speedometer drive gear.
"Governor assembly.
"Intermediate clutch accumulator.
"Requires a procedure different than described under
Disassembly and Assembly.
GOVERNOR (WITHOUT REMOVING TRANSMISSION)
Removal
1 . H o i s t car, disconnect speedometer cable at
transmission.
2. Remove governor cover retainer and governor cover.

(NOTE: Be careful not to damage cover and "0" ring seal.)

ERTER ASSEMBLY

OUTPUT SHAFT

VALVE
BODY

INPUT SHAFT

SUCTION

Fig. 7A3-14-Turbo Hydra-Matic 350

TURBO HYDRA-MATIC 350 INFORMATION CHART

INTERMEDIATE CLUTCH
Body
TYpe

Transmission
Code

Engine

DIRECT CLUTCH

FORWARD CLUTCH

LOW AND REVERSE CLUTCH

Speedometer
Drive
Gear

No. of
Faced
Plates

No. of
Steel
Plates

Clutch
Piston
Thickness

No. of
Faced
Plates

No. of
Steel
Plates

Clutch
Piston
Thickness

No. of
Faced
Plates

No. of
Steel
Plates

Clutch
Piston
Thickness

No. of
Faced
Plates

No. of
Steel
Plates

Clutch
Piston
Thickness

KL

*Starfire

231 V-6
2 Bbl. VIN A

7 Tooth

1.184"

1.014"

1.405"

3.091 "

KG

**Starfire

231 V-6
2 Bbl. VIN A

9 Tooth

1.184"

1.014"

1.405"

3.091"

Omega

231 V-6
2 Bbl. VIN A

17 Tooth

1.184"

1.014"

1.405"

3.091"

Omega &
Cutlass

305 V-8
2 Bbl. VIN U
305 V-8
4 Bbl. VIN H

19 Tooth

.992"

.833"

1.223"

2.906"

JD

Omega &
Cutlass

350 V-8
4 Bbl. VIN L

18 Tooth

.992"

.833"

1.223"

2.906"

KE

Cutlass
& 88

231 V-6
2 Bbl. VIN A

17 Tooth

1.184"

1.014"

1.405"

3.091"

LD

Cutlass
& 88

260 V-8
2 Bbl. VIN F

19 Tooth

1.184"

1.014"

1.405"

3.091"

LA

***88

350 V-8
4 Bbl. VIN R

19 Tooth

,992"

.833"

1.223"

2.906"

LH

a88

350 V-8
4 Bbl. VIN R

19 Tooth

.992"

,833"

1.223"

2.906"

LC

-88

403 V-8
4 Bbl. VIN K

19 Tooth

,992"

333"

I .223"

2 .9Obw

LK

-88

403 V-8
4 Bbl. VIN K

18 Tooth

,992"

.833"

1.223"

2.906"

---

--

1
-

LE

088

403 V-8
4 Bbl. VIN K

19 Tooth

.992"

,833"

1.223"

2.906"

LJ

Custom
Cruiser

350 V-8
Diesel
VIN N

19 Tooth

.992"

.833"

1.223"

2.906"

WC

Starfire

305 V-8
2 Bbl. VIN U

9 Tooth

1.184"

1.014"

1.405"

3.091 "

*2.93 Axle Ratio

**2.56 Axle Ratio
***Except High Altitude
r

High Altitude
2.41,2.56,2.73,3.08 Axle Ratios Except High Altitude
3.23 Axle Ratio Except High Altitude

TURBO HYDRA-MATIC 350 7A3-17

3. Remove governor. Inspect weights and valve for

freeness.
Installation
1. Install governor.
2. Install governor cover using a brass drift around the
outside flange of the cover.
1

(NOTE: DO not mstort cover on installation. Be sure "0"

fing seal is not cut or damaged .)
2. (Engine Off) Move carburetor
lever and hold i n wide open

3. Install retainer.
4. Connect speedometer cable, lower car and check
transmission oil level.
INTERMEDIATE CLUTCH ACCUMULATOR

,''A

/-"/

3. Push "S nap-Lock" downward

u n t i l f l u s h with rest of cable.
4. Release carburetor lever.

Removal
1. Remove two transmission oil pan bolts below the
intermediate clutch accumulator cover. Install 5-23069 in
place of bolts removed.
2 . Press in on cover and remove retaining ring with an
awl as shown in Fig. 7A3-16.
3. Remove cover "0" ring seal, spring and intermediate
clutch accumulator.

Fig. 7A3-17-Downshift Cable Adjustment

3. Hoist car.
4. Remove retaining bolt for downshift cable. Remove
downshift cable from link. Plug hole. (If console equipped,
remove shift control cable .)
5. Disconnect transmission cooler lines at transmission.
6. Remove catalytic converter support bracket (Starfire
only).
7. Remove flywheel cover pan and three bolts holding
the converter t o the flywheel. Support engine. (Fig. 7A3-18)
(NOTE: Mark flywheel and converter for reassembly in the
same manner .)

Fig. 7A3-16-Tool J-23069

Installation
1. Install intermediate clutch accumulator piston.

(NOTE: Rotating piston slightly when installing will help to

get rings started in bore .)

ring.

2. Position spring, "0" ring seal and cover in place.

3. Press in on cover with 5-23069 and install retaining
4. Remove tool and install oil pan bolts.

8. Disconnect the vacuum modulator line.

9. Disconnect speedometer cable.
10. Remove cotter pin and manual shift linkage.
1 1. Remove propeller shaft.
12. Remove transmission support to transmission mount
bolts and transmission support to frame bolts.
13. Raise transmission with a jack and remove support.
14. Lower transmission slightly and remove transmission
to engine bolts.
15. Lower transmission being careful not t o damage
cooler lines, downshift cable, modulator line and shift
linkage.
16. If transmission is to be moved, install converter
holding Tool J -2 1654.
Installation
1. Place transmission on locating pilots. Install
downshift cable in clip on transmission, insert oil level
dlpstick tube and bolt tube in place. Install transmission to
engine bolts and torque to 40 ft. lbs.
(NOTE: The downshift cable to case bolt is metric .)

Removal
1. At the carburetor end of the detent cable, lift the
"snap-lock", then slacken the cable from the carburetor
bracket and linkage. (Fig. 7A3-17)
2. Remove transmission oil level dipstick and upper
bolt on dipstick tube (from above).

(NOTE: Rotate converter to permit coupling of flywheel

and converter with original relationship .)

2. Install transmission support and torque support to

frame nuts to 25 ft. lbs. Torque support to transmission

Fig. 7A3-20-Transmission Oil Cooler Lines

The oil cooler is located in the side tank of the radiator
and its purpose is to cool the oil in the event excessive
temperature tends to develop. The oil cooler is a sealed
container providing a passage for oil to flow from the inlet to
the outlet.
In a major transmission failure, where particles of metal
have been carried with the oil throughout the units of the
transmission, it will be necessary to flush out the oil cooler
and connecting lines. To flush the oil cooler and lines, use
the following procedure :
1. Disconnect both cooler lines from the transmission.
2. Place a hose over the end of the cooler inlet line
(from the top of the cooler) and insert the hose into an
empty container.
3. Flush clean oleum solvent or equivalent through the

return line (from the bottom of the cooler) using an oil

suction gun until clean solvent comes out of the hose. This
will "back flush" the cooler.
4. Remove the hose from the inlet cooler line and place
it on the return line.
5 . Flush clean oleum solvent or equivalent through the
inlet line until clean solvent comes out the return line.
Remove remaining solvent from cooler with compressed
air applied to the return line and flush with transmission
fluid.
6. Reconnect oil cooler lines and torque nuts t o 12 ft.
lbs.

MODULATOR AAND FILLER PIPES

Refer to Figs. 7A3-2 1 and 7A3-22.

V A C U U M MODULATOR

VIEW OF P I P E
INSTALLATION

Fig. 7A3-21-Filler and Modulator Pipes (Starfiie)

7A3-20 TURBO HYDRA-MATIC 350

Fig. 7A3-22-Modulator and Filler Pipes

SHIFT RODJSHIFTCABLE ADJUSTMENT
Refer to Figs, 7A3-23 through 7A3-27.
SHIFT INDICATOR NEEDLE ADJUSTMENT
Refer to Sections 3 and 8.
GENERAL SERVICE PRECAUTIONS
When servicing the transmission, it is recommended that
upon disassembly of a unit, all parts should be cleaned and
inspected as outlined under CLEANING AND INSPECTION.
The unit should be reassembled before disassembly of other

2. Disassembly and reassembly of the unit and the

subassemblies must be made on a clean work bench. AS in
repairing any hydraulically operated unit, cleanliness is of the
utmost importance; therefore, the bench, tools, and parts
must be kept clean at all times.
3. ~ e f o r einstalling cap screws into aluminum parts,
ALWAYS DIP SCREWS INTO OIL to prevent cap screws
from galling the aluminum threads and also to prevent the
screws from seizing.
4. Always use a torque wench
installing cap
screws into aluminum parts to prevent the possibility of
stripping the threads.
5. If tapped, threads in aluminum parts are stripped or
damaged, the part can be made serviceable by the use of
Heli-Coils or equivalent.
6. Seal protecting tools must be used when assembling
the units to prevent damage to the seals. The slightest flaw in
the sealing surface of the seal can cause an oil leak.
7. The aluminum castings and the valve parts are very
susceptible to nicks, burrs, etc., and care should be exercised
when handling them.
8. The internal snap rings should be expanded and the
external snap rings compressed if they are to be reused. This
will insure proper seating when installed.
9. Replace all "0"rings, gaskets and oil seals that are
(NOTE: Teflon oil seal rings should not be removed unless
damaged. The service rings are hook type .)

10. During assembly of each unit, all internal parts must

be lubricated with oil.

PARTS CLEANING AND INSPECTION

After complete disassembly of a unit, all metal parts
should be washed in a clean solvent and dried with
compressed air. All oil passages should be blown out and
checked to make sure that they are not obstructed. S m a
passages, should be checked with tag wire. All parts should
be inspected to determine which parts are to be replaced.
The various inspections of parts are as follows:
1. Inspect linkage and pivot points for excessive wear.
2. Bearing and thrust surfaces of all parts should be
checked for excessive wear and scoring.
3. Check for broken seal rings, damaged ring lands and
damaged threads.
4. Inspect seals and "0" rings.
5 . Mating surfaces of castings and end plates should be
checked for burrs and irregularities. If a good seal is not
apparent, burrs and irregularities may be removed by lapping
the surface with crocus cloth. The crocus cloth should be laid
on a flat surface, such as a piece of plate glass.
6. Castings should be checked for cracks and sand
holes.
7 . Gear teeth should be checked for chipping, scoring,
and excessive wear.
8. Valves should be free of burrs and the shoulders of
the valves must be square. Any burrs or irregularities may be
removed by honing. Valves should be free t o slide in their
respective bores.
9. Inspect composition clutch plates for damaged
surfaces and loose facings. If flakes of facing material can be
removed with thumbnail, the plates should be replaced;
however, composition plate discoloration is not an indication
of failure.

12. When inspecting bushings, fit the mating part into

the bushing and observe the amount of looseness. Bushing
clearance is excessive if more than .008" exists when checked
with a wire feeler gage.
13. If the transmission shows evidence that foreign
material has circulated throughout the transmission the oil
filter should be discarded and a new one installed upon
assembly of the transmission. The oil cooler and lines should
be flushed (follow procedure).
(NOTE: Replace converter only for reasons given in
TORQUE CONVERTER DIAGNOSIS, Fig. 7 ~ 1 - 1 0 . 1

14. Check for lubrication holes in turbine shaft to be

sure they are open.

"IEW @
S PR I N G

SHIFT ROD ADJUSTMENT

1.

WITHSHIFTRODCLAMPSCREW LOOSENED,
SET TRANSMISS ION OUTER LEVER I N NEUTRAL
POS ITION.

2. HOLD UPPER SHlFT LEVER AGAINST NEUTRAL

POSITION STOP I N UPPER STEERING COLUMN.
(DO NOT RAISE LEVER)

TRANS. OUTER

3. TIGHTEN SCREW I N CLAMPON LOWER END OF

SHIFT ROD TO SPECIFIED TORQUE.
4. CHECK OPERATION :
A. WlTH KEY I N "RUN" POS ITION AND
TRANSMISS ION I N "REVERSE" BE SURE
THAT KEY CANNOT BE REMOVED AND THAT
STEERING WHEEL I S NOT LOCKED.
B. WlTH KEY I N "LOCK" POSITION AND
SHIFT EVER I N "PARK", BE SURE THAT
I <

(20FT. LBS.)

"

KEY CAN BE REMOVED THAT STEERING

WHEEL IS LOCKED. AND THAT THE TRANS M I S S I O N REMAINS I N PARK WHEN THE
STEERING COLUMN I S LOCKED.

C. WlTH BRAKES FIRMLY APPLIED. CHECK

TO MAKE SURE THAT THE STARTER WILL
NOT WORK I N ANY SHlFT LEVER POSITION
.
EXCEPT NEUTRAL AND PARK.

Fig. 7A3-23-Column Shift Control

9

SHlFT CABLE ADJUSTMENT

1. LOOSEN SHIFT ROD C L A M P SCREW, LOOSEN P I N I N TRANSM I S S I O N MANUAL LEVER.

2. PLACE SHIFT LEVER I N "PARK" POS ITION. PLACE TRANS-

SHIFTER ASSEMBLY

M I S S I O N M A N U A L LEVER I N "PARK" POSITION AND I G N I T I O N

KEY I N LOCK POSITION.

3. TIGHTEN CABLE P I N NUT TO 20 FT. LBS.

4. ROTATE THE TRANSMISS ION M A N U A L LEVER FULLY AGAINST
THE "PARK" STOP. THEN RELEASE THE LEVER.

5. PULL SHlFT ROD DOWN AGAINST LOCK STOP TO ELIMINATE

LASH AND TIGHTEN CLAMP SCREW TO 20 FT. LBS.

SHIFT ROD

6. CHECK OPERATION:

TRANSM l SS ION
M A N U A L LEVER

CABLE P I N

CLAMP

C L A M P SCREW

A. MOVE SHlFT HANDLE INTO EACH GEAR POSITION AND SEE

THAT TRANSMI SS ION M A N U A L LEVER I S ALSO I N DETENT
POS ITION.
B. W I T H KEY I N " R U N 1 ' POSITION AND T R A N S M I S S I O N I N
"REVERSE", BE SURE THAT KEY CANNOT BE REMOVED AND
THAT STEERING WHEEL I S NOT LOCKED.
C. W I T H KEY I N "LOCK" POSITION AND TRANSMISS ION I N
"PARK", BE SURE THAT KEY C A N BE REMOVED AND THAT
STEERING WHEEL I S LOCKED.
D. ENGINE MUST START I N PARK AND NEUTRAL
E. W l T H BRAKES F I R M L Y APPLIED, CHECK TO MAKE SURE
THAT THE STARTER W I L L NOT WORK I N A N Y S H l F T LCVER
POSITION EXCEPT NEUTRAL AND PARK.

Fig. 7A3-24-Console Shift Cable (Cutlass)

TRANSMISSION CONTROL
-CABLE
ASSEMBLY

C----

TRANSMISSION CONTROL
SHl FTER ASSEMBLY

lel

TRANSMISS I O N CONTROL CABLE ADJUSTMENT

TRANSMISSION

TRANSM(SSI0N CONTROL
CABLE BRACKET

1. LOOSELY ASSEMBLE NUT (E) AND P. WASHER TO

P I N (C) THRU TRANSMISSION LEVER (D) W l T H
TRANSMISS I O N CONTROL CABLE ASSEMBLED TO
P I N (C). TRANSMISS ION CONTROL SHIFTER
ASSEMBLY(6) AND TRANSMISS ION CONTRO;
CABLE BRACKET.
2. PLACE TRANSMISS I O N CONTROL SHIFTER ASSEMBLY
(B1 IN NEUTRAL'POS ITION':
3. PLACE TRANSMISS I O N E V E R ( D l i N "NEUTRAL"
POS ITION. NOTE: OBTAIN "NEUTRAI" POS ITION BY
M O V I N G TRANSMISSION LEVER (D)COUNTER CLOCKWISE TO L l DETENT THEN CLOCKWISE THRU
TWO (2) DETENT POS ITIONS. (L2 & D l TO
NEUTRAL .
4. TI GHTEN NUT (El TO INDICATED TORQUE.
5. WlTH BRAKES F I R M L Y APPLIED. CHECK
TO MAKE SURE THAT THE STARTER W ILL
NOT WORK I N ANY SHIFT LEVER POSITION
EXCEPT NEUTRAL AND PARK.

TURBO HYDRA-MATIC 350 7A3-23

TRANSMISSION DISASSEMBLY

Ic.

1 . With trar,smission in holding fixture, oil pan up,

remove Holding Tool 5-21654 and remove torque converter
assembIy and attach 5-8763-02 transmission holding tool.
(Fig. 7A3 -28 & 7 A3-29)
2. Remove vacuum modulator assembly attaching bolt
and retainer. (Fig. 7A3-30)
3. Remove vacuum modulator assembly, "0" ring seal
and modulator valve from case. (Fig. 7A3-31)
4. Remove extension housing to case attaching bolts.
(Fig. 7A3-32)
5. Remove extension housing and square cut "0" ring
seal. (Fig. 7A3-33)
6. Remove "0" ring from extension housing.
7. Remove extension housing lip seal using screwdriver.
(Fig. 7A3-34)
8. Depress speedometer drive gear retaining clip, then
slide speedometer drive gear off output shaft and remove
clip. (Fig. 7A3-35)
9. Remove governor cover retainer (Fig. 7A3-36),
remove cover (Fig. 7A3-37) and remove "0" ring. (Fig.
7A3-38)

NUT

LEVER ASSEMBLY

BRACKET

Fig. 7A3-27-Console Shifter Assembly (Cutlass & 88)

Fig. 7A3-28-Torque Converter

(NOTE: To remove the governor cover, use a screwdriver

and pry between the case and the governor cover flange.

Fig. 7A3-29-Transmission in
Holding Fixture

Fig. 7A3-30-Removing Vacuum

Modulator

V A C U U M MODULATOR

Fig. 7A3-31-Removing Modulator

Fig. 7A3-32-Removing Extension

Fig. 7A3-33-Extension Housing "0"Ring

'
I

!+

ii
I
I

Avoid denting the cover or gouging the transmission case as

t h s destroys the sealing surfaces. The dimple in the center of
the cover provides the proper end play for the governor; do
not hammer on the cover .)

11. Remove oil pan attaching screw and washer

assemblies, oil pan and gasket. (Fig. 7A340)
12. Remove oil pump suction filter to valve body
attaching screws and remove filter and gasket. (Fig, 7AqA1,

10. Withdraw governor assembly from case. (Fig.

7A3-39)

(NOTE: The gasket is n

(NOTE: Check governor bore and governor sleeve for

scoring.)

13. Remove bolt and detent roller and spring assembl

Y
from valve body. Remove
case attaching bolts.
(Fig. 7 A3 -42)

ER DRIVE G E A

RETAINING CLIP

gj:i
Itd

'

Fig. 7A3-34-Extension Housing Seal

Fig. 7A3-35-Speedometer Drive Gear

Fig. 7A3-36-Governor Retainer

Fig. 7A3-37-Governor Cover

Fig. 7A3-38-Governor Cover "0"Ring

Fig. 7A3-39-Governor Assembly

Fig. 7A3-41 -Oil Pump Filter

Fig. 7A3-42-Detent Roller and Spring

Fig. 7A3-40-Oil Pan

TURBO HY DRA-MATIC 350 7A3-25

14. Lift valve body while guiding manual valve link from

,mge selector inner lever. Remove valve body and link.

Remove &tent control valve link from detent actuating

lever. (Fig. 7A343)

15. Remove valve body to spacer plate gasket. (Fig.

7 ~ 3 4 4 )This new gasket is now identified by a yellow ink
stripe.
16. Remove spacer ~~~~~~t plate bolts. Remove spacer
plate. (Fig. 7 A3 4 5 )
17. Remove valve body spacer plate and spacer plate to
ase
(Fig. 7A3-46)

Fig. 7A3-43-Removing Valve Body

Fig. 7A3-46-Spacer Plate and Gasket

Fig. 7A3-49 -Governor Screen

18. Remove (4) check balls from passages in case

face-note location of each. (Fig. 7A3-47)
19. Remove oil pump pressure screen from oil pump
pressure hole in case. (Fig. 7 A 3 4 8 )

(NOTE: The oil pump pressure screen is now plastic.)

20. Remove governor screen from case. (Fig. 7A349)

21. Remove manual shaft t o case retainer. (Fig. 7A3-50)
22. Loosen jam nut holding range selector inner lever t o
manual shaft. (Fig. 7A3 -5 1)

Fig. 7A3-44-Spacer Plate Gasket

Fig. 7A3-47-Check Balls

Fig. 7A3-50-Manual Shaft Retainer

Fig. 7A3-45 -Spacer Support Plate

Fig. 7A3-48-Oil Pump Pressure Screen

Fig. 7.A3-51 -Manual Shaft Nut

TURBO HYDRA-MATIC 350 7A3-27

(J-8001)
DIAL INDICATOR

Fig. 7A3-58-Removing Intermediate

Fig. 7A3-59-Checking End Play

Fig. 7A3-60-Oil Pump

TER

5-2

Fig. 7A3-61-Removing Pump

'

Fig. 7A3-63-1ntermedia te Clutch

Cushion Spring

Fig. 7A3-62-Pump to Case Gasket

35. Remove intermediate clutch faced plates and steel

separator plates. (Fig. 7A3-64 and Chart, Fig. 7A3-15)
36. Remove intermediate clutch pressure plate. (Fig.
7A3-65)
37. Remove intermediate overrun brake band. (Fig.
7A3-66)

I
Fig. 7A3-64-Intermediate Clutch Plates

Fig. 7A3-65-Intermediate Clutch

Pressure Plate

INTERMEDIATE OVERRUN
BRAKE BAND
Fig. 7A3-66-Intermediate Overrun
Brake Band

7A3-28 TURBO HY DRA-MATIC 350

38. Remove direct and forward clutch from case as an

assembly. (Fig. 7A3-67)
39. Remove forward clutch housing to input ring
gear-front thrust washer. (Fig. 7A3-68)

(NOTE: Washer has (3) wide tangs on the O.D.)

40. Remove input ring gear. (Fig. 7A3-69)
41 . Remove input ring gear t o output carrier needle
thrust bearing. (Fig. 7A3-70)
42. Remove output carrier to output shaft snap ring.
(Fig. 7A3-71)
43. Remove output carrier assembly. (Fig. 7A3-72)
44. Remove sun gear drive shell assembly. (Fig. 7A3-73)
45. Remove sun gear drive shell t o roller clutch inner
race thrust washer.

(NOTE: Washer has (4) tangs on the I .D.)

retaining ring. (Fig. 7A3-74)

47. Remove low and reverse roller clutch and support
assembly and retaining spring. (Fig. 7A3-75)

(NOTE: Bump roller clutch support lightly with output

shaft t o loosen .)
48. Remove low and reverse clutch faced plates and steel
separator plates. (Fig. 7A3-76 and Chart on Fig. 7A3-15)
49. Remove reaction carrier assembly from output ring
gear and shaft assembly. (Fig. 7A3-77)
50. Remove output ring gear and shaft assembly from
case. (Fig. 7A3-78)
51 . Remove reaction carrier to output ring gear needle
thrust bearing. (Fig. 7A3-79)
52. Remove output ring gear t o output shaft snap ring
and remove ring gear from output shaft. (Fig. 7A3-80)
53. Remove output ring gear t o case needle bearing
assembly. (Fig. 7A38 1)

46, Remove low and reverse roller clutch support to case

Fig. 7A3-67-Forward and Direct

Clutch Assemblies

Fig. 7A3-68-Input Ring Gear

Thrust Washer

Fig. 7A3-69-Input Ring Gear

TO OUTPUT SHAF

Fig. 7A3-70-Output Carrier Needle

lhrust Bearing

Fig. 7A3-7 1 -Output Shaft Snap Ring

Fig. 7A3-72-Output Carrier

r
Fig. 7A3-73-Sun Gear Drive Shell

TURBO HYDRA-MATIC 350 7A3-29

I2

ROLLER CLUTCH AND SUPPORT 1

Fig. 7A3-74-Removing Roller Clutch

Support Retaining Ring

Fig. 7A3-75-Roller Clutch Support

Fig. 7A3-77 -Reaction Carrier

Fig. 7A3-78--Output Ring Gear and

Shaft Assembly

Fig. 7A3-76-Low and Reverse

Clutch Pack

OUTPUT R I N G
GEAR TO CASE
NEEDLE B E A R I N G

Fig. 7A3-79-Output Shaft

Fig. 7A3-80-Output Ring Gear to

Output Shaft Snap Ring

Fig. 7A3-81 -Needle Bearing

'11

7A3-30 TURBO HYDRA-MATIC 350

54. Install tool 5-23327 and compress low and reverse

clutch piston spring retainer and remove piston retaining ring
and spring retainer. Remove tool. (Figs. 7A3-82 and 7A3-83)
55. Remove spring and spring seat assembly. (Fig.

7A384)
5 6. Remove low and reverse clutch piston assembly.
(Fig. 7A3-85)
57. Remove low and reverse clutch piston outer seal.
(Fig. 7A386)

I
!i

inner seal. (Fig. 7 ~ 3 - 8 7 )

59. Install tool J -23069 t o compress intermediate clutch
accumulator cover and remove retaining ring. ( ~ i 7~~ .3 . 8 ~ )
60. Remove intermediate clutch accumulator piston
cover. Remove cover "0" ring seal and discard. (Fig. 7A34393
6 1. Remove intermediate clutch accumulator piston
spring. (Fig. 7A3-90)
62. Remove intermediate clutch accumulator piston
assembly. (Fig. 7A3-91)

58. Remove low and reverse clutch piston center and

CLUTCH SPRING SEATI

ncv t ~ a LLUTCH
t
J-23327-2
\
S P R I N G RETAINER

1 CLUTCH PISTON
'

Ill i

Fig. 7A3-82-Piston Spring Compressor

Fig. 7A3-83-Tool Setup (J-23327)

Fig. 7A3-84-Clutch Piston Return Spring.

Fig. 7A3-85-Piston Removal

Fig. 7A3-86-Clutch Piston Oute:r Seal

Fig. 7A3-87 -Clut ch Piston Seals

Fig. 7A3-88-Piston Compressor Tool

Fig. 7A3-89 -Accumulator Piston Cover

Fig. 7A3-90-Accumulator Piston Spring

TURBO HYDRA-MATIC 350 7A3-31

INTERMEDIATE CLUTCH
\ACCUMULATOR PISTON

out all passages.

2. Inspect governor sleeve for nicks, burrs, scoring or
galling.
3. Check governor sleeve for free operation in bore of
transmission case.
4. Inspect governor valve for nicks, burrs, scoring or
galling.
5. Check governor valve for free operation in bore of
governor sleeve.
6. Inspect governor driven gear for nicks, burrs, or
damage.
7. Check governor driven gear for looseness on
governor sleeve.
8. Inspect governor weight springs for distortion or
damage.
9. Check governor weights for free operation in their
retainers.
10. Check valve opening at entry (.020" minimum) with
a feeler gage, holding governor as shown with governor
weights extended completely outward. (Fig. 7A3-93)
11. Check valve opening at exhaust (.02OV minimum
with a feeler gage, holding governor as shown with governor
weights completely inward. (Fig. 7A3-94)

Fig. 7A3-91 -Accumulator Piston

SERVICING UNITS
GOVERNOR ASSEMBLY
All parts of the governor assembly, with the exception of
the driven gear, are a select fit and each assembly is
calibrated. The governor, including the driven gear is serviced
as a complete assembly. However, the driven gear can also be
serviced separately.
It is necessary t o disassemble the governor assembly in
order to replace the driven gear. Disassembly may also be
necessary due to foreign material causing improper
operation. In such cases, proceed as follows:
Disassembly
1. Cut off one end of each governor weight pin and
remove pins, governor thrust cap, governor weights are
interchangeable from side to side and need not be identified.
(Fig. 7A3-92)
Fig. 7A3-93-Checking Valve Opening (Entry)

Fig. 7A3-92-Removing Governor Weight Pins

2. Remove governor valve from governor sleeve. Be
careful not to damage valve.
3. Perform the following inspections and replace
governor driven gear, if necessary.

Inspection
1 . Wash all parts in cleaning solvent , air dry and blow

Fig. 7A3-94-Checking Valve Opening (Exhaust)

MANUAL VALVE AND LINK ASSEMBLY

PRESSURE REGULATOR VALVE
PRESSURE REGULATOR VALVE SPRING
REVERSE AND MODULATOR BOOST VALVE
INTERMEDIATE BOOST VALVE
BOOST VALVE S L E E V E
RETAINING P I N
2 - 3 SHIFT VALVE
2 - 3 SHIFT VALVE SPRING
2-3 SHIFT CONTROL VALVE
2-3 S H I F T CONTROL VALVE SPRING
2 - 3 S H I F T CONTROL VALVE S L E E V E
RETAINING P I N

1 - 2 S H I F T VALVE
1 - 2 S H I F T CONTROL VALVE
1 - 2 S H I F T CONTROL SPRING
1 - 2 SHIFT CONTROL S L E E V E
RETAINING P I N
MANUAL LOW CONTROL VALVE
MANUAL LOW CONTROL SPRING
PLUG
RETAINING PIN
D E T E N T REGULATOR VALVE
DETEP:T REGULATOR SPRING SEAT
D E T E N T REGULATOR SPRING
RETAINING P I N

Fig. 7A3-98-Valve Body Assembly - Exploded View

DETENT VALVE OUTER SPRING

DETENT VALVE
D E T E N T VALVE OUTER SPRING SEAT
D E T E N T VALVE SPRING RETAINER
DETENTVALVESTOP
DETENT VALVE BRACKET
D E T E N T VALVE ACTUATING L E V E R
RETAINING BOLT
RETAINING P I N
DIRECT CLUTCH ACCUMULATOR SPRING
OIL SEAL RING (TEFLON)
DIRECT CLUTCH ACCUMULATOR PISTON
RETAINER RING

11f

7A3-34 TURBO HYDRA-MATIC 350

VALVE BODY (Fig. 7A3-98)

I/

/i
I
t

Disassembly
1. Position valve body assembly with cored face up and
direct clutch accumulator piston pocket positioned as shown.
2. Remove manual valve from lower left hand bore (A).
3. From lower right hand bore (B), remove the pressure
regulator valve train' retaining pin, -boost valve' sleeve,
intermediate boost valve, reverse and modulator boost valve,
pressure regulator valve spring, and the pressure regulator
valve.
4 . From the next bore (C), remove the 2-3 shift valve
train retaining pin sleeve, control valve spring, 2-3 s h f t
control valve, shift valve spring, and the 2-3 shift valve.
5. ~ r o mthe next bhre YD), remove the 1-2 s i f t valve
train retaining pin, sleeve, shift control valve spring, 1-2 shift
control valve and the 1-2 shift valve.
6. From the next bore (E), remove retaining pin, plug,
manual low control valve spring, and the manual low control
valve.
7. From the next bore (F), remove the retaining- pin,
spring, seat, and the detent regdator valve.
8 . From the upper left hand bore (G), remove the
detent actuating leve; retaining pin, actuating lever, bracket
bolt, bracket, stop, spring retainer, seat, outerspring, and the
detent valve.
9. Install tool 5-22269 on direct clutch accumulator
piston (H) and remove retaining "E" ring. (Fig. 7A3-99)
10. Remove direct clutch accumulator piston with
teflon oil seal ring" and s ~ r i n"g .

7. In the lower bore (B), install the pressure regulator

valve (2), spring (3), reverse and modulator boost mlve (4)
intermediate boost valve (5), sleeve (6), and retaining pin (7)'
8 . In the upper left bore (G), install outer spring (z7)'
detent valve (28), spring seat (29), spring retainer (30),
(31), actuating lever bracket (32), lever (33), retaining pin
(35).
, ,, and bolt (34).
. ,

stoi

'

1.
I/'

(NOTE: Install lever and pin after bracket is bolted to valve

body .)
9 . Install manual valve (I) in lower left bore (A).

OIL PUMP
Disassembly
1. Remove pump cover to body attaching bolts. (Fig.
7A3-100)
2. Remove intermediate clutch return spring and
retainer assembly and the intermediate clutch piston
assembly.
3 . - ~ e m o v eintermediate clutch piston inner and outer
seals. (Fig. 7A3-101)
4. ~ e m o v e(3) direct clutch to pump hub hook type oil
rings. (Fig. 7A3-102)

Assembly (Fig. 7A3-98)

, I . In bore (H) install direct clutch accumulator piston
spring (36), and piston (38).
2. Install tool 5-22269 on direct clutch accumulator
piston to install "E" ring (39). Remove tool.
3. In the to^ right bore (F). install the detent regulator
(25), and retainkg pin
valve (231, spring seat (24),
(26).
4. In the next bore down (E), install the manual low
control valve (1
dui- (2. I),, . and retaining- pin
. 9).
,, spring
- (20),
.
(22)5. In the next bore down (D), install the 1-2 shift valve
(14), 1-2 shift control valve (1 5), spring (1 6), sleeve (17), and
the retaining pin (1 8).
6 . In the next bore down (C), install the 2-3 shift valve
(8), shift spring (9), 2-3 shift control valve (1 O), shift control
spring (1 1), sleeve (1 2), and the retaining pin (1 3).
L

, ?

INTERMEDIATE
CLUTCH SPRING

Fig. 7A3-99 -Accumulator Piston

(NOTE: Do not remove the teflon forward clutch oil seal

rings unless damaged .)
5. Remove ~ u m vcover to direct clutch drum needle
thrust bearing a n d .Ol?" shim. (Fig. 7A3-103)

(NOTE: .017" slum may or maynot be installed. It is used

to correct input shaft end play. During assembly, follow
procedure t o obtain correct input shaft end play.)
- ,
A

h
Jnsnect
If- -r-i--na ~-is- cut
or -frozen -in-a. --. ---r - - - steadv -rest
- - - -ring.
--groove, it must be removed and replaced with the same color
ring.
..

- -

- -

.
.

(NOTE: Steady rest rings are identified by color. Four

different color steady rest rings are used; purple, green,
yellow and white, with each color ring having a different
depth. This ring must be replaced by the same color ring.)

7. Remove pump cover and stator shaft assembly from

pump body. (Fig. 7A3-104)

-.

Im mN T F R M F n l A Tm F f I l l Tu f mUI
~

nL

ULV I

PISTON OUTER SEAL

Fig. 7A3-100-Pump Cover Bolts

Fig. 7A3-101 -Clutch Piston Seals

F
f

TURBO HY DRA-MATIC 350 7A3-35

8. Remove pump drive gear and driven gear from pump

body. (Fig. 7A3-105)
9 . Remove pump to case square cut "0" ring seal. (Fig.
7~3-106)
10. ~f required, remove pump body t o converter hub lip
-1. (Fig. 7A3-107)
11 . Remove cooler by-pass valve seat. Pack cavity with
and tap 5-23 134 with hammer to lift seat. (Fig.
7~3-108)

12. Remove check ball and spring.

Assembly (Fig. 7A3-112)

1 . Che& (3) pump cover hub lube holes to make
certain tthey are not restricted, (Fig. 7A3-109)
2. Install spring, check ball and seat. Using tool
J-23 1 12 tap seat into bore until top of seat is flush with face
of pump body. (Fig. 7A3-110)

Fig. 7A3-102-Pump Oil Rings

Fig. 7A3-103-Needle Thrust Bearing

and .017" Shim

Fig. 7A3-104-Pump Cover and

Stator Shaft

Fig. 7A3-105-Oil Pump Gears

Fig. 7A3-106-Oil Pump "0" Ring

Fig. 7A3-107-Oil Pump Seal

Fig. 7A3-108-~ooler ByPass Valve Seat Fig. 7A3-109-Pump Lubrication Holes

Fig. 7A3-110-Cooler By-Pass valve Seat

(NOTE: If drive gear has off-set tangs, assemble with tangs

face up to prevent damage by converter .)
5. Install pump cover to direct clutch drum needle
thrust bearing with black side or lip side face down. (Fig.

iron rings.
8. Install intermediate clutch piston inner and out
seals.
9 . Install pump cover on pump body.
10. Install intermediate clutch piston into pump
with the aid of a piece of .020" music wire crimped in
copper tubing .

(NOTE: Refer to input shaft end play reaQng recorded with

dial indicator during disassembly.)

11. Install intermedate clutch spring and retaine

Fig. 7A3-113-Needle Thrust Bearing and .017" Shim

Fig. 7A3-111 -Installing Oil Seal

b

SHAFT ASSEMBLY

AND PUMP.

P U M P COVER TO P U M P BODY
A T T A C H I N G BOLTS ( 5 )

/
A

Fig. 7A3-112-Oil Pump Assembly

TURBO HYDRA-MATIC 350 7A3-37

.,

--RECT CLUTCH AND INTERMEDIATE OVERRUN

1 FR CLUTCH
y " Y i --[ t
x .

RETAINER RING

direct clutch and intermediate overrun roller

dutch assembly from input shaft.

7 Remove intermediate overrun clutch front retainer

*g. (Fig. 7A3-114)

2. Remove overrun clutch retainer. (Fig. 7A3-115)

4I

Remove intermediate overrun clutch outer race.

pig.7A3-116)

5. Remove intermediate overrun roller clutch assembly.

(Fig. 7A3-117)

(NOTE: Roller clutch inner cam is a press fit on direct

m. Do not

remove unless replacement is

6. From inner hub, remove direct clutch drum to

foward clutch housing needle thrust bearing. (Fig. 7A3-118)
7. Remove direct clutch pressure plate t o clutch drum,
retaining ring and pressure plate. (Fig. 7A3-119)
8. Remove direct clutch lined and steel plates, see Figs.
7A3-120 and 7A3-15.

RRUN CLUTCH

INTERMEDIATE OVERRU

Fig. 7A3-115-Overrun Clutch

Outer Retainer

Fig. 7A3-116-Overrun Clutch

Outer Race
1

- 1 1

1
"

I lllr
r

. .-

Fig. 7A3-114-Overrun Clutch Retainer Ring

INTERMEDIATE OVERRUN

Fig. 7A3-117-Intermediate Overrun

Roller Clutch Assembly

I ~%

,STEEL P L A T E S

PRESSURE PLATE
DIRECT CLUTCH D RUM

ASSEMBLY

Fig. 7A3-118-Needle Bearing

Fig. 7A3-119-Retainer Ring and

Pressure Plate

Fig. 7A3-120-Direct Clutch Plates

12. Remove direct clutch piston inner and outer seals.

Assembly (Fig. 7A3-124 and 7A3-125)

1 . Install direct clutch drum center seal.
2. Install direct clutch piston inner and outer seals.

4. Install direct clutch piston return spring and seat

assembly and retaining ring using snap ring pliers and tools as
shown in Fig. 7A3-12 1. Remove tools.

7. If removed, install intermediate overrun roller clutch

inner cam on hub of direct clutch drum.
8. Install intermediate overrun roller clutch assembly.
9 . Install intermediate clutch overrun outer race.

(NOTE: When the intermediate overrun clutch outer race is

installed, it should free wheel in the counterclockwise
direction only .)

IRECT CLUTCH PISTON

RE

DIRECT CLUTCH

Fig. 7A3-121-Direct Clutch Piston

Spring Seat - Ring

Fig. 7A3-122-Direct Clutch

Piston Springs

Fig. 7A3-123-Direct Clutch Piston Seals

DIRECT C L U T C H DRUM
STEEL SEPARATOR

DIRECT CLUTCH
PISTON ASSEMBLY

RETAINING RING

FACED PLATE
DIRECT CLUTCH PRESSURE PLATE

Fig. 7A3-124-Direct Clutch Assembly

TURBO HYDRA-MATIC 350 7A3-39

CAUTION: I F ROLLER FALLS OUT DURING ASSEMBLY OPERATION-REINSTALL ROLLER

FROM INSIDE TO OUTSIDE CAGE DIRECTION TO AVOID BENDING SPRING
INTERMEDIATE CLUTCH
OVERRUN OUTER RACE
(LOCKS O N CLOCKWISE ROTATION)

RETAINING RING
DIRECT CLUTCH DRUM
AND INTERMEDIATE CLUTCH
OVERRUN INNER CAM

POSITION WITH 4 HOLES

TOWARD FRONT OF TRANSMISSION

Fig. 7A3-125-Intermediate Roller Clutch Assembly

10. Install intermediate overrun clutch retainer.
11. Install overrun clutch retainer ring.

(NOTE: Some retainer rings will be dished shape, if used,

the ring must be installed so that it compresses the retainer.

It will be necessary t o force the retainer ring into its groove .)

12. Install direct clutch drum t o forward clutch housing

needle thrust bearing on hub of roller clutch inner race. (Fig.
7A3-118)

CLUTCH PISTON
C E N T E R SEAL

Fig. 7A3-126-Direct Clutch Drum Center Seal

Fig. 7A3-127-Installing Clutch Piston

7A3-40 TURBO HYDRA-MATIC 350

te flon seal ring for damage. 1f the

""""
lerwise damaged, it must be replaced. some
:uffingof the shaft is normal. (Fig. 7 ~ 3 -34)
1
"'y":

retaining ring. (Fig. 7A3-128)

2. Remove forward clutch pressure plate.

IIII

(NOTE: Three thicknesses of pressure $lates will be used,

.245"-.255",
.275"-.285"
and .305 -.315". Clearany
between top faced plate and pressure plate should be .011
to .082" with retaining ring in place. Fig. 7A3-129 shows
correct plate m e a s ~ r e m ~ n.j
ts -

3. Remove forward clutch housing faced plates and

steel plates. See Fig. 7A3-15 for quantity of plates. Remove
cushon spring. (Fig. 7A3-130)
4. Install Tool 5 4 6 7 0 and Adapter R n g 5-8765 or use
a press to compress springs. (F
5. Remove forward
ring and
remove tools.
6 . Remove spring and seat assembly. (Fig. 7A3-132)
7 . Remove forward clutch piston assembly. (Fig.

11,'

8. Remove forward clutch piston inner and outer seals.

(Fig. 7A3-133)

$ 1

Fig. 7A3-128-Forward Clutch

Pressure Plate

Removal
1 . Remove seal with a sharp pointed knife by inserting
under the seal and cutting, making sure not to damage the
seal land area. (Fig. 7 ~ 3 - 1 3 5 )
I

~ 1 1 O L U U 1lb

vv

O"UA,

--A

7-1 7,)
'n"-'""J

2. Slide teflon seal p artidly down tool taper by hand.

3 . Position 5-9392-01i or 9/16" box end wrench over
_-,
-,
,,,,,,_-,
n,,.,,lT,
UL J - L L T I L ) aiiu N U W ~ ~push
.
teflon seal down taper and
-L,.L-~
,.-A
--oove. (Fig. 7A3-136)
--L-

U1lLu

g1

'lLU

(NOTE: Do not leave seal on untapered or middle of tool as

tch the sea'
this will

Fig. 7A3-129-Measuring Pressure Plate

FORWARD CLUTCH PISTON

Fig. 7A3-130-Forward Clutch Hates

NOTE : INSERT HOOKS J-4670-01

IN EXISTING HOLES

,I
I

.T

l-"&*La
lrino .
1-77974
and J-9392-01 (six
,
com~ressor
t 001s). Position J -22974
- - with large open end on top of input shaft chamfer. (Fig,

IL

rvlinAer
2ir
- - - -,--------- conditioner

II

FORWARD CLUTCH DRUM

I
-

Fig. 7A3-131-Compressing Forward

Clutch Springs

Fig. 7A3-132-Forward Clutch

,.,
-

,LUTCH
a - -

PISTON

-- .

Fig. 7A3-133-Forward
n.
n .Clutch
_l_
riston 3ea1s
L -

TURBO HYDRA-MATIC 350 7A3-41

I
SCORED AREAS

Fig. 7A3-134-Input Shaft Inspection

Fig. 7A3-135-Teflon Seal Removal

Fig. 7A3-136-Installing Teflon seal

4. After the seal is on the shaft, it must be sized. Dip

end of input shaft in autoniatic transmission fluid to
lubricate seal and shaft and slowly insert seal and shaft into
the output shaft three times before final assembly of
transmission. (Fig. 7A3-137) Check that seal has not been
cut and is free in the groove.
(NOTE: THM 350 model WC uses the bushing in the output
shaft as previous THM 350's. The bushing will continue to be
serviced for this transmission only. For bushing removal and
installation, refer to the Turbo Hydra-Matic 350 Bushing
Service Section of this manual. The service input shaft for
this transmission (WC) will have the teflon seal design
incorporated. To accomodate the teflon seal design input
shaft, the bushing in the output shaft will have to 'Pe
removed, and the inside diameter of the output shaft
polished, so as not to damage the teflon seal on the
replacement shaft .)
Fig. SA3-137-Sizing Teflon Seal

Assembly (Fig. 7A3-138)

1. Check forward clutch ball check exhaust. (Fig.
7A3-139)
2. Install forward clutch piston inner and outer seals.
3. Install forward clutch piston (Fig. 7A3-132) with
the aid of a .008" feeler gage. (Fig. 7A3-140)

on the forward clutch pistons are no longer required. Refer

to Turbo Hydra-Matic 350 information chart for dimensions
arid model usage, Fig. 7A3-15)

(NOTE: Make sure correct forward clutch piston is installed.

With the use of the spring and seat assembly, the projections

4. InstalJ forward clutch return spring and seat

assembly .

FORWARD CLUTCH PISTON ASSEMBLY

FORWARD CLUTCH DRU

STEEL SEPARATOR PL
CUSHION SPRING

RETAINING RING

FACED PLATE
FORWARD CLUTCH PRESSURE PLATE

Fig. 7A3-138-Forward Clutch Assembly - Exploded v i e d

1
1
1

7A3-42 TURBO HYDRA-MATIC 350

FORWARD CLUTCH
BALL CHECK
EXHAUST

FORWARD CLUTCH DRUM

Fig. 7A3-139-Forward Clutch Ball Check

ti,!
I

11

Fig. 7A3-140-Installing Forward Clutch Piston

5 . Install tool 5-4670 and Adapter k n g 5-8765 or use a

press to compress springs. Install forward clutch piston spring
seat retaining ring.
6. Lubricate with transmission fluid and install forward
clutch housing. cushon spring, steel plates and faced plates.
See Fig. 7 ~ 3 -5ifor the q u S i t y of each. Start with cushion
spring and alternate steel and faced.
7. Install forward clutch pressure plate. (Fig. 7A3-141)
8. Install pressure plate retaining ring.
9. Use feeler gage t o check for .0llU t o .082"
clearance between faced plate and pressure plate.
10. Install direct clutch drum on input shaft and align
faced plates with splines on forward clutch housing.
SUN GEAR AND SUN GEAR DRIVE SHELL
Disassembly
1. Remove sun gear t o sun gear drive shell rear
retaining ring. (Fig. 7A3-142)
2. Remove sun gear t o drive shell flat rear thrust
washer. (Fig. 7A3-143)
3. Remove sun gear and front retaining ring from drive
shell. (Fig. 7A3 -144)
4. Remove front retaining ring from sun gear.

-SUN

Fig. 7A3-141 -.Forward Clutch Pressure Plate

Assembly
1 . Install
over stress.
2. Install
3. Install
4. Install
retaining ring.

new front retaining ring on sun gear. Do not

sun gear and front retaining ring in drive shell.
sun gear to drive shell flat rear thrust washer.
new sun gear t o sun gear drive shell rear

GEAR

Fig. 7A3-142-Sun Gear Retaining Ring

Fig. 7A3-143-Sun Gear Thrust Washer

Fig. 7A3-144-Sun Gear Front

Retaining Ring

TURBO HYDRA-MATIC 350 7A3-43

LOW AND REVERSE SUPPORT AND OVERRUN

R ~ ~ L ECWTCH
R

LOW & R E V E R S E CLUTCH TO SUN

GEAR SHELL THRUST WASHER-

m s s e mbly
1. Remove low and reverse clutch to sun gear shell
thrust
washer. (Fig. 7A3-145)
2. Remove low and reverse overrun clutch i m e r race.
(Fig. 7 ~ 3 - 1 4 6 )
3. Remove low and reverse roller clutch retaining ring.
(Fig. 7A3-147)
' " 4. Remove low and reverse roller clutch assembly. (Fig.
7~3-149)

!f

Assembly (Fig. 7A3-148)

1. Install low and reverse roller clutch assembly.
2. Install low and reverse roller clutch retaining ring.
3. ~nstalllow and reverse overrun clutch inner race.

(NOTE: Inner race should free wheel in the clockwise

direction only.)

Fig. 7A3-146-Overrun Clutch Race

Fig. 7A3-145.-Low and Reverse Clutch Thrust Washer

Fig. 7A3-147 -Roller Clutch

Retaining Ring

Fig. 7A3-149-Roller Clutch Assembly

I
LOW A N D REVERSE
/CLUTCH
SUPPORT

I N N E R RACE

I@
Ii

/
i
ij
I

i\
THRUST WASHER

ASSEMBLY W I T H INS PECTION

TOWARD REAR OF TRANSMlSS ION.

IF ROLLER F A L L SOUT, ~ N S T A L CR O L L E R
FROM 'OUTSIDE IN ' A S S H O W N 1 0

Fig. 7A3-I 48-Low and Reverse Clutch Assembly

--

7A3-44 TURBO HYDRA-MATIC 350

TRANSMISSION ASSEMBLY
1 . Install intermediate clutch accumulator piston
assembly. (Fig. 7A3-150)
2. Install intermediate clutch accumulator piston
spring. (Fig. 7A3-15 1)
3. Place "0" ring seal on intermediate clutch
accumulator piston cover.
4. Install accumulator piston cover. (Fig. 7A3-152)
5 . Install tool 5-23069 to compress intermediate clutch
accumulator cover and install retaining ring. Remove tool
5-23069. (Fig. 7A3-153)
6. Install low and reverse clutch piston center and inner
seal on piston. (Fig. 7A3-154)
7. Install low and reverse clutch piston outer seal. (Fig.
7A3-155)
8. Install low and reverse clutch piston assembly. (Fig.
7A3-156)
(NOTE: Make sure correct low and reverse clutch piston
assembly is installed. Refer to Turbo Hydra-Matic 350, Fig.
7A3-15, information chart for dimensions and model usage.
Notch in low and reverse clutch piston must be installed
adjacent to parking pawl .)

INTERMEDIATE CLUTCH

\ ACCUMULATOR PISTON

TEFLON SEAL R l NG

9 . Install piston return spring and seat assembly i,

piston.
10. Compress low and reverse clutch piston spring seat
with tool 3-23327 and install retaining ring. Remove too,
5-23327. (Fig- 7A3-157 and 7A3-158)
1 1 . Install output ring gear to case needle bearing
assembly, ~houlderdown. (Fig- 7A3-159)
12. Assemble output ring gear on output shaft. Instau
new snap ring on shaft. (Fig. 7A3-160)
13. Install reaction carrier to output ring gear needle
thrust bearing with black side Or lip side face up. (Fig,
7A3-161)
14. Install output ring gear and shaft assembly in cae.
(Fig. 7A3 -1 62)
15. Install reaction carrier assembly on output ring gear
and shaft assembly. (Fig. 7A3-163)
16. Lubricate with transmission fluid and install low and
reverse clutch steel separator plates and faced plates. See Fig,
7A3-15 for usage chart. Start with a steel plate and alternate
with faced plates. ( ~ i g7A3-164)
.

(NOTE: Notch in steel plates in toward bottom of case.)

ilu.

Fig. 7A3-150-Accumulator Piston

Fig.
- 7A3-15 1-Accumulator Piston
Springs

Fig. 7A3-152-Accumulator Piston Cover

SEAL

Fig. 7A3-153-Accumulator Piston

Compressor

Fig. 7A3-154-Piston Seals

Fig. 7A3-155-Piston Outer Seal

TURBO HYDRA-MATIC 350 7 A 3 4 5

URN S P R I N G AND RETAIN

PRlNG COMPR

Fig. 7A3-158-Tool Setup (5-23327)

Fig. 7A3-157-Spring Compressor

Fig. 7A3-156-Clutch Piston

Return Springs

Fig. 7A3-160-Ring Gear Snap Ring

Fig. 7A3-159-Needle Bearing

OUTF'UT RING

Fig. 7A3-161 -Output Shaft Needle

Thrust Bearing

'PUT RlNG GEAR

A N D OUTPUT SHAFT

ASSEMBLY
CLUTCH PACK

Fig. 7A3-162-output Shaft Assembly

Fig. 7A3-163-Reaction Carrier

'

Fig. 7A3-164-Low and Reverse

Clutch Pack

TURBO HYDRA-MATIC 350 7A3-47

INPUT RING GEAR

Fig. 7A3-17 1 -Front Thrust Washer

INTERMEDIATE OVERRUN
Fig. 7A3-174-Intermediate
Overrun Band

Fig. 7A3-172-Installing Input

Ring Gear

Fig. 7A3-173-Direct and Forward Clutch

INTERMEDIATE CLUTCH
Fig. 7A3-175-Intermediate Clutch
Pressure Plate

30. Install intermediate clutch cushion spring. (Fig.

7A3-177)
31. Lubricate case bore, then install new pump to case
gasket in bore. (Fig. 7A3-178)
32. Install pump cover to direct clutch drum needle
thrust bearing with black side or lip side face down.

Fig. 7A3-176-Intermediate Clutch Plates

index the faced plates with their respective parts. This

condition mast be corrected before the pump is bolted into
place.)

(NOTE: Refer to input shaft end play reading recorded with

dial indicator during disassembly.)
Total end play should be between .030" and -079"
During assembly, use the following procedure:
If end play is correct, install the original number of
shims between the pump and needle thrust bearing if any
were found during disassembly.
If end play is incorrect, remove or add one or *two
-017'' shims, wluchever is needed to obtain correct end play.
(*Do not use more than two .017" shims. If more than two
-017'' shims are required, excessive wear or improper
installation of oil pump assembly parts is indicated.
33. Install (2) guide pins made from pump attaching
bolts in case.
(NOTE: If the input shaft cannot be rotated clockwise as
the Pump is being bolted into place, the direct clutch and
clutch housing has not been properly installed to

Fig. 7A3-177-Intermediate Clutch Cushion Spring

TO CASE ATTACHING
IF REPLACEMENT IS REO
ALUMlNUM QI L SEAL R I N
IMTERNIEaIATE SERVO

TURBO HYDRA-MATIC 350 7A3-49

MANUAL

Fig. 7A3-185-Parking Pawl Rod

Fig. 7A3-186-Manual Shaft Seal

47. lnstall manual shaft jam nut. Torque to 30 ft . lbs.

(Fig. 7A3-188)
48. Install manual shaft retainer. (Fig. 7A3-189)
49. Install governor screens in case. (Fig. 7A3-190)
50. Install oil pump pressure screen in oil pump pressure
hole in case. (Fig. 7A3-191)

Fig. 7A3-187-Manual Shaft

(NOTE : Ring end of screen must be installed first .)

5 1 . Install four check balls in correct passages in case
face. (Fig. 7A3-192)
52. Install valve body spacer plate to case gasket and
spacer plate. (Fig. 7A3-193)

LEVER TO M A N U A L

Fig. 7A3-188-Manual Shaft Nut

Fig. 7A3-189-Manual Shaft Retainer

Fig. 7A3-190-Governor Screen

ALL

Fig. 7A3-191-Oil Pressure Screen

Fig. 7A3-192-Oil Passage Check Balls

Fig. 7A3-193-Spacer Plate and Gasket

TURBO HYDRA-MATIC 350 7A3-5 1

affect the material characteristics of

this type of plastic.
housing lip seal using Installer
housing square cut "0" ring seal.
housing. Torque bolts t o 35 ft. lbs.

66. Lubricate new modulator "0" ring. Install on

modulator.
67. Install vacuum modulator valve in case (Fig.
7A3-206) Install vacuum modulator assembly and retain with
retainer. (Fig. 7 A3-207)
68. Install torque converter, engaging lugs, and install
Holding Tool 5-2 1654.

ER DRIVE GEAR

SEAL

RETAINING CLIP

Fig. 7A3-200-Governor Cover

Fig. 7A3-201-Governor Retainer

Fig. 7A3-203 -Installing Extension

Housing Seal

Fig. 7 A 3 - 2 0 5 - ~ ~ t ~ ~ sHousing
ion

Fig. 7A3-202-Speedometer Drive Gear

Fig. 7A3-204-Installing Housing

"0" Ring

Fig. 7A3-206-Installing Vacuum Modulator

Fig. 7A3-207-Vacuum Modulator

7A3-52 BUSHINGS TURBO HYDRA-MATIC 350

TORQUE SPECIFICAT
APPLICATION
Pump Cover to Pump Body Bolts . . . . . . . . . . . . . . . .
Pump Attaching Bolts . . . . . . . . . . . . . . . . . . . . .
. . . . . . .
Range Selector Inner Lever to Manual Shaft Jam Nut
. . . . . . . . . . . . . . .
Park Lock Bracket Attaching Bolts
Valve Body to Case Attaching Bolts . . . . . . . . . . . . . . .
Oil Pump Screen (Strainer) Attaching Screws . . . . . . . . . . .
Extension Housing to Case Attaching Bolts . . . . . . . . . . . .
Crossmember to Frame Bolts . . . . . . . . . . . . . . . . . .
Crossmember to Mount Bolts . . . . . . . . . . . . . . . . . .
Starfire . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan Attaching Bolts
V8
. . . . . . . . . . . . . . . . . . . . . . . . . . .
V-6
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
Converter to Flywheel

TORQUE SPECIFICATIONS FOR METRIC EXTERNAL FASTENERS

APPLICATION
Transmission mount to transmission - M-10-1.5 thread size . . . . .
Speedometer sleeve retainer on extension housing - Mh.3-1 .O thread size
. . . . . . . . . . .
Detent cable to case - M h .3-1.0 thread size
Nut on end of selector lever shaft - M-10-1.5 thread size . . . . . .

. 48 N*m

17 N - m

. 8.5 Nan. 27 N-m

TURBO HYDRA-MATIC 350

BUSHING SERVICE
Service bushings are available for replacement in thirteen
locations in the Hydra-Matic 350 transmission. The
replaceable bushings are located as follows: (Fig. 7A3-208)
Case
Extension Housing
Pump Body
Stator Shaft, Front
Stator Shaft, Rear (2)
Output Shaft
Reaction Carrier
Sun Gear (2)
Input Ring Gear
Direct Clutch Drum
Governor Bore

BUSHINGS TURBO HYDRA-MATIC 350 7A3-53

EXTENSION
4 HOUSING

Fig. 7A3-211-Removing or Installing

Extension House Bushing

Fig. 7A3-212-Remvoing Pump Body Bushing

Fig. 7A3-213-Installing Pump Body Bushing

BUSHINGS TURBO HYDRA-MATIC 350 7A3-55

FRONT STATOR SHAFT BUSHING (Figs. 7A3-214 and

7 ~ 3 -15)
2
Thread 5-21465-15 into bushing, install Adapter
J-26194 on slide hammer, thread adapter into J-21465-15.
lnstaU weight of slide hammer in vise and pull pump body
from bushing. Clean out stator shaft. Support pump body on
wooden block. Use J-21424-7 or 5-23062-14 to install
bushing. Tap in until bushing seats on shoulder in stator
shaft. (The bushing will then be about 114" below the end of
the shaft .)

SLIDE HAMMER

PUMP COVER
AND STATOR
SHAFT ASSEMBLY

,REAR STATOR SHAFT BUSHINGS (Figs. 7A3-216 and

7~3-217)
Remove bushings in same manner as front stator shaft
bushing. Outer bushing must be removed t o remove inner
bushing. Clean out stator shaft. Support pump on wooden
block. Install inner bushing one inch below end of shaft.
~nstallouter bushing flush to .010" below chamfer on shaft.

Fig. 7A3-216-Removing Stator Shaft Rear Bushing

PUMP COVER
AND STATOR
SHAFT ASSEMBL

ADAPTER

i
Fig. 7A3-217-Installing Stator Shaft Rear Bushing

PUMP BODY

\PUMP COVER
A N D STATOR
SHAFT ASSEMBLY

OUTPUT SHAFT BUSHING (Figs. 7A3-218 and 7A3-219)

Thread 5-9534-1 into bushing and remove with 5-6125
slide hammer. Use 5-23062-7 or 5-23062-16 and tap in
bushng until installer bottoms on output shaft.

Fig. 7A3-214-Removing Stator Shaft Front Bushing

J-8092
DRIVE
HANDLE

j
f
t

J-23062-14
or

PUMP COVER
AND STATOR

OUTPUT SHAFT

SLtDE HAMMER

Fig. 7A3-215-Installing Stator Shaft Front Bushing

Fig. 7A3-218-Removing Output Shaft Bushing

7A3-56 BUSHINGS TURBO HYDRA-MATIC 350

1
I

II,[

Fig. 7A3-219-Installing Output Shaft Bushing

;
!

!/I

/i I

!/

i'i

'1

II

1,
fj',

REACTION CARRIER BUSHING (Figs. 7A3-220 and

7A3-221)
Use Tool 5-23062-3 or 5-23062-16 to tap out bushing.
Turn reaction carrier over and use same tool to install
bushing until it is flush with inner hub.

SUN GEAR BUSHING (Fig. 7A3-222)

Use 5-23062-3 and Drive Handle 5-8092 to drive both
bushngs out through sun gear. Use J-23062-3 to install
bushng in each end until flush to .010" below counterbore
of sun gear shaft.
INPUT RING GEAR BUSHING (Fig. 7A3-223)
Use Tool 5-23062-5 to tap bushing out of ring gear.
Make sure bushing is properly aligned. Use Tool 5-23062-5 to
tap bushing in until it is flush to .010" above surface of ring
gear.

Fig. 7A3-220-Removing Reaction Carrier Bushing

Input Ring Gear Bushing

BUSHINGS TURBO HYDRA-MATIC 350 7A3-57

DIRECT CLUTCH DRUM BUSHING (Fig. 7A3-224)

Use 58092 and 5-23062-10 to remove the bushing. Use
~~~l 5-8092 with tool J-230624 or 5-23062-15 to carefully
tap bushing in until it is .010" below slots in direct clutch
hub.

(NOTE: The direct clutch housing with the aluminum

bushing can be used only with the cast iron pump cover. The
housing with the bronze bushing can be used either with the
steel sleeve pump cover or the cast iron pump cover.)
GOVERNOR BORE BUSHING
With transmission in Holding Fixture 5-8763 check
governor cover to case surface. If uneven or rough, smooth
surface as shown in Fig. 7A3-225.
Assemble tools as shown in Fig. 7A3-226. Torque the
fixture to case bolts t o 10 Ft. Lbs. Do not over-torque as the
arbor must rotate freely, if not, realign fixture and re -torque
bolts.

Fig. 7A3-226-Installing Tools

Oil the reamer, alignment fixture and governor bore with
transmission fluid. With reamer installed as shown in Fig.
7A3-227 apply 5 to 10 lbs. of down pressure while cutting.
Do not apply any side pressure as it will result in an egg
shaped bore. After each ten revolutions of the reamer,
remove the reamer and dip reamer into a container of
transmission fluid to remove chips and provide lubrication.

Fig. 7A3-224-Removing or Installing

Direct Clutch Drum Bushing

Fig. 7A3-225-Cleaning Tool Surface

Fig. 7A3-227 -Reaming Governor Bore

7A3-58 BUSHINGS TURBO HYDRA-MATIC 350

the end of the bore, continue

reaming until the reamer bottoms on the governor dowel pi1
After bott~--:-- nfintifi110"amino ten additional revolution
~lh...+
VV11b11

h r
~p a m ~ r ~ .
~ v u l ~ a-------

rlrv

Fig. 7A3-228-Locating Governor Bore Bushing

will insure ,
correct
location
other towards the. .bottom. This
---l t - I , , : , ,
,
,
Of bushing slots wltn governor rleeu
11ult;;s111 Ldac.
Drive bushing in until flush with top of governor bore.
. _ .

Fig. 7A3-ZZY-1nsta1nng buvernul

DW G

UU3111115

TOOLS 7A3-59

SLIDE HAMMER
ADAPTER, SL IDE HAMMER
SLI DE HAMMER
DR IVER HANDLE
BUSHING REMOVER
CASE BUSHING REMOVER AND INSTALLER
STATOR SHAFT BUSHING INSTALLER (BOTH REAR)
SUN GEAR BUSHING INSTALLER
DIRECT CLUTCH BUSHING REMOVER AND INSTALLER
INPUT R ING GEAR BUSHING REMOVER AND INSTALLER
OUTPUT SHAFT BUSHING INSTALLER
DR IVER HANDLE EXTENS ION
STATOR SHAFT AND SUN GEAR BUSHING REMOVER
O I L PUMP BUSHINGS, REMOVER AND INSTALLER
EXTENS ION HOUSING BUSHING REMOVER AND INSTALLER
ALIGNMENT FIXTURE
AL IGNMENT ARBOR
REAMER
Fig. 7A3-230-Bushing Tools

TURBO HYDRA-MATIC 400 & 425 DIAGNOSIS 7A4-1

TURBO HYDRA-MATIC
TRANSMISSION
DIAGNOSIS GUIDE THM 400 AND 425

INDEX
In many of the following diagnosis procedures, it is
recommended that air pressure be applied. The purpose of
this is to help determine if seals, rings or pistons are stuck,
missing or damaged.. Therefore, when air is applied, it is
important to listen carefully for escaping air and piston
action as air is applied to a particular area.
In the event of a major transmission failure, replace the
filter assembly and flush the oil cooler and lines.
PAGE
Case Porosity Repair
Diagnosis Guide Chart
Downshift Switch
.

. . . . . . . . . . . . . 7A4-1
. . . . . . . . . . . . 7A4-7
. . . . . . . . . . . . 7A4-2 1

OIL LEAKS
The suspected area should be wiped clean of all oil
before inspecting for the source of the leak. Red dye is used
in the transmission oil at the assembly plant and will
indicate if the oil leak is from the transmission.
When an oil leak is found the following procedure will
assist in locating the leak.
1. Clean the area with solvent to remove all traces of

2. Remove the flywheel lower cover, if leak is

suspected at rear of engine or front of transmission.
3. Spray suspected leak areas with a pressurized foot
4. Start engine and run at high idle.
5. Repair any leaks which are detected and recheck as
necessary. Reinstall previously removed parts.
The use of a "black light" to identify the oil at the
source of the leak is also helpful. Comparing the oil from
the leak to that on the engine or transmission dipstick
(when viewed by black light) will determine the source of
Oil leaks around the engine and transmission are
generally carried toward the rear of the car by the air
skeam. For example, a transmission "oil filler tube t o case
leak" will sometimes appear as a leak at the rear of the
transmission. In determining the source of an oil leak, it is
most helpful to keep the engine running.
A "black light" testing unit such as J-6640 may be
from service tool suppliers.

' ~ g b l e Points of Oil Leaks

A. Transmission Oil Pan
1. Attaching bolts not correctly torqued.
2- Pan gasket improperly installed or damaged.
3- Oil pan case mounting face not flat.

SUBJECT
Information Chart
Oil Leak Diagnosis
Oil Pressure Charts

PAGE

. . . . . . . . . . . . . 7A4-14
. . . . . . . . . . . . . . 7A4-1
. . . . . . . . . . . . . . 7A4-6

B. Cover and Plate Assembly Sprocket Housing Leak

1. Attaching bolts not correctly torqued.
2. Housing t o case gasket aged.
3. Mounting surfaces not flat.
D. Case Leaks
1. FilIer pipe "0" ring seal damaged or missing.
2. Mispositioning of filler pipe mounting bracket loading one side of "0" ring seal.
3. Modulator assembly "0" ring seal damaged or
improperly installed.
4. Governor cover "0" ring and bracket damaged or
loose.
5 . Line pressure tap plug loose or stripped .
6. Cooler connectors loose, cracked or stripped.
7. Porosity in case. See Case Porosity Repair.
E. Rear Extension Leak
1. Attaching bolts not correctly torqued.
2, Rear seal assembly - damaged or improperly
installed.
3. Gasket (extension to case) damaged or improperly
installed,

F. Oil Comes Out Vent Pipe

1. Transmission overfilled. Refer
Maintenance".
2. Water in oil.
3. Vent system plugged or damaged.
4. Porous casting.

to

"Periodic

Case Porosity Repair

Leaks caused by case porosity can be repaired with the
transmission in the car by using the following procedures:
1. Road test and bring the transmission to operating
temperature.

7A4-2 TURBO HYDRA-MATIC 400 & 425 DIAGNOSIS

2. Raise car, with engine running, to locate source of

oil leak. Check for leaks in low, drive, and reverse.

(NOTE: T H I S CHECK BALL I S NONFUNCTIONAL. O M I T I T DURING

REASSEMBLY,)

(NOTE: Use of a mirror is helpful in finding leaks.)

3. Shut engine off and thoroughly clean area to be

repaired with a suitable solvent and a brush - air dry.
(NOTE: A clean, dry soldering acid brush can be used to
clean the area and also to apply the epoxy cement.)

1111

4. Using instructions of the manufacturer, mix a

sufficient amount of epoxy,
- No. 13600 16, or equivalent, to
make the repair.

FRON

VENT

SPACER PLATE

70 CASE GASKET

MODULATOR OR
INTERMEDIATE

MODULATOR OR
INTERMEDIATE

Fig. 7A4-4-Spacer Plate - 400 (Typical)

PRESSURE REGULA
FEED HOLE

Fig. 7A4-2-Pump Cover - 400

Fig. 7A4-5-Check Ban Location - 425

TURBO HYDRA-MATJC 400 & 425 DIAGNOSIS 7A4-3

P U M P INTAKE

CONVERTER RETURN

LOIRNIEF I C E

LINE
EX

&ND

L ~ N ~

IN1

/-

--

M O D TO I 2 A C C U M

Fig. 7A4-9-Oil Passages - 425

r\-

Fig. 7A4-6-Spacer Plate - 425 (Typical)

.-. . ,

CONVERTER FEED

Fig. 7A4-10-Oil Passages - 425

Fig. 7A4-7-Case Oil Passages - 400

LINE,

DRIVE

MODULATOR

I
LUBE (FROM COOL

INTERMEDIATE

Fig. 7A4-8-Case Oil Passages - 400

Fig. 7 A4-11 -Oil Passages - 425

7A4-4 TURBO HYDRA-MATIC 400 & 425 DIAGNOSIS

5 . While the transmission case is still HOT, apply the

epoxy to the area to be repaired.
(NOTE: Make certain the area t o be repaired is fully
covered .)

6. Allow cement to cure for three hours before

starting engine.
7. Road test and check for leaks.

VACUUM MODULATOR DIAGNOSIS

Vacuum Diaphragm Check
Insert a pipe cleaner as far as possible into the vacuum
connector pipe and check for the presence of transmission
fluid. If transmission fluid is found, the modulator should
be replaced.
(NOTE: Gasoline or water vapor may settle in the vacuum
side of the modulator. If this is found without the presence
of oil, proceed to the next check.)

Fig. 7A4-12-41 Passages - 425

Atmospheric Leak Check
1. Apply a liberal coating of soap bubble solution to
the vacuum connector pipe seam, the crimped upper to
lower housing seam. (Fig. 7A4-15)

SERVO OIL
THRU EXHAUST

LINE
/\

/\ MOPULATOR

Fig. 7A4-13-Case Oil Passages - 425

TURBO HYDRA-MATIC 400 & 425 DIAGNOSIS 7A4-5

1. O I L FROM SUMP TO FILTER

11. CONVERTER TO PUMP COVER PLATE PASSAGE

2. FILTER TO CASE PASSAGE

12. PUMP COVER PLATE PAS SAGE TO CASE

PASSAGE

3. CASE PASSAGE TO PUMP COVER PLATE

PASSAGE

1 4. PUMP COVER PLATE PASSAGE TO PUMP

5. PUMP TO PUMP COVER PLATE PASSAGE
6. PUMP COVER PLATE PASSAGE TO CASE
PASSAGE

7. CASE PASSAGE TO PRESSURE REGULATOR

VALVE
8. PRESSURE REGULATOR VALVE TO CASE
PASSAGE

9 . CASE PASSAGE TO PUMP COVER PLATE

PASSAGE

10. PUMP COVER PLATE PASSAGE TO CONVERTER

13. CASE PASSAGE TO COOLER

14. COOLER RETURN TO CASE PASSAGE

15. CASE PASSAGE TO PUMP COVER PLATE
PASSAGE
16. PUMP COVER PLATE PASSAGE TO TRANSM I SS ION
POWER TRAIN (ALL INTERNAL LUBRICATION)
NOTE: THE NUMBERS I N THE CROSS SECTION
INDICATE THAT THERE ARE ADDITIONAL
LUBRICATION HOLES I N THI S AREA THAT
ARE NOT SHOWN IN THE CROSS SECTION
17. FRONT SEAL DRAIN BACK HOLE
18. PRESSURE REGULATOR VENT HOLE

Fig. 7A4-14-Lubrication Chart - 425

~ffi!

7A4-6 TURBO HYDRA-MATIC 400 & 425 DIAGNOSIS

J\k

2. Using a short piece of rubber hose, apply air

pressure to tfie vacuum pipe by blowing into the fube and
looking for bubbles. If bubbles appear, replace the
modulator.

111;

mOTE: Do not use any method other than human lung

power for applying air pressure, as pressures over 6 psi may
damage the modulator .)
Bellows Comparison Check
This check is made using an available tool. BT-6733.
The gage compares the loaduof a known goodmodulator
with a modulator being checked.
1. Install the kodulator that is known to be
acceptable on either end of the gage.
2. Install the modulator in auestion on the owwosite
end of the gage. (Fig. 7A4-16)
3. Holding the modulators in a horizontal position,
bring them together under pressure until either modulator
sleeve end just touches the line in the center of the gage.
The gap between the opposite modulator sleeve end and the
gage line should be 1/16" or less. If the distance is greater
than this amount, the modulator in question should be
replaced.
1

[Iil1
,

(NOTE: When making the comparison, make sure that

both modulators are of the same type. The part numbers
are stamped on the dome of the modulator.)

d ,:

LOWER HOUS ING

PART NO.
STAMPED
HERE

VACUUM CONNECTOR
S EAM

i111

HOUS ING SEAL

Fig. 7A4-15-Modulator Assembly

I

/
-

VACUUM P O R i s o d
BOTH AIOUULATORS
Mus7~pEh

Sleeve Alignment Check

Roll the main body of the modulator on a flat surface
and observe the sleevi for concentricity to the can. If the
sleeve is concentric and the ~lungeris free. the modulator is

/[ (:/ :;
I{,

' 5

above checks, it is an acceptable part a i d ihould be reused.

J
Fig. 7A4-16-Checking Modulator

ij '
i;',

HIGH LINE PRESSURES - NOTE (2)

I1

I/!i
I

I\

ENGINES WITH EGR VALVES

With Exhaust Gas Recirculation (EGR), the throttle is
open enough in "Drive" range 1000 rpm to cause the EGR
valve to open. When the EGR valve opens, exhaust gas
enters the intake manifold which lowers intake manifold
vacuum. When intake manifold vacuum is lowered, the
transmission line oil pressure raises accordingly, and may go
above the upper specification limit. For this reason, if high
line pressuresare obtained, proceed as follows:
1. Disconnect the EGR vacuum line at the EGR valve
and plug the vacuum line.
2. Recheck line pressures as indicated on the
Preliminary Checking Procedure Chart on page 7A4-7.
3. If high
- line pressures are still obtained, continue
below.

ENGINES WITHOUT EGR VALVE OR IF HIGH LINE

PRESSURES WERE OBTAINED WITH THE EGR
VACUUM LINE PLUGGED
If high line pressures are experienced with the EGR line
plugged, it may be that the engine is not producing enough
vacuum to lower transmission line pressure within
specifications. The newer engines with emission controls
characteristically have lower engine vacuum than older past
model engines. To obtain line pressures suitable for
evaluation. it is recommended that vacuum be applied to
the modulator, using an external vacuum source' such as
J-23738 hand operated vacuum device or its equivalent.
The unit allows definite amounts of vacuum t o be applied
to the modulator so that consistent line pressures may be
obtained for evaluation as follows:
1. Disconnect the vacuum hose to the modulator at
the modulator and plug the vacuum hose.
2. Attach the'haid operated vacuum device and apply
20" of vacuum.
3. Recheck line pressures according t o the
Preliminary Checking procedure Chart, on page 7 ~ 4 - 7 .
4. If line pressures are still high, proceed to the
specific diagnosis chart that applies to the malfunction
encountered.
5. If line pressures are normal with external vacuum
applied, check endne vacuum and vacuum systems for
l&ks.
w

'

TURBO HYDRA-MATIC 400 & 425 DIAGNOSIS 7A4-7

TURBO HYDRA-MATIC 350 DIAGNOSIS GUIDE

Dependability of t h i s Diagnosis Guide depends upon:

1. Careful analysis of symptoms so that proper m a l f u n c t i o n o n t h e

charts w i l l be used.
2. Accurate o i l pressure check w i t h a known good gage is made
as indicated o n t h e c h a r t and these readings recorded so that
they can be compared w i t h t h e following diagnosis charts.
3. O i l pressure readings m u s t be made w i t h transmission o i l at
n o r m a l operating temperatures.
4. Refer to detailed diagnosis charts f o r additional diagnosis o n 1-2
a n d 2-3 s h i f t m a l f u n c t i o n diagnosis.
5. Engine m u s t be properly t u n e d to specifications.
DIAGNOSIS
PRELIMINARY

CHECKING PROCEDURES

1. Check transmission oil level.

Check vacuum hoses under hood (connections - cracks - leaks - pinch).
Connect tachometer t o engine.
Install v x u u m pump at modulator - apply 15-20"vacuum and check for leakdown.
Install oil pressure gage.

2.
3.
4.
5.

6. Check oil pressure using the chart on the next page.

CAUTION: Total test running time for these four (4) tests not t o exceed two (2) minutes.

See Caution Above For These Tests

Pressure Drop
Occurs While
Engine RPM
Increases From
1000 t o 3000 RPM
Wheels Free
to Move* *

Drive
Idle

Drive
Brakes
Applied
1000 RPM

Super or Lo
Brakes
Applied
1000 RPM

Reverse
Brakes
Applied
1000 RPM

Drive-Brakes
Applied 1000 RPM
Downshift
Switch Activated*

55-70

60-85

60-90

135-160

95-150

90-110

Drop of
10 PSI or More

55-70

Normal

Normal

Normal

Normal

Normal

Normal

10 PSI Drop
or More

Normal

Neutral
Brakes
Applied
1000 RPM

(1 Drive
30 MPH
Closed
Throttle

Possible Cause
of Malfunction

Normal
Oil Pressure

No 1-2 Upshift
Andlor Delayed
Upshift

Slipping-~everse

Normal

Normal

Normal

Normal

Normal

Normal

Less Than
10 PSI Drop

Normal

Normal

High

High

Normal

Normal

Normal

Drop

High

High

High

High

Normal

High

Normal

Normal

Normal

Normal

Low

Normal

Drop

Normal

Malfunction in
Control Valve Assy.
Malfunction in
Governor or
Governor Feed
System
Malfunction in
Detent System
Malfunction in
Modulator or
Vacuum Feed System
to Modulator
Oil Leak in Feed
System to the
Direct Clutch
J

Slipping-1st Gear
No Detent
Downshifts

Normal
Normal

Low to
Normal

Low to
Normal

Low to
Normal

Normal

Normal

Normal

Normal

Normal

Low t o
Normal
Low

Normal

Low to
Normal
Normal

Oil Leak in Feed

System to the
Forward Clutch
Malfunction in
Detent System

A dash (-1 in space = Pressure reading has no meaning

(1) Coast from 30 mph - read before reaching 20 rnph
(2) If high line pressures are experienced see "High Line Pressure" note.
switch closed by hand
** Downshift
Drive range, vacuum line disconnected from modulator
L

'L

7 A 4 8 TURBO HYDRA-MATIC 400 & 425 DIAGNOSIS

NO 1-2 UPSHIFT AND/OR DELAYED UPSHIFT

1. Record oil pressures as directed i n preliminary checking
procedure.
2. Leave oil pressure gage connected and connect vacuum
gage i n series with vacuum modulator hose g v a c u u m
modulator.
I

CHECK TRANS. OIL LEVEL

1
DISCONNECT ELECT. PLUG
FROM TRANS. AND TEST CAR
I

NO UPSHIFT
I

WITH BRAKES APPLIED

CHECK LINE PRESSURE I N DR. A T 1000 RPM

CHECK AND CORRECT DETENT SWITCH

OR WIRING-CHECK FOR
i

C J
60-90 PSI

SEE CHART C FOR GOVERNOR-CONTROL

VALVE ASSEMBLY CHECK PROCEDURE

90-15.0 PSI

WITH BRAKES APPLIED

CHECK LINE PRESSURE I N NEUT. A T 1000 RPM
1

70-160 PSI

55-70 PSI

DETENT SYS.

CHECK SOLENOID FOR

FUNCTION OR DAMAGE

CHECK FOR VACUUM LEAKS OR

N O VACUUM SEE CHART D

CHECK MODULATOR VALVE

FOR FREENESS

CHECK FEED ORIFICE

"LINE TO DETENT"
I N SPACER PLATE

I
CHECK DETENT VALVE TRAIN

- CHART C

CONTROL VALVE ASSEMBLY-GOVERNOR

PRESSURE CHECK

CHECK CASE FOR DAMAGE

OR POROSITY A T MOD. VALVE

LlNE

1, INSTALL LlNE PRESSURE GAGE

2. DISCONNECT VACUUM L l N E TO MODULATOR.
3. WlTH CAR O N HOIST (REAR WHEELS, OFF GROUND), FOOT OFF
BRAKE, I N DRIVE, CHECK LINE PRESSURE A T 1000 RPM.
4. SLOWLY INCREASE ENGINE RPM TO 3000 RPM AND DETERMINE
I F A PRESSURE DROP OCCURS, (10 PSI OR MORE)
5. I F PRESSURE DROP OF 10 PSI OR MORE OCCURS, DISASSEMBLE,
CLEAN A N D INSPECT CONTROL VALVE ASSEMBLY.
6. IF PRESSURE DROP IS LESS T H A N 10 PSI:
<A. INSPECT GOVERNOR
6. GOVERNOR FEED SYSTEM
1. STUCK VALVE.
1. CHECK SCREEN(S).
2. WEIGHT FREENESS.
2. CHECK FOR RESTRICTIONS
3. RESTRICTED ORIFICE I N
I N GOVERNOR PIPE.
GOVERNOR VALVE.
4. CHECK GOVERNOR.

- CHART D CAUSES OF IMPROPER VACUUM

A T MODULATOR
1. ENGINE
A. TUNE UP
8. LOOSE VACUUM FITTINGS
C. VACUUM OPERATED UNIT LEAK
(HOSES, VACUUM ADVANCE, ETC.)
D. EXHAUST GAS RECIRCULATION
(E.G.R.)
2. VACUUM LlNE TO MODULATOR
A. LEAK
B. LOOSE FITTING
C. RESTRICTED ORIFICE
D. CARBON BUILD UP A T MOD. VAC. FITTING
E. PINCHED LlNE
F. GREASE I N PIPE (NO OR DELAYED UPSHIFTCOLD)

--

TURBO HYDRA-MATIC 400 & 425 DIAGNOSIS 7A4-9

SUB-STANDARD 1-2 SHIFT FEEL

1. Record oil pressures as directed i n preliminary checking
procedure.
2. Leave oil pressure gage connected and connect vacuum
gage i n series with vacuum modulator hose $vacuum
modulator.

1 CHECK TRANS.
+
CHECK ENGINE TUNE

SOFT SHIFT. SLIPS, OR L O N G DRAWN OUT

SHIFT WITH END BUMP

CUECK VACUUM SYSTEM FOR RESPONSE AT

MOWUTOR-VAC. AND LINE PRESSURE SHOULD
VARY AND RESPOND RAPIDLY TO QUICK
CHANGES IN T H R O W OPENINGS

RECHECK SHIFT FEEL

4
WITH BRAKES APPLIED
C H K K LlNE PRESSURE I N DR. AT 1OW RPM

I +-?

NORMAL

NORMAL

AND SOLENOID

CHECK FOR LORRECT

NUMBER AND CORRECT
LOCATION OF CHECK BALLS

s
-

CHECK 1-2 ACCUM.

SYSTEM I N
CONTROL VALVE ASSY.

CHART B

REMOVE CONTROL VALVE ASSEMBLY AND DETENT SOLENOID

CAUSES OT HlGH LlNE PRESSURE

REAR ACCUM FEED RESTRICTED

I N TRANS CASE

CHECK SPACER PLATE FOR

1 V A C W M LEAK
A NU U * K V A C W M LINE M X O N N K T I D
m PARTIAL U A K I N UN FROM NOIN TO MODUUTOR
C I M m W R I N G I N VACUUM
0 V A C W Y m A l O U N I T LEAK (HOSS. V A C W M
ADVANCE WC I
1 DAMbQD MODULATOR
A STUCK VALm w b n a IN r r o w i r r o n
c MOT O r r r r n m m o r n ~ r
3 D n m T SYSTEM
A
s m r c N A n u A n D OR s ~ o l r t o
I DCIH~w l n l r n %O.TH)
C D m N l SOLENOID STUCK O R N
D DCRNT rao or~ncr
IN KACH
n*n uocrn,
DCRNT I O o l D L O O I (
6 DCIHn V U W U W UW D N A G DmM R W V A L W PIN SHOlll
4 N U *
A P R E S M I RG AND/OR WOOST VALVE STUCK
I I N C O I R ~ m m w f i REQ ~ I M G
C T O 0 MANY PRESSUIS R W V A L V I SPACERS
D PUMP CASnNO B 4 D
1 CMKY
v u n rsrtvur
A cwu
v A L n ASSY TO YAQR a s a n ow LOCATION

CHECK 1-2 ACCUM. VALVE SYSTEM

CHECK FRONT ACCUM. PISTON L OIL RINGS

mw

NO. AND TYPE

OF PLATES

CHECK REAR ACCUM. PISTON,

RINGS b CASE BORE

CHECK FOR DAMAGED REAR

m orvnr rmicmD

II
1

- CHART A CAUSE OF COW U N E PRESSURE

I LOW RANSMISIION 011 U V l l

I M O D U U I O R bSS&?MUY
REHR TO CWCKINQ CIOCEWRE

1
I

CHECK CENTER SUPPORT BOLT TORQUE AND

SUPPORT LOOSENESS. AIR CHECK INT. CLUTCH
FOR LEAKAGE AT SEALS OR RINGS

a
EXCESSIVE

4 4
W MNOT
P
NUJOU Y A C H S I N RESSUm I K W U T O I
8 m u s u n REOUUTO~
IIWO,
TOO WEAK
C Q A I C L U R A K L DAM*-.
WORN

I IWIIBNAL C l K U T U A K l
A FORWARD CLUTCH LEAK ( m c s s u a c NORMAL IN NEUTRAL AND REVERYPRESSURE LOW I N D I f V I
1 C M K K W M P RlWOS
a CWK FOIWARD crvtcn l u ~ s
m DIRECT CLUTCH UAK lmrrrut NORMAL IN NCUTRAL, LOW. SWR
AND n n I V t - m E s w a E LOW IN WVIRYI

REMOVE AND INSPECT INT. CLUTCH A N D

CENTER SUPWRT-CHECK CASE TO SUPPORT
FACE. CHECK FOR MISSING ORIFICE CUP PLUG I N
CENTER SUPPORT, EXC. TORONADO.

a
NORMAL

CUECK INT. CLUTCH FOR PROPER TYPE

CLUTCH PLATES AND NUMBER OF RELEASE
SPRINGS OR COCKED RELEASE SPRINGSCHECK INT. CLUTCH PISTON FOR FLATNESS

- CHART A -

- CHART B -

C A U S E O F L O W L I N E PRESSURE

C A U S E O F HIGH L I N E PRESSURE

1 . LOW TRANSMISSION OIL LEVEL.

2. MODULATOR ASSEMBLY
REFER TO CHECKING PROCEDURE.

3. FILTER
A. BLOCKED OR RESTRICTED.
B. "0" RING O N INTAKE PIPE OMITTED OR DAMAGED.
C. SPLIT OR LEAKING INTAKE PIPE.
4. PUMP
A. NOT ENOUGH SPACERS I N PRESSURE REGULATOR.
B. PRESSURE REGULATOR SPRING, TOO WEAK.
C. GEAR CLEARANCE, DAMAGED, WORN.
5. INTERNAL CIRCUIT LEAKS
A. FORWARD CLUTCH LEAK (PRESSURE NORMAL I N NEUTRAL AND REVERSEPRESSURE LOW I N DRIVE).
1. CHECK PUMP RINGS.
2. CHECK FORWARD CLUTCH SEALS.
B. DIRECT CLUTCH LEAK (PRESSURE NORMAL I N NEUTRAL, LOW, SUPER
AND DRIVE-PRESSURE LOW I N REVERSE).

1. VACUUM LEAK
A FULL LEAK-VACUUM LlNE DISCONNECTED.
B. PARTIAL LEAK I N LlNE FROM ENGINE TO MODULATOR.
C. IMPROPER ENGINE VACUUM.
D. VACUUM OPERATED UNIT LEAK. (HOSES, VACUUM
ADVANCE, ETC.)
2. DAMAGED MODULATOR
A. STUCK VALVE.
B. WATER I N MODULATOR.
C. NOT OPERATING PROPERLY.
3. DETENT SYSTEM
A. DETENT SWITCH ACTUATED OR SHORTED.
B. DETENT WIRING SHORTED.
C. DETENT SOLENOID STUCK OPEN.
D. DETENT FEED ORIFICE I N SPACER PLATE BLOCKED.
E. DETENT SOLENOID LOOSE.
F. DETENT VALVE BORE PLUG DAMAGED.
G. DETENT REG. VALVE PIN SHORT.
4. PUMP
A. PRESSURE REG. AND/OR BOOST VALVE STUCK.
8. INCORRECT PRESSURE REG. SPRING.
C. TOO MANY PRESSURE REG. VALVE SPACERS.
D. PUMP CASTING BAD.
5. CONTROL VALVE ASSEMBLY
A. CONTROL VALVE ASSY. TO SPACER GASKET OFF LOCATION.
B. GASKETS SWITCHED.

IMPORTANT: BEFORE CHECKING TRANSMISSION FOR WHAT I S BELIEVED TO BE

"TRANS. NO1 SE", MAKE CERTAIN THE NOISE I S NOT FROM THE WATER PUMP,
ALTERNATOR, A I R CONDITIONER, POWER STEERING, ETC. THESE COMPONENTS
CAN BE ISOLATED BY REMOVING THE PROPER BELT AND RUNNING THE ENGINE
NOT MORE THAN TWO MINUTES AT ONE TIME.

s
c
TRANSMISSION

NOISY

PARK, NEUTRAL & A L L DR I V I N G 8 A N G E S

11

CHECK OUTSIDE MANUAL LINKAGE &CORRECT

1. PARKING BRAKE ROD ASSY. (CHECK ACTUATOR

FOR CHAMFER].
2. PARKING PAWL BROKEN, CHAMFER OMITTED.
3. PARKING BRAKE BRACKET LOOSE, BURR OR ROUGH
EDGES, OR INCORRECTLY INSTALLED.
4. PARKING PAWL RETURN SPRING M I S S I N G , BROKEN
OR INCORRECTLY HOOKED.

I
1

NO

ENGINE BRAKING
RANGE IS7 GEAR

LO

PUMP ASSEMBLY

.*

1'

INTERNAL LINKAGE

PUMP CAVITATION'

0 IL LEVEL LOW
PLUGGED OR RESTRICTED FILTER
WRONG FILTER
INTAKE PIPE "0" R I N G DAMAGED
INTAKE PIPE SPLIT, POROSITY I N CASE INTAKE
P I P E BORE.
WATER I N O I L
POROSITY OR VOIDS AT TRANS. CASE (PUMP FACE]
l NTAKE PORT,
PUMP TO CASE GASKET OFF LOCATION.

GEARS DAMAGED, OR DEFECTIVE

D R I V I N G GEAR ASSEMBLED BACKWARDS.
CRESCENT l NTERFERENCE
B U Z Z I N G NOISE - ORIFICE CUP PLUG I N

CONVERTER
LOOSE BOLTS (CONVERTER TO FLYWHEEL)
CONVERTER DAMAGED.

[PLANETARYGEAR SET
GEARS OR THRUST BEARINGS DAMAGED.
FRONT l NTERNAL GEAR R l NG DAMAGED.
THPOUGHLY CLEAN THRUST BEARINGS AND
RACES. INSPECT NEEDLES FOR ROUGH
SURFACE AND PITTING.

CASE ASSEMBLY
LO-REVERSE CHECK BALL M I SPOS ITIONED OR
MISSING. CASE DAMAGED AT LO - REVERSE
CHECK BALL AREA.
J

I
REAR SERVO
OIL SEAL RING, BORE OR PISTON DAMAGED
REAR BAND APPLY P I N SHORT, IMPROPERLY
ASSEMBLED

TRANSMISSION OR COOLER LINES

GROUNDED TO UNDERBODY. MOTQR
MOUNTS LOOSE OR BROKEN.
J
I

DURING A C C E L E R A T I O ~
ANY GEAR

1.

TORONADO ONLY - DRIVE L I N K ASSEMBLY,

WORN OR DAMAGED, M A Y SOUND LIKE
POPCORN POPPING.

REAR BAND
BROKEN, BURNED (CHECK FOR CAUSE]
NOT ENGAGED ON ANCHOR P I N S AND/OR
SERVO PIN.
SQUEAL AT LOW VEHICLE
SPEEDS

SPEEDOMETER DRIVEN GEAR SHAFT SEAL,

SEAL REQUIRES LUBRICATION OR REPLACEMENT.

O I L RINGS AND/OR BORES LEAKING OR

I
FRONT BAND

BROKEN, BURNED (CHECK FOR CAUSE),

NOT ENGAGED ON ANCHOR P I N AND/OR
SERVO P I N .

THERE I S NO APPROVED WAY OF CHECKING OR CLEANING THE FILTER.

I F THE FILTER I S SUSPECTED OF BEING PLUGGED OR RESTRICTED, I T
MUST BE REPLACED.

NO DETENT DOWNSHIFTS
I

(ENGINE NOT OPERATING)

I

DISCONNECT ELECT. PLUG FROM TRANS.

CONNECT TEST LIGHT TO "DETENT"TERMlNAL
OF DISCONNECTED WlRE HARNESS AND TO GROUND.
I

LOOSE CONNECTION TO DETENT SOLENOID.

SOLENOID BURNED OUT. VALVE STUCK OR
ORIF ICE PLUGGED.

1.

DEPRESS ACCELERATOR FULLY

DETENT SWITCH
MALADJUSTED - REFER TO DETENT SWITCH
ADJUSTMENT PROCEDURES.

2. DEFECTIVE SWITCH, CONNECTIONS, FUSE,

SHORTED WIRE*

CONTROL VALVE ASSY.

CHECK DETENT VALVE TRAIN

SHORTED SOLENOID WlRE CAN CAUSE FUSE

TOBLOW.

WlTH BRAKES APPLIED, CHECK LlNE

PRESSURE IN DRIVE AT 1000 R.P.M.

FORWARD CLUTCH FEED

PASSAGE NOT DRILLED

CHECK CAUSE

CHECK LO ROLLER CLUTCH FOR

DAMAGE OR INSTALLED BACKWARDS.

NO REVERSE OR SLIPS IN REVERSE

w
I

CHECK TRANS. OIL LEVEL

I

CHECK OUTSIDE MANUAL LINKAGE &CORRECT

I
WlTH BRAKES APPLIED, CHECK LlNE PRESSURE
IN REVERSE AT 1000 R.P.M.

CONTROL VALVE ASSEMBLY

1.

2.
3.

2-3VALVE TRAIN STUCK OPEN (THIS

WILL ALSO CAUSE A 1-3 UPSHIFT IN
DRIVE RANGE)
REVERSE FEED PASSAGE -CROSS CHANNEL
LEAK, POROSITY I N CASE OR VALVE BODY
PASSAGE, GASKETS LEAKING.
LO-REV BALL CHECK MISSING OR
MISPOSITIONED; OR CASE AND/OR
SEPARATOR PLATE DAMAGED IN THIS
AREA.

I
FORWARD CLUTCH
CLUTCH DOES NOT RELEASE (WILL ALSO

2.

3.

DRIVE IN,NEUTRAL

LINKAGE AND CORRECT

INTERNAL LINKAGE

REAR SERVO & ACCUMULATOR

1.

DIRECT CLUTCH BURNED

CHECKCAUSE

SERVO PISTON SEAL RING DAMAGED OR MISSING.

SHORT BAND APPLY PIN (THIS MAY ALSO CAUSE
NO OVERRUN BRAKING OR SLIPS IN OVERRUN
BRAKING. LO RANGE)
REFER TO SERVICE MANUAL FOR PIN SELECTION
DEFECTIVE REAR SERVO PISTON OR BORE.

MANUAL VALVE DISCONNECTED OR END

- I
/

BROKEN, BURNED, LOOSE LINING, APPLY

PIN OR ANCHOR PINS NOT ENGAGED.

I
CENTER SUPPORT
OIL SEAL RINGS OR GROOVES DAMAGED
OR WORN

PUMP ASSEMBLY
TRANS. LUBE PRESSURE LEAKING INTO
FORWARD CLUTCH APPLY PASSAGE

FORWARD CLUTCH
BURNED PLATES CHECK CAUSE
INCORRECT CLUTCH PLATE USAGE
SEE CHART IN SERVICE MANUAL

_T1

TURBO HYDRA-MATIC 400 & 425 DJAGNOSIS 7A4-13

,,

CAUSES OF BURNED CLUTCH PLATES

K)RwARD CLUTCH

A CHECK BALL IN CLUTCH HOUSING DAMAGED, STUCK OR MISSING.

CLUTCH PISTON CRACKED. SEALS DAMAGED OR MISSING.
C: LOW LINE PRESSURE. SEE CHART A.
MANUAL VALVE MISPOSITIONED.
E ' RESTRICTED OIL F E E D TO FORWARD CLUTCH (EXAMPLES: CLUTCH HOUSING TO INNER AND OUTER
NOT DRILLED, RESTRICTED OR POROSITY IN PUMP).
F PUMP COVER OIL SEAL RINGS MISSING. BROKEN OR UNDERSIZE; RING GROOVE OVERSIZE.
C: CASE VALVE BODY FACE NOT FLAT OR POROSITY BETWEEN CHANNELS.
H. MANUAL VALVE B E N T AND CENTER LAND NOT GROUND PROPERLY.

ARGA~

?, INTERMEDIATE CLUTCH

A. CONSTANT BLEED ORIFICE IN CENTER SUPPORT MISSING (EXC. TORONADO).

B. REAR ACCUMULATOR PISTON OIL RING, DAMAGED OR MISSING.
C. 1-2 ACCUMULATOR VALVE STUCK IN CONTROL VALVE ASSEMBLY.
D. INTERMEDIATE CLUTCH PISTON SEALS DAMAGED OR MISSING.
E, CENTER SUPPORT BOLT LOOSE.
F. LOW LINE PRESSURE. S E E CHART A.
G. INTERMEDIATE CLUTCH PLUG I N CASE MISSING.
H. CASE VALVE BODY FACE NOT FLAT OR POROSITY BETWEEN CHANNELS.
I. MANUAL VALVE B E N T AND CENTER LAND NOT GROUND PROPERLY.

3. DIRECT CLUTCH
A. RESTRICTED ORIFICE IN VACUUM L I N E T O MODULATOR (POOR VACUUM RESPONSE).
B. CHECK BALL I N DIRECT CLUTCH PISTON DAMAGED, STUCK OR MISSING.
C . DEFECTIVE MODULATOR BELLOWS.
D. CENTER SUPPORT BOLT LOOSE. (BOLT MAY BE T I G H T IN SUPPORT BUT NOT HOLDING SUPPORT
TIGHT TO CASE).
E. CENTER SUPPORT OIL RINGS OR GROOVES DAMAGED OR MISSING.
F. CLUTCH PISTON SEALS DAMAGED OR MISSING.
G. FRONT AND REAR SERVO PISTONS AND SEALS DAMAGED.
H. MANUAL VALVE B E N T AND CENTER LAND NOT CLEANED UP.
I. CASE VALVE BODY FACE NOT FLAT OR POROSITY BETWEEN CHANNELS.
J. INTERMEDIATE SPRAG CLUTCH INSTALLED BACKWARDS.
K. 3-2 VALVE, 3-2 SPRING OR 3-2 SPACER PIN INSTALLED IN WRONG
LOCATION I N 3-2 VALVE BORE.
NOTE: IF DIRECT CLUTCH PLATES A N D FRONT B A N D ARE BURNED, CHECK MANUAL LINKAGE.
NOTE: BURNED CLUTCH PLATES C A N BE CAUSED BY INCORRECT USAGE OF CLUTCH PLATES. ALSO, ANTI-FREEZE IN
TRANSMISSION FLUID C A N CAUSE SEVERE DAMAGE, SUCH AS LARGE PIECES OF COMPOSITION CLUTCH PLATE MATERIAL PEELING OFF.

METRIC THREAD USAGE

THREAD SIZE

IDENTIFICATION

Manual Shaft

MI0 x 1.5-6g

Groove on metric
end of shaft with
drill point in end
of shaft.

TransmisionCase:
Speedometer
Attaching Bolt Hole

M6.3~1-6H

NONE

Case Extension:
Transmission
Mount
Bolt Holes

M10x1.5-6H

Letter"MVInk
Stamped on case
extension.

All other thread sizes on the transmission are U S . Standard. 1

-

Fig. 7A4-18-Metric Chart

TURBO HYDRA-MATIC INFORMATION

400 & 425

FORWARD CLUTCH

DIRECT CLUTCH

INTERMEDIATE CLUTCH
I

Flat Steel
Plates

No. of
Waved
' Steel
Thickness Plates

No. of
Dished
Steel
Plates

No. of
Composition
Plates

No.of
Flat
Steel
Plates

No.of
Waved
Steel
Plates

No. of
Composition
Plates

No.of
Flat
Steel
Plates

No.of
Waved
Steel
Plates

No. of
Composition
Plates

Body Type

Engine

Converter
identification
Number

OB
(400)

98

350 C.I.D. 4 Bbl.

OD*
(400)

98

403 C .l.D. 4 Bbl.

OC**
(400)

98

403 C.I.D. 4 Bbl.

18 Tooth

0775"

0J
(425)

Toronado

403 C.I.D. 4 BbI.

4 & Green
Dot

14Tooth

.0915"

Transmission
Code

Speedometer
Drive Gear

No.

.O77Sn

'I

*
**

Used with 2.41 and 2.56 Axle Ratios

Used with 3.08 and 3.23 Axle Ratios

Fig. 7A4-17-Turbo Hydra-Matic Information Chart 400 & 425

TURBO HYDRA-MATIC 400 7A4-15

TURBO HYDRA-MATIC
400 TRANSMISSION
FOR ADDING AND CHECKING OIL, REFER TO SECTION 7 A 3
INDEX
PAGE
Bushing Service . . . . . . .
Case Porosity Repair . . . . .
. . . . . . .
Center Support
. . . . .
Converter C h e c h g
Description of Operation
. . .
magnosis . . . . . . . . . .
Direct Clutch . . . . . . . .
~ownshift~witchAdjustments
Forward Clutch . . . . . . .
Governor . . . . . . . . . .
~nformationChart . . . . . .

.
.
.
.
.
.
.
.
.
.
.

.
.
.
.
.
.
.
.
.
.
.

.
.
.
.
.
.
.
.
.
.
.

. . . . 7A4-131
. . . . . 7A4-1
. . . . 7A4-52
. . . . 7A4-58
. . . . 7A4-15
. . . . .7A4-1
. . . . 7A4-47
. . . . 7A4-21
. . . . 7A442
. . . . 7A4-34
. . . . 7A4-14

GENERAL DESCRIPTION

The Turbo Hydra-Matic transmission is a fully

automatic unit consisting primarily of a three element
hydraulic torque converter and a compound planetary
gear-set Three multiple-disc clutches, two roller clutches
and two bands provide the friction elements required to
obtain the desired function of the compound planetary

The torque converter couples the engine to the

planetary gears through oil and provides hydraulic torque
multiplication when required. The compound planetary
gear-set produces three forward speeds and reverse.
The three element torque converter consists of a pump
or driving member, a turbine or driven member, and a
stator assembly. The stator is mounted on a one-way roller
clutch which allows the stator t o turn clockwise but not
~~unterclockwise.
The torque converter housing is filled with oil and is
attached to the engine crankshaft by a flex plate. The
converter pump is an integral part of the converter housing.
The pump blades, rotating at engine speed, set the oil
within the converter into motion and direct it to the
turbine, causing the turbine to rotate.
As the oil passes through the turbine it is traveling in
such a direction that if it were not redirected by the stator
It would hit the rear of the converter pump blades and
Impede its pumping action. At low turbine speeds, the oil is
redirected by the stator to the converter pump in such a
manner that it actually assists the converter pump t o deliver
power, or multiply engine torque.
As turbine speed increases, the direction of the oil
leaving the turbine changes and flows against the rear side
of the stator vanes in a clockwise direction. Since the stator
now impeding the smooth flow of oil, the roller clutch
and the stator revolves freely on its shaft. Once the
becomes inactive, there is no further multiplication
Of engine torque within the converter. At this point, the
converter is merely acting as a fluid coupling, as both the
converter pump and turbine are being driven at
approximately the same speed - or at a one-toane ratio.

SUBJECT

PAGE

Linkage Adjustments . . .
Oil Pump . . . . . . . .
Pinion Gears
. . . . . .
Speedometer Drive Gear
.
Tools
. . . . . . . . .
Torque Converter Diagnosis
Torque Specifications
. .
Transmission Disassembly .
Transmission Reassembly .
Transmission Removal And
Installation
. . . . . .
Valve Body . . . . . . .

.
.
.
.
.
.
.
.
.

.
.
.
.
.
.
.
.
.

.
.
.
.
.
.
.
.
.

. . . . . . 7A4-20
. . . . . . 7A4-39
. . . . . . 7A4-55
. . . . . . 7A4-56
. . . . . .7A4-136
. . . . . . . 7A1-4
. . . . . .7A4-130
. . . . . . 7A4-22
. . . . . . 7A4-62

. . . . . . . . .
. . . . . . . . .

7A4-17
7A4 -37

A gear-type pump provides the worlung pressure

required to operate the friction elements and automatic
controls.
External control connections to transmission are :
Manual Linkage
Engine Vacuum
12-Volt Electrical
Signal

To select the desired operating

range.
- To Operate a vacuum modulator
unit.
- To Operate an electrical detent
solenoid.

Approximate gear or torque ratios of the transmisison

are as follows:
First

- 2 5 gear ratio X 2.0 converter stall

ratio
Second - 1.5: 1 gear ratio
- 1.O:l
Third
Reverse - 2 .O: 1 gear ratio X 2.0 converter stall
ratio

5.0: 1

(NOTE: Converter stall ratio 2.0.)

Second and third are also multiplied.

A vacuum modulator is used to automatically sense any

change in the torque input to the transmission. The vacuum
modulator transmits this signal to the pressure regulator for
line pressure control, to the 1-2 accumulator valve, and t o
the shift valves so that all torque requirements and shift
speed requirements of the transmission are met and smooth
shifts are obtained at all throttle openings.
The det ent solenoid is activated by an electric switch in
the throttle linkage. When the throttle is fully opened, the
switch located above the accelerator pedal is closed,
energizing the detent solenoid and causing the transmission
to downshift at speeds below approximately 7 0 mph.

TURBO HYDRA-MATIC 400 7A4-17

Fig. 7A4-20-Turbo Hydra-Matic 400 Oil Circuit

OPERATIONS NOT REQUIRING REMOVAL OF

TRANSMISSION
Some of the parts and/or units can be removed from
the transmission without removing the transmission
assembly from the car. The procedures for such operations
are not specifically outlined; however, the basic procedure
and specifications as outlined under DISASSEMBLY OF
THE TRANSMISSION and ASSEMBLY OF THE
TRANSMISSION will apply.

Governor Feed Screen.

Pressure Switch Assembly
Check Balls
Front Servo

UNITS OR PARTS THAT CAN BE READILY REMOVED

FROM THE TRANSMISSION ARE:

(NOTE: Mark flywheel and converter so they can be

installed in the same position.)

Oil Cooler Lines

Speedometer Driven Gear
Speedometer Drive Gear

TRANSMISSION REMOVAL
1 . Remove flywheel cover.
2. Remove torque converter attaching bolts.

3. Install Engine Support Bar. (Fig. 7A4-2 1)

4. Disconnect electrical plug, speedometer cable and
manual shift linkage at side of transmission,
5. Remove oil filler tube.
6. Disconnect oil cooler lines, vacuum modulator line
and filler pipe.
7. Disconnect parking brake cable.
8. Remove propeller shaft assembly.
(NOTE: Scribe marks on drive shaft and companion flange
for correct assembly.)

9. Remove catalytic converter support bracket.

10. Position transmission jack under transmission.
11. Remove crossrnember.
12. Remove transmission t o block attaching bolts.
13. Move transmission away from engine and install
Tool 5-2 1654 t o hold converter in place. (Fig. 7A4-262).
14. Lower transmission and remove from car.

AND BT-6424-2. USE APPROPRIATE

S IZE WOODEN BLOCK BETWEEN

Fig. 7A4-21 -Engine Support Bar

TRANSMISSION INSTALLATION
To install, reverse the removal procedure and include
the following:
Before installing the flex plate t o converter bolts, make
certain that the weld nuts on the converter are flush with
the flex plate and the converter rotates freely by hand in
this position. Hand start the three bolts and tighten finger
tight, then torque to specifications. This will insure proper
converter alignment. Install new oil seal on oil filler tube
before installing tube.
Connect propeller shaft to companion flange. Torque
bolts to 20 ft . lbs.
CAUTION: The propeller shaft to
companion flange fastener is an
important attaching part in that it
could affect the performance of
vital parts and systems, and/or
could result in major repair
expense. I t must be replaced with
one of the same part number or
w i t h an equivalent part if
replacement becomes necessary. DO
not use a replacement part of lesser
quality or substitute design. Torque
values must be used as specified
during reassembly to assure proper
reten tion of this part.
CHECKING AND ADDING FLUID
Refer to Section 7A3. If work has been performed on
the transmission, add the following quantity of fluid then
check fluid as outlined in Checking and Adding Fluid,
Section 7A3.
TURBO HYDRA-MATIC (400)
Pan Removal
.. ... ..
. . . . .
Converter Change
Overhaul . , . , . . . . .

. . . . . . . - 3 Quarts
. . . . . . . . 6 Quarts
. . . . . . . 10 Quarts

A point to remember when adding fluid to the

transmission is that the quantity of fluid alone is not
important. The important factor is the relation of the fluid
level to the "FULL HOT" mark, dependent on
temperature, on the dip stick.
The end result of the checking and adding procedure is
to assure that the fluid level is at the "FULL HOT" mark
when the transmission is at operating temperature.
After installing the transmission and before operating
the car, check the operation of the neutral-start switch. The
engine should start in neutral and park position only. If
necessary to adjust, refer to Section 3B4.

MINOR SERVICE OPERATIONS

SERVICING THE OIL COOLER

The oil cooler is located in the side tank of the radiator
and its purpose is to cool the oil in the event excessive
t emperatwe tends to develop. (Fig. 7A4-23) The oil cooler
is a sealed container providing a passage for oil to flow from
the inlet to the outlet.
In a major transmission failure, where articles of metal
have been carried with the oil throughout the units of the
transmission, it will be necessary to flush out the oil cooler
and connecting lines. To flush the oil cooler and lines, use
the following procedure:
1.Disconnect b o t h cooler lines from the
transmission. (Fig. 7A4-23)
2. Place a hose over the end of the cooler inlet line
(from the top of the cooler) and insert the hose into an
empty container.
3. Flush clean oleurn solvent or equivalent throu@
the return line (from the bottom of the cooler) using an
suction gun until clean solvent comes out of the hose- Tm
will '%back flush" the cooler.
4. Remove the hose from the inlet cooler b e and
place it on the return line.
5. Flush clean oleurn solvent or equivalent thro!@'
the inlet line until clean solvent comes out the return lae'

7A4-20 TURBO HYDRA-MATIC 400

Fig. 7A4-24-Modulator And Filler Pipe

Remove remaining solvent from cooler with compressed air
applied to the return line and flush with transmission fluid.
6. Reconnect oil cooler lines and torque nuts to 12 ft.
SHIFT INDICATOR NEEDLE ADJUSTMENT
(Refer to Section 3B4)

SHIFT ROD ADJUSTMENT

The shift rod adjustment provides proper clearance
between the "D" detent in the transmission and the stop
for the manual shift lever in the upper steering column mast
jacket. The adjustment is made as outlined in Fig. 7A4-25.

GENERAL SERVICE PRECAUTIONS

(NOTE: Do not change or exchange the converter unless

the converter or pump should fail.)
When servicing the transmission, it is recommended
that upon disassembly of a unit, all parts should be cleaned
and inspected as outlined under CLEANING AND
INSPECTION. The unit should be reassembled before
disassembly of other units to avoid confusion and
interchanging of parts.
1. Before disassembly of the unit, thoroughly clean
the exterior.

2. Disassembly and reassembly of the unit and the

subassemblies must be made on a clean work bench. As in
repairing any hydraulically operated unit, cleaniness is of
the utmost importance; therefore, the bench, tools, and
parts must be kept clean at all times.
3. Before installing cap screws into aluminum parts,
ALWAYS DIP SCREWS INTO TRANSMISSION OIL to
prevent cap screws from galling the alumirlum threads and
also to prevent the screws from seizing.
4. Always use a torque wrench when installing cap
screws into aluminum parts t o prevent the possibility of
stripping the threads.
5. If tapped threads in aluminum parts are stripped or
damaged, the part can be made serviceable by the use of
Heli-Coils or equivalent.
6. Seal protecting tools must be used when
assembling the units to prevent damage to the seals. The
slightest flaw in the sealing surface of the seal can cause an
7. The aluminum castings and the valve parts are very
susceptible to nicks, burrs, etc., and care should be
exercised when handling them.
8. The internal snap rings should be expanded and the
external snap rings compressed if they are to be reused*
This will insure proper seating when installed.
9. Replace all "0" rings, gaskets and oil seals that are
r emoved.
10. During assembly of each unit, all internal pads
must be lubricated with transmission oil.
PARTS CLEANING AND INSPECTION
After complete disassembly of a unit, all metal pa*S
should be washed in a clean solvent and dried with

TURBO HYDRA-MATIC 400 7A4-21

air. All oil passages should be blown out and

t o make sure that they are not obstructed. Small
should be checked with tag wire. All parts should
be inspected to determine which parts are t o be replaced.
~ h tvarious
:
inspections of parts are as follows:
1. Inspect linkage and pivot points for excessive wear.

2. Bearing and thrust surfaces of all parts should be

checked for excessive wear and scoring.
3. Check for broken seal rings, damaged ring lands
and damaged threads.
4. Inspect seals and "0" rings.
5. Mating surfaces of castings and end plates should

r
+-

SPRING

SHIFT ROD ADJUSTMENT

1. WITH SHIFT ROD CLAMP SCREW LOOSENED,
SET TRANSllllSS ION OUTER LEVER IN NEUTRAL
POSITION.
2. HOLD UPPER SHIFT LEVER AGAINST NEUTRAL
POSITION STOP I N UPPER SEERING COLUMN.
(DO NOT RAISE LEVER)

3. TIGHTER SCREW I N CLAMPON LOWER END OF

SHIFTROD TO SPECIFIED TORQUE.

LEVER (COL.

4. CHECK OPERATION.

A. W I T H KEY IN "RUN" POSITION AND

TRANSMI SS ION I N "REVERSE" BE SURE
THAT KEY CAWJOT BE REMOVED AND THAT
STEERINGWHEEL IS NOT LOCKED.

B, WITH KEY IN "LOCK" POSITION AND

SHIFT LEVER I N "PARK" BE SURE THAT
KEY CAN BE REMOVED THAT STEERING
WHEEL f S LOCKED AND THAT THE TRANS M I S S I O N REMAINS I N PARK WHEN THE
STEERING COlUPrlN I S COCKED.

ASSEI\IIBk..Y

C. W ITH BRAKES FIRMLY APPLIED. CHECK

TO MAKE SURE THAT THE STARTER W Ill
NOT WORK I N ANY SHIFT LEVER POSITION
EXCEPT NEUTRAL AND PARK.

Fig. 7A4-25-Shift Rod Adjustment

7

DOWNSHIFT SWITCH ADJUSTMENT

1. PUSH PLUNGER OF DOWNSHIFT SWITCH

2. PUSH ACCELERATOR PEDAL TO W IDE

OPEN THROTTLE POS ITION TO SET

CONNECTOR
-

Fig. 7A4-26-Downshift Switch Adjustment

7A4-22 TURBO HYDRA-MATIC 400

be checked for burrs and irregularities.If a good seal is not

apparent, burrs and irregularities may be removed by
lapping the surface with crocus cloth. The crocus cloth
should be held on a flat surface, such as a piece of plate
glass.
6. Castings should be checked for cracks and sand
holes.
7. Gear teeth should be checked for chipping, scoring,
and excessive wear.
8. Valves should be free of burrs and the shoulders of
the valves must be square. Any burrs or irregularities may
be removed by honing. Valves should be free to slide in
their respective bores.
9. Inspect composition faced clutch plates for
damaged surfaces and loose facings. If flakes of facing
material can be removed with the thumbnail, the plates
should be replaced; however, composition plate
discoloration is not an indication of failure.
10. Inspect steel clutch plates for scored surfaces.
11. Inspect springs for distortion or collapsed coils.
Slight wear (bright spots) on the sides of the springs is
permissible.
12. When inspecting bushings, fit the mating part into
the bushing and observe the amount of looseness. Bushing
clearance is excessive if more than .008" exists when
checked with a wire feeler gauge.
13. If the transmission shows evidence that foreign
material has circulated throughout the transmission or if
the oil filter is dirty, the oil filter should be discarded and a
new one installed upon assembly of the transmission.
14. Check lubrication holes in turbine shaft to be sure
they are open.

Fig, 7A4-27 -Transmission In Holding Fixture

TRANSMISSION DISASSEMBLY
CONVERTER AND MODULATOR
Removal
1. With transmission in cradle on portable jack,
remove the converter assembly by pulling straight out.

(NOTE: The converter contains a large amount of oil,)

Fig . 7 A4-28 -Removing Modulator Retaining Bolt

2. Install Holding Fixture 58763-01 on the

transmission so that the modulator assembly will be located
on the side of the holding fixture that is nearest the bench.
(NOTE: Do not over torque fixture holding screw.)
3. Install Fixture and transmission into Holding Tool
Base 5-3289-20 with bottom pan facing up. (Fig. 7A4-27).
4. Remove modulator assembly attaching bolt and
retainer. (Fig. 7A4-28)
5. Remove modulator assembly and "0" ring seal
from case. Discard "0" ring. (Fig. 7A4-29)
6. Remove modulator valve from transmission case.
7. Remove attaching screw, retainer and speedometer
driven gear and sleeve.
GOVERNOR, PAN, FILTER AND INTAKE PIPE
Removal
1. Remove attaching bolts, governor cover and gasket.
(Fig. 7A4-30) Discard gasket.
2. Remove governor assembly from case. (Fig.
7 A4-3 1)
3. Remove bottom pan attaching bolts.
4. Remove pan and gasket, discard gasket.

1
Fig. 7A4-29-Removing Modulator And Valve

5 . Remove filter retainer bolt. (Fig. 7A4-32)

6. Remove intake pipe and filter assembly. (Fig.
7~4-33)
7. Remove intake pipe from filter assembly and
discard filter.
8. Remove the intake pipe to case "0" ring seal from
the intake pipe and discard.

CONTROL VALVE ASSEMBLY, GOVERNOR PIPES,

GOVERNOR SCREEN ASSEMBLY AND DETENT
SPRING ASSEMBLY
Removal
1. Remove the control valve assembly attaching bolts
and detent roller spring assembly. (Fig. 7A4-34)
(NOTE: Do not remove solenoid attaching screws. If
transmission is in the car, the front servo parts may drop
out as the control valve assembly is removed.)

2 . Remove the control valve assembly and governor

pipes. (Fig. 7A4-35)
(NOTE: Do not allow manual valve t o fall out of control
valve assembly .)
3. Remove governor screen assembly from governor
feed pipe hole in the case or from end of governor fezd

Fig. 7A4-30-Removing Governor Cover

Fig. 7A4-33-Removing Filter Assembly

Fig. 7A4-31 -Removing Governor

Fig. 7A4-32-Removing Filter Retaining Bolt

DETENT ROLLER AND

SPRING ASSEMBLY

Fig. 7A4-34 -Removing Detent Roller And Spring Assembly

GOVERNOR SCREEN

GOVERNOR FEED

-7

TURBO HYDRA-MATIC 400 7A4-25

2. Remove the rear servo assembly from the case.

(Fig. 7A4-41)
3. Remove rear servo accumulator spring. (Fig.
7~4-42)
4. Make band apply pin selection check. (Fig.

bind.
b. Apply 25 ft . lbs. torque and select proper pin to be
used during assembly of transmission.
There are three selective pins identified as shown in the
following chart. (Fig. 7A4-44)

Band Apply Pin Selection

a. Attach the band apply pin selection Gauge

The identification ring is located on the band lug end

of the pin. Selecting the proper pin is the equivalent of
adjusting the band.

J-21370-6, t o the transmission case with attaching bolts,

checking to make certain Gauge Pin 5-21370-5 does not

(NOTE: If the transmission is in the car, be careful when

the detent solenoid is removed t o prevent the spacer plate,
gasket and check balls from dropping down.)
5. Remove the detent solenoid attaching screws,
solenoid assembly and gasket. (Fig. 7 A4-45)
6. Withdraw electrical connector and "0" ring seal
case. (Fig. 7A4-46)

(NOTE: Use an 11/16" box wrench to compress the

connector tangs.)
1

PINIDENT.

SIZE

TO P STEP
O P ABOVE

THREE R INGS

LONG

T H I S AREA

TWO R I N G S

MED.

LOWER
STEP OR
BELOW

ONE R I N G

SHORT

STEP LOCATION

Fig. 7A4-41 -Removing Rear Servo From Case

GJ-21370-5

Fig. 7A4-44-Pin Selection Chart

Fig. 7 A4-42-Removing Rear Accumulator Spring

Fig. 7A4-45 -Removing Detent Solenoid Gasket

Fig. 7A4-43-Checking Rear Band Apply Pin

Fig . 7 A4-46-Removing Electrical Connector

--

7 A4-26 TURBO HYDRA-MATIC 400

7. Remove the control valve assembly spacer plate

and gaskets. (Fig. 7A4-47)
8. Remove six check balls from cored passages in
transmission case. (Fig. 7A448)
9. Remove the front servo piston, retainer ring, pin,

Fig. 7A4-47 -Removing Spacer Plate And Gasket

retainer and spring from transmission case. (Figs. 7A4.49

and 7A4-50)

REAR OIL SEAL AND EXTENSION HOUSING

Removal
1. If necessary to replace, pry the rear oil seal from
the extension housing. (Fig. 7A4-5 1)
2. Remove the extension housing t o case a t t a c h g
bolts and studs.
3. Remove the extension housing and extension
housing to case gacket . (Fig. 7A4-52)
4. Make front unit end play check as follows: (Fig.
7A4-5 3)
a, Remove one front pump attaching bolt, and
bolt seal.
b . Install a Slide Hammer Bolt into bolt hole in
Pumpc. Mount a dial indicator on the rod and index
indicator to register with end of turbine shaft.
d. Push on turbine shaft rearward.
e. Push output shaft forward.
f. Set dial indicator t o zero.
g. Pullturbine shaft forward.
Read the resulting travel or end play which should be
-003" t o .024".
The selective washer controlling this end play is the
washer located between the pump cover and the forward
clutch housing. If more or less washer thickness is required

Fig. 7A4-48 -Check Ball Location

Fig. 7A4-50-Removing Front Servo Spring And Retainer

Fig. 7 A4-49 -Removing Front Servo

Fig. 7 A4-5 1-Removing Rear Oil Seal

TURBO HYDRA-MATIC 400 7A4-27

2. Remove the pump attaching bolts. Install bolts

with Slide Hammers 5-6125, into threaded bolt holes in
pump body and remove pump assembly and gasket. Discard
gasket. (Fig. 7A4-55)
3. Remove and discard pump t o case seal "0" ring.
4. Remove forward clutch assembly and turbine shaft
from transmission. (Fig. 7A4-56)
5. Remove forward clutch hub to direct clutch
housing thrust washer, if it did not come out with forward
clutch housing assembly.
6. Remove the direct clutch assembly. (Fig. 7A4-57)
7. If necessary, remove manual linkage as follows:
a. Unthread the jam nut holding detent lever to
manual shaft. (Fig. 7A4-5 8)
b. Remove manual shaft retaining pin frorn case.
(Fig. 7A4-59)

Fig. 7A4-52-Extension Housing And Gasket

Fig. 7A4-54-Removing Front Seal

1

Fig. 7A4-53-Checking Front Unit End Play

to bring end play within specifications, select the proper
washer from the chart below:

Thickness

Colors

No.

.060" to
.071" to
.082" to
.093" to
.104" to
.115" to
.126" to

Yellow
Blue
Red
Brown
Green
Black
Purple

0
1
2
3
4

.064"
.075"
.086"
.097"
.108"
.119"
.130r1

(NOTE: An oil soaked washer may tend t o discolor so that

it will be necessary t o measure the washer for its actual
thickness.)
OIL PUMP
Removal
1. If necessary to replace, pry front seal from pump.
(Fig. 7A4-54)

Fig. 7A4-55 -Removing Pump

11!'

7A4-28 TURBO HYDRA-MATIC 400

c. Remove jam nut and the detent lever from the

manual shaft. (Fig.
. - 7 A4-60)

(NOTE: Do not lose the jam nut as it becomes free from

the manual shaft.)
d. Remove manual shaft from case.
e. Remove attaching bolts and parking bracket.
(Fig. 7A4-61)

Fig. 7A4-59 -Removing Retaining Pin

Fig. 7A4-56-Removing Forward Clutch Assembly

Fig. 7A4-60-Removing Detent Lever

Fig. 7A4-57 -Removing Direct Clutch Assembly
i

SHAFT

Fig. 7A4-58 -Removing Manual Shaft Nut

Fig. 7 A461 -Removing Parking Bracket

TURBO HYDRA-MATIC 400 7A4-29

f.

Remove parking pawl return spring. (Fig.

.,,

(NOTE: The following steps are t o be completed only if

or more of the parts involved require replacement .)
RETURN SPRlN

Remove parking pawl shaft retainer. (Fig.

7 ~c63)
h. Remove parking pawl shaft cup plug by
inserting a screwdriver between the parking paw1 shaft
and the case rib, and prying outwards. (Fig. 7A4-64)
i. Remove parking pawl shaft and parking pawl.
(Fig. 7A4-65)
8. Remove the front band assembly. (Fig. 7194-66)

Fig. 7 A4-62 -Removing Parking Pawl Return Spring

Fig. 7 A4-65 -Removing Parking Pawl

Fig. 7A4-63 -Removing Parking Pawl Retainer

Fig. 7A4-64-Removing Cup Plug

Fig. 7A4-66-Removing Front Band

7A4-30 TURBO HYDRA-MATIC 400

9. Remove the sun gear shaft. (Fig. 7A4-67)

10. Check rear end play as follows: (Fig. 7A4-68)

a. Install 5-21661 into an extension housing

attaching bolt hole.
b. Mount the Dial Indicator, 5-8001, on the rod
and index with the end of the output shaft.
c. Move the output shaft in and out to read the
end play. End play should be from -007" to .019". The
selective washer controlling this end play is the steel
washer having three lugs that is located between the
thrust washer and the rear face of the transmission
case.
If a different washer thickness is required t o bring
the end play w i t h specification, it can be selected from
the following chart.

Thickness

.074" to
.082" to
.090" to
.098" to
.106" t o
.114" to

.078"
.086"
.094"
.102"
.110"
.118"

Notches and/or Numeral

None . . . . . . . . . . .
1 Tab Side . . . . . . . . .
2 Tabs Side . . . . . . . . .
1 Tab O.D. . . . . . . . . .
2 Tabs O D . . . . . . . . .
3 Tabs O.D. . . . . . . . .

.1
.2
.3
.4
.5
.6

11. Remove the center support t o case bolt with a

318" 12 point thin-wall deep socket. (Fig. 7A4-69)
12. Remove the intermediate clutch backing plate to
case snap ring. (Fig. 7A4-70)

Fig. 7A4-69-Removing Center Support Bolt

Fig. 7A4-67 -Removing Sun Gear Shaft

Fig. 7A4-70-Removing Snap Ring

TURBO HYDRA-MATIC 400 7A4-31

13. Remove the intermediate clutch backing plate and

steel clutch plates. (Figs. 7A4-71 and 7A4-17)

14. Remove the center support t o case retaining snap

ring. (Fig. 7A4-72)

15. Remove the entire gear unit assembly b y lifting

with Gear Assembly Installing and Removing Tool 5-2 1795
and 5-6125 Slide Hammer. (Fig. 7A4-73)
16. Remove the output shaft to case metallic thrust
washer from the rear of the o u t ~ u shaft
t
or inside the case.
(Fig. 7 ~ 4 - 7 4 )
17. Place the gear unit assembly with output shaft
facing down in hole in work bench or Holding Fixture
J-6116. (Fig. 7A4-75)
I

Fig. 7A4-7 1 -Removing Clutch Plates

THRUST 'WASHER
(METAL)

Fig. 7A4-74-Removing Thrust Washer

Fig. 7 A4-72 -Removing Center Support Snap Ring

HAMMER 1-6125

BOLTS J-21661l S PEEDOMETER DR l V E

GEAR REMOVER BOLTS)

Fig. 7A4-73-Removing Gear Assembly

Fig. 7A4-75 -Positioning Unit In Holding Fixture

7A4-32 TURBO HYDRA-MATIC 400

18. Remove the rear unit selective washer from the

transmission case. (Fig. 7A4-76)
19. Remove support to case spacer. (Fig. 7A4-77)
20. Remove the rear band assembly. (Fig. 7A4-78)

DISASSEMBLY AND ASSEMBLY OF INDIVIDUAL UNITS

GEAR UMT

2. Remove the center support t o reaction carrier

(NOTE: One of the races may have been removed with the
center support.)
4. Remove the reaction carrier and roller clutch
assembly. (Fig. 7A4-82)
5. Remove front internal gear ring from output
carrier assembly. (Fig. 7A4-83)
6. Remove sun gear. (Fig. 7A-84)
7. Remove reaction carrier to output carrier thrust
washer. (Fig. 7A4-85)
8. Turn assembly over.
9. Remove "0" ring from output shaft on Models
that use an "0" ring.
10. Remove output shaft to output carrier snap ring
and remove output shaft. (Fig. 7A4-86)

Fig. 7 A4-79 -Removing Center Support

Fig. 7A4-77 -Removing Spacer

ORIFICE PLUG

Fig. 7A4-78-Removing Rear Band

Fig. 7A4-80-Removing Thrust Washer

TURBO HYDRA-MATIC400 7A4-33

llllllilil-

MAIN SHAF

ANGED
RACE
THRUST BEARINGS
I.D. FL.ANGED

/ RACE

Fig. 7A4-84-Removing Sun Gear

Fig. 7A4-81-Removing Sun Gear Races and Bearing

ROLLER CLUTCH

PLASTIC GEAR

Fig. 7A4-85 -Removing Thrust Washer

Fig. 7A4-82-Removing Readion Carrier And Roller Clutch

F ig .7A4-83-Removing Gear Ring

Fig. 7A4-86-Removing Snap Ring

7A4-34 TURBO HYDRA-MATIC 400

11. Remove output shaft to rear internal gear thrust

bearing and two races. (Fig. 7A4-87)
12. Remove the rear internal gear and mainshaft. (Fig.

(NOTE: Do not drop bearings.)

13. Remove the rear internal gear to sun gear thrust
bearing and two races. (Fig. 7144-89)
14. If necessary, remove the rear internal gear t o
mainshaft snap ring, to remove the mainshaft.
. FLANGED RA

GOVERNOR ASSEMBLY
All parts of the governor assembly, with the except ion
of the driven gear, are a select fit and each assembly is
calibrated. The governor, including the driven gear, is

Fig, 7A4-89-Removing Thrust Bearing

serviced as a complete assembly. However, the driven gear
can also be serviced separately.
It is necessary to disassemble the governor assembly in
order to replace the driven gear. Disassembly may also be

remove pins, governor thrust cap, governor weights, and

springs. Governor weights are interchangeable from side to
side and need not be identified. (Fig. 7A4-90)
2. Remove governor valve from governor sleeve. Be
careful not t o damage valve.
3. Perform the following inspections and replace
governor driven gear, if necessary.

Fig. 7A4-87 -Removing Thrust Bearing

Fig. 7A4-90 -Removing Governor Weight Pins

5. Check governor valve for free operation in bore of

7. Check governor driven gear for looseness on

Fig. 7A4-88-Removing Rear Internal Gear And Mainshaft

retainers.

TURBO HYDRA-MATIC 400 7A4-35

10. Check valve opening at entry (,020" minimum)

with a feeler gauge, holding governor as shown with
weights extended completely outward. (Fig.
7 ~ 4 -19)
11. Check valve opening at exhaust (.020" minimum)
with a feeler gauge, holding governor as shown with
governor weights completely inward. (Fig. 7A4-92)

retainer split pin. Replacement of gear must be performed

with care in the following manner:
1. Drive out governor gear retaining split pin using
small punch or 118" drill rod,
2. Support governor on 7/64" plates installed in
exhaust slots of governor sleeve, place in press, and with a
long punch, press gear out of sleeve.
3. Carefully clean governor sleeve of chps that
remain from original gear installation.
4. Support governor on 7/64" plates, installed in
exhaust slots of sleeve, position new gear in sleeve and, with
a suitable socket, press gear into sleeve until nearly seated.
Carefully remove any chips that may have shaved off gear
hub and press gear in until it bottoms on shoulder. (Fig.
7 A4-93)
5. A new pin hole must be drilled through sleeve and
gear. Locate hole position 90' from existing hole, center
punch, and then while supporting governor in press, drill
new hole through sleeve and gear using a standard 118"
drill. (Fig. 7A4-94)
6. Install retaining pin, making sure each end is
slightly below top of hole.
7. Stake both ends of pin hole, two places.
8. Wash governor assembly thoroughly to remove any
chips that may have collected.

(NOTE: Sleeve must be tight in carrier.)

Governor Driven Gear Replacement
To facilitate governor repair in the field, governor
driven gear and replacement pins are available for service
use. The service package contains a nylon driven gear, two
governor weight retaining pins and one governor gear

Fig. 7A4-91 -Check Valve Opening (Entry)

Fig. 7 A4-93 -Installing Driven Gear

Fig. 7A4-92-Check Valve Opening (Exhaust)

Fig. 7A4-94-Drilling Hole In Driven Gear

-7A4-36 TURBO HYDRA-MATIC 400

Assembly (Fig. 7A4-95)

1. Install governor valve in bore of governor sleeve.
2. Install governor weights and springs, and thrust cap
on governor sleeve.
3. Align pin holes in thrust cap, governor weight
assemblies and governor sleeve, and install new pins. Crimp
both ends of pin to prevent them from falling out.
4 . Check governor weight assemblies for free
operation on pins and governor valve for free operation in
governor sleeve.
-

SLEEVE AND CARRIER ASSEMBLY

--

---

GEAR RETAINING PIN

4. Remove washer, spring, and I

(NOTE: Do not remove the teflon
require replacement. If small ring req
service aluminum ring. If large ring
use only the teflon oil ring.)
Inspection
1. Inspect freedom of accumulator rings in piston and
their respective bores.
2. Inspect fit of band apply pin in servo piston and
case bore.

SPRINGS ( 2 )

SECONDARY WEIGHT 121

THRUST CAP

PRIMA?.' WEIGHT ( 2 ,

Fig. 7A4-95-Governor Assembly

FRONT SERVO (Fig. 7A4-96)

ACCUMULATOR PISTON

Inspection
(NOTE: Do not remove the teflon oil seal ring from the
front servo piston unless the oil seal ring requires
replacement. For Service, the oil seal ring will be
aluminum .)

Fig. 7A4-97-Removing Accumulator Piston

1. Inspect servo pin for damage.

2. Inspect piston and oil ring for damage.
3. Check fit of servo pin in pist on and case bore.

TEFLON OIL SEAL RING

I
Fig. 7A4-98-Removing "E" Ring
RETAINING
E RING
SERVO F'!SlON

Fig. 7A4-96-Front Servo

REAR SERVO ASSEMBLY

Disassembly
1. Remove the rear accumulator piston from rear
servo piston. (Fig. 7A4-97)
2. Remove "E" ring retaining rear servo piston to
band apply servo pin. (Fig. 7A4-98)
3. Remove rear servo piston and seal from band apply
pin. (Fig. 7A4-99)

L '

SERVO PIN

Fig. 7A4-99-Rear Servo And Accumulator Assembly

3, inspect band apply pin for s o r e s or cracks.

4. rnspect servo piston for cracks or porosity.

C ~ ~ ~ RVALVE
O L ASSEMBLY (Fig. 7A4-101)
VOTE: As each valve train is removed, place the
valve train in a separate location relative to its
psition in the valve body. Also, place each part of each
valve
train in the order that it is removed from the valve
bore. None of the valves or springs are interchangeable.
Keep them in the proper valve train .)

3. Remove the accumulator piston retaining ring as

Fig. 7A4-100-Removing Front Accumulator

2 3 4

dewl

& e x

17

23

MODELS BB, O D & O C

-

24

20

19

25

26 27

- - -- -

MODEL 0 6

1 MANUAL VALVE
2 RETAINING PIN

18

BORE PLUG
4 DETENT VALVE
5 . DETENT REGULATOR VALVE
6 SPACER PIN
7 DETENT REGULATOR SPRlNG
8 1-2 SHIFT VALVE
9 1-2 DETENT VALVE
10 1-2 REGULATOR SPRING

11

1-2 REGULATOR VALVE

12
13
14

1-2 MODULATOR BUSHING

RETAINING PIN
GROOVED RETAINING PIN

15 BORE PLUG
16 1-2 ACCUMULATOR VALVE
17 2 3 SHIFT VALVE
18 3-2 INTERMEDIATE SPRlNG
19 2-3 MODULATOR VALVE
20 2-3 VALVE SPRING

Fig. 7A4-101 -Valve Body Assembly

21
22

2 - 3 MODULATOR BUSHING

23

3-2 VALVE

24
25

3-2 VALVE SPRING

26
27

BORE PLUG
RETAINING PIN

28
29

1 2 ACCUMULATOR PRlMARY SPRING

1 2 ACCUMULATOR SECONDARY SPRING

RETAINING PIN
SPACER PIN

7A4-38 TURBO HYDRA-MATIC 400

9, At the other end of the assembly, top bore, remove

the retaining pin and bore plug.
10. Remove the detent valve, detent regulator valve,
spring and spacer.
11. From the next bore down, remove the 1-2
accunlulator retaining pin, bore plug, 1-2 accumulator valve
and 1-2 primary or secondary spring. (model BC primary
and model OB secondary spring). Models BB, OD and OC
do not require a 1-2 accumulator primary or secondary

(NOTE: Do not remove the teflon oil seal ring from the

OIL SEAL RING

CCUMULATOR SPRING

Fig. 7A4-102 -Front Accumulator

1. Inspect all valves for scoring, cracks and free

movement in their respective bores.
2. Inspect the bushing for cracks, scratches or
distort ion.
3. Inspect the body for cracks or scored bores.
4. Check all springs for distortion or collapsed cods,
5. l9spect accumulator piston and oil ring for
damage.

Assembly
1. Install front accumulator spring and piston into
valve body.
2. Using tools as shown in Fig. 7A4-103, install the
accumulator spring and piston and secure with retaining
ring. While installing servo, jiggle valve body while rotating
screw t o prevent piston bindmg.
3 . In lower left bore, install the 1-2 accumulator
primary spring (if required) and the 1-2 accumulator valve,
stem end out. Install the 1-2 accumulator secondary spring
(if required) and the bore plug. lnstall retaining pin from
cast surface side of valve body, with the grooves of pin
entering hole last. Tap pin with a hammer until it is flush
with the cast surface side of valve body.
4. Install the detent regulator spring and spacer in
next bore up. (Fig. 7A4- 104)

(NOTE: Compress spring and retain in pIace using a .005"

t o .0 15" feeler gauge .)
5. Install the detent regulator valve, wide land first.
6. Install the detent valve, narrow land first.
7. Install bore plug, open end out, and install
retaining pin. Remove the feeler gauge.
8. In the lower right hand bore, install the 3-2 valve.
9. lnstall the spacer, 3-2 valve spring, bore plug with
hole out and retaining pin.
10. In next bore up, install the 2-3 shift valve, hole end
out, and 3-2 intermediate spring.
1 1. Install the 2-3 modulator valve into the bushing
and install both parts into the valve bore.
12. Install the 2-3 valve spring and install the retaining
13. In the next bore, install the 1-2 valve, stem end
14. Install the 1-2 regulator valve, larger stem first,
spring and 1-2 detent valve, hole end first, into the 1-2
modulator bushing aligning spring in bore of detent valve
and install parts into the valve body bore.
15. Compress the bushing against the spring and instal
the retaining pin,

E EELER C 4 U G t
DFTFYT

Fig. 7A4-103-Installing Front Accumulator

Fig. 7A4-104-Installing Detent And Detent

Regulator Valves

TURBO HYDRA-MATIC 400 7A4-39

16. Install the manual valve with detent pin groove to

the right,

OIL PUMP
L

Djsssembly
1. Place pump assembly in hole in bench or Holding
Fixture 5-6116.
2 . Compress the regulator boost valve bushing against
the pressure regulator spring and remove the snap ring,
u d g J-5403 Pliers. (Fig. 7A4-105)
3. Remove the regulator boost valve bushing and
valve
4. Remove the pressure regulator spring.
5 . Remove the regulator valve, spring retainer and
spcer(s) if present. (Fig. 7A4-106)
6. Remove pump cover to body attaching bolts and
remove pump cover from body.
7. Remove the retaining pin and bore plug from the
pressure regulator bore. (Fig. 7A4107)
8. Check condition of oil rings, then remove them
from the pump cover if necessary. (Fig. 7A4-108)
9. Remove the pump to forward clutch housing
selective washer.
10. Mzrk drive and driven gears for reassembly in same
position and remove drive gear. (Fig. 7A4-109)

Fig. 784-107-Removing Pin And Bore Plug

(NOTE: A piece of copper will mark and not damage the

11. Remove the driven gear from pump body. (Fig.
7A4-1 10)
SNAP RING

REGULATOR BOOST VALVE

BUSHING AND VALVE
,REGULATOR SPRING

Fig. 7A4-108-Removing Oil Rings

PUMP DRIVE GEAR

Fig. 7A4-105 -Removing Snap Ring

PRESSURE
EGULATOR

Fk. 7A4-106-Removing

SPRING
RETAINER
WASHER

Valve, Spacer And Retainer

Fig. 7A4-109 -Removing Pump Drive Gear

7A4-40 TURBO HYDRA-MATIC 400

7. Check bushing for scores or nicks.

8. Inspect the pump attaching bolt seals for damage
replace if necessary.
9. Inspect pump cover face for over-all flatness.
10. Check for scores or chips in pressure regulator
bore.
11. Check that all passages are open and not
interconnected. (Fig. 7A4-114)
12. Check for scoring or damage at pump gear face.
13. Inspect stator shaft for damaged splines or scored
bushings.
14. Inspect oil ring grooves for damage or wear.
15. Inspect selective washer thrust face for wear
damage.
16. Inspect pressure regulator and boost valve for free
operation.

Fig. 7A4-l l O-Removmg Pump Driven Gear

Pump Inspection

(NOTE: The solid type pressure regulator valve does not

contain oil holes and an orifice cup plug like previous
pressure regulator valves. The solid style valve must only be
used in the pump cover with the squared off pressure
regulator boss (pressure boost bushing end.) (Pig. 7A4-111)
The previous pressure regulator valve with the oil holes and
orifice cup plug will be used t o service either type pump
cover .)
1. Inspect the gear pocket and crescent for scoring,
galling or other damage.
2 . Place pump gears in pump and check end
clearance. Pump body face t o gear face clearance should be
.0008" to .0035". (Fig. 7A4-112)
3. Check face of pump body for scores or nicks.
4. Check oil passages, (Fig. 7A4- 1 13)
5. Check for damaged cover bolt attaching threads.
6. Check for over-all flatness of pump body face.

Fig. 7A4-112-Checking Clearances

I
VENT

PUMP COVER

-SEAL

REG. BOSS.

MODULATOR OR
INTERMEDIATE

Fig. 7A4-113-Pump Body

Fig. 7A4-111 -Pump Cover

* *t%@rn

DRAIN

TURBO HYDRA-MATIC 400 7A4-41

17. Inspect pump cover for open 118" dia. breather

hole (See Fig. 7A4-114 for location.)

~ ~ m b(Fig.
l y 7A4-1 15)

pmP1.
Install the drive and driven pump gears into the

I-

DRIVE

-- .,
r\

r P

MODULATOR OR
"-../INTERMEDIATE

pump body with alignment marks up. (Figs. 7A4-109 and

7A4-110)
(NOTE: Some pump driven gears have a rectangular or
triangular identification mark on the face of a tooth. If so,
the mark must be installed with the I D . mark down .)
(NOTE: Install the drive gear with drive tangs up.)

2. Protect stator shaft and install pump cover in vise.

3. Install the spacer(s) if used, retainer and spring,
into the pressure regulator bore.
4. Install the pressure regulator valve from opposite
end of bore, stem end first.
5. Install the boost valve into the bushing, stem end
out, and install both parts into the pump cover by
compressing the bushing against the spring. Insert a small
screwdriver between a spring coil and the bore of the boost
valve t o keep the spring compressed, so the retaining ring
can be installed. (Fig. 7A4-116)
6. Install the pressure regulator valve bore plug and
retaining pin into opposite end of bore.
7. Install the previously selected front unit selective
thrust washer over the pump cover delivery sleeve.
8. install oil seal rings if' removed. (Fig. 7A4-117)

PRESSURE REGULATOR
FEED HOLE

LII;EI
;

Fig. 7A4-114-Pump Cover

(NOTE: If teflon rings are being used, make sure slit ends
are assembled in same relation as cut, Fig. 7A4-118. Also,
make sure oil seal rings are seated in ring grooves t o prevent
damage t o rings during reassembly of mating parts over
rings.)

PRESSURE REGULATOR VALVE

PRESSURE REGULATOR SPACER,
SPRING RETAINER WASHER

PUMP COVER
PRESSURE BOOST VALVE

\PRESSURE BOOSTBUSHING
SNAP RING

THRUST WASHER
PUMP OIL SEAL RINGS

Fig.7A4-115-Oil Pump Cover (Exploded View)

ARD CLUTCH HOUSING

3
RIGHT

WRONG

TURBO HYDRA-MATIC 400 7 ~ 4 - 4 3

3. Remove the forward clutch hub and thrust

(Fig. 7A4-122)
4. Remove composition-faced, and flat steel clutch
(Fig. 7A4- 123 and 7A4-17)
5. Using tools as shown in Fig. 7A4-124, compress
the spring retainer and remove the snap ring.
6. Remove the tools, snap ring, spring retainer and 16
clutch release springs. (Fig. 7A4-125)

,&ers.

clutch pistons look almost the same. Make sure the forward
clutch piston is identified during disassembly so it wd be
reassembled into the forward clutch housing. The
production built forward clutch piston will be aluminum or
stamped steel.)

7. Remove the forward clutch piston. (Fig. 7A4-126)

(NOTE: Current transmissions use a direct clutch piston

\ ~ i t h ~ au tcheck ball. Therefore, the forward and direct

Fig. 7A4-124-Removing Snap Ring

Fig. 7A4-123-Removing Clutch Plates

Fig. 7A4-125 -Removing Release Springs

7A4-44 TURBO HYDRA-MATIC 400

Inspect ion
1. Inspect the composition-faced and steel
plates for signs of burning, scoring, or wear.
2. Inspect 16 springs for collapsed coils or ig,,
,c
-0"w1
distortion.
3. Inspect the clutch hubs for worn splines,
lubrication holes, thrust faces.
4. Inspect the piston for cracks or porosity.
5. Inspect the clutch housing for wear, scoring, open
oil passages and free operation of the ball check.

8. Remove the inner and outer clutch piston seals.

(Figs. 7A4-127 and 7A4-128)
9. Remove the center piston sea 1 from the forward
clutch housing. (Fig. 7A4-129)

Turbine Shaft Inspection

1. Inspect for open lubrication passages at each end
and cross holes to make certain they are open t o oil flow.
2 . Inspect the splines for damage.
3. Inspect the ground b ~ s h journals
g
for damage.
4. Inspect the shaft for cracks or distortion.
(NOTE: Turbine shaft can be removed from clutch hub by
using arbor press.)

Assembly (Figs, 7A4-130 and 7A4-131)

(NOTE: Apply transmission fluid to all seals and clutch
plates before reassembly .)
1. Place new inner and outer oil seals on clutch

Fk.
" 7A4-127-Removing: Outer Piston Seal
t

Fig. 7A4-129-Removing Center Seal

FORWARD CLUTCH HOUSING

FORWARD CLUTCH CENTER SE

FORWARD CLUTCH INNER SEAL

FORWARD CLUTCH PISTON
CLUTCH RELEASE SPRINGS

'1
I
I

Fig. 7A4-128-Removing Inner Piston Seal

Fig. 7A4-130-Forward Clutch ~ssembly

FORWARD CLUTCH

FLAT STEEL

FORWARD

DIRECT

Fig. 7A4-134-Installing Piston Center Seal

WASHERS

Fig. 7A4-131 -Forward Clutch Assembly

Fig. 7A4-135 -Installing Clutch Piston

Fig. 7A4-132-Installing Piston Outer Seal

Fig. 7A4-136-Installing Release Springs

7A4-46 TURBO HYDRA-MATIC 400

10. Install the direct clutch hub a ~ l dretaining snap

ring. (Fig. 7A4-140)
1 1 . Place forward clutch housing on pump delivery
sleeve and air check clutch operation. (Fig. 7A4-141)

6. Using tools as shown in Fig. 7A4-137, compress

the spring retainer and install the snap ring.
7. Place clutch hub t o clutch housing thrust washers
on clutch hub making sure bronze washer is installed on
side of hub facing forward clutch housing. Retain with
petrolatum.
8. Place forward clutch hub into forward clutcll
housing. (Fig. 7A4-138)
9. Install one (1) waved steel plate (plate with "U"
notch), composition-faced and flat steel clutch plates,
starting w i t h t h e waved plate and alternating
composition-faced and flat steel clutch plates. (Fig.
7A4-139 and 7A4-17)

COMPOSITION

FORWARD CLUTCH HOUSING

Fig. 7A4-140-Installing Snap Ring

Fig. 7 A4- 137 -Installing Snap Ring

1

Fig. 7A4-I38 -Installing Forward Clutch Hub

Fig. 7A4-141 -Air Checking Forward Clutch

TURBO HYDRA-MATIC 400 7A4-47

i

DIRECT CLUTCH AND INTERMEDIATE ROLLER

CLUTCH ASSEMBLY

~isassembl~
1. Remove roller retainer snap ring and retainer. (Fig.
7 A4- 1 42)
2. Remove roller outer race (Fig. 7A4-143), and rollel

3. Turn unit over and remove backing plate t o &rect

clutch housing snap ring. (Fig. 7A4-145)
4. R e m o v e d i r e c t c l u t c h b a c k i n g p l a t e ,
composition-faced and steel clutch plates. (Fig. 7A4-146)
5. Using Clutch Compressor Tool 5-4670-14, 5-61 29,
and 5-8765, compress spring retainer and remove snap ring.
(Fig. 7 A4-1 47)
6. ~ e m o v retainer
e
and 14 piston release springs.

(NOTE: Keep springs separate from forward clutch release

a

springs.)

SNAP R I N G

Fig. 7A4-142-Removing Snap Ring

INTERMEDIATE
OUTER RACE

ROLLER
ASSEMBLY
INTERMEDIA1
CLUTCH

DIRECT CLUTCH
HOUSING

Fig. 7A4-145 -Removing Snap Ring

Fig. 7A4-143-Removing Intermediate RoUa Clutch

Outer Race
INTERMEDIATE CLUTCH
ROLLER ASSEMBLY

4 FLAT S EEL PLAttS

3 COI'JPUS ITION PLATES

DIRECT CLUTCH HOUSING

A N D C A M ASSEMBLY

Fig. 7A41444emoving Roller Clutch

Fig. 7A4-146-Removing Direct Clutch Plates

7A4-48 TURBO HYDRA-MATIC 400

7. Remove the direct clutch piston. (Fig. 7A4-148)

(NOTE: Current transmissions use a direct clutch pist on

without a check ball. Therefore, the forward and direct
clutch pistons look almost the same. Make sure the direct
clutch piston is identified during disassembly so it will be
re-assembled into the direct clutch housing. The service
replacement direct clutch piston contains a check ball. The
production built direct clutch piston will be aluminum or
stamped steel.)

4. Inspect the composition faced and steel clutch

plates for sign of wear or burning.
5. Inspect the backing plate for scratches or other
damage.
6. Inspect the clutch pist on for cracks.

9. Remove the inner seal from the piston. (Fig.

3. Inspect the clutch housing for cracks, wear, proper

opening of oil passages or wear on clutch plate drive lugs.

Fig. 7A4-149-Removing Piston Outer Seal

Fig. 7A4-147 -Removing Snap Ring

Fig. 7A4-148 -Removing Direct Clutch Piston

TURBO HYDRA-MATIC 400 7A4-49

7. Inspect springs for collapsed coils or signs of

distortion.

(NOTE: The 14 direct clutch release springs are not

%,vicedm If one or more of these springs require
replacement, discard all of them and install the 16 service
direct clutch release springs.)

8. Inspect the clutch housing for free operation of

check ball. (Fig. 7A4- 152)
Assembly (Figs. 7A4-15 3 and 7 A4-15 4)

(NOTE: Apply transmission fluid t o all oil seals and clutch

$ales before reassembly.)
1. Install a new inner clutch piston seal on piston
with lip facing away from spring pockets. (Fig. 7A4-155)

Fig. 7A4-153-Direct Clutch Assembly

Fig. 7A4-152-Inspecting Check Ball

Fig. 7A4-155 -Installing Piston Inner Seal

SNAP R l N G
INTERMEDIATE CLUTCH RETAINER

I N T E R M E D I A T E C L U T C H O U T E R RACE
I N T E R M E D I A T E ROLLER C L U

DIRECT CLUTCH H O U S I N G
AND RACE ASSEMBLY
IRECT CLUTCH CENTER SEAL

DIRECT CLUTCH INNER SEAL

DIRECT CLUTCH PISTON
DIRECT CLUTCH PISTON RELEASE SPRINGS
DIRECT CLUTCH SPRING RETAINER
SNAP R l N G
L

Fig. 7A4-154-Direct Clutch And Intermediate Clutch Assembly

TURBO HYDRA-MATIC 400 7A4-51

9. Install the clutch backing plate and the backing

plate retaining ring. (Fig. 7A4-161)
10, Install rollers that may have come out of the roller
cage by compressing the energizing spring with forefinger
and inserting the roller from the outer side,
1 1 . Turn unit over and install intermediate clutch
rofler assembly. (Fig. 7A4-162)
12. Install outer race over roller clutch assembly with
clockwise turning motion. (Fig. 7A4-163)
(NOTE: Outer race should only turn clockwise after
installation.)
13. Install roller retainer and snap ring, (Fig. 7 A 4 1 64)
14. Place direct clutch assembly over center support
and air check operation of direct clutch. (Fig. 7A4-165)

(NOTE: If air is supplied through reverse passage (right oil

feed hole) it will escape from direct clutch passage (left oil
feed hole). This is considered normal. Apply air through
left oil feed hole to actuate piston and move direct clutch
plates.)

r\\\

DIRECT CLUTCH I BACKING PLATE

Fig. 7A4-163-Installing Intermediate Clutch Outer Race

DIRECT CLUTCH
HOUSING

Fig. 7A4-164-Installing Snap Ring

Fig. 7A4-161 -Installing Snap Ring

INTERMEDIATE CLUTCH
ROLLER ASSEMBLY

DIRECT CLUTCH HOUSING

Fig. 7A4-162 -1nstaUing Intermediate Clutch

Roller Assembly

Fig. 7A4-165-Air Checking Direct Clutch

011 SEAL RINGS

TURBO HYDRA-MATIC 400 7A4-53

6. Remove the inner piston seal. (Fig. 7 A4-17 2)

7 . Remove the outer piston seal. (Fig. 7A4-173)

Assembly (Fig. 7A4-174)

1. Lubricate and install new inner seal on the ist ton
with lip of seal facing away from the spring pocket: (Fig.
7A4-172)
2. Lubricate and install new outer seal with lip of seal
facing away from the spring pockets. (Fig. 7A4-173)
3. Install Inner Seal Protector Tool 5-21363, on the
center support hub, install the piston, indexing sprinjj
vockets in drum and is ton. (Fig. 7A4-175)

~ T E Do
: not remove the three screws retaining the
IoUer clutch inner race t o the center support .)
lnspect ion
1. Inspect the roller clutch inner race for scratches or
Be sure the lubrication hole and .020"
bleed orifice is open. (Fig. 7A4-210)
2. Inspect the bushing for scoring, wear or galling.
3. Check oil ring grooves and oil rings for damage.
4. Air check the oil passages t o be sure they are open
and not interconnected.
5. Inspect the pist on sealing surfaces for scratches.
6. Inspect the piston seal grooves for nicks or other
darnage.
7. Inspect the piston for cracks or porosity.
8. Inspect the release springs for distortion.
9. Inspect support to case spacer for burrs or raised
edges.

(NOTE: If present, remove with fine stone or fine abrasive

CLUTCH OUTER SEAL

Fig. 7A4-173-Removing Or Installing Piston Outer Seal

Fig. 7 A4- 17 2 -Removing Or Installing Pist on Inner Seal

Fig. 7A4-175-Installing Intermediate Clutch Piston

- -

ROLLER
ASSEMBLY

Fig. 7A4-174-Center Support Assembly

RELEASE SPRING ( 3 )

3
RIGHT

WRONG

TURBO HYDRA-MATIC 400 7A4-55

4. Inspect the thrust washer surfaces for signs of

9. Inspect the roller clutch cage and retaining springs

for damage.
10. Inspect the front internal gear for damaged teeth.
11. Inspect the output carrier pinions for damage,
rough bearings or excessive tilt.
12. Check output
end play. Pinion end play
should be .009" t o .024 . (Fig. 7A4-184)
13. Inspect the parking pawl lugs for cracks or damage.
14. Inspect the output shaft locating splines for
damage.
15. Inspect front internal gear ring for flaking or
cracks.

ini ion

PINION GEARS
Removal and Instahtion
1. Support the carrier assembly on its front face.
2. Using a 112" dia. drill, remove the stake marks
from the end of the pinion pin, or pins, to be replaced. This
will reduce the probability of cracking the carrier when
pinion pins are pressed out.

(NOTE: Do not allow drill t o remove any stock from the

carrier, as this will weaken the part .)
3. Using a tapered punch, drive or press the pinions
out of the carrier. (Fig. 7A4-185)

INTERMED l ATE CLUTCH

Fig. 7A4-181 -Air Checking Intermediate Piston

Fig. 7A4-184-Checking Output Carrier Pinion Gear End Play

1

Fig. 7A4-182-Inspecting Reaction Carrier Spacer Ring

I

Fig. 7A4-183-Checking Piston Gear End Phy

Fig. 7 A4-185 -Removing Pinion Gears

BRONZE WASHER
STEEL WASHER

NEEDLE BEARINGS

BRONZE WASHER

111

TURBO HYDRA-MATIC 400 7 ~ 4 - 5 7

The nylon speedometer drive gear is installed at the

service replacement speedometer drive
fadory Only.
gears are STEEL. When replacing the nylon speedometer
drive gear with a steel gear, discard the retaining clip and
proceed as indicated in step 2 below.

seel Speedometer Drive Gear

1. Install Speedometer Gear Removing Tool 5-2 1427
and suitable puller such as J-6123-01 on output shaft and
remove speedometer drive gear. (Fig. 7A4-19 1)
2. Install new steel speedometer drive gear using
1-21470 and postioning gear at the following dimensions:
~ ~ d e OB,
l s OC and OD - 5-21/32", from rear end of
shaft to rear face of gear. (Fig. 7A4-192)

Fig. 7A4-192-Installing Steel Speedometer Gear

Rear Internal Gear

1. Inspect the gear teeth for damage or wear.
2. Inspect the splines for damage.
3. Inspect the gear for cracks.
Sun Gear
1. Inspect the gear teeth for damage or wear.
2. Inspect splines for damage.
3. Be sure oil lubrication hole is open.

Fig. 7A4-190-Nylon Speedometer Drive Gear Clip

Sun Gear Shaft

1. Inspect shaft for cracks or splits.
2. Inspect splines for damage.
3. Inspect bushings for scoring or galling.
4- Inspect the ground bushing journals for damage.
5 - Be sure the oil lubrication hole is open.
Mainshaft
1. Inspect the shaft for cracks or distortion.
2. Inspect the splines for damage.
3. Inspect the ground bushing journals for damage.
4. Inspect the snap ring groove for damage,
5 . Make sure the oil lubrication holes are open,
Front and Rear Bands
1. Inspect the lining for cracks, flaking, burning or
looseness.
2. Inspect the bands for cracks or distortion.
3. Inspect the end for damage at the anchor lugs or
apply lugs.
Case Extension
1. Inspect the bushing for excessive wear or damage.
2. Inspect the gasket mounting face for damage and
flatness.
3. Inspect the housing for cracks or porosity.
4. Be sure rear seal drain back port is not obstructed.

71\4-391-Removing Steel Speedometer Gear

Modulator and Va k e
1. Inspect the modulator assembly for any signs of
bending or distortion.
2. Inspect the "0" ring seal seat for damage.

7A4-58 TURBO HYDRA-MATIC 400

tt

3. Apply suction t o the vacuum tube and check for

diaphragm leaks.
4.-inspect the modulator valve for nicks or damage.
5. Check freeness of valve operation in case bore.
6. Check modulator bellows, modulator plunger is
under pressure (1 6 lbs.). If bellow is damaged the plunger
will have very little pressure.

Checking Converter
1. Check converter for
7A4-196)
a. Install Tool J-21369 and tighten.

_______ RFVFRqF

(NOTE: See "Vacuum Modulator Diagnosis.")

Manual and Parking Linkage (Fig. 7A4-193)

1. Inspect the parking actuator rod for cracks or
broken spring retainer lugs.
2. 1ns~ectthe actuator s ~ r i n" gfor damage.
3. inspect actuator for a free fit on thg actuator rod.
4. Inspect the parking pawl for cracks or wear.
5. Inspect the manual shaft for damaged threads, or
loose lever.
6. Inspect the inside detent lever for cracks or a loose
pin.
7. Inspect the parking pawl shaft for damaged
retainer groove.
8. inspect the parking pawl return spring for
deformed coils or ends.
9. Inspect the parking bracket for cracks or wear.
10. Inspect detent roller and spring assembly.

II.

I"
ill

'

1 ,
[I;\' i ; :

Fig. 7A4-194-Case Passage Identification

Case Assembly
1. inspect case assembly for cracks, porosity or
interconnected passages. (Figs. 7A4-194 and 7A4-195)

(NOTE: If the case assembly requires replacement, make

sure the center support to-case spacer is removed from the
old case and reinstalled in the new case. Also, remove the
nameplate from the old case and reinstall it onto the new
case, ;sing the truss head nameplate attaching screw that is
serviced with the case .)
2 . Check for good retention of band anchor pin.
3. Inspect all threaded holes for thread damage.
4. Inspect the intermediate clutch plate lugs for
damage or brinelling.
5. Inspect the snap ring grooves for damage.
6. Inspect the bore of the governor assembly for
scratches or scoring.
7. Inspect the modulator valve bore for scoring or
damage.
8. Inspect the cup plugs inside the case for good
staking. (Fig. 7A4-194)

Fig. 7A4-195-Case Inspection

Fig. 7A4-193-Manual And Parking Linkage

Fig. 7A4-196-Air Checking Converter

*"

TURBO HYDRA-MATIC 400 7A4-59

b . Fill converter with air, 80 psi.

c. Submergeinwaterandcheck for leaks.
2 . Check converter hub surfaces for signs of scoring
Or wear.

3. Check converter end clearance as follows:

a. Install Tool J-21371-8 and tighten brass nut.
(Fig. 7A4-197)
b. Install Tool 5-2137 1-3 and tighten hex nut.
(Fig. 7A4- 198)
c. Install Dial Indicator and set at ZERO as
shown in Fig. 7A4-198.
d. Loosen hex nut. When nut is fully loosened,
the reading obtained on the dial indicator will be the
converter end clearance. End clearance should be less
than .050".If converter end clearance is greater than
-050",the converter must be replaced.
4. Check "Converter Stator Operation" as outlined
hv Drocedurein Fig. 7A1-10.

GEAR UNIT (Fig. 7A4-199)

Assembly
1. Install rear internal gear on end of mainshaft.
2. Install internal
retaining snap ring. (Fig.
7A4-200)
3. install the sun gear to internal gear t hmst races and
bearings against the inner face of the rear internal gear as
follows, and retain with petrolatum or equivalent.
a. Place the large race against the internal gear
with flange facing forward or up. (Fig. 7A4-201)
b . Place the thrust bearing against the race.
c. Place the small race against the bearing with
the inner flange facing into the bearing or down.
4 . Install the output carrier over the mainshaft so that
the pinions mesh with the rear internal gear. (Fig. 7A4-202)
5. Place the above portion of the "build-up" through
hole in bench so that mainshaft hangs downward.

Fig. 7A4-197 -Installing Tool J-2137 1-8

Fig. 7A4-198 -Checking Clearance

SNAP

SPEEDOMETER
DRIVE GEAR

O-RING
O.D. FLANGE

THRUST WASHER
(METAL OR NON -METAL)
SUN GEAR

I.D. FLANGE

ASSEMBLY

ASSEMBLY

SUN GEAR
SHAFT

RACE

Fig. 7A4-199-Gear Units

TURBO HYDRA-MATIC 400 7A4-61

12. Install the sun gear, I.D. splines with chamfer

down. (Fig. 7 A4-206)
13. Install front internal gear ring over output carrier.
(Fig.-7~ 4 - 2 0 7 )
14, Install the sun gear shaft, longer splined end first.
15. Install the reaction carrier. (Fig. 7~4-208)

(NOTE: When a new ouput carrier and/or reaction carrier

being installed, and if the front internal gear ring prevents
assembly of the carriers, replace the front internal gear ring
with the SERVICE ring.)
js

16. Install the center support t o sun gear thrust races

and bearings as ~ O ~ ~ O W S :
a. Install the large race, center flange up over the
sun gear shaft.
b . Install the thrust bearing against the race.
c. Install the second race, center flange up. (Fig.
7A4-209)
Fig. 7A4-207 -Installing Gear Ring

Fig. 7A4-208 -Installing Reaction Carrier

Fig. 7A4-205-Installing Thrust Washer

I.D. FLANGED
THRUST BEARINGS
I.D. FLANGED

Fig. 7A4-206-Installing Sun Gear

Fig. 7A4-209 -Installing Thrust Bearings

"

17. Install the center support t o reaction carrier thrust

washer "to the recess
the center support. Retain with
petrolatum (Fig. 7A4-2 10)
18. instau railers that may have come out of the roller
cage by conlpressing the e n e r g h a spr"g with forefinger
and inserting the roller from the outer side. (Fig. 7 ~ 4 -121)
19 Instau the roUtx clutch assembly into the reaction
carrier outer race. (Fig. 7A4-212)
2 0 hstafl the center support into the reaction carrier
and roller clutch assembly. (Fig. 7 A4-2 13)

(NOTE: With reaction carrier held, center support should

only turn counterclockwise.)

2 . Install the parking pawl shaft retainer clip. (Fig.

71\4-2151
3. Install parking pawl shaft cup plug and drive into
the case using a 318' dia rod? untg the P"*"c
pawl shaft
bottoms on the Use r i b (Fig*7A4-216)
4. Install the parking pawl return spring, square end
*4-217)
hooked on pawl and *the* end On caw
5. Install the parking pawl bracket with guides over
parkhg pawl and torque 20 l b s (Fig- 7A44d18)
6. Install the rear band assembly so that two lugs
index with the two anchor pins. (Fig. 7 A4-219) Check band
On lugs'0 be sure band ends are

ASSEMBLY OF UNITS INTO TRANSMlSSlON CASE

(NOTE: The first three steps can be omitted if the parts

involved were not removed on disassembly.)
1. Install the parking pawl tooth toward the inside of
case and parking pawl shaft. (Fig. 7A4-214)

Fig. 7 A4-2 1 1-Installing Roller In Cage

Fig. 7 A4-213 -Installing Center Support

TURBO HYDRA-MATIC 400 7A4-63

7. Install the support to case spacer against the

shoulder at the bottom of case s lines and the gap located
adjacent to the band anchor pin. b i g . 7A4-220)

(NOTE: Do not confuse this spacer (.040N thick and both

sides flat) with either the center support t o case snap ring
(one side beveled) or the intermediate clutch backing plate
to case snap ring (.093" thick and both sides flat .)
8. Install the proper rear selective washer (proper
washer determined by previous end play check) into slots
provided inside rear of transmission case. (Fig. 7A4-221)

Fig. 7A4-214-Installing Parking Pawl

Fig. 7A4-21 7 -Installing Return Spring

Fig. 7 A 4 2 15 -Installing Retainer Clip

Fig. 7A4-218 -Installing Parking Bracket

&'I.

Fig. 7A4-216-Installing Cup Plug

Fig. 7A4-219 -Installing Rear Band

--

7A4-64 TURBO HYDRA-MATIC 400

bolt hole is properly aligned with the hole in the case. (Fig.
7A4-223)
11. Oil and install center support to case retaining snap
ring with the bevel side up (flat side against center support)
and locating gap adjacent t o band anchor pin. Make certain
ring is properly seated in case. (Fig. 7A4-224)
12. Install case to center support bolt by placing the
center support locating Tool 5-23093 into the case direct
clutch passage, with the handle of the tool pointing to the
right as viewed from the front of the transmission and
parallel to the bell housing mounting face. (Fig. 7A4-225)
Apply pressure downward on the tool handle which
will tend to rotate the center support counter clockwise as
viewed from the front of the transmission. While holding
the center support firmly counterclockwise against the case
splines, torque case to center support bolt to 20-25 ft. lbs.
using a 3/8' 12 point thin wall deep socket.

9. Install output shaft t o case METAL thrust washer

onto rear face of output shaft, tabs in pocket and retain
with petrolatum or equivalent. (Fig. 7A4-222)
(NOTE: This must be a METAL washer .)
10. Install the complete gear unit assembly into the
case, using Tool 5-21795 making certain the center support

(NOTE: When using the locating tool, care should be taken

not to raise burrs on the case valve body mounting face.)

Fig. 7A4-220-Installing Spacer

Fig. 7 A4-221 -Installing Selective Washer

(METAL)

Fig. 7A4-222-Installing Thrust Washer

Fig. 7 A4-223-Installing Center Support And Gear Unit

I
Fig. 7A4-224-Installing Center Support To Case Snap Ring

---.I

TURBO HYDRA-MATIC 400 7A4-65

13. Lubricate with transmission oil two (2) flat and

one (1) waved steel plates and three (3) composition
intermediate clutch plate assemblies and install, starting
with waved steel plate and alternating composition faced
and steel plates. (Fig. 7A4-226 and 7A4-17)
14. Install the intermediate clutch backing plate, ridge
UP-

15. Install the intermediate clutch backing plate to

CENTER SUPPORT
LOCATING TOOL

Fig. 7A4-225 -Installing Center Support Bolt

case snap ring, locating gap opposite band anchor pin. (Fig.
7A4-227)

(NOTE: Both sides of this snap ring are flat, and it is .093"
thick .)
16. Check Rear End Play as follows:
a. Install 5-21661 into an extension housing
attaching bolt hole. (Fig. 7A4-228)
b. Mount the Dial Indicator 5-8001, on the rod
and index with the end of the output shaft.
c. Move the output shaft in and out to read the
end play. End play should be from .007" to -019".The
selective washer controlling this end play is the steel
washer having three lugs that is located between the
thrust washer and the rear face of the transmission
case.
If a different washer thickness is required to bring the
end play within specification, it can be selected from the
following chart :

Thickness

Notches and/or N u m a l

.074" to .078"
.082" to .086"
.090" to ,094"
.098" to ,102"
.106" to -1 10"
.114" to -118"

None . . . . . . . . . . . . . 1
1 Tab Side . . . . . . . . . . 2
2 Tab Side . . . . . . . . . - 3
1 Tab O.D. . . . . . . . . . - 4
2 Tabs O D . . . . . . . . . . 5
3 Tabs O.D. . . . . . . . . - 6

17. Install front band with anchor hole placed over the
band anchor pin and apply lug facing servo hole. (Fig.
7 A4-229)
18. install manual linkage as follows:
a. If necessary, install a new manual shaft seal
into the case using a 314" diameter rod to seat the seal.
b. Insert the actuator rod into the manual detent
lever from the side opposite the pin.
c. lnstall the actuator rod ~lunger under the
parking bracket and over the $rkin;
pawl. (Fig.
7A4-230)
d. install the manual shaft through the case and
detent lever. (Fig. 7 A4-23 1)
e. Install retaining hex locknut on the manual
shaft. (Fig. 7A4-232) Tlghten detent retaining nut. (20
ft. Ibs.)
f. Install retaining pin, indexing with groove in
manual shaft. (Fig. 7A4-233)

Fig. 7A4-226-Installing Clutch Plates

<

Fig. 7A4-227-Installing Intermediate Clutch Snap Ring

Fig. 7A4-228 -Checking Rear Unit End Play

7A4-66 TURBO HYDRA-MATIC 400

19. Install the direct clutch and intermediate roller

assembly. It will be necessary to twist the housing to allow
the roller outer race to index with the clutch plates. The
housing hub will bottom on the sun gear shaft. (Fig.
7A4-234)

(NOTE: After clutch plates have been aligned, applying the

intermediate clutch plates, with air pressure, will assist in
installing the direct clutch assembly. Air is applied at the
center support bolt hole .)

1 I:!

20. Install the forward clutch hub to direct clutch

housing thrust washer on the forward clutch hub, if not

mlflIvi

Fig. 7A4-231-Installing Detent Lever

Fig. 7A4-232-Tightening Jam Nut

4

Fig. 7A4-229-Installing Front Band

Fig. 7A4-230-Installing Manual Shaft

Fig. 7A4-233-Installing Retaining Pin

TURBO HYDRA-MATIC 400 7A4-67

21. Install the forward clutch assembly and turbine

shaft, indexing the direct clutch hub so end of the
rnainshaft will bottom on end of the forward clutch hub.
When forward clutch is seated the housing will be
approximately 1-1/4" from pump face in case. (Fig.
7~4-235)
22. Install the front pump gasket and pump assembly.
23. Using new attaching bolt sealing washers, install all
but one pump attaching bolt and washer. Torque to 25 ft.
lbs.
(NOTE: If the turbine shaft cannot be rotated as the pump
is being pulled into place, the forward or direct clutch
housings have not been properly installed to index with aU
the clutch plates. This condition must be corrected before
the pump is pulled fully into place.)
24. If necessary to install a new front seal, use a
non-hardening sealer on outside of seal body; and using
Tool 5-2 1359 drive seal in place. (Fig. 7A4-236)
25. Check Front Unit End Play as follows: (Fig.
7A4-237)
a. Install a Slide Hammer bolt into bolt hole in
Pump
b. Mount a Dial Indicator 5-8001 on the rod and
index indicator to register with end of turbine shaft.

c. Push on turbine shaft rearward.

d.. Push output shaft forward.
e. Set Dial Indicator to Zero.
f. Pull turbine shaft forward.
Read the resulting travel or end play, which should
be -003" to -024". The selective washer controlling this end
play is the washer located between the pump cover and the
forward clutch housing. If more or less washer thickness is
required t o bring end play within specifications, select the
proper washer from the chart below:
Thickness

Color

No.

.060" to
,071" to
.082" to
.093" to
.104" to
.115" to
.126" to

Yellow
Blue
Red
Brown
Green
Black
Purple

0
1
2
3
4
5
6

.064"
.07S1'
.08611
.097"
.108"
.11911
.13Ot1

(NOTE: An oil soaked washer may tend t o discolor so that

it will be necessary to measure the washer for its actual
thickness.)
26. Install the remaining front pump attaching bolt
and sealing washer. Torque bolt t o 25 ft . lbs.

EXTENSION HOUSING
1. Install the extension housing to case gasket on the
extension housing.

Fig. 7A4-234-Installing Direct Clutch

Fig. 7A4-236-Installing Front Pump Seal

Fig. 7A4-235 -Installing Forward Clutch Assembly

Fig. 7A4-237 -Checking Front Unit End Play

7A4-68 TURBO HYDRA-MATIC 400

2. Attach the extension housing t o the case using

attaching bolts and studs. Install studs, longer threaded end
first. Torque to 25 ft .lbs.

3. Install control mlve spacer plate-to-case ga*n

(gasket with extension for detent solenoid and a
front servo location). (Fig. 7A4-242)
4. Install control valve spacer plate.

3. If necessary to install a new rear seal, use a

non-hardening sealer on outside of seal body and using Tool
5-21 359, drive seal in place. (Fig. 7A4-238)

CHECK BALLS, CONTROL VALVE SPACER PLATE &

GASKET, DETENT SOLENOID, FRONT SERVO AND
ELECTRIC CONNECTOR.
Installation
1. Install two guide pins as shown in Fig. 7A4-239.

(NOTE: Guide pins can be made by cutting the heads off

two bolts which are the same size as the valve body
attaching bolts.)

(NOTE: During reassembly, omit the direct clutch exhaust

check ball. It is non-functional. If transmission is in car,
install check balls into ball seat pockets on spacer plate.
Refer to Fig. 7A4-241 for location.)

Fig. 7A4-240-Check Ball Locatiov

(NOTE: THIS CHECK BALL IS NON-

Fig. 7A4-238-Installing Rear Oil Seal

LO CASE GASKET

Fig. 7A4-241-Check Ball Location Trans. In Car

Fig. 7A4-239 -Installing Control Valve Assembly

Fig. 7A4-242-Installing Spacer Plate And Gasket

TURBO HYDRA-MATIC 400 7A4-69

5, Install detent solenoid gasket.

6 . ~nstall detent solenoid assembly with connector

8. Install retainer ring in front servo pin groove and

install pin into case so that tapered end contacts band.
Make certain retainer ring is installed in servo pin groove.
9. Install seal ring on servo piston, if removed, and
install on servo pin with flat side of piston positioned
toward bottom pan. (Fig. 7A4-245)

facing outer edge of case. (Fig. 7124-243) Do not tighten

bolts at this time.
7 , hstall front servo spring and spring retainer into
case. (Fig. 7A4-244)

(NOTE: The teflon ring allows the front servo piston to

slide very freely in the case. The free fit of the ring in the
bore is a normal characteristic and does not indicate leakage
during operation. The teflon ring should only be replaced if
it shows damage or if evidence of leakage during operation
exists .)
(NOTE: If transmission is in car, assemble front servo
group as shown in Fig. 7A4-246 and install this group of
parts into front servo bore in case and hold. Slip a length of
straight, clean feeler gauge or shim stock (about .020"
thick) between spacer plate and front servo piston to
temporarily retain front servo group. Fig. 7A4-247)

Fig. 7A4-243-Installing Detent Solenoid And Gasket

(NOTE: Do not tighten bolts at this time.)

10. Install the "0" ring seal on the case connector.
11. Lubricate and install electrical connector with lock
tabs facing into case, positioning locator tab in notch on
side of case. (Fig. 7A4-248)
12. Connect detent solenoid lead wire to the electrical
connect or. (Fig. 7A4-249)
(NOTE: Check by pulling on detent connector wire. If
detent connector wire can be removed, turn wire connector
over and reinstall into electrical connector .)
I

TEFLON OIL SEAL RING

\r\

Fig. 7A4-244-Installing Front Servo Spring

SERVO PISTON

SPRING RETAlNtR

,SERVO

PISTON

Fig. 7A4-245 -Installing Servo Piston

Fig. 7A4-246-Front Servo

Fig. 7A4-247 -Installing Servo - Trans. In Car

STEP LO CAT ION

P I N IDENT.

SIZE

TOP STEP
OP ABOVE

THREE R INGS

LONG

THIS AREA

TWO

LOWER
STEP OR
BELOW

ONE RING

b+
J-21370-5

R l NGS

MED.

SHORT

TURBO HYDRA-MATIC 400 7A4-71

REAR SERVO ASSEMBLY

6. Remove guide pins and install detent roller and

spring assembly and remaining bolts. Torque bolts to 8 ft.
lbs.
7. Tighten the solenoid and control valve attaching
bolts. Torque bolts to 6-10 ft. lbs.

Fig. 7 A4-25 3-Installing Rear Servo

Fig. 7A4-255-Installing Spacer To Valve Body Gasket

Fig. 7A4-254-Installing Servo Cover And Gasket
CONTROL VALVE ASSEMBLY, GOVERNOR PIPES &
GOVERNOR SCREEN ASSEMBLY
Installation
1. Install valve body to spacer plate gasket (identified
with a "VB" new front servo location). (Fig. 7A4-255)
2 . Install governor pipes into control valve assembly.
Governor pipes are interchangeable. (Fig. 7A4-256)

(NOTE: If transmission is in the car, before installing the

control valve assembly and governor pipes as outlined in
Step 3 below insert governor screen, closed end first, into
governor feed pipe. This pipe locates in the governor feed
pipe hole in the case nearest the center of the transmission.)

Fig. 7 A4-25 6-Installing Governor Pipes

3 . Install governor screen assembly, open end first,

into governor feed pipe hole in case (hole nearest the center
of transmission). (Fig. 7A4-257)
4. Install control valve assembly and governor pipes
on transmission, while carefully aligning the governor feed
pipe over the governor screen. Make certain gasket and
spacer do not become mispositioned.

(NOTE: Check manual valve to make sure it is indexed

properly with pin on detent lever and governor pipes to
make certain they are properly seated in case holes.)
5 . Start control valve assembly attaching bolts.
(NOTE: If transmission is in the car, remove feeler stock
before tightening any control valve bolts. Fig. 7A4-247)

Fig. 7A4-257 -Governor Screen

7A4-72 TURBO HYDRA-MATIC 400

FILTER AND INTAKE PIPE

Installation
1. Install the case to intake pipe "0" ring on intake
pipe and install intake pipe into new filter.
(NOTE: Intake pipe is marked "case" and "filter". Install
"filter" end into filter.)
2. Position the filter and intake pipe assembly. (Fig.
7A4-258) Note positioning of pipe locator tabs in case.
3 . install filter retaining bolt. Torque 10 ft .lbs. (Fig.

MODULATOR VALVE AND VACUUM MODULATOR

Installation
1. Install the modulator v a l ~ einto the case, stem end
out. (Fig. 7A4-260)
2. Install new "0 " ring seal on vacuum modulator.
3. Install the vacuum modulator into the case.

4. Install the modulator retainer and attaching bolt.

Torque bolt to 20 ft. lbs.

SPEEDOMETER DRIVEN GEAR INSTALLATIONS

1. Install speedometer driven gear into gear sleeve and
install assembly into transmission case.
2. Install speedometer driven gear retainer with tangs
in sleeve positioning bosses. Torque attaching bolt to 6 ft.
lbs.
GOVERNOR AND CONVERTER ASSEMBLY
Installation
1. Install the governor assembly into the case. (Fig.

2. Attach the governor cover and gasket with four

attaching bolts. Torque bolts t o 20 ft. lbs.
3. Rotate transmission holding fixture so pump faces
UP.
4. Install converter, aligning the drive tangs in the
pump with the notches in the converter.
5. Install Converter, Holding Tool 5-2 1654 as shown
in Fig. 7A4-262.

Fig. 7A4-258 -Installing Filter Assembly

Fig. 7A4-259-Filter Retainer Bolt

Fig. 7A4-261 -Installing Governor

TURBO HYDRA-MATIC - TORONADO 425 7A4-73

Fig. 7A4-262-Converter Holding Tool

TURBO HYDRA-MATIC
425 TRANSMISSION
TORONADO
FOR ADDING AND CHECKING OIL, REFER TO SECTION 7 A 3
SUBJECT

PAGE

Bushing Service . . . . . .
Case Porosity Repair . . . .
. . . . . .
Center Support
Description of Operation
. .
Diagnosis . . . . . . . . .
Direct Clutch and
Intermediate Sprag . . . .
Downshift Switch Adjustments
Forward Clutch . . . . . .
Gear Units
. . . . . . . .
Information Chart . . . . .
. . . .
Linkage Adjustment
Minor Service Operation
. .
Pinion Gears
. . . . . . .

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

. .7A4-13 1
. . . 7A4-1
. . 7A4-91
. . 7A4-73

. . . . . . . . . 7A4-1

. . . . . . . .7A4-113
. . . . . . . 7A4-2 1
. . . . . . . .7A4-110

.
.
.
.
.

.
.
.
.
.

.
.
.
.
.

.
.
.
.
.

. . . .7A4-100
. . . . 7A4-14
. . . . 7A480
. . . . 7A480
. . . . 7A4-99

SUBJECT
Reaction Carrier, Roller Clutch
and Output Carrier . . . . . . . . . . .
Rear Servo
. . . . . . . . . . . . . . .
Speedometer Driven Gear . . . . . . . . .
Support and Gear Unit
. . . . . . . . . .
Tools
. . . . . . . . . . . . . . . . .
Torque Converter Diagnosis . . . . . . . .
Torque Specifications
. . . . . . . . . .
Transmission Assembly . . . . . . . . . .
Transmission Disassembly . . . . . . . . .
Transmission Inspection
. . . . . . . . .
Transmission Removal and
. . . . . . . . . . . . . .
Installation
Valve Body . . . . . . . . . . . . . . .

PAGE

. 7A4-98
.7A4-104
. 7A4-8 1
. 7A4-93
.7A4-136
. .7A14
.7A4-130
.7A4-118
. 7A4-8 1
. 7A4-103

7A4-76
.7A4-106

GENERAL DESCRIPTION

direction. This in effect is a reverse in the direction of

engine torque due to the side mounting of the gear unit.

The T u b o Hydra-Matic transmission is a fully

automatic unit consisting primarily of a three element
hydraulic torque converter and a compound planetary
gear-set. Three multipledisc clutches, one sprag, one roller
clutch, and two bands provide the friction elements
required to obtain the desired function of the compound
planetary gear-set . In addition, the Toronado Turbo
Hydra-~aticincorporates a dual sprocket and link belt
assembly.
.
The torque converter couples the engine to the
planetary gears through oil and provides hydraulic torque
multiplication when required. The compound planetary
gear-set produces three forward speeds and reverse.
In the Toronado transmission, the torque converter
couples the engine to the planetary gear-set through the use
of a drive sprocket, a link belt and a driven sprocket.
Clockwise engine torque turns the drive sprocket clockwise.
This, in turn, drives the driven sprocket in a clockwise

OIL FLOW CIRCUITS AND POWER FLOW CHARTS

These are the same as used in 1974 and are not in this
manual.
The Turbo Hydra-Matic 400 uses six check balls and
the Turbo Hydra-Matic 425 uses 8. An explanation of the
additional two balls follows:
BALL NO. 7 - This ball is enclosed in a capsule or
metal jacket that provides an open flow in one direction
but an orificed flow in the other direction. This ball is
located in the reverse h e to the direct clutch providing an
orificed feed to the outer area of the direct clutch for a
slow smooth apply of the clutch. When shifting from
reverse to neutral the reverse oil from the direct clutch will
unseat the ball and give a quick exhaust of clutch oil.
BALL NO. 8 - This ball is located in the case, against
the spacer plate, in the Lo-Reverse line leading to the rear

--

7A4-'74 TURBO HYDRA-MATIC - TORONADO 425

OPERATIONS NOT REQUIRING

TRANSMISSION REMOVAL

servo piston. The ball is in parallel with an orifice hole so

servo apply oil unseats the ball for quick band apply, but
seats to give a slow band release.

1. Oil cooler fitting replacement.

2. Governor assembly service.

The combined effect of the two check balls insures that

when selecting reverse the band is applied before the direct
clutch and when selecting neutral the clutch will release
before the band. This results in smooth shift feel between
N-Rev and Rev-N.

INTERMEDIATE SPRAG CLUTCH

REAR SERVO
ASSEMBLY

CENTER
SUPPORT
BOLT

3.
4.
5.
6.
7.

DETENT
SOLENOID

Vacuum modulator, and valve service.

Speedometer driven gear service.
Oil level check.
Oil pressure check with oil pressure gauge.
Governor driven gear.

FRONT SERVO
ASSEMBLY

Fig. 7A4-263-Turbo Hydra-Matic Transmission - 425

TURBO HYDRA-MATIC - TORONADO 425 7A4-75

Fig. 7A4-263A-Turbo Hydra-Matic Transmission Oil Circuit - 425

7A4-76 TURBO HYDRA-MATIC - TORONADO 425

UNITS THAT CAN BE SERVICED

AFTER REMOVAL OF OIL PAN
(Fig. 7A4-264)
1. Oil pan and pan to case gasket.
2 . Pressure regulator valve assembly.
3. Valve body assembly.
4. Rear servo and accumulator assembly.
5. Front servo and accumulator assembly.
6. Governor pipes.
7. Detent solenoid.
8. Electrical connector.
9. Parking linkage.
10. Valve body to case spacer and gaskets.
11. Check balls (8). See Fig. 7A4-265 for proper
location.
12. Detent roller and spring assembly.
13. Filter assembly.

6 . Remove five upper final drive to transmission

attaching bolts, and bolt "B"-Fig. 7A4-278.

(NOTE: Remaining five bolts and one nut are removed

after car is hoisted .)
7 . Remove five transmission to engine bolts.

(NOTE: Remaining bolt is removed after car is hoisted.)

8 . Hoist car.
9. Loosen, DO NOT WMOVE, upper L.H. bolt
securing flywheel cover. (Bolt "A" Fig. 7A4-272)

(NOTE: Bolt can be loosened using 2 - 3/8" x 12" and 1 .

3J8" x 6" extensions. Extensions should be positioned
along the oil cooler lines.)

General disassembly and assembly instructions should

be followed whenever service is performed with the
transmission remaining in the car.

Fig. 7A4-266 -Oil Cooler Lines

Fig. 7 A4265 -Check Ball bcation

GENERAL SERVICE NOTES

In the event of a major transmission failure, replace
filter assembly and flush cooler and lines.
A new filter should always be installed in the event of a
converter, clutch or pump failure.
Do not change or exchange the converter unless the
converter or pump fails.

TRANSMISSION
Removal (less final drive)
1 . Disconnect battery.
2. Disconnect oil cooler lines at transmission.
3. Disconnect speedomet er cable.
4. Remove governor assembly. Cover hole to prevent
5. Install engine support tools as shown in Figs.
7A4-267,7A4-268 and 7A4-269.

Fig. 7A4-268 -Installing Right Support Bar

TURBO HYDRA-MATIC - TORONADO 425 7A4-77

Fig. 7A4-267 -Installing Support Bars

FLU1 D l N D l CATOR

Fig. 7A4-270-Transmission Attachment

Fig. 7A4-269-Instaling Left Support Bar

Fig. 7A4-27 1 -Tmnsmission To Engine Attachment

7A4-78 TURBO HYDRA-MATIC - TORONADO 425

10. Remove starter assembly.

11. Remove flywheel cover bolts "B ", "C" and "D"
and remove cover by pivoting the cover out of the upper
L .H.bolt slot. (Fig. 7A4-272)
12. Remove three converter to flywheel bolts.

(NOTE: Rotate flywheel to gain access.)

13. Disconnect vacuum modulator line and electrical
connector.
14. Remove the remaining transmission to engine bolt.
15. Position transmission lift (Figs. 7A4-274, 7A4-276
and 7A4-277).
16. Disconnect shift control linkage at transmission.
17. Remove three bolts and one nut (R.H. side)
retaining final drive to engine.
18. Remove two bolts securing engine mount bracket
to rear of engine.
19. Remove two bolts securing rear engine mounts to
frame crossmember. (Fig. 7A4-278)
(NOTE: Bolts are accessible through holes in the bottom
of the crossmember. Engine supports remain attached t o
the bracket and the bracket need not be removed.)

Fig. 7A4-274-Transmission Lift In Position

20. Slide transmission rearward to disengage splines.

2 1. LOOSEN, final drive to engine bolt.

VACUUM MODULATOR

Fig. 7A4-273 -Modulator Pipe

Fig. 7A4-275-Transmission To Engine Attachment

Fig. 7A4-272Starter And Converter Attachment

TURBO HYDRA-MATIC - TORONADO 425 7A4-79

22. Remove two bolts securing R.H. output shaft

bracket to engine. Final drive will now pivot downward.

23. Remove transmission assembly. Install converter

holding t sol 5-2 1654.

(NOTE: Before removing the output shaft bracket

attaching bolts, use a sharp awl and scribe as far around the
rnhers as possible.)

(NOTE: Tool 5-21654 should be notched on left side so

that it will not be necessary to remove the upper L.H.
Flywheel attaching bolt .)

60 FT. LBS.

Fig. 7A4-278 -Engine Mount Attachment

Fig. 7A4-276-Transmission On Lift

Installathn
To install transmission, reverse removal procedure. To
assist in the engagement of the final drive to transmission
splines, make sure that the final drive to transmission
mounting faces are in alignment with each other. After the
splines are engaged, loosely install two final drive to
trahsmission lower attaching bolts.
After the final drive and transmission are mated, then
align the transmission bell housing with the engine and
install the remaining attaching bolts. Torque bolts as
follows:
(NOTE: Before installing the flex plate to converter bolts,
make certain that the weld nuts on the converter are flush
with the flex plate and the converter rotates freely by hand
in this position. Then hand start all three bolts and tighten
finger tight. Torque to specifications. This will insure
proper converter alignment .)

8 INCH SUPPORT1

GAUGE PLUG

Fig. 7A4-277 -Transmission On Lift

Fig. 7A4-279-Support Bolt Location

7A4-80 TURBO HYDRA-MATIC - TORONADO 425

30 ft . lbs.

60 ft . lbs.
Engine Bracket to Rubber Mount
12 ft. lbs.
Oil Cooler Lines to Transmission
Oil Cooler Lines to Radiator
25 ft. lbs.
30 ft. lbs.
Final Drive to Transmission Bolts
Torque Converter to Flywheel Bolts
40 ft. lbs.
Flywheel Housing Cover
6 ft. lbs.
Starter to Engine
35 ft .lbs.
Apply sealer to bolts "E", "F" and "G" (Fig. 7A4-270)

AND BEFORE OPERATING THE CAR, CHECK THE

OPERATION O F THE NEUTRAL-START SWITCEI. THE
ENGINE SHOULD START IN NEUTRAL AND PARK
POSITION ONLY. IF NECESSARY TO ADJUST, REFER

CHECKING AND ADDING FLUID

Refer to Section 7A3. If work has been performed on
the transmission, add the following quantity of fluid, then
check fluid as outlined in steps 1 , 2 and 3 under Checking
and Adding Fluid (Transmission at room temperature,

TURBO HYDRA-MATIC(425)
Pan Removal
. . . . . . . . . . . . . . . 4 Quarts
. . . . . . . . . . . . . 6 Quarts
Converter Change
Overhaul . . . . . . . . . . . . . . . . 12 Quarts

MINOR SERVICE OPERATIONS

SERVICING THE OIL COOLER
The oil cooler is located in the side tank of the radiator
and its purpose is to cool the oil in the event excessive
temperature tends to develop. (Fig. 7A4-266) The oil
cooler is a sealed container providing a passage for oil to
flow from the inlet to the outlet.
In a major transmission failure, where particles of metal
have been carried with the oil throughout the units of the
transmission, it will be necessary t o flush out the oil cooler
and connecting lines. To flush the oil cooler and lines, use
the following procedure:
1. Disconnect b o t h cooler lines from the
transmission. (Fig. 7A4-266)
2. Place a hose over the end of the cooler inlet line
(from the top of the cooler) and insert the hose into an
empty container.
3. Flush clean oleum solvent or equivalent through
the return line (from the bottom of the cooler) using an oil
suction gun until clean solvent comes out of the hose. This
will "back flush" the cooler.
4. Remove the hose from the inlet cooler line and
place it on the return line.
5. Flush clean oleum solvent or equivalent through
the inlet line until clean solvent comes out the return line.
Remove remaining solvent from cooler with compressed air
applied to the return line and flush with transmission fluid.
6 . Reconnect oil cooler lines and torque nuts to 12 ft.
Ibs.

SHIFT ROD ADJUmMENT

The shift rod adjustment provides proper clearance
between the "D" detent in the transmission and the column
shift lever. (Fig. 7A4-280)
1

I, tOOSEN CYIMPSCREW AND BE SURE ROD I S FREE 10 SLIDE I N CLAMP.

INSTALL WASHER IN
THIS POSITION

2, PLACE U P E R SHIFT E V E R AGAINST NEUTRAL STOP I N STEERING

COLUMN. A DETENT W I LL HOLD I T THERE.
3, SETTRANSMISSIONOUTER LEVER INNEUTRAL POSITION.
4, TIGHTEN CLAMP SCREW TO 20 FT. LSS,

~k)

CLAMP
SCREW

SLEEVE

COL .
LEVER

SHlFT

5. CHECK OPERATION:
A. W I T H KEY IN "RUN" POSITION AND TRANSMISS (ON I N "REVERSE",
BE SURE THAT KEY CANNOT BE REMOVED AND THAT STEERtNG
WHEEL I S NOT LOCKED.
B. W l T H KEY IN "LOCK" POS i T l O N AND SHIFT LEVER IN "PARK",
BE SURE THAT KEY CAN BE REMOVED, THAT STEE R I N G WHEEL I S
LUCKED, AND THAT THE UPPER SHIFT E V E R CANNOT BE REMOVED
FROM "PARK".
C. W ITW BRAKES FIRMLY APPLIED CHECK TO MAKE SURE THAT THE
STARTER W t LL NOT WORK IN ANY S H lFT LEVER POS I T I O N EXCEPT
NEUTRAL AND PARK.

SHIFT
/

CLAMP
SCREW

RELAY
BRACKET

SHIFT
ROD

'

FRONT
OF

CAR

LEVE R
BUSHING

Fig. 7A4-280-Toronado Shift Linkage

TURBO HYDRA-MATIC - TORONADO 425 7A4-81

N E U T R A L START
AD JuSTMENT

AND

BACK-UP

SWITCH

Refer to Section 3B4.

SHIFT INDICATOR NEEDLE ADJUSTMENT

Refer to Section 3B4.
TRANSMISSION DISASSEMBLY
CONVERTER, MODULATOR, AND SPEEDOMETER
DRIVE GEAR
~ernoml
1. With the transmission in cradle or portable jack,
remove the torque converter assembly by pulling straight
out from the transmission housing.

(NOTE: The torque converter is heavy due t o the large

amount of oil that it contains.)
2. Install two 318 x 8 inch bolts into the case to
engine mounting face. (Fig. 7A4-279)
3. Remove the speedometer driven gear attaching
screw and retainer clip. (Fig. 7A4-28 1)
4. Remove speedometer driven gear assembly from
case bore. Remove and discard "0" ring seal. (Fig.
7A4-282)
5. Remove the governor attaching clip.
6. Remove governor assembly and "0" ring seal from
case bore. (Fig. 7A4-283)
7. Remove two studs from output end of case and
place a piece of plywood under output end of case, place
transmission on work bench with bottom pan facing the
outside edge of work bench. (Let pan overhang edge of

bench.) Stand transmission on the two eight inch bolts and

the output flange end of the transmission case. (Fig.
7A4-284)
8. Remove vacuum modulator assembly attaching
screw and retainer clip. (Fig. 7A4-285)
9. Remove vacuum modulator assembly and "0" ring
seal from case bore. (Fig. 7A4-286)
10. Remove vacuum modulator valve from bushing in
case. (Fig. 7A4-287)

(NOTE: Modulator bushing may be press fit in case bore

and should not be removed with force.)

BOTTOM PAN, FILTER, AND INTAKE PIPE "0" RING

SEAL
BP
Removal
1. Remove thirteen bottom pan attaching screws.
2. Remove bottom pan and discard gasket.
3. Remove oil filter assembly. (Fig. 7A4-289)
4. Remove and discard the intake pipe to case "0"
ring seal from the oil filter assembly or from the case
counterbore.

Fig. 7 A4-283 -Removing Governor

Fig. 7A4-28 1-Removing Retainer

Fig. 7A4-282 -Removing Speedometer Driven Gear

Fig. 7A4-284-Transmission On Bench

TURBO HYDRA-MATIC - TORONADO 425 7A4-83

2. Remove the pressure boost valve bushing and valve

from the case bore. (Fig. 7A4-29 1)
3. Remove the pressure regulator spring from the case
bore.
4. Remove pressure regulator valve, spring retainer,
and spacer(s) if present, from the case bore.
5. Disconnect detent solenoid lead wire from
electrical connector. (Fig. 7A4-292)
6. Remove governor feed pipe by pulling straight o u t .
(Fig. 7A4-293)
7 . Remove control valve body t o case attaching
screws, detent roller spring and assembly. Leave two top
bolts in until all other bolts are removed.

8. Remove control valve body assembly, gasket, and

remaining governor pipe. (Fig. 7A4-294)

(NOTE: Do not allow manual valve to fall out of control

valve assembly during removal of control valve assembly.)
9. Remove the remaining governor pipe from control
valve assembly. (Fig. 7A4-295)

(NOTE : Do not remove detent solenoid attaching screws.)

(NOTE: If the transmission is in the car, the front servo
parts may drop down as the control valve assembly and
governor pipe are removed .)

"

PRESSURE REGULATOR VALVE,

PlPE HOLES

SPRING RETAINER WASHER

Fig. 7A4-293-Removing Governor Feed Pipe

PRESSURE BOOST VALVE
PRESSURE BOOST BUSHING
SNAP RING

Fig. 7A4-29 1 -Pressure Regulator Valve

Fig. 7A4-294-Removing Control Valve

G O V E R N O R PlPE

Fig. 7A4-292-Removing Lead From Connect or

Fig. 7A4-295 -Removing Governor Pipe

Band Apply Pin Selection

a. Attach Adapter Plate J-21370-8 to case nlYe
body face and torque to 18 ft. lbs. Install fixture Gauge
J-2 1370-6 to J-21370-8 Adapter Plate with two bolts
and insert 5-21370-7 Gauge Pin. Be sure the pin does
not bind when tightening bolts t o adapter plate and to
case face.
b. Apply 25 ft. lb. torque and note position of
step on gauge pin. Below first step required short pins
Above top step requires long pin, and between steps

Fig. 7A4-298 -Removing Front Servo

Fig. 7 A4-299 -Removing Rear Servo

Fig. 7A4-300-Checking Band Apply Pin

-________7

TUKBO HYDRA-MATIC - TORONADO 425 7A4-85

medium length pin. (Fig. 7A4-301)

The three selective pins are identified as follows:
t

PIN IDENTIFICATION

d. Withdraw manual shaft from case bore and

remove and discard "0" ring seal from manual shaft.
(Fig. 7A4-304)

PIN LENGTH

(NOTE: Be careful not to drop jam nut inside case .)

3 Rings
2 Rings
1 Ring

Medium
Short

The identification ring is located near the shoulder end

of the pin. Selecting the proper pin length is the equivalent
of adjusting the band.
16. If necessary, remove the manual linkage as follows:
a. Loosen the jam nut holding detent lever to
manual shaft. (Fig. 7A4-302)
b. Remove manual shaft retaining pin from case.
Pull straight out. (Fig. 7A4-303)
c. Loosen detent lever from machined flats on
manual shaft.

e . Remove detent lever, parking pawl actuator

rod, and jam nut from case.
17. Remove two attaching screws and parking bracket.
(Fig. 7A4-305)
18. Remove parking pawl shaft retaining pin from case.
Pull straight out. (Fig. 7A4-306)
19. Remove parking pawl shaft, parking pawl, and
return spring from case. (Fig. 7A4-307)
20. Remove electrical connector from case. (Fig.
7A4-308)
21. Remove and discard "0" ring seal from connector
sleeve.

SPROCKET HOUSING COVER AND PLATE ASSEMBLY,

LINK BELT DRIVE AND DRIVEN SPROCKETS
Removal
1 . Remove sprocket housing cover attachmg bolts.
2. Remove cover and gasket. Discard gasket.
3. Install 5-4646 snap ring pliers into sprocket bearing
retaining snap rings located under the drive and driven

Fig. 7A4-301 -Pin Selection Chart

Fig. 7A4-302-Removing Jam Nut

Fig. 7A4-304-Removing Manual Shaft And Detent Levers

Fig. 7A4-303-Removing Retaining Pin

Fig. 7A4-305 -Removing Parking Bradcet

TURBO HYDRA-MATIC - TORONADO 425 7A487

*

5 . Remove link belt from drive and driven sprockets.

6. If damaged, remove the teflon oil seal ring from

turbine shaft. (Fig. 7A4-312) If necessary to replace, the
,,,,ice ring is a cast iron hook type ring.
7. Inspect drive and driven sprocket bearing
asemblies for rough or damaged bearings.

DRIVING ON

(NOTE: Do not remove bearing assemblies from drive and

driven sprockets unless they need replacement .)

8. If removal of bearing assembly from drive and/or

driven sprockets is necessary, proceed as follows:
a. Remove sprocket to bearing assembly retaining
snap ring using J-5586, snap ring pliers. (Fig. 7A4-3 13)
b. Mount sprocket, with turbine or input shaft
placed in hole in work bench, on two 2" x 4" x 10"
pieces of wood.
c. With a hammer and brass rod, drive the inner
race, alternately through each of the access openings,
until the bearing assembly is removed frbm the
sprocket hub. (Fig. 7A4-3 14)
Fig. 7A4-314-Removing Bearing

DRlVE SPROCKET AND TURBINE SHAFT, AND LINK

BELT
I

1. Inspect drive sprocket teeth for nicks, burrs,

scoring, galling, and excessive wear.
(NOTE: Wear patternat bottom of teeth is normal.)

2. Inspect drive sprocket to ball bearing retaining

snap ring for damage.
3. Inspect drive sprocket ball bearing inner race
mounting surface for damage.
4. Inspect turbine shaft for open lubrication passages.
Run a tag wire through the passages to be sure they are
open. See lubrication chart in Diagnosis Sect ion.
5. Inspect spline for damage.
6. Inspect the bushing journals for damage.
7. Inspect the oil seal ring groove for damage or
excessive wear.
8. Inspect turbine shaft oil seal ring for damage. Do
not remove unless replacement of the ring is required. For
service, the ring will be hook type cast iron,
9. Inspect the turbine shaft for cracks or distortion.
10. Inspect the link belt for damage or loose links.
Fig. 7A4-312-Oil Seal Ring

OIL PASSAGES

SNAP RING

(NOTE: Check the guide links. Guide links are the wide
outside links on each side of the link belt.)
DRIVEN SPROCKET AND INPUT SHAFT
Inspection
1. Inspect driven sprocket teeth for nicks, burrs,
scoring, galling, and excessive wear.
(NOTE: Wear pattern at bottom of teeth is normal.)

Fig, 7A4-313-Removing Retaining Ring

2. Inspect sprocket t o ball bearing retaining snap ring

for damage.
3. Inspect ball bearing inner race mounting surface
for damage.
4. Inspect input shaft for open lubrication holes. Run
a tag wire through the holes t o be sure they are open.
5 . Inspect spline for damage.
6. Inspect bushing journal for damage.

7A4-88 TURBO HYDRA-MATIC-

SPROCKET BEARINGS
Installation
1. Turn sprocket so that turbine or input shaft is
pointing upward.
2. Install new sprocket bearing as follows:
a. Install support snap ring, letter side down,
onto shaft.
c. Using 5-6133-A, drive the bearing assembly
onto the hub of the sprocket until it is resting on the
bearing seat of the sprocket. (Fig. 7A4-315)
d . Install sprocket to bearing assembly retaining
snap ring into groove in sprocket hub.
3. If necessary, install hook type cast iron oil seal ring
on turbine shaft. (Fig. 7A4-312)

(NOTE: Turbine andlor input shaft may appear not to be

pressed fully into the sprockets. DO NOT attempt pressing
shaft into sprocket further as a specific length dimension is
held during initial assembly.)

e. Push end play tool down t o remove slack,

f. Push and hold output flange upward, Place
screwdriver in case opening at parking pawl area and
push upward on output carrier.
g. Place another screwdriver between the metal
lip of the end play tool and the driven sprocket
housing, now push upward on the metal lip of the end
play tool and read the resulting end play, which should
be between .003" and -024".
The selective washer controlling this end play is the
thrust washer located between the pump cover plate and
the forward clutch housing. If more or less washer thickness
is required to bring the end play within specifications,
select the proper washer from the chart below.

.060" to
.071" to
.082" to
.093" to
.104" to
.115" to
.126" to

.064"
.07511
.086"
.097"
.108"
-119"
.1301'

(NOTE: An oil soaked washer may tend to discolor so that

it will be necessary to measure the washer with micrometers
to determine its actual thickness.)
OIL PUMP
Removal
1, Remove two opposite pump attaching bolts from
the drive support housing.
2. Install two 5/16" x 4" guide pins or bolts. (Fig.
7A4-317)
3. Remove the remaining pump attaching bolts from
the drive support housing.
4. With one hand, hold the under side of the pump,
gently tap the guide pin until the pump is removed from
the case.

Fig, 7A4-315-Installing Bearing

FRONT UNIT END PLAY CHECK

1. Make front unit end play check as follows:
a. Install front unit end play checking Tool
5-22241 into driven sprocket housing so that the soft
plastic on the tool can engage the splines in the forward
clutch housing. Let the tool bottom on the mainshaft
and then withdraw it approximately 1/16" to 1/8" and
tighten wing nut. (Fig. 7A4-316)
b. Remove two of the 5/16" bolts from the
driven support housing.
c. Install 5116" threaded slide hammer bolt with
jam nut into one bolt hole in driven support housing.

(NOTE: Do not thread slide hammer bolt deep enough to

interfere with forward clutch housing travel.)
d. Mount dial indicator on rod and index
indicator to register with the forward clutch drum that
can be reached through second bolt removed from
driven support housing.

Fig. 7A4-316-Checking Front Unit End Play

TURBO HYDRA-MATIC - TORONADO 425 7A4-89

5. If necessary to remove the drive and driven

sprocket support housing assemblies, proceed as follows:
a. Remove the remaining sprocket support to
pump cover plate attaching bolts.
b . Using a plastic mallet, strike the stator shaft of
the drive sprocket support (Fig. 7A4-320) and the hub
of the driven sprocket support (Fig. 7A4-321) until
they are removed from their pump cover plate bores.

(NOTE: When driving the housings out of the pump cover

plate avoid damaging or distorting the stator shaft or the
ring grooves in the hub of the driven housing.)

Fig. 7A4-317 -Oil Pump Removal

PUMP COVER PLATE AND DRIVE AND DRIVEN

SUPPORT HOUSING ASSEMBLIES

c. Remove and discard housing t o pump cover

plate gaskets.
d. Remove and inspect converter out check valve
from pump cover. (Fig. 7A4-322)
e. Install converter out check valve, tanged end
first, into oil passages and coil remainder of valve
within itself. (Fig. 7A4-322)

Removal
I . Remove the pump cover plate to case attaching
screws. Do not remove sprocket support housing bolts at
this time.
2. Remove pump cover plate and plate to case face
gasket. Discard gasket. (Fig. 7A4-318)
3. Check condition of all seal rings and remove from
the driven support housing if necessary. (Fig. 7A4-3 19)
4. Remove the front unit end play selective thrust
washer from the hub of the driven support housing.

(NOTE: Drive and driven support housing assemblies are

pressed into and removed with the pump cover plate. Do
not remove them unless it is necessary.)

STATOR SHAFT

SPROCKET SUPPORT HOUSINGS

Fig. 7A4-320 -Removing Drive Sprodtet Support

PLASTIC
HAMMER\

Fig. 7 A 4 3 18-Removing Support Housings And Cover Plate

--.I.

n
HOUSING
?EVENT
VE

Fig. 7A4-319 -Removing Or Installing

Oil Rings And Thrust Washer

Fig. 7A4-321 -Removing Driven Sprocket

7A4-90 TURBO HYDRA-MATIC - TORONADO 425

Fig. 7A4-322 -Removing Or Installing Check Valve

Fig. 7A4-324-Installing Teflon Oil Seal Ring

DRIVE AND DRIVEN SPROCKET

FORWARD CLUTCH,DIRECT CLUTCH, FRONT BAND

ASSEMBLY AND SUN GEAR SHAFT
(NOTE: Steps I through 6 can be omitted if parts were not
1. Install drive sprocket support housing to pump
cover plate gasket.
2. Install drive sprocket support housing into pump
cover plate by using a plastic mallet to seat the housing. Use
bolts for guides. (Fig. 7A4-323)
3. Install driven sprocket support housing to pump
cover plate gasket.
4. Install driven sprocket support housing to pump
cover plate attaching bolts for gasket guides.
5, Install driven sprocket support housing into pump
cover plate by using a plastic mallet to seat the housing.
6. Install all but two driven support housing to pump

Removal
1. Remove forward clutch housing assembly, using
Tool 5-22241. (Fig. 7A4-325)
2. Remove forward clutch hub to direct clutch
housing thrust washer if it did not come out with the
forward clutch housing assembly.
3. Remove direct clutch housing assembly. (Fig.
7 A4-32 6)
4. Remove the front band. (Fig. 7A4-327)
5. Remove sun gear shaft from gear unit assembly.
(Fig. 7A4-328)

REAR UNIT END PLAY CHECK

1. Make rear unit end play check as follows:
a. Install 3/8" bolt for slide hammer into one of
the final drive attaching bolt holes. Allow end of case
to hang over edge of bench. (Fig. 7A4-329)
b. Mount dial indicator on the bolt and index
with end of output flange.

FRONT UNIT END PLAY

CHECKING TOOL

USE BOLTS F O

Fig. 7A4-323-Installing Drive Sprocket

Fig. 7A4-325 -Removing Forward Clutch Housing

**-)*T@PgQ%%$"

TURBO HYDRA-MATIC - TORONADO 425 7A4-91

c. Move the output flange in and out toread the

end play. End play should read .007" to .019". The
selective washer controlling this end play is the steel
washer having three lugs that is located between the
output flange thrust washer and the rear face of the
transmission case.
If a different washer thickness is required to bring the
end play within specifications, it can be selected from the
following chart :

Thickness
.m4" to
.082" to
.090" to
.098" to
.106" to
.114" to

.078"
.086"
.094"
.102"
.110"
.118"

Notches and/or Numeral

None . . . .
1 Tab Side .
2 Tab Side .
1 Tab O D . .
2 Tabs O.D.
3 Tabs O D .

. . . . . . . . .1
. . . . . . . . .2
. . . . . . . . .3
. . . . . . . . .4
. . . . . . . . .5
. . . . . . . . -6

CENTER SUPPORT; GEAR UNIT ASSEMBLY, SPACER,

REAR BAND ASSEMBLY, AND REAR UNIT
SELECTIVE WASHER
Removal
1. Remove the center support to case bolt, using a
318" 12-point thin wall deep socket. (Fig. 7A4-330)

Fig. 7A4-328-Removing Sun Gear Shaft

Fig. 7A4-326-Removing Direct Clutch

Fig. 7A4-329-Checking Rear End Play

Fig. 7A4-327 -Removing Front Band

F&.7A4-330-Removing Center Support Belt

INTERMEDIATE CLUTCH

DIRECT CLUTCH

TURBO HYDRA-MATIC - TORONADO 425 7A4-93

8. Remove support to case spacer. (Fig. 7A4-337)

9. Remove the rear band assembly. (Fig. 7A4-338)
10. Remove the rear unit selective washer from the
case. (Fig. 7A4-339)

DISASSEMBLY AND ASSEMBLY OF

INDIVIDUAL UNITS
SUPPORT AND GEAR UNIT
Disassembly
1 . ~ i m o v e the center support assembly. (Fig.
7A4-340)
2. Remove the center support t o reaction carrier
thrust washer. (Fig. 7A4-342)

Fig. 7A4-337-Removing Spacer

Fig. 7A4-340 -Removing Center Support

THRUST WASHER
Fig. 7A4-338-Removing Rear Band

Fig. 7A4-339 -Removing Selective Thrust Washer

Fig. 7A4-341 -Removing Thrust Washer

7A4-94 TURBO HYDRA-MATIC - TORONADO 425

3. Remove the center support to sun gear races and

thrust bearing. (Fig. 7A4-342)
4. Remove the reaction carrier and roller clutch
assembly. (Fig. 7A4-343)
5. Remove roller clutch assembly from reaction
carrier. (Fig. 7A4-344)
6. Remove front internal gear ring from output
carrier assembly. (Fig. 7A4-345)
7. Remove sun gear. (Fig. 7A4-346)
8. Remove reaction carrier to output carrier thrust
washer. (Fig. 7A4-347)
9. Turn assembly over.
10. Remove output flange to output carrier snap ring.
(Fig. 7A4-348)
11. Remove out put flange. (Fig. 7A4-349)
12. Remove output flange t o rear internal gear thrust
bearing and two races. (Fig. 7A4-350)
13. Remove rear internal gear and mainshaft. (Fig.
7A4-35 1)

Fig. 7A4-344-Removing Roller Clutch

MAIN SHAFT

d!

I.D. FLANGED

T BEARINGS
ANGED

Fig. 7A4-345-Removing Front Internal Gear Ring

r

Fig. 7A4-342-Removing Sun Gear Races And Bearings

Fig. 7A4-343-Removing Reaction Carrier

Fig. 7A4-346-Removing Sun Gear

TURBO HYDRA-MATIC - TORONADO 425 7A4-95

O.D.

I.D. FLANGED
>RACE

Fig. 7A4-350-Removing Thrust Bearing And Races

REAR

Fig. 7A4-35 1 -Removing Rear Internal Gear And Mainshaft

Fig. 7A4-352-Removing T h s t Bearing And Races

7A4-96 TURBO HYDRA-MATIC - TORONADO 425

3. Remove the spring retainer and six clutch

springs. (Fig. 7A4-356)
4. Remove the nylon spring guide.
5. Remove the intermediate clutch piston.
7A4-357)
6. Remove and discard the inner piston seal, (p
7A4-358)
7. Remove and discard the outer piston seal. (F
7A4-359)

CENTER SUPPORT
Disassembly
1 . Remove the four (4) oil seal rings from the center
support. (Fig. 7A4-354)
2 . Using clutch compressor or tools J-6129 and
54670-14, compress the spring retainer and remove snap
ring. (Fig. 7A4-355)

(NOTE: Do not remove the three screws retaining

roller clutch inner race to the center support .)

INTERNAL G E A R

Inspection
1 . Inspect the roller clutch inner race for scratches
indentations. Be sure the lubrication hole is open
running a tag wire through this hole. See lubrication ch
for location of holes.
2. Inspect the bushing for scoring, wear, or galling.
3. Check oil ring grooves for damage or excessive
wear.
4. ~ i check
r
the oil passages to be sure they are open
and are not interconnected. See lubrication chart for
location of holes.
5. Inspect the piston sealing surfaces for scratches.

SNAP RING

INTERMEDIATE CLUTCH
RELEASE SPRING ( 6 )

Fig. 7A4-353-Removing Snap Ring

1
1

L SEAL RINGS

Fig. 7A4-356-Removing Intermediate Clutch Springs

Fig. 7A4-354-Removing Oil Seal Rings

Fig. 7A4-355 -Removing Snap Ring

Fig. 7A4-357 -Removing Intermediate Clutch Piston

TURBO HYDRA-MATIC - TORONADO 425 7A4-97

6. Inspect the piston seal grooves for nicks and other

6. Inspect oil seal rings for damage.

TE: ply transmission oil t o all seals before installing

no)

3. ~nstallinner seal protector. Tool 5-21 363, on the

a t e r support hub. Install the piston, indexing spring
pocketsin the piston and center support. (Fig. 7A4-361)

MOTE: Spring pocket recesses in the piston must match

k k e t s in center support .)

Fig. 7A4-358-Removing Or Installing Inner Seal

I
ROLLER
ASSEMBLY

CENTER SUPPORT
ASSEMBLY

CLUTCH OUTER SEAL

Fig. 7A4-359-Removing Or Installing Outer Seal

Fig. 7A4-361 -Installing Intermediate Clutch Piston

7A4-98 TURBO HYDRA-MATIC - TORONADO 425

4. Install nylon spring guide in piston. (Fig. 7A4-362)

5. Install six release springs into the piston, space
equally.
6. Place the spring retainer and snap ring over the
springs.
7. Using clutch compressor tools 5-6129 and
5-4670-14, compress the springs and install the snap ring.
(Fig. 7 A4-355)
8. Install the four (4) oil seal rings on the center
support. (Fig. 7A4-354)
(NOTE: If teflon rings are being used, make sure slit ends
are assembled in same relation as cut, Fig. 7A4-363. Also,
make sure oil seal rings are seated in ring grooves to prevent
damage to rings during reassembly of mating parts over
rings.)

9. Air check operation of intermediate clutch and

pist on. (Fig. 7A4-364)
F@. 7 A4-364-Air Checking Intermediate Clutch And Piston

RE ACTION CARRIER, ROLLER CLUTCH, AND

OUTPUT CARRIER
Inspection
1. If the reaction carrier has a spacer ring in an
undercut at the bottom of the roller cam ramps, inspect it
for damage. (Fig, 7A4-365)
(NOTE: The reaction carrier with the undercut and spacer
ring is used optionally and interchangeably with the
reaction carrier which does not have an undercut and spacer
ring ,)
I

REACTION

Fig. 7A4-362-Installing Nylon Spring Guide

Fig. 7A4-365 -Inspecting Reaction Carrier Spacer Ring

3
RIGHT

WRONG

Fig. 7A4-363-Inst alling Teflon Oil Seal Rings

Fig. 7A4-366-Checking Piston End Play

TURBO HYDRA-MATIC - TORONADO 425 7A4-99

4. Inspect the thrust washer surfaces for signs of

scoringor Wear.
5 . Inspect the bushing for damage. If bushing is
damaged,the reaction carrier must be replaced.
6 . Inspect the pinions for damage, rough bearings, or
,xossive tilt.
7. Check pinion end play. Pinion end play should be
to .024".(Fig. 7A4-364)
8 . Inspect the roller clutch for damage.
9: Inspect the roller cage and retaking springs for
darnage.
10. Inspect the front internal gear in output carrier
for damaged teeth.
1 1 . Inspect the output carrier pinions for damage,
roughbearings, or excessive tilt.
12. Check output carrier pinion end play. Pinion end
play should be .009" to -024". (Fig. 7A4-367)
13. Inspect the parking pawl lugs for cracks or damage.
14. Inspect the output locating splines for damage.
15. Inspect the front internal plastic gear
ring for
flaking or cracks.

6. Place a steel and bronze washer on each side of

pinion so steel washer is against pinion. Hold in place with
petrolatum or equivalent.
7. Place the pinion assembly in position in the carrier
and install a pilot shaft through the rear face of the
assembly to hold the parts in place.
8. Drive a new pinion pin into place while rotating
pinion from the front. Be sure that the head end is flush or
below the face of the carrier. (Fig. 7A4-370)

.wtt

PINION GEARS
Removal and Installation
1. Support the carrier assembly on its front face.
2. Using a 1/2" drill, remove the stake marks from
the end of the pinion pin, or pins, t o be replaced. This will
reduce the possibility of cracking the carrier when the
pinion pins are pressed out.

Fig. 7A4-368-Removing Pinion Pins

P I N O N PIN

TNZE
w-HE>E.

WASH,%

7 PLANET PINION

CAUTION: Do not allow drill to

remove any stock from the carrier
as this will weaken the part.
3. Remove the pinions, thrust washers, and roller
needle bearings. (Fig. 7A4-368)
4. Inspect the pinion pocket thrust faces for burrs
and remove if resent.
5. 1nstalf eighteen needle bearings into each pinion,
using petrolatum to hold the bearings in place. Use a pinion
pin as a guide, (Fig. 7A4-369)

Fig. 7A4-367-Checking Output Carrier Pinion End Play

I
HEADED END

L-.

i, -

I
NEEDLE LARINGS

STEEL WASHER

saoNzE wAsneu A
Fig. 7A4-369-Planet Pinion Gears - Exploded

PLANET PINION PIN

HEAD END UP

Fig. 7A4-370-Installing Pinion Pin

7A4-100 TURBO HYDRA-MATIC - TORONADO 4

:e a- large ,
~ u n c h-_in a bench
vise to be used as an
9. Plac_
anvil while staking the opposite end of the pinion pin in
three places. (Fig. 7A4-37 1)
.

.-_

(NOTE: Both ends of the pinion pins must lie be1.ow the
face of the carrier or interference may occur.)

OUTPUT FLANGE
Inspection

Tnsnect
~ --s h- Di n-for
-1 .. -- - - - - the
-- - - h
- ~- --p- wear
--- or
-- alli in^.
2. Inspect the governor drive gear for rough or
damaged teeth.
3. Inspect the drive lugs for damage.
4. Ins~ectlubrication ~assanes.
D----U7

'

Rear Internal Gear

1. Inspect the gear teeth for damage or wear.
2. Inspect the splines for damage.
3. Inspect the gear for cracks.
4. Inspect bearing and thrust surfaces for wear
ing .

1
a

Sun Gear
1. Inspect the gear teeth for damage or wear.
2. Inspect splines for damage.
3. Be sure oil lubrication hole is owen. See Il~hrin-+:,chart for location of holes.
Sun Gear Shaft
1. Inswect shaft for cracks or splits.
2. 1nGect splines for damage. *
3. Inspect bushings for scoring or galling.
4, Inspect the bushing journals for damage.
5. Be sure the oil lubrication holes are m e -n- --lubrication chart for location of holes.
I

YY"

Mainshaft
1. Inspect the shaft for cracks or distortion.
2. 1nGect the splines for damage.
3. Inspect the bushing journals for damage.
4. Inspect the snap ring groove for damage.
5. Inspect for open lubrication passages.

THREE LOCATION

GEAR UNIT (Fig. 7A4-372)

Assembly
1. Install rear internal gear on end of mainshaft and
;all snap ring. (Fig. 7 ~ 4 - 3 7 3 )
2. Install the sun gear to internal gear thrust races and
bea rings against the inner face of the rear internal gear as
follows: (Retain with petrolatum or equivalent). (Fig.
a. Place the large race against the internal gear
with O.D. flange facing rearward or up.

Fig. 7A4-37 1 -Staking Pinion Pin

FLANGED
THRUST
WASHER

BEARING

CARRIER

GEAR RING

ASSEMBLY
SHAFT
P

Fig. 7A4-3724ear Unit -Explode(..

I.D. FLANGE
RACE

TURBO HYDRA-MATIC - TORONADO 425 7A4-101

b. Place the thrust bearing against the race.

c. Place the small race against the bearing with
the inner flange facing into the bearing or down.
4. Install the output carrier over the mainshaft so that
the pinions mesh with the rear internal gear. (Fig. 7A4-375)
5. Place the above portion of the build-up through
hole in bench so that the mainshaft hangs downward.
6. Install the rear internal gear t o output flange thrust
races and bearings as follows: (Retain with petrolatum or
equivalent). (Fig. 7A4-376)
a. Place the small diameter race against the
internal gear with the center flange facing up.
b. Place the bearing on the race.
c. Place the second race on the bearing with the
outer flange cupped over the bearing.
7. lnstall the output flange into the output carrier
assembly. (Fig. 7A4-377)
8. Install the output flange to the output carrier snap
ring. (Fig. 7A4-378)
9. Turn assembly over and support so that the output
flange faces downward.

Fig. 7 A4-37 3 -Installing Snap Ring

O.D. FLANGED
RACE

THRUST
BEARlNG

/
1.0. FLANGED
'RACE

Fig. 7A4-374-Installing Thrust Bearing And Races

Fig. 7 A4-37 6-Installing Thrust Bear mg And Races

OUTPUT
FLANGE

Fig. 7A4-375 -Installing Output Carrier

Fig. 7A4-377-Installing Output Flange

TURBO HYDRA-MATIC - TORONADO 425 7A4-103

2. Inspect the bands for cracks or distortion.

3 . Inspect the end for damage at the anchor lugs or
apply lugs.

VOTE: with reaction carrier held, center support should

turn clockwise.)
19. Instau output flange t o case METAL thrust washer,
&bs in ~ockets.Retain with petrolatum or equivalent. (Fig.
7~4-387)

Modulator and Valve

I . Inspect the modulator assembly for any signs of
bending, distortion, or presence of water or oil.
2. lnspect the "0"ring seal seat for damage.
3 . Apply suction to the vacuum tube and check for
diaphragm leaks.
4. Inspect the modulator valve for nicks or damage.
5. Inspect case bushing for nicks or scoring.
6. Check freeness of valve operation in case bushing
bore.

VOTE: This must be a METAL washer .)

INSPECTION

Front and Rear Bands

1. Inspect the lining for cracks, flaking, burning or
looseness.

1.D. FLANGED

THRUST BEARING
I.D. FLANGED

Fig. 7A4-385 -Installing Roller Clutch

Fig. 7A4-38 3-Installing Sun Gear Thrust Bearing And Races

THRUST WASHER

Fig. 7 A4-384-Installing Thrust Washer

Fig. 7A4-386-Installing Center Support

! I

7A4-104 TURBO HYDRA-MATIC - TORONADO 425

4. Check converter end clearance as Outhed in

"CHECKING CONVERTER".
5. Check converter stator operation as outlined in
DIAGNOSIS SECTION.

REAR SERVO
Disassembly
1. Remove the rear accumulator piston from rear
servo piston. (Fig. 7A4-388)
2. Remove E q h g retaining rear servo piston to band
apply pin. (Fig. 7A4-389)
3. Remove rear servo piston and seal from band apply
pin.
4.Remove washer, spring and retainer. (Fig.
7A4-390)

1/11

Fig. 7A4-387 -1nst alling Thrust Washer

I

7. Check modulator bellows. modulator plunger is

under pressure (16 Ibs.). If bellows are damaged the p6nger
will have very little pressure. (Refer to "VACUUM
MODULATOR~IAGNOSIS")

Manual and Parking Linkage

1. Ins~ect the oarking actuator rod for cracks.
damage, or broken sprGg retaker lugs.
2. Inspect the actuator spring for damage.
3. Inspect actuator for a free fit on the actuator rod.
4. Inspect the parking pawl for cracks or wear.
5. Inspect the manual shaft for damaged threads,
rough oil seal groove or loose lever.
6. Inspect the inside detent lever for cracks or a loose

(NOTE: Do not remove the teflon oil seal rings from the
rear accumulator piston, unless the oil seal rings require
replacement. If the teflon inner oil seal ring, (small
diameter) requires replacement, use the aluminum oil seal
ring. The rear accumulator piston, large diameter rine
depth, is rnachmed shalfower t o tace the large tefloi
oil seal ring, if this requires replacement, use only the teflon
oil seal ring.)

retainer grobves, or rough surface.

8. Inspect the parking pawl return spring for
deformed coils or ends.
9. Inspect the parking bracket for cracks or wear.
10. Inspect the detent roller and spring assembly.
Case

(NOTE: If the case assembly requires replacement, make

sure the center support to-case spacer is removed from the
old case and reinsii~edin the new case.)

I
/

E
I
i

1';

11
I

1. Inspect case assembly for cracks, porosity, or

interconnected passages. Air can be blown through passages
t o determine if they are interconnected. See lubrication
chart for Iocation of passages,
2. Check for good retention of band anchor vins.
3. Inspect a l l h e a d e d holes for thread damage.
4. Inspect the intermediate clutch plate lugs for
damage or brinelling.
5. Inspect the snap ring grooves for damage.
6. Inspect the bore of the governor assembly for
scratches or scoring.
7. Inspect the modulator bushing bore for scoring or
damage.
8. Inspect the pressure regulator bore for scoring or
damage.
Converter
1. Check converter for cracks or broken welds.
2. Check converter hub surfaces for signs of scoring
or wear.
3. Check converter for leaks as outlined in
"CHECKING CONVERTER".

1 1

ACCUMULA?OR PISTON
Fig. 7 A4-388-Removing Accumulator Piston
SERVO PISTON

Fig. 7A4-389 -Removing "E" Ring

TURBO HYDRA-MATIC - TORONADO 425 7A4-105

GOVERNOR ASSEMBLY
1. Inspect freeness of accumulator rings in piston
nd apply pin determined by band
d apply pin in servo piston.
ly pin and servo piston for scores

1. Install spring retainer, cup end first, spring and

washeron band apply pin. (Fig. 7A4-390)
2. Install rear servo piston to band, apply pin and
secure with E-ring. (Fig. 7A4-389)
3. If removed, install oil seal ring on servo pist on.
4. If removed, install outer and inner oil rings on
piston. Assemble into bore of servo piston.
( ~ j g .7A4-388)

-~

RETAINING
"E" RING
SERVO PISTON

ACCUMULATOR PISTON

All parts of the governor assembly, with the exception

of the driven gear, are a select fit and each assembly is
factory calibrated. The governor, including the driven gear,
is serviced as a complete assembly. However, the driven gear
can also be serviced separately.

Governor Inspection
1. Wash in cleaning solvent, and blow out all passages.
2. Inspect governor sleeve for nicks, burrs, scoring or
galling.
3. Check governor sleeve for free operation in bore of
transmission case.
4. Check governor valve for free operation in bore of
governor sleeve.
5. Inspect governor driven gear for nicks, burrs, or
damage,
6. Check governor driven gear for looseness in
governor sleeve.
7 . Inspect speedometer drive gear for nicks, burrs, or
damage.
8. Check speedometer drive gear for looseness on
governor sleeve.
9 . Inspect governor springs for distortion or damage.
10. Check governor weights for free operation in their
retainers.
11. Check valve opening at entry and exhaust (.020"
minimum).

SERVO OIL SEAL

SERVO PIN

Fig. 7A4-390-Rear Servo And Accumulator

FRONT SERVO (Fig. 7A4-391 )

Inspection
(NOTE: Do not remove the teflon oil seal ring from the
front servo piston unless the oil seal ring requires
replacement. For Service, the oil seal ring will be
aluminum.)

1. Inspect servo pin for damage. Roll pin on a flat

surface to determine the straightness of pin.
2. Inspect piston and oil ring for damage.
3. Inspect piston for cracks or porosity.
4. Check fit of servo pin in piston.
TEFLON O I L SEA1 RING

SERVO SP RING

Governor Driven Gear Replacement

To facilitate governor repair in the field, governor
driven gear and a replacement retaining pin are available for
service use. The service package contains a nylon driven
gear, and one governor gear retainer split pin. Replacement
of gear must be performed with care in the following
manner:
1. Place governor sleeve on a block of wood and drive
retaining pin out, using a small punch or 118" drill rod.
2. Remove governor driven gear as follows:
a. Insert governor driven gear in a vice.
b. Firmly grip governor sleeve with hands and
twisting and pulling at the same time, pull governor
sleeve away from the governor driven gear.
c. Discard governor driven gear.
3. Remove governor valve and wash all parts in
cleaning solvent and blow off parts.
4. Install governor valve, end with holes last, into
governor sleeve.
5 . Support governor on 7/64" plates, installed in
exhaust slots of sleeve, position new gear in sleeve and with
a 7/16" socket, press gear into sleeve until seated. (Fig.
7 A4-392)
6. A new hole must be drilled through sleeve and
gear. Locate hole position 90 degrees from existing hole,
center new hole through sleeve and gear using a standard
1/8" drill. (Fig. 7A4-393)
7 . Install split retaining pin, making sure each end is
slghtly below top of hole.

CA U TION: Extreme care must be

taken
parts.

to prevent damaging the

SPRING RETAINER

Fig. 7A4-39 1 -Front Servo

8 . Stake both ends of pin hole, two places.

9 . Thoroughly wash governor assembly in cleaning
solvent and blow out all passages.

7A4-106 TURBO HYDRA-MATIC - TORONADO 425

accumulator piston and remove retaining E-ring. (F.

7 A4-39 6)
45
7. Release Tool J-22269 and remove the tool, the
front accumulator piston, and spring from valve assembly.
8 . Using a pair of needle nose pliers, compress the
bore plug and remove the retaining pin from the 3-2 valve

Fig. 7A4-392-Installing Governor Gear

Fig. 7A4-394-Removing Detent Solenoid

REAR SERVO

Fig. 7A4-393-Drilling Governol Gear

CONTROL VALVE

FRONT ACCUMUL

Fig. 7A4-395-Removing Manual Valve

Disassembly

(NOTE: As each valve train is removed, place the

individual valve train in a separate location relative to its
position in the valve body. Also, place each part of each
valve train in the order that it is removed from the valve
bore. None of the valves or springs are interchangeable.
Keep them in the proper valve train.)
1. Remove two detent solenoid to valve assembly
attaching screws. (Fig. 7A4-394)
2. Remove detent solenoid and solenoid gasket.
Discard gasket.
3. Position valve assembly with lapped face up so that
the servo bore and the front accumulator piston are
positioned as shown in Fig. 7A4-395.
4. Remove mdnual valve from bore. (Fig. 7A4-395)
5. Use a No. 1 easy-out q d remove retaining pin and
plug from manual valve bore.
6. Install available compressor Tool 5-22269 on front

Fig. 7A 4-396 -Removing Front Accumulator Piston

TURBO HYDRA-MATIC - TORONADO 425 7A4-107

bore located in the extreme upper right hand corner of the

valve assembly. (Fig. 7A4-397)
9. Remove the bore plug, 3-2 valve, spring and 3-2
rnlve pin from the valve assembly.
10. Remove the retaining pin from the 2-3 valve train
bore located directly below and at a right angle to the 3-2
valve.
1 1 . Remove the 2-3 modulator bushing, 2-3 modulator
valve and spring, the 3-2 intermediate spring, and the 2-3
valve.

12. Remove the retaining pin from the 1-2 valve bore
located directly below the 2-3 valve train bore.
13. Remove the 1-2 modulator valve bushing, 1-2
regulator valve, 1-2 detent valve and spring and the 1-2
valve.
14. Remove the retaining pin from the detent regulator
bore located directly below the 1-2 valve bore.
15. Remove the bore plug, detent valve, detent
regulator valve, detent regulator pin and spring.
16. Remove the 1-2 accurnuIator retaining pin and
bore plug from the hole located to the right of the manual
valve.
17. Remove 1-2 accumulator valve and the 1-2
accumulator primary spring.

RETAINING PIN

Inspection (Fig. 7A4-398)

(NOTE: Do not remove the teflon oil seal ring from the
front accumulator piston unless the oil seal ring requires
replacement. For service, the oil seal ring will be cast iron.)

RIGHT
CORNER

1. Thoroughly wash and clean valve body in a clean

solvent to remove the oil.
2. Inspect valve body for cracked lands in the valve
port areas, scratches or porosity in bores, nicks on the
machined face, and cracks, scratches, nicks or distortion in
the servo bores.

Fig. 7A4-397-Removing 3-2 Valve Retaining Pin

1.
2.
3.
4.
5.
6.
7.
8.
9.

MANUAL VALVE
DETENT SOLENO ID
GASKET
FRONT ACCUMULATOR SPR ING
011 RING
ACCUMULATOR P ISTON
E-RING
3-2 VALVE P I N
3-2 VALVE SPRING

19.
20.
21.
22.
23.
24.
25.
26.
27.

*/

10.
11.
12.
13.
14.
15.
16.
17.
18.

3-2 VALVE
3-2 BORE PLUG
RETAINER PIN
2-3 VALVE
3-2 INTERMED IATE SPR l NG
2-3 MODULATOR VALVE
2-3 MODULATOR BUSHING
2-3 VALVE S PR ING
RETAINER PIN

33

34

1"

35

-- 36

28.
29.
30.
31.
32.
33.
34.
35.

1-2 VALVE
1-2 DETENT VALVE
1-2 REGULATOR S PR ING
1-2 REGULATOR VALVE
1-2 MODULATOR BUSHING
RETAINER PIN
DETENT REGULATOR PIN
DETENT REGULATOR SPR ING
DETENT REGULATOR VALVE

DETENT VALVE
VALVE BORE PLUG
RETAINER PIN
VALVE BORE PLUG
RETAINER PIN
1-2 ACCUMULATOR PRIMARY SPRING
1-2 ACCUMULATOR VALVE
1-2 ACCUMULATOR VALVE PLUG
36, RETAINER PIN

Fig. 7 A4-398-Valve Body - Exploded

7A4-108 TURBO HYDRA-MATIC - TORONADO 425

3. Inspect front servo pin for scqring, cracks, and

squareness of corner shoulders.

(NOTE: Valve corners should be sharp and square.)

4. Inspect bushings for galling, scratches, or
distortion.
5. Check all springs for distortion or collapsed coils.
6. Inspect accumulator piston and oil ring for

Inspection
1. Inspect gear pocket and crescent for nicks, burrs,
scoring or galling.
2. Inspect drive gear for nicks, burrs, scoring,
galling.
3. Inspect driven gear for nicks, burrs, scoring,
galling.
4. Place pump gears in pump body and check the
following gear face to pump face clearances.
a. Pump body face to gear face can be checked

Assembly (Fig. 7A4398)

1 . Install the 1-2 accumulator primary spring and the
1-2 accumulator valve (stem end out) into the 1-2
accumulator bore in valve body.
2 . Install the 1-2 accumulator plug (hole end out)
into the bore.
3. Install grooved retaining pin, with the grooves
entering the pin hole last, and tap with a hammer until
flush with cast surface of the valve body.
4. Install spring, detent regulator pin, detent regulator
valve (stem end out), detent valve (small land first), bore
plug (hole end out) and retaining pin into detent bore.
(Compress spring with screwdriver t o aid installation of
detent valve into the valve body).
5. Install 1-2 valve into 1-2 valve bore, long stem end
6. Install 1-2 regulator valve, beveled stem out, into
1-2 regulator bushing. Install 1-2 regulator spring into
bushing over beveled end of 1-2 regulator valve. Position
1-2 modulator valve over spring in bushing, hole end first.
7. Install 1-2 modulator valve bushing assembly into
1-2 valve bore (open end of bushing first) and install
retaining pin into valve body,
8. Install 3-2 intermediate spring into 2-3 valve and
install both parts into 2-3 bore, open end out.
9. Install 2-3 modulator valve (open end first) into

Fig. 7A4-399 -Removing Or Installing Pump Drive Gear

11. Install 3-2 valve spring, spacer and 3-2 valve (either
end first) into 3-2 valve bore,
12. Install valve bore plug (hole end out) and retaining
pin into valve body.
13. Using Tool 5-22269, install front servo spring,
front servo piston, and retaining E-ring into front
accumulator piston pocket.
14. Install detent solenoid gasket, detent solenoid, and
attaching screws on reverse side of valve body assembly.
15. Check all valve trains t o see that they are operating
freely by compressing the valves on the springs.
16. Install manual bore plug and retaining pin.
17. Inst all manual valve into manual bore.

OIL PUMP

3. Remove and discard pump body t o case "0" ring

seal. (Fig. 7A4-401)

Fig. 7A4-401 -Removing Or Installing Pump To Case seal

TURBO HYDRA-MATIC - TORONADO 425 7A4-109

by placing a dial indicator on the J-8619-11 gauge and

reading the flatness between the pump face and the
pump gears. End clearance should be .0013" to .0035".
(Fig. 7A4402)
5. Check face of pump body for nicks, burrs, scoring,
or galling.
6 . Check pump body face flatness. Overall flatness
should b e -000"to . h 2 " .use J-8619-11 and Dial Indicator
J-8001.
7. Inspect bushing for nicks, burrs, scoring, galling,
out-of-round, or excessive wear.
a. To check for out-of-round, install pump body
on the converter hub and look for eccentricity between
pump bushing and converter hub. (Fig. 7A4-403)
8, Check for damaged pump cover plate bolt holes.
9. Inspect front seal for damage. If replacement of
front seal is necessary, use a standard 314" cold chisel and
pry front seal from pump body. (Fig. 7A4-404)

2. Install the driven gear into the pump body. (Fig.

7A4-400) Alignment mark up.
(NOTE: Some pump driven gears have a rectangular or
triangular I.D. mark on the face of a tooth. If so, the driven
gear must be installed with the I.D. mark facing down.)

3 . Install the drive gear into the pump body with

drive tangs up. (Fig. 7A4-399) Alignment mark up.
4. Install the new pump to case "0" ring seal. (Fig.
7 A4-40 1)

Assembly
1. If necessary, install a new front seal, using Tool
5.21359 to drive the seal in place. Use Sealer No. 1050026
or eauivalent on outside of seal before installing into pump.

Fig . 7 A 4 4 4 -Removing Front Seal

Fig. 7A4-402-Checking Gear End Clearance

Fig. 7 A4-403-Checking Bushing Runout

Fig. 7A4-405 -Installing Front Seal

DIRECT CLUTCH HUB

TURBO HYDRA-MATIC - TORONADO 425 7A4-111

7. Remove the forward clutch piston. (Fig. 7A4412)

4. Inspect the piston for cracks or excessive porosity

on sealing surfaces.
5. Inspect the clutch housing for wear, scoring, open
oil passages, and free operating of the ball check. Run a tag
wire through lubrication holes. See lubrication chart for
location of holes.

(NOTE: Current transmissions use a direct clutch piston

without a check ball. Therefore, the forward and direct
clutch pistons look almost the same. Make sure the forward
piston is identified during disassembly so it will be
reassembled into the forward clutch housing. The
built forward clutch piston will be aluminum or
stamped steel .)

k m b l y (Figs. 7A4416 and 7A4417)

RJOTE: Apply transmission

reassembly-)

8. Remove and discard inner and outer clutch piston

seals. (Figs. 7A4413 and 7A4-414)
9. Remove and discard the center piston seal from the
forward clutch housing. (Fig. 7A4-4 15)

oil to all seals before

1. Place new inner and outer seals on clutch pist on,

lips away from spring pockets. (Figs. 7A4-413 and
7A4-414)
2. Place a new center seal on the clutch housing, lip
faces up. (Fig. 7A4-415)

hspection
1. Inspect the composition faced and steel clutch
plates for signs of burning, scoring, or wear.
2. Inspect the sixteen springs for collapsed coils or
signs of distortion.
3. Inspect the clutch hubs for worn splines, thrust
faces and open lubrication holes. Run a tag wire through
each lubrication hole. See lubrication chart for location of
holes.

Fig. 7A44134emoving Or Installing h a Oil Seal

Fig. 7A4-411 -Removing Or Installing Forward

Clutch Springs

CLUTCH OUTER SEAL

/
FORWARD CLUTCH PISTON

Fig. 7A4-414-Removing Or Installing Outer Oil Seal

I
Fig. 7A4-412 -Removing Forward Clutch Piston

CLUTCH CENTER SEAL

Fig. 7A4-415-Removing Or Installing Center Oil Seal

on side of hub fachg forward dutch housing. Retain with

petrolatum or equivalent. (Fig. 7A4-420)
8. Place forward clutch hub into forward clutch

DIRECT CLUTCH

FORWARD CLUTCH ASSEMBlY

FORWARD CLUTCH INNER SEAL

SPRING RETAINER

TURBO HYDRA-MATIC -TORONADO 425 7A4-113

FORWARD CLUTCH

10. Install the direct clutch hub and retaining snap

ring. (Figs.. 7A4-422 and 7A4-423)
11. Air check clutch and piston operation. (Fig.
7 A4-424)
DIRECT CLUTCH AND INTERMEDIATE SPRAG

Disassembly
1. ~ e m o v esprag retainer snap ring and retainer. (Fig.
7A4-425)
2. Remove sprag outer race, bushings, and sprag
assembly. (Fig. 7A4426)
3. Turn unit over and remove backing plate t o direct
clutch housing snap ring. (Fig. 7A4-427)
4. Remove direct clutch backing plate, five
composition faced and five flat steel clutch plates. (Fig.
7A4-428)
5 . Using Clutch Compressor Tools 5-6129, J-4670-14.
and 5-8765,compress springs and remove snap ring. (Fig.
7A4429)

Fig. 7A4418-Installing Forward Clutch Piston

Fig. 7A4-419-Installing Snap Ring

Fig. 7A4-42 1 -Installing Forward Clutch Plates

Fig. 7A4-420 -Installing Forward Clutch Hub

Fig. 7A4-422 -Installing Direct Clutch Hub

FORWARD CLUTCH

-- -

HOUSING

- - - -

Fig. 7A4-423 -Installing Snap Ring

APPLY AIR
TO OEJE HOLE

BLOCK

REMAINING

I
I

Fig. 7A4-424-Air Checking Clutch And Piston

Fig. 7A4-425 -Removing Snap Ring

TURBO HYDRA-MATIC - TORONADO 425 7A4-115

6. Remove retainer and fourteen piston release

springs-

(NOTE: Keep release springs separate from forward clutch

release springs.)
7. Remove the direct clutch piston. (Fig. 7 A4-430)
(NOTE: Current transmissions use a direct clutch piston
a check baU. Therefore, the forward and direct
clutch pistons look almost the same. Make sure the direct
clutch piston is identified during disassembly so it will be
into the direct dutch housing. The serrice
replacement direct clutch piston contains a check ball. The
production built direct clutch piston will be aluminurn or
damped steel-)

10. Remove and discard the center piston seal from the
direct clutch housing. (Fig. 7A4-433)
Inspect ion
1. Inspect sprag assembly for damage.
2. Inspect sprag bushings for wear or distortion.
3. Inspect the inner and outer races for scratches or
wear that can be felt with finger nail.
4. Inspect the clutch housing for cracks, wear, proper
opening of oil passages, or wear on clutch plate lugs. Probe
oil passages with a tag wire to see that hole is open. See oil

8. Remove and discard the outer seal from the piston.

pig. 7 A 4 4 3 1)

9. Remove and discard the inner seal from the pist on.
(Fig. 7A4-133)
1

Fig. 7A4-431 -Removing Or Installing Clutch Outer Seal

SNAP RING

HOUSING

Fig. 7A4-429-Removing Snap Ring

Fig. 7 A4-432-Removing Or Installing Clutch Inner Seal

Fig. 7A4-430-Removing Direct Clutch Piston

Fig. 7A4-433-Removing Or Installing Clutch Center Seal

7A4-116 TURBO HYDRA-MATIC - TORONADO 425

chart for Iocat ion of oil lubrication passages.

5. Inspect the composition faced and steel clutch

8. Inspect springs for collapsed coils or signs of

(NOTE: The 14 direct clutch release springs are not

serviced. If one or more of these springs require
replacement, discard all of them and install the 16 service
direct clutch release springs.)
9. Inspect clutch housing for free operation of check
ball. (Fig. 7A4-434)
Assembly (Figs. 7A4-435 and 7A4-436)

(NOTE: Apply transmission oil to all seals.)

Fig. 7A4-434-Inspecting Check Ball

3. Install a new inner clutch piston seal on piston

with lip facing away from spring pockets. (Fig. 7A4-432)

FLAT STEEL PLATES (5)

D IRECT CLUTCH

D I RECT CLUTCH

COMPOS I T ION PLATES (5)

HOUS ING

SNAP R I N G

Fig. 7A4-435 -Direct Clutch Asembly

CT CLUTCH CENTER SEAL

DIRECT CLUTCH HOUSl

A N D RACE ASSEMBLY
DIRECT CLUTCH OUTER SEA1
DIRECT CLUTCH INNER SE
DIRECT CLUTCH PISTON
DiRECT CLUTCH PISTON RELEASE SPRINGS
DIRECT CLUTCH SPRING RETAl

Fig. 7 A4-436-Direct Clutch Assembly

TURBO HYDRA-MATIC - TORONADO 425 7A4-117

2. Install a new outer clutch piston seal with lip

facing away from spring pockets. (Fig. 7A4431)
3. Install a new center seal on clutch housing with lip
of seal facing up. (Fjg. 7 A4-433)

NOTE: Current transmissions use a direct clutch housing

with a check ball (Fig. 7A4-434). If the housing requires
replacement and the replacement housing does not contain
&eck ball, replace the direct clutch piston with the
service piston which has a check ball. EITHER THE
DIRECT CH-JTCH HOUSING AND/OR THE PISTON
MUST CONTAIN A CHECK BALL.)
4. Place

Seal Protectors, Tool J-2 1362-Inner,

J-2 1409Outer , over hub and clutch housing and install

clutch piston with a rotating motion. (Fig. 7A4-437)

5 . Install fourteen springs into spring pockets in
piston, leaving two pockets 180" opposite each other
with no springs.
6. Place spring retainer and snap ring on springs.
7. Using Clutch Compressor Tools 3-6129, J-4670-14,
and 5-8765, install snap ring. (Fig. 7A4-438)
8. Oil and install five composition and five flat steel
plates, starting with a flat steel plate and then alternating
and steel. (Fig. 7114-439)

9. Install the clutch backing plate.

10. Install the backing plate retaining snap ring, (Fig.
7A4-440)
11. Turn unit over and install one spr ag bushing, cap
side up, over inner race.
12. Install Sprag assembly into outer race,
13. With ridge or shoulder on inner cage up, start sprag
and outer race over inner race with counterclockwise
motion. (Fig. 7A4-441)
(NOTE: Outer race should turn only counterclockwise.
(Fig. 7A4-442)
14. Install sprag bushing over sprag, cup side down.
15. Install sprag retainer and snap ring. (Fig. 7A.F-443)

DIRECT CLUTCH
BACK l NG PLATE

(NOTE: Refer to "Information Chart" for clutch plate

usage, Fig. 7 A4-17 .)

- FLAT STEEL PLATES

COMPOS l T l O N PLATES

Fig. 7A4-439-Installing Clutch Plates

Fig. 7A4-437-Installing Clutch Piston

DIRECT
CLUTCH
HOUSING

Fig. 7 A4-438 -Installing Snap Ring

DIRECT 'CLUTCH
BACKING PLATE

Fig. 7 A4-440-Installing Snap Ring

TURBO HYDRA-MATIC - TORONADO 425 7A4-119

Fig. 7A4-446-Installing Rear Band

4. Install the complete gear unit assembly into the

case using Tool 5-21795 with 5-6125 slide hammer. Be sure
locating bolt hole in center support lines up with case hole.
(Fig. 7A4448)
5. Oil and install center support t o case retaining snap
ring with the bevel side up (flat side against center support).
Locate gap adiacent t o band anchor pin. Make certain ring
is properly seated in case. (Fig. 7A4-449)
6. Install center support to case bolt by placing the
center support locating tool into the case direct clutch
passage, with the handle of the tool pointing t o the LEFT
as viewed from the front of the transmission and parallel t o
the bell housing mounting face. (Fig. 7A4-450)
7. Lift UPWARD on the tool which will tend to
rotate the center support counterclockwise as viewed from
the front of the transmission, While holding the center
support firmly counterclockwise again st the case s p h e s ,
torque the case to center support boit to 20-25 ft. lbs: using
a 318" 12-point thin wall deep socket.

(NOTE: When using the locating tool, care should be taken

not to raise burrs on the case valve body mounting face.)
8. Install three steel and three composition faced
intermediate clutch plates, Start with steel and alternate the
composition faced and steel clutch plates. (Fig. 7A4-45 1)
9. Install the intermediate clutch backing plate, ridge
up. (Fig. 7A445 1)

Fig. 7A4-447 -Installing Case Spacer

Fig. 7A4-449 -Installing Center Support

Fig. 7A4448-Installing Gear Unit Into Case

Fig. 7A4-450-InstaIling Center Support Bolt

TURBO HWRA-MATIC - TORONADO 425 7A4-12 I

15. Install the forward clutch hub t o direct clutch

housing thrust washer on the forward clutch hub, if not
already installed. Retain with petrolatum or equivalent.
16. Install the forward clutch assembly, indexing the
direct clutch hub SO end of the mainshaft will bottom on
end of the forward cl2tch. If seated it will be
approximately flush to 114 below pump cover plate face
in case. (Fig. 7A4-456)
17. Install pump cover plate assembly and gasket. (Fig.
7~ 4 - 4 5 7 )

Fig. 7A4-455-Installing Direct Clutch And Sprag

18. Install pump cover plate attaching bolts. Torque

bolts t o 20 ft. lbs. (Fig. 7A4-458)

(NOTE: If the forward clutch housing cannot be rotated

(using the driven sprocket as a driver) as the pump cover
plate is being pulled into place, the forward or direct clutch
housings have not been properly installed to index with all
the clutch plates. This condition must be corrected before
the pump cover plate is pulled fully into place.)
19. Check front unit end play- as follows: (Fin.
. 7A4-459)
a. Install a 5/16" threaded slide hammer bolt or
5-6126 into bolt hole in pump cover plate. (Install End
Play Checking Tool 5-22241 into pump cover plate and
forward clutch housing .)
b. Mount a dial indicator on the bolt. Index
indicator t o register with the forward clutch drum that
can be reached through second bolt omitted from cover
plate.
c. Push End Play Tool 5-22241 down t o remove
slack.
d. Push and hold output flange upward. Place
screwdriver in case opening at parking pawl area and
push upward on output carrier.
e. Set dial indicator t o zero.
f. Pull end play checking tool upward by placing
another screwdriver between metal lip of end play tool
and the driven sprocket housing.
Read the resulting travel or end play which should be
.003" to .024". The selective washer controlling this end

FLTBOLTS
1"
I 12s
E-5 SOLTS ' ) a 18 \ 875
sj16

-6

BOLTS

5'1 6-

18

1 50

L*

Fig. 7A4-458-Pump Cover Plate Attaching Bolts

REMOVE

1-

END PLAY CHECKING TOO-

Fig. 7A4-45 6-Installing Forward Clutch

SPROCKETSUPPORT HOUSINGS

Fig. 7A4-457-Installing Pump Cover Plate

Fig. 7A4-459-Checking Front Unit End Play

7144-122 TURBO HYDRA-MATIC - TORONADO 425

play is the washer located between the driven support

housing and the forward clutch housing. If more or less
washer thickness is required to bring end play within
specifications, select the proper washer from the chart
below :
Thickness

Color

.06OV to ,064"
.07 1" to .075"
.082" to .086"
.093" to -097"
.104" to .108"
.115" to .119"
.126" to .130"

Yellow
Blue
Red
Brown
Green
Black
Purple

DRIVE SPROCKET

(NOTE: An oil soaked washer may tend t o discolor so that

it will be necessary to measure the washer for its actual
thickness.)

Fig. 7A4-460-Installing Sprockets And Link Assembly

20. Install the remaining pump cover plate attaching

bolts. Torque bolts to 20 ft. lbs.
INSTALLATION OF FRONT PUMP
1. Mount two 5/16" x 4" guide pins in pump
attaching screw holes.
2. Align guide pins with matching holes in pump
cover plate and insert bolts into open holes in pump body.
(Keep the crescent to the out side of the case .)
3. Tighten bolts, remove guide pins, and insert
remaining attaching bolts and tighten t o 18 ft .lbs.

LINK BELT, DRNE AND DRIVEN SPROCKET COVER

PLATE AND SPROCKET HOUSING
Assembly
1. Place link belt around the drive and driven
sprockets so that the links engage the teeth of the
sprockets, colored guide link which has etched numerals
facing link cover.
2. Simultaneously place link belt, drive and driven
sprockets into support housing. (Fig. 7A4-460)
3. Using a plastic mallet, gently seat the sprocket
bearing assemblies into the support housings.
4. Install sprocket assembly to support housing snap
rings using J-4646 snap ring pliers. (Fig. 7A4-461)
5. Install new case to cover and plate assembly
sprocket housing gasket.
6. Install sprocket housing cover and plate assembly
and eighteen attaching bolts. Torque bolts to 8 ft .lbs.

PARKING PAWL SHAFT

RETURN SPRING

(NOTE: One sprocket cover housing attaching bolt is 114

inch longer. This bolt must be installed in the tapped hole
located directly over the cooler fittings on the transmission
case .)

DETENT LEVER
AND PARKING

PARKING PAWL, BRACKET AND MANUAL LINKAGE

(Fig. 7A4-462)
Installation
1. Install parking pawl (tooth toward the inside of
case), pawl return spring and parking pawl shaft into case.
(Fig. 7 A4-463)
2. Install the parking pawl shaft retaining pin. (Fig.
7 A4-464)
3. Install the parking bracket into case (pawl below
finger on bracket). Torque the attaching bolts to 18 ft. Ibs.
(Fig. 7 A4-465)

L:-O-RING SEAL

Fig. 7A4-462-Manual And Parking Linkage

TURBO HYDRA-MATIC - TORONADO 425 7A4-123

4. hstall a new manual shaft "0" ring seal on manual

shaft5 . Install the actuator rod plunger under the parking
bracket and over the parking pawl and through hole in
&tent lever.
6. Install the manual shaft assembly through the case

and detent lever. Install the retaining hex-lock nut on the

manual shaft. Lever points away from oil pan. (Fig.
7A4-466)
7. Install manual shaft retaining pin into case. Install
the long, smooth end into case first. (Fig. 7A4-467)
8. Torque jam nut t o 18 ft . lb. (Fig. 7A4-468)

Fig. 7 A4-463 -Installing Parking Pawl Shaft

Fig. 7A4-466-Installing Manual Shaft

Fig. 7A4-464-Installing Retaining Pin

Fig. 7 A4-467 -Installing Retaining Pin

Fig. 7A4-465 -Installing Parking Bracket

jr

Fig. 7A4-468 -Installing Jam Nut

REAR SERVO
Installation
(NOTE: Before installing the rear servo assembly check
band apply pin using Tool J-21370 as follows:)

F R O W SERVO, CHECK BALLS, GASKETS, S P A C ~

AND SOLENOID
Installat ion
1. Install front servo spring and spring retainer on
front servo pin. (Fig. 7A4-473)
2. Install retainer ring in front servo pin groove.

1. Atrach the band apply pin selection gauge adaptor

plate J-21370-8, 5-2 1370-6, and 5-21370-7 t o the
transmission case with attaching bolts as shown. (Fig.

(NOTE: Install tool attaching bolts finger tight and check

freeness of selective pin. Torque attaching bolts and
recheck pin to make certain it does not bind.)

STEP LOCATION

ii_----

J -21370-7

TOP STEP
OR ABOVE

THREE R I N G S

LONG

T H l S AREA

TWO R I N G S

MED.
4

LOWER
STEP OR
5ELOW

ONE R I NG

Fig. 7 A4-470 -Pin Selection Chart

Fig. 7A4469-Checking Band Apply Pin

2. Apply 25 ft . lb. torque and select proper servo pin

t o be used from scale on tool.
3. Remove the tool and make note of the proper pin
t o be used during assembly of the transmission. (Fig.

Fig. 7A4-47 1 -Holding Bracket

The identification rings are located on the band lug end

of the pin. Selecting the proper pin is the equivalent of
adjusting the band.

(NOTE: If the transmission is in the car, a sheet metal

bracket will be required t o hold the rear servo assembly,
front servo assembly, check balls, valve body to spacer plate
gasket and valve body spacer plate, until the control valve
assembly is installed. (Fig. 7A4-47 1)
1. Install rear accumulator spring into case.
2. Lubricate and install the rear servo assembly into
case. (Fig. 7A4472)

Fig. 7 A4-472-Installing Rear Servo

SHORT

TURBO HYDRA-MATIC - TORONADO 425 7A4-125

4. Install piston into case so that tapered end of pin is

contacting band. Make sure the retainer ring is installed in
front
groove. (Fig. 7A4-474)

(NOTE: If transmission is in the car, place check balls into

bd seat pockets on spacer plate.)

6. Install the valve body spacer to case gasket and
spacer plate, install guide pins for alignment. (Fig. 74-476)
Fig. 7A4-475-Checkball Location

(NOTE: Valve bo:y spacer to case gasket should extend

approximately 118 beyond the spacer plate over the void
case channel. (Fig. 7A4-477) If service gaskets are being
installed, the valve body spacer t o case gasket has an
extension which will cover the void case channel.)
7. Install the "0" ring seal on the case electrical

TEFLON OIL SEAL RING

SPRING RETMNER

Fig. 7A4-476 -Installing Spacer Plate

Fig. 7A4-473-Front *vo

i *e?
SPACER

I,'

e
kI

Fig. 7A4-474-Installing Front Servo

Fig. 7A4-477 -Valve Body Spacer To Case

Gasket Identification

GOVERNOR PIPE

TURBO HYDRA-MATIC - TORONADO 425 7A4-127

PlPE HOLES

Fig, 7A4-483-Installing Governor Feed Pipe

Fig. 7A4-484-Connect ing Electrical Lead To

Electrical Connector

B-9 BOLTS '/2-20

x 1.88

C-3 BOLTS
LTS

PIPE POSITIONS

5/1

6-1

5/16-1

8 x 1.38
8 x 1.88

Fig. 7A4-482 -Attaching Bolt Location

7A4-128 TURBO HYDRA-MATIC - TORONADO 425

PRESSURE REGULATOR VALVE

Installation (Fig. 7A4-485)
1. Install regulator valve (stem end out), spring
retainer, and spacer, if present, into case bore.
2. Install pressure regulator spring into bore.
3. Install pressure boost valve bushing and boost valve
(st em end first) into case bore.
4. Compress the pressure boost valve bushing against
the pressure regulator spring and install the retaining snap
ring into the case, using 5-5403pliers. (Fig. 7A4-486)
PRESSURE REGULATOR VALVE
PRESSURE REGULATOR SPACER

Fig. 7A4-487 -Installing Filter

Fig. 7 A4-488 -Installing Vacuum Modulator

Fig. 7A4-48 6 -Installing Pressure Regulator Valve

FILTER AND INTAKE PIPE

4. Install the modulator retainer and attaching bolt.

Torque bolt t o 18 ft. lbs. (Fig. 7A4-489)

1. Install the case to intake pipe "0"ring seal on

filter and intake pipe assembly. (Fig. 7A4-487)
2. Install the filter and intake pipe assembly. (Wire
under filter intake pipe.)
3. Using a new bottom pan gasket, install pan. Torque
attaching screws t o 12 ft .lbs.

GOVERNOR
Installation
1. Lay the transmission on the oil pan.
2. Position new "0" ring seal on governor assembly
then install into the case. (Fig. 7A4-490)
3. Attach the governor with the retaining clip,

MODULATOR VALVE AND VACUUM MODULATOR

Installation
1. Install the modulator valve into the case bushing
bore with stem end out.
2. Install the "0" ring seal on vacuum modulator.
3. Install the vacuum modulator into the case. (Fig.

*-*%a%%%@@@+

INSTALL SPEEDOMETER DRIVEN GEAR

1. Install new "0" ring seal on speedometer driven
gear assembly.
2. Install speedometer driven gear assembly into
transmission. (Fig. 7A4-49 1)
3. Install retainer clip and screw, torque to 3 ft. lbs.
(Fig. 7 A4-492)

" " " ~$**t*4*$qt)gs*

f

TURBO HYDRA-MATIC - TORONADO 425 7A4-129

mSTALL CONVERTER ASSEMBLY

With transmission in cradle or portable jack, install
~onverter into pump, making certain the converter hub
slots engage the pump drive gear tangs.

Fig. 7A449 1-Installing Speedometer Driven Gear

Fig. 7A 4 4 8 9 -Installing Modulator Retaining Bolt

Fig. 7A4-490-Installing Governor

Fig. 7A4-492--Installing Retainer Clip

7 A 4 - 1 3 0 SPECIFICATIONS

METRIC THREAD USAGE

LOCATION

THREAD SIZE

IDENTIFICATION

Manual Shaft

M I 0 x 1.5.6g

Groove on metric
end of shaft with
drill point in end
of shaft .

Transmission Case:
Speedometer
Attaching Bolt Hole

M 6 . 3 x 1-6H

NONE

Case Extension:
Transmission
Mount
Bolt Holes

MlO x 1.5.6H

Letter "M" Ink

Stamped on case
extension .

All other thread sizes on the transmission are U.S. Standard .

TORQUE SPECIFICATIONS
FT . LBS.

APPLICATION
Solenoid Assembly to Pump Or Valve Body
. . . . . .
. . . . . . . . . . . . . . .
Line Pressure TakeOff
Oil Cooler Lines at T~ansrnission . . . . . . . . . . .
. . . . . . . . . . . . .
Oil Cooler Lines at Radiator
Race To Center Support . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
Solenoid Assembly To Case
. . . . . . . . . . . . . . . .
Valve Body To Case
Sprocket Cover To Case . . . . . . . . . . . . . . .
Pump Assembly To Case . . . . . . . . . . . . . . .
Pump Body To Cover . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .
Driven Support To Cover
Cover Plate To Case . . . . . . . . . . . . . . . . .
Rear Servo Cover To Case . . . . . . . . . . . . . .
Governor Cover To Case . . . . . . . . . . . . . . .
. . . . . . . . .
Vacuum Modulator Retainer To Case
. . . . . . . . . . . . . . . . . .
Oil Pan To Case
Case Extension To Case . . . . . . . . . . . . . . .
Case To Center Support . . . . . . . . . . . . . . .
Manual Shaft To Inside Detent . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
Filter To Valve Body
Transmission Case To Cylinder Block Bolts (Toronado) . .
Transmission Case To Cylinder Block Bolts (Exc . Toronado)
. . . . . . . .
Flywheel To Converter Attaching Bolts
. . . . . . . . .
Transmission Mount To Transmission
. . . . . . . .
Prop Shaft To Rear Companion Flange
Speedometer Driven Gear To Case Attaching Bolt . . . .
Crossmember To Frame .98 . . . . . . . . . . . . .
. . . . . . . . . . . .
Transmission To Crossmember
Crossmember To Rear Engine Mounts (Toronado) . . . .
L

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3
15

12
25

10
10
10
10
20
20
20
20
20
20
20
13
25
25
20
10
30

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. . . . . . . . . . . . . . . . . . . . . . . . 40
. . . . . . . . . . . . . . . . . . . . . . . . 40
. . . . . . . . . . . . . . . . . . . . . . . . 45
. . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . . 40
. . . . . . . . . . . . . . . . . . . . . . . . 60
. . . . . . . . . . . . . . . . . . . . . . . . 60

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--

BUSHINGS - TURBO HYDRA-MATIC 400 & 425 7A4-131

TURBO HYDRA-MATIC
BUSHING SERVICE
400 AND 425
(NOTE: When inspecting bushings, fit the mating part into
the bushing and observe the amount of looseness. Bushing
clearance is excessive if more than -008" exists when
checked with a wire feeler gauge.)
Bushings are available and can be replaced in the
following units. Service bushings do not require reaming.
1. Pump Body
2. Sun Gear Shaft
3. Center Support
4. Output Shaft or Output Flange
5. Case
6. Extension Housing
7. Stator Shaft
a.. Front Bushing
b . Rear Bushing

PUMP BODY BUSHING(Figs, 7A4-493,7A4494 and 7A4-495)

With pump disassembled and front seal removed,

support pump body on wood blocks. Drive bushing out as
shown using 58092 Drive Handle and J-2 1465-1'7 Bushing
Remover and Installer. Use a lead or brass hammer to drive
out bushing.

Clean pump bushing bore, install new bushing on

shoulder of Tool J-2 1465-17 with 5-8092; and drive
bushing squarely into the bore until it is flush t o .OIOf'
below gear pocket face. Remove tool and inspect bushing.

'

7A4-132 BUSHINGS - TURBO HYDRA-MATIC 400 Rt 425

OUTPUT SHAFT OR OUTPUT FLANGE BUSHING

With output shaft or output flange properly supported

usine. Tool 5-21465-16, with Slide Hammer 5-2619 and
~ d a s e Tool
r
3-2619-4,iernove bushing. (Fig. 7A4-496)

Using Tool 3-21465-1, with Drive Handle 5-8092, press

or drive replacement bushing into place until tool bottoms.
(Fig. 7 A4-497)

(NOTE: Output flange bushing must be installed with oil

hole in bushing aligned with oil hole in hub of output
flange and notch in bushing outward.)

11; !I

Fig. 7A4-496-0ut put Flange Bushing Removal

Fig. 7 A4-497 -Output Flange Bushing Installation

SUN GEAR SHAFT BUSHING-FRONTAND REAR

With sun gear shaft properly supported, using Tool
5-21465-15, with Slide Hammer Tool 5-2619 and Adapter
J-2619-4,remove bushing. (Fig. 7A4-498)

Using Tool 5-21465-5 with Drive Handle 58092, press

or drive replacement bushing into place until tool bottoms.
(Fig. 7 A4-499)

9
1
Fig. 7 A4498 -Sun Gear Shaft Bushing Removal

Fig. 7A4-499-Sun Gear Shaft Bush

BUSHINGS - TURBO HYDRA-MATIC 400 & 425 7A4-133

CENTER SUPPORT BUSHING(Figs. 7A4-500 and 7A4-501)

Position center support, oil delivery sleeve down, on
wooden blocks that are long enough t o clear bushing during
removalAssemble remover Tool J-2 1465-6t o Drive Handle
~ 3 0 9 2and drive bushing out as shown using a lead or brass
hammer-

Invert center support and using the same tools drive

new bushing squarely into the bore until bushing is flush to
.OIOr' below end of oil delivery sleeve as shown. Remove
tools and inspect bushing and oil hole alignment.

VOTE: Slot in bushing must be aligned with the drilled

hole in the oil delivery sleeve closest to the pist on.)

\n

CASE CENTER

SUPPORT

Fig. 7A4-500 -Center Support Bushing Removal

Fig. 7A4-501 -Center Support Bushing Installation

TRANSMISSION CASE BUSHING400 (Figs. 7A4-502,7A4-503 and 7A4-504)

Position transmission case (converter end down).
Assemble Remover Tool 5-21465-8 on Drive Handle 5-8092
and drive bushing out using a lead or brass hammer, as
shown.
Invert transmission case in holder. Assemble Drive
Handle J4092 and Adapter J-21465-13 on Installer
J-21465-8. Assemble Adapter Ring J-21465-9 on installer
and install new bushing on shoulder of installer with lube

Fig. 7A4-502 -Transmission Case

Bushing Removal

passage facing adapter ring, see illustration. Drive bushing

squarely into bore with lead or brass hammer until a d a ~ t e r
ring bottoms, as shown. This will leave the bushing -040 to
.05 5 " above the selective thrust washer surface.
Remove tools and stake bushing with Tool J-21465-10
as shown in Fig. 7A4-504, Stake marks must be in the
bushing groove. Remove staking tool and inspect bushing.

Fig. 7A4-503-Transmission Case

Bushing Installation

Fig. 7A4-504-Staking Transmission

Case Bushing

7A4-134 BUSHINGS - TURBO HYDRA-MATIC 400 & 425

EXTENSION HOUSING BUSHING - 400

(Figs. 7A4-505,7 44-506 and 7A4-507)
With rear seal removed, position extension housing on
bench, seal end up. Assemble Remover 5-2 1465-17 on Drive
Handle 5-8092 and drive out bushing with lead or brass
hammer, as shown.
Assemble Drive Handle 38092 and new bushing on
Tool 5-21465-17 and drive bushing squarely into bore until
flush to ,010" below oil seal counter bore surface using a

Fig. 7A4-505 -Removing Extension

Housing Bushing

Remove tools and use Tool 5-21465-10 to stake

bushing in place as shown in Fig. 7A4-507. Stake marks
must be in bushing lubrication grooves. Remove tool and
inspect bushing.

Fig. 7A4-506-I~talling Extension

Housing Bushing

Fig. 7A4-507 -Staking Extension

Housing Bushing

STATOR SHAFT-REAR BUSHING - 400

(Figs. 7A4-508 and 7A4-509)
Mount pump cover and stator shaft in vise as shown.
Use brass jaws to protect shaft. Assemble Remover
3-21465-15 to 5-2619 Slide Hammer and 5-26 19-4 Adapter Thread remover into rear bushing and remove bushing with
slide hammer.

Clean all shavings from stat or shaft bore. Install pump

cover in vise supporting shaft on wood block. Assemble
Installer 5-21465-2 to 5-8092 Drive Handle. Install new
bushing on shoulder of installer and drive bushing squarely
into the bore to a depth of 19/32". Remove tools and
inspect bushing.

PUMP

COVER

Fig. 7A4-508 -Removing Stator Shaft Rear Bushing

Fig. 7A4-509 -Installing Stator Shaft Rear Bushing

BUSHINGS - TURBO HYDRA-MATIC 400 & 425 7A4-135

STATOR SHAFT - FRONT BUSHING - 400

(Figs. 7A4-510 and 7A4-511)

Mount pump cover and stator shaft in vise as shown.

t o protect shaft. Assemble Slide Hammer
J-2619 and Adapter J-2619-4 on Remover J-21465-15.
r h e a d remover into front bushing and remove bushing

use brass jaws

Clean all shavings from stator shaft. Assemble Installer

5-21465-3 t o Drive Handle 3-8092. Locate new bushng on
shoulder of installer and drive bushing squarely into bore
with a lead or brass hammer, as shown. Remove tool and
inspect bushing.

SUPPORT H U B ON
SOFT MATERIAL ru

PROTECT R I N G LANDS

Fig. 7A4-510-Removing Stator Shaft Front Bushing

Fig. 7A4-511-Installing Stator Shaft Front Bushing

STATOR SHAFT BUSHING - 425

(TORONADO)

'

With drive sprocket support and stator shaft properly

sumorted. using
Tool 5-21465-15 or 5-8647-1. with Slide
I-&krner 5-261; -and Adapter Tool J-261914, remove
bushing. (Fig. 7 A4-5 12)
7

Fig. 7 A4-512-Stator Shaft Bushing Removal

Using Tool J-21465-3 with Drive Handle 5-8092, press

or drive replacement bushing into place until tool bottoms.
(Fig. 7~ 4 - 153)

Fig. 7 A4-5 1 3 -Stator Shaft Bushing Instal

7A4-136 TOOLS

Holding Tool Base

J-8763

Transmission Holding Fixture

Clutch Spring Compressor

J-8765

"C" Washer

Snap Ring Pliers

J-21369

Converter Leak Text Fixture

Snap Ring Pliers

J-21371-3-8

Converter StatorlTurbine End

Play Checking Fixture

J-21654

Converter Holding Strap

J-21664

Adapter Was her

J-21795

Gear Unit Assembly Holding Fixture

J -22269

Accurnu lator Piston Remover

Holding Fixture
Slide Hammer Assembly
5116" to 318" Adapters
Spring Compressor

STEEL SPEEDOMETER DRIVE GEAR TOOLS

J-21427
REMOVAL (F I G. 7A4-191)
J-6123-01
INSTALLATION (FIG. 7A4-192) J-21470

Fig. 7A4-5 14-Tools

TOOLS 7A4-137

BT- 6603
J-21661

t'L

J-8619-11

BT-7412-L

BT-30-16
J - 5907
J - 6133
BT- 6424- 1
BT- 6603
BT-6733
BT-7412-R-L
J - 8001
J-8619-11

Engine Support Bar

Pressure Checking Gauge
Bearing and Speedometer Gear l nstaller
Engine Support Bar
Toronado Engine Support Bar
Modulator Gauge
Toronado Engine Side Support Bars
Dial Indicator Set
Gauge Plate (Used to hold dial indicator w h e n
checking pump end clearance)
Pump Oil Seal Installer

J-21362
J-21363
1-21368
J-21370
J-21409
J-21661
J - 22241
1-23093
J-23456
E-Z OUT

Fig. 7A4-515-Tools

Clutch l n n e r Seal Protector

Clutch l n n e r Seal Protector
Pump Body and Cover Alignment Band
Band Apply P i n Gauge
Clutch Outer Seal Protector
Extens ion Rod
Toronado Forward Clutch End Play
Checking Tool
Center Support Locating Tool
Clutch Pack Compressor
Size 1

-15

-16

*
jC

J - 95'34
J-2619
J -2619-4
J - 6125
J-6125-2
J -8092
J -21424-9
J -21465-1
J-21465-2
J-21465-3
5-21465-5
J-21465-6
5-21465-8
J-21465-9
J-21465-10

J-21465-13
J-21465-15
J-21465-16
5-21465-17

j- 8092

INDICATES TOOLS NOT INCLUDED I N SET

Output Shaft Bushing Remover

Slide Hammer (Large)
Slide Hammer (Thread Reducer Adapter)
Slide Hammer (Small)
Slide Hammer (Thread Reducer Adapter)
Driver Handle (Universal)
Bushing Installer
Output Shaft Bushing Installer
Stator Shaft Rear Bushing I nstaller
Stator Shaft Front Bushing l nstaller
Sun Gear Shaft Bushing Installer
Case Center Support Bushing Remover and Installer
Transmission Case Bushing Remover and Installer
Transmission Case Bushing l nstaller Adapter Ring
Transmission Case and Extension Housing Bushing
Staking PI iers
Transm ission Case Bushing Extension Handle
Sun Gear Shaft and Stator Shaft Bushing Remover
Output Shaft Bushing Remover
Pump Body Bushing and Extension Housing Bushing
Remover and l nstaller

Fig. 7A4-5 16-Tools

x--~%t**va*4q@@~f@%vFme~

CORRECTION

POSSIBLE CAUSE
Slips Out of High Gear
a.

b,
C,

d.
e.
f.
g.
h.
i.

Transrnissionlooseonclutchhousing.
Shift rods interfere with engine mounts or clutch
throwaut lever.
Shift linkage does not work freely, binds.
Damaged mainshaft pilot bearing.
Main drive gear bearing retainer broken or loose.
Dirt between transmission case and clutch housing.
Stiff shift lever seal
Pilot bearing loose or damaged.
Misalignment of transmission

a.
b.
c.
d.
e.
f.
g.
h.
i.

Tighten mounting bolts.

Replace levers or rods to eliminate
interference.
Adjustandfreeupshiftlinkage.
Replace pilot bearing.
Tighten or replace main drive gear bearing retainer.
Clean mating surfaces.
Replaceseal.
Replace bearing.
Refer to TRANSMISSION ALIGNMENT.

Noisy In All Gears

a.
b.
c.
d.
e.

Insufficient lubricant.
Worn countergear bearings.
Worn or damaged main drive gear and countergear.
Damaged main drive gear or mainshaft bearings.
Worn or damaged countergear anti-lash plate.

a.
b.
c.
d.
e.

Fill to correct level.

Replace countergear bearings and shaft.
Replace worn or damaged gears.
Replace damaged bearings or main drive gear.
Replace countergear.

Noisy In High Gear

a.

b.

a.
b.

Damaged main drive gear bearing.

Damaged mainshaft bearing.

Replace damaged bearing.

Replace damaged bearing.

Noisy In Neutral With Engine Running

a.
b.
c.

d.

Damaged main drive gear bearing.

Damaged or loose mainshaft pilot bearing.
Worn or damaged countergear anti-lash plate.
Worn countergear bearings.

a.
b.
c.
d.

Replace damaged bearing.

Replace pilot bearing.
Replace countergear.
Replace countergear bearings and shaft.

DIAGNOSIS
THREE SPEED AND FOUR SPEED
POSSIBLE CAUSE

CORRECTION
Noisy In All Reduction Gears

a.
b.

Insufficientlubricant.
Worn or damaged main drive gear or countergear.

a.
b.

Fill to correct level.

Replace faulty or damaged gears.

Noisy In First Only

IP

a.
b.

Damaged or worn first speed constant mesh gears.

Side cover improperly machined - sleeve mispositioned .

a.
b.

Replace gears.
Replace side cover.

Noisy In Second Only

a.
b.

Damaged or worn second-speed constant mesh gears

Worn or damaged countergear rear bearings.

a.
b.

Replace damaged gears.

Replace countergear bearings and shaft.

Noisy In Reverse Only

a.
b.
c.

Worn or damaged reverse idler gear.

Worn reverse idler bushings.
Damaged or worn reverse countergear

a.
b.
c.

Replace reverse idler gear assembly.

Replace reverse idler gear assembly.
Replace countergear assembly.

Excessive Backlash In All Reduction Gears

a.
b.

Worn counter gear bearings.

Excessive end play in countergear

a.
b.

Replace bearings.
Replace countergear thrust washers.

Main Drive Gear Bearing Retainer Burned or Scored By Input Shaft

a.
b.

Loose or damaged mainshaft pilot bearing.

Misalignment of transmission.

a.
b.

Replace bearing.
Align transmission.

h k s Lubricant
a.
b.
c.
d.
e.
f.

g.

Excessive amount of lubricant in transmission.

Loose or broken main drive gear bearing retainer.
Main drive gear bearing retainer gasket damaged.
Side cover loose or gasket damaged.
Rear bearing retainer oil seal leaks.
Coun tershaft loose in case.
Shift lever seals leak.

a.
b.
c.
d.
e.
f.
g.

Drain to correct level.

Tighten or replace retainer.
Replace gasket.
Tighten cover or replace gasket.
Replace seal.
Replace case.
Replace seal.

DIAGNOSIS FIVE SPEED

DIAGNOSIS FIVE SPEED

Noisy In Fourth Gear

a.

Worn or damaged drive gear and/or countergear.

a.

Replace as necessary.

Noisy In Fifth Gear

a.

Worn or damaged fifth speed gear and/or countergear.

a.

Replace as necessary.

Noisy In Reverse Gear

a.
b.

Worn or damaged reverse gear, and/or countergear.

Worn or damaged reverse idler gear.

a.
b.

Replace as necessary.
Replace gear.

High Whine Noise

a.

Failed needle thrust bearings.

a.

Inspect and replace as necessary.

Excessive Gear Rattle

a.

Shift forks.

a.

Inspect and replace shift fork pads.

Hard Shifting
a.
b.
c.
d.

Shift lever cover.

First and re verse synchronizer.
Second and third synchronizer.
Fourth and fifth synchronizer.

a.
b.
c.
d.

Loosen bolts and align.

Inspect and replace keys, springs, or synchronizer.
Inspect and replace keys, springs, or synchronizers.
Inspect and replace keys, springs, or synchronizers.

3SPEED MANUAL TRANSMISSION 7B-5

THREE SPEED MANUAL

TRANSMISSION
INDEX
SUBJECT
Adjustments
Description
~i~posis .
Rear Oil Seal
sidecover .
specifications

PAGE

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. . . 7B-5
. . . 7 B-5
. . . 7B-1
. . . 7B-7
. . . 7B-8
. . . 7B44

THREESPEED MANUAL
TRANSMISSION

General Description (Fig. 7 B-l )

A three speed transmission synchronized in all forward
gears is used as standard equipment on the Omega and
Cutlass with a 231 C .I .D. engine.
The transmission is identified by 1" high letters (S9 or
RZ)located on the right hand side of the case.
The transmission is both column and floor controlled.
The transmissions regardless of control are identical.
The transmissions incorporate all helical gears which are
machined from drop forged steel gear blanks, heat treated
and shot peened for strength and long life. The shafts are
machined from high grade steel, heat treated and ground t o
close limits. The rear end of the clutch gear is supported by a
heavy duty ball bearing at the front end of the transmission
case and is piloted at its front end in a ball bearing. The front
end of the mainshaft is piloted in a roller bearing set into the
hollow end of the clutch gear and the rear end is carried by a
ball bearing.
The countergear is carried on roller bearings at both ends
while thrust is taken on thrust washers located between each
end of gear and the case. An anti-lash plate and two damper
springs are retained to the countergear by three rivets.

SUBJECT

PAGE

Speedometer Driven Gear

. . . . . . . . . . . 7B-8
Transmission Alignment
. . . . . . . . . . . . .7B-14
Transmission Disassembly
. . . . . . . . . . .7 ~ ~ 1 0
Transmission Reassembly . . . . . . . . . . . . 7 ~ - 1 3
Transmission Removal & Installation . . . . . . . 7B-8
Tools . . . . . . , . . . . . . . . . . . . . 7 B 4 5

The reverse idler gear is carried on a bronze bushng.

Gear shifting is manual through shift control rods to the
transmission, by two rotating cranks which directly engage
the gears to be shifted.
Periodc or seasonal changes of lubricant are not
recommended. The lubricant level should be checked at each
engine oil change interval. Use SAE 80W, SAE 80W-90 GL-5
gear lubricant or equivalent.

Shift Linkage Adjustment - Cutlass (Fig. 7B-2)

The shift linkage is attached as shown in Fig. 7B-2. To
adjust, proceed as follows:
1. Turn ignition switch to the "OFF" position and
raise car on hoist.
2. Remove retainer on the shift rods.
3. Set transmission shift levers in neutral.
4. Set shift control lever in neutral position. Align
control levers and install gage pin into levers and bracket.
5. Loosen nuts on shift rod and adjust trunnion and
pin assembly on Reverse - lst, then tighten nuts and install
shift rod and retainer.
6. Loosen nuts on shift rod and adjust trunnion and
pin assembly on 2nd - 3rd, then tighten nuts and install s h f t
rod and retainer.
7. Remove gage pin from control lever assembly and
check operation of control lever. Readjust as required.
8. Lower and remove car from hoist.

Fig. 7B-1-Three Speed Manual Transmission

-7

3-SPEED MANUAL TRANSMISSION 7B-7

shift Linkage Adjustment - Omega (Column Shift)

The shift linkage is attached as shown in F i p . 7B-3. TO

adjust, proceed as follows:
1. Position the transmission in reverse and raise car on
hoist.
2. Loosen the swivel bolts on the shift rods at the
transmission. Be Sure shift rods are free to move in the

7 . Turn ignition t o run position and place transmission

in second gear. Check to make sure the ignition key cannot
be removed and the steering wheel will turn.

3. ~ h l holding
e
relay in position in the 1st-Rev. lever
push up on reverse shift rod until detent in column is felt and
tighten swivel bolt for first and reverse rod t o recommended
torque
4. Position the transmission in neutral and insert a
3/16" rod through the 2-3 shift lever and into the alignment
hole. (Fig. 7B-4) Tighten the swivel bolt for the 2-3 shift
lever to recommended torque.
5 , Lower hoist and check shift operation with the
wgine off. Start engine and recheck.
6. Place transmission in reverse and ignition in lock
position. Check to make sure the ignition key can be
removed, the steering wheel will not turn, and the
transmission will not shift out of reverse.

TOOL J-4830-02

EXTENSION HOUSING

Fig. 7B-6-Removing Bushing

)j

TOOL .I-6403-6

Fig. 7B-7-Installing Bushing

Fig. 7B-5-Removing Seal

REAR BEARING RETAINER OIL SEAL

AND BUSHING REMOVAL
1. Remove propeller shaft.
2. Tap seal inward to break bond then using Tool
BT-6629-1 and BT-6629-2 remove seal. (Fig. 7B-5)
3. After removing the seal, if bushing replacement is
necessary, the bushing can be removed as shown in Fig. 7B-6.
4. If the bushing was removed, it can be installed using
tools as shown in Fig. 7B-7. Coat ID of bushing with
automatic transmission fluid.

7B43 3-SPEED MANUAL TRANSMISSION

TRANSMISSION SIDE COVER

Fig. 7 B 4 -Installing Seal

5. Coat the outside of new seal sparingly with Sealer
No. 1050026, or equivalent. Apply Lubricant No. 1050169,
or equivalent to the sealing lip of seal.
6. Drive seal into the rear bearing retainer using Tool
5-21359 until seal is fully seated (Fig. 7B4)

CAUTION: The propeller shaft to

pinion flange strap bolt is an
important attaching part in that it
could affect the performance of
vital
arts and systems, and/or
could' result in major repair
expense. I t must be replaced with
one of the same part number or
w i t h an equivalent part if
replacement becomes necessary. 00
not use a replacement part of lesser
quality or substif ute design.

SPEED0
DR IVEN
GEAR

Removal and Installation

1. Disconnect shift rods from levers.
2 . Remove cover assembly from transmission.
3. Remove outer shifter lever retainer bolts and
washers and pull levers from shafts.
4. Remove snap ring. This will allow removal of s&ftere
shaft, fork assembly and cam assembly, or interlock, from
cover .
5. Replace necessary parts. Coat shift shaft "0seal with transmission lubricant before installing in cover.
Install shifter interlock detent cams and snap ring.
6. Install 1st-Rev. and 2nd-3rd levers and retaining
screws .
7. With transmission gears in neutral and shifter fork
in neutral, install cover to transmission using a new gasket,
Coat screws with 1050026 Sealer or equivalent. Tighten ca
screws to 18 ft . lbs. torque.
8. Attach shift rods to shifter levers.
9. Fill transmission with SAE 80, SAE 80W-90 or GL
gear lubricant or equivalent.
MAJOR SERVICE OPERATIONS
Removal
1 . Raise car.
2. Remove propeller shaft.
3 . Disconnect shift rods from shift levers.
4. Install Engine Support Bar BT-6424-1 as shown
Section 7A.
5 . Remove transmission support bar to transmiss
mount bolts and transmission support bar to frame bolts.
6. Remove transmission support bar to transmiss
mount attaching nut.
7. Remove catalytic converter support bracket.
8. Disconnect speedometer cable.
9. Remove transmission upper attaching bolts. In
aligning studs 112" - 13 x 2" threaded headless bolts.

(NOTE : Aligning studs must be used to support tr

to prevent distortion of the clutch driven plate
removing transmission .)
10. Remove transmission lower attaching bolts.
11 . Carefully slide transmission rearward and rem
from car.

SLEEVE
Fig. 7B-9-Speedometer Driven Gear

SPEEDOMETER DRIVEN GEAR

Disconnect speedometer cable, remove retainer to
housing bolt and remove retainer and adapter. Insert
screwdriver into retainer slot in sleeve and pry sleeve and
driven gear from housing. (Fig. 7B-9)
Coat seal and speedometer gear shaft with automatic
transmission lubricant and insert gear. Push sleeve into
housing until the retainer can be inserted into the groove in
the sleeve and install the retainer.

Installation
1, Inspect clutch pilot bearing and replace if neces
2. Reverse removal procedure, using the folio
specified torque ratings for the attaching pdts:
a. Transmission to engine
b. Transmission support bar to
frame bolts
c. Transmission support bar to
transmission mount bolts
d. Transmission support bar to
transmission mount nut
e. Propeller shaft strap bolts

3-SPEED MANUAL TRANSMISSION 7B-9

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Gear T h r u s t Washer
B e a r i n g T h r u s t Washer
B e a r i n g Rollers (27)
Countergear
B e a r i n g Rollers (27)
Spacer
Tanged Washer
Countershaft
Key
Bearing Retainer
Gasket
Seal
Bearing Snap R i n g
Bearing Retaining Snap R i n g
M a i n D r i v e Gear B e a r i n g
Transmission Case
M a i n D r i v e Gear
M a i n s h a f t Pilot Bearings (14)
3rd Speed Blocker R i n g
Snap R i n g

2-3 S y n c h r o n i z e r Sleeve
S y n c h r o n i z e r C i u t c h Key S p r i n g
S y n c h r o n i z e r C l u t c h Hub
2nd Speed Blocker R i n g
2nd Speed Gear
Mainshaft
Gasket
Snap R i n g
Reverse I d l e r Gear
Tanged T h r u s t Washer
Reverse I d l e r Shaft
Key
1 s t Speed Gear
1st Speed Blocker R i n g
Synchronizer Clutch Hub
1st Speed S y n c h r o n i z e r Sleeve
Snap R i n g
Reverse Gear
Reverse Gear T h r u s t Washer
S p r i n g Washer

41. Rear B e a r i n g
42. Snap R i n g
43. Speedometer D r i v e Gear
43A. Drive Gear Clip
44. Gasket
45. Rear B e a r i n g Snap R i n g
46. Case Extension
47. Rear O i l Seal
48. 2nd and 3 r d S h i f t Fork
49. 1st a n d Reverse S h i f t Fork
50. 2nd and 3 r d S h i f t e r Lever
51. 1st a n d Reverse S h i f t e r Lever
52. Seal
53. Seal
54. Snap R i n g
55. Detent Cam S p r i n g
56. Detent Cam
57. Detent Cam
58. Transmission Side Cover
58A. P l u g
59. S y n c h r o n i z e r C l u t c h Key
60. B u s h i n g

Fig. 7B-11 -Three Speed Manual Transmission

7B-10 3SPEED MANUAL TRANSMISSION

if replacement becomes necessary.

Do not use a re~lacement art of
/esser quality o i s~bstitute'desi~n.
Torque values must be used as
specified during reassembly ao
assure proper retention o f this part.

,,.,a"

Main Drive Gear Bearing Seal Replacement

1. Remove transmission from car.
.
2. Remove main drive gear bearing r etainer and gaSKet.
3.. . Remove seal from retainer by prying out with
screwdriver. .,
.,
,'
ringly with Sealer,
4. Loat tne outslue or new seal spa
No. 1050026 , or equivalent - Apply Lubricant. luo- luDuloy
or equivalent to the sealing lip of the seal.
5 . Center. seal
i? retainer,
spring side out using
.
, - . - ---.
J 4 6 1 5 , tap seal Into place. (big. /B-1U)

IT

DISASSEMBLY (Fig. 7B-11)

1. Remove side cover attaching screws and remow qida
cover assembly and shift forks.
2. Remove main drive gear bearing retainer.
3. Remove main drive gear bearing to gear stem sn
aP
ring, then remove main drive gear bearing by pulling outward
on main drive gear until a screwdriver or other suitable tool
can be inserted between bearing large snap ring and case tn
complete removal. (Fig. 78-12)'~hemain drivegear be;;&
is a slip fit on the gear and into the case bore. ( T h ~ sprovides
clearance for removal of main drive gear
and mainshaft
assembly.)

+ n r n */ n

---a.

4. Remove extension to case attaching bolts.

5 . Remove the reverse idler shaft snap ring.
6. Remove main drive gear, mainshaft and extension
assembly together through the -rear case opening.
7. Using snap ring pliers, expand the snap ring in the
extension which retains the rn&shaft rear bearjne (pig
-0.
7B-13) and remove the extension.
u

\-

MAIN DRIVE GEAR

BEARING RETAINER

INSTALL SEAL I N
RETAINER, S P R I N G
S I DE OUT.

Fig. 7B-l O-Main Drive Gear Bearing Seal

Fig. 7B-14-Removing Counter Shaft

8 . Using J -22246 at the front of the countershaft, dri*

the shaft and its woodruff key out of the rear of the case*
(Fig. 7B-14) Tool 5-22246 wili now hold the roller bearin$
in position within the countergear bore. Remove the gear and

-7

3-SPEED MANUAL TRANSMISSION 7B-11

REAR BEARING

REVERSE l DLER
SHAFT

Fig. 7B-1 %Removing Reverse Idler Gear

Fig. 7B-17-Removing Reverse Gear and Rear Bushing

'
i

2. Check the front and rear faces for burrs and if

present, dress them off with a fine mill file.
3 . Check bearing bores in case and, if damaged, replace
case.
Front and Rear Bearings
1. Wash the front and rear ball bearings thoroughly in a
cleaning solvent.
2. Blow out bearings with compressed air.

1
Fig. 7B-16-Removing Speedometer Drive Gear

(NOTE: Do not allow the bearings to spin, t:lm them slowly

by hand. Spinning bearings will damage the race and balls.)
3 . Make sure bearings are clean, then lubricate with
light engine oil and check them for roughness by slowly
turning the race by hand.

10. Using snap ring pliers, remove the second and

third-speed sliding synchronizer hub snap ring from
mainshaft and remove synchronizer assembly, secondspeed
blocker ring and second-speed gear from front of mainshaft.
Mark hub for re -installa tion.
11. Depress speedometer drive gear retaining clip and
slide gear from mainshaft. (Fig. 7B-16)
12. Remove rear bearing snap ring from mainshaft
groove.
13. Support reverse gear with suitable press plate and
Press on rear of mainshaft to remove reverse gear, thrust
washer, spring washer, rear bearing and snap ring. (Fig.
7B-17)

1. Inspect all gears for excessive wear, chips or cracks

and replace any that are worn or damaged.
2. Inspect reverse gear bushing and if worn or damaged,
replace the entire gear.

~ O T E When
:
pressing rear bearing, be careful to center

(NOTE : Reverse gear bushing is not serviced separately .)

gear, washers, bearings and snap ring on mainshaft before

attempting to press.)

Bearing Rollers
All main drive gear and countergear bearing rollers
should be inspected closely and replaced if they show wear.
Inspect countershaft and reverse idler shaft at the same time,
replace if necessary. Replace all worn washers.
Gears

3 . Check both synchronizing sleeves to see that they

slide freely on their hubs.

14. Remove the first and reverse synchronizer hub snap

rbl!from mainshaft and remove the synchronizer assembly,

first-speed blocker ring and first-speed gear from the rear of
the mainshaft. Remove hub and mark for reinstallation.

CLEANING AND INSPECTION

Tmnsmission Case
1. Wash the transmission thoroughly inside and outside
with cleaning solvent, then inspect the case for cracks.

Reverse Idler Gear Bushing

The b u s h g used in the idler gear is pressed into the gear
and finish bored in place. This insures the positive alignment
of the bushing and shaft as well as proper meshing of the
gears. Because of the high degree of accuracy to which these
parts are machined, the bushng is not serviced separately.
Countergear Anti-Lash Plate
Inspect the plate teeth for wear or other damage. The

3-SPEED MANUAL TRANSMISSION 7B-13

be installed into different key cavities on either

SP" g, slide the sleeve onto the hub aligning the marks made
side

before disassembly.

(NOTE: A groove around the outside of the synchronizer

hub identifies the end that must be opposite the fork slot in
fie
when ass:,mbled. This groove in&cates the end of
the hub with a 1116 greater recess depth.)
gxtension Oil Seal or Bushing
Refer to "Rear Bearing Retainer Oil Seal" and "Bushing
~ ~ ~ ~ v(on
a . car)
l " for correct tools.
Main Drive Gear Od Seal
Refer t o "Main Drive Gear Bearing Seal Replacementm
mder "Major Service Operations" for necessary tools and
procedure.

ASSEMBLY

(NOTE: When installing new gaskets, do not coat with

grease .)
Mainshaft (Fig. 7B-20)
Turn the front of the mainshaft upward, then install the
following on the mainshaft :
1. Install the second-speed gear with synchronizing
teeth upward. The rear face of the gear will butt against the
flange on the mainshaft.
2.Install a blocking ring with clutching teeth
downward over the synchronizing surface of the
second-speed gear. All three blocker rings used in this
transmission are identical.
3. Install the second and third synchronizer assembly
with the fork slot downward, press it onto splines on the
mainshaft until it bottoms out. Both synchronizer assemblies
used in this transmission are identical.
(NOTE: Be sure the notches of the blocker ring align with
the keys of the synchronizer assembly.)

Fig. 7B-2 1-Installing Speedometer Drive Gear

Assembly of Parts into Case
1 . Using Tool 5-22246, load a row of roller bearings
(27) and a bearing thrust washer at each end of the
countergear. Use petrolatum sparingly to hold them in place.
2. Place countergear assembly through case rear
opening along with a countergear thrust washer (tang away
from gear) at each end and install countergear shaft and
woodruff key from the rear of case.

(NOTE: Be sure countershaft picks up both thrust washers

and that the tangs are aligned with their notches in the case.)
3. Install reverse idler gear and shaft with its woodruff
key from the rear of case. Do not install idler shaft snap ring
at t h s time.
4. Using snap ring pliers, expand the snap ring in the
extension and assemble extension over rear of mainshaft and
onto rear bearing. Seat snap ring in rear bearing groove. (Fig.
7B-22)

4. Install synchronizer hub t o mainshaft snap ring.

Both synchronizer snap rings are identical.
(NOTE: Turn the rear of the mainshaft upward, then install
the following parts on the mainshaft :)
5 . Install the first-speed gear with clutching teeth
upward. The front face of the gear will butt against the
h g e on the mainshaft.
6 . Install a blocker ring with clutching teeth downward
Over synchronizing surface of the first-speed gear.
7 . Install the first and reverse synchronizer assembly
fork slot downward; press it onto splines on the
mainshaft.

~ T E Be: sure the notches of the blocker ring align with

keys of the synchronizer assembly.)

8. Install synchronizer hub to mainshaft snap ring.

reverse gear with synchronizing teeth

9. Install

10. Install reverse gear thrust washer (steel).

11. Install reverse gear spring washer.
12. Install rear ball bearing with snap ring slot

t$~ard;
:.

press onto mainshaft.

l3. Install rear bearing to mainshaft snap ring.

l4. Install speedometer drive gear. (Fig. 7B-21)
This completes the assembly of the mainshaft.

Fig. 7B-22-Installing Rear Bearing Snap Ring

5. Load the mainshaft pilot bearings (14) into the main

drive gear cavity with light grease and assemble the
third-speed blocker ring onto the main drive gear clutching
surface with its teeth toward the gear.

7B-14 3-SPEED MANUAL TRANSMISSION

6. Pilot the main drive gear, pilot bearings and

third-speed blocker ring assembly over the front of the
mainshaft assembly. Do not assembly bearing to gear at this

Procedure
1. Remove the transmission from the car md
completely disassemble as outlined.

(NOTE: Be sure the notches in the blocker ring align with

the keys in the 2-3 synchronizer assembly.)

(NOTE: In any case where the main drive gear pilot or pilot
bearing is excessively loose or worn, the pilot bearing
bushing should be replaced before checking the transmission
rear bearing bore alignment by the dial indicator method.)

7. Place extension to case gasket at rear of case and,

from the rear of case, assemble the main drive gear,
mainshaft and extension to case as an assembly,
(NOTE: Be sure the maindrive gear engages the teeth of the
countergear anti-lash plate .)

8. Install extension to case retaining bolts.

9. Install main drive gear bearing outer snap ring to
bearing and position bearing over stem of main drive gear and
into front case bore.
10. Install snap ring to main drive gear stem and main
drive gear bearing retainer and gasket to case.
(NOTE: The retainer oil return hole should be at the
bottom, and gasket positioned for free oil return .)
11. Install reverse idler gear retainer "E" ring to shaft.
Be sure thrust washer tang engages notch in case.
12. Shift synchronizer sleeves to neutral positions and
install cover, gasket and fork assembly to case. Be sure forks
align with their synchronizer sleeve grooves.
13. Tighten all bolts to specified torque.

2. Install the case extension on the case and tighten the

extension to case bolts securely.
3 . Carefully instau the special tool with the did
indicator into the transmission case with the face of the
indicator and the tracing finger to the rear of the
transmission. Secure in place with a main drive gear bearing
retainer.
4. Carefully rotate the gear and make final adjustment
of the indicator with the tracing finger of the indicator in the
center of the rear bearing bore in the case extension.
5. Assemble the transmission case to the clutch housing
and tight en the four transmission mounting bolts securely.
(NOTE: Be sure to clean off any paint or other foreign
material on the mating faces of the clutch housing and
transmission as any foreign material on these faces
change alignment. Also, check carefully for dings or burrs on
these mating surfaces and carefully remove as necessary.)

6. Install transmission support and support to

transmission mounting block bolts.
7. Remove the jack or other support from under t
engine, let the weight of the engine rest on the transrnissio
mounting in the normal position.
8. Dial indicate the transmission rear bearing bore
record the indicator readings in 12, 3, 6 and 9 o'
positions, with the weight on the transmission mounti
outlined above.
(NOTE: Start the reading at the 6 o'clock position the
record the 9, 12 and 3 o'clock readings .)

9. Install temporary shims between the transmissio

case and the clutch housing at the bolt locations as necess
to bring misalignment at the transmission rear bearing b
to a maximum of .OIO1' indicator reading in either
vertical or horizontal plane.

Fig. 7B-23-Checking Transmission Alignment

(NOTE: Installation of a .002" shim between

transmission case and the clutch housing at two
locations opposite to the high indcator reading will ch
the transmission rear bore reading approximately .003

ALL MANUAL TRANSMISSIONS

TRANSMISSION ALIGNMENT (Fig. 7B-23)
If transmission slips Out of high gear, particularly at 50
mph and up, after all other probable causes have been
corrected as outlined under DIAGNOSIS, the alignment of
the engine crankshaft pilot, clutch housing bore and the
transmission should be checked.
A special tool on which is mounted a dial indicator is
necessary to check the transmission rear bearing bore
alignment. This tool may be made from a new, or good used,
main drive gear which has a good bearing surface on the
crankshaft pilot and main drive gear bearing.
The splines on the clutch gear shaft should be ground off
so the shaft may be rotated in a clutch disc hub without
interference when assembled in the car. Weld a piece of 1/4"
rod 8" long in the mainshaft pilot bore. Assemble a good
bearing on the shaft and secure it with the snap ring.

10. After the position and quantity of shims has b

determined and recorded, transmission case may be rem0

(NOTE: The clutch housing should then be marked,

the position where shims are to be installed and the t
of shims at each location .)
11. Inspect the clutch teeth of the main drive 8
Inspect the second and third-speed clutch teeth and
internal clutch teeth of the high gear (fonvard end). lf
teeth of either gears are worn or tapered due to
continued previous dsengagement, the gears should
replaced. Reassemble transmission.
12. Install the transmission assembly to the c1
housing, using the correct number of shms at the Pr
locations as previously determined.

4-SPEED MANUAL TRANSMISSION 7B-15

FOUR SPEED MANUAL

TRANSMISSION
INDEX

SUBJECT

PAGE

~dj~stments .
.
Description
. .
1)iaPosis
Rear Oil Seal .
Side C o ~ r . .
spedficati0ns

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

PAGE

SUBJECT

. . .
Speedometer Driven Gear
Transmission Alignment
. . . .
Transmission Disassembly
. . .
Transmission Reassembly . . . .
Transmission Removal & Installation
TOOIS . . . . . . . . . . . .

. 7B-16
. 78-15
. 78-1
. 7B-18
. 7B-18
.7B44

.
.
.
.

.
.
.
.
.
. .

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

. . . 7B-18
. . .7~-14
. . .7 ~ - 2 0
. . . 7 B-24
. . .7~-18
. . .7B45

GENERAL DESCRIPTION (Fig. 7B-24)

A four speed (M-20) transmission, synchronized in all
forward gears, is used as standard equipment on the Starfire.
The transmission is identified by 1" high letters "ZR",
b 6 ~ M ""S4"
,
or "RH" located on the right hand side of the
i

case.

The four speed transmission is representative of a

contant -mesh transmission design. Basic parts of the four

speed are the case which houses the gears and shaft; the
control cover, which houses the shifter mechanism; and the
various shafts and gears. The input shaft has an integral main
drive gear and rotates with the clutch driven plate (disc); that
is, the shaft rotates all the time the clutch is engaged and the
engine is running. The input shaft is supported in the case by

'28 \29\30

I
1

1.
2.
3.
4.
5.

i~

6.

7.
8.
9.
10.
11.

12

Clutch Gear
Bearinq Retainer
Pilot skarings
Case
4th Speed Blocker
Ring
4-3 Synch. Snap Ring
4-3 Synch. Hub
3rd speed B locker
Ring
3rd Speed Gear
2nd Speed Gear
2nd Speed B locker
Ring
1-2 Speed Sync h.
Hub

31

32

33

34

35

13. 1-2 Speed Synch.

Snap Ring
14. 1st Speed Blocker
Ring
15. First Gear
16. Reverse Gear Thrust
and Spring Washers
17. Snap Ring-Bearing 1:O
Mainshaft
18. Extension
19. Vent
20. Speedometer Drive
Gear and Clip

f x / -

29. Snap Ring-Bearing to

Extension
30. Rear Bearing
31. Countergear Roller
Bearinq
21. Mains haft
32. Magnet
22. Rear Oil Seal
33. 4-3 Synch. Sleeve
22a. Rear Extension
34. Coun tergear
Housing Bushing
Assembly
23. Retainer Oil Seal
35. Counter Shaft
,, ,_
.,
- .
36. Reverse Idler Shaft
~ 4 .Snap ~ l n g - b e a r i n g
+37. 1-2 Speed Synch.
IU b e d l
qr
,-.,. .A-L Gear Bearing
Sleeve and keverse
L3. LIULLll
n:
Gear
LO. 3r1ap ~ ~ n g - B e a r i n g
38. Reverse Idler Gear
10 Lase
37
Th....,+
(Sliding)
LI.
IIII Uhl
Washer-Front 39. Clutch Key
28. Thrust
her-Rea 40. Woodruff Key
pa..u

Q~

I----

I-

n - _ _

Fig. 7B-24-Four Speed Manual Transmission

7B-16 4-SPEED MANUAL TRANSMISSION

a ball bearing and at the front end by the pilot bearing

mounted in the end of the engine crankshaft. The drive gear
is in constant mesh with the countershaft drive gear. Since all
gears in the countershaft cluster are integral to the shaft,
they also rotate at the time the clutch is engaged. The
countergear is carried on roller bearings at both ends and
thrust is absorbed by thrust washers located between the
countergear and thrust bosses in the case. The transmission
mainshaft is held in line with the input shaft by a pilot

Helical gears are incorporated throughout, except reverse

gear which is a spur gear. The mainshaft gears are free t o
rotate independently on the mainshaft and are in constant
mesh with the countershaft gears. The reverse idler gear is
carried on a bushing; finish bored in place, and thrust is
taken on the thrust bosses of the case.
The transmission is fully synchronized in all forward
speeds, however, reverse gear is not. The synchronizer
assemblies consists of a hub, sleeve, two key springs and
three synchronizer keys. The synchronizer hubs are splined
t o the mainshaft and retained by snap rings. These assemblies
permit gears to be selected without clashing, b y
synchronizing the speeds of mating parts before they engage.
Periodic or seasonal changes of lubricant are not
recommended. The lubricant level should be checked at each

Fig. 7B-26RShift Linkage (Cutlass)

5. Tighten (1st-2nd) shift rod nut against swivel.

MAINTENANCE AND ADJUSTMENTS

NOT REQUIRING TRANSMISSION REMOVAL
SHIFT LINKAGE ADJUSTMENT (Fig. 7B-25 and 7B-26)
1. Turn ignition switch to the "OFF" position and
raise car on hoist.
2. Loosen lock nuts at swivels on the shift rods. Rods
should pass freely through the swivels.
3 . Set transmission shift levers in neutral.
4. Set shift control lever in neutral position. Align
control levers and install gage pin into levers and bracket.

NOTCH

Shift Linkage Adjustment - Cutlass (Fig. 7B-27)

The shift linkage is attached as shown in Fig. 7B-27. To
adjust, proceed as follows:

@:&!zf5

SHIFTER ASSEMBLY

3rd AND 4th ROD

Fig. 7B-25-Shift Linkage (Starfire)

Fig. 7B-27-Shift Linkage (Cutlass)

'
1

4-SPEED MANUAL TRANSMISSION 7B-17

1. Turn ignition switch to the "OFF" position and

raise car on hoist.
2. Remove retainer on the shift rods.
3. Set transmission shift levers in neutral.
4. Set shift control lever in neutral position. Align
control levers and install gage pin into levers and bracket.
5. Loosen nuts on shift rod and adjust trunnion and
pif assembly on Reverse-lst, then tighten nuts and install
shift rod and retainer .
6. Loosen nuts on shift rod and adjust trunnion and
pin assembly on 2-3, then tighten nuts and install shift rod
and retainer .
7. Remove gage pin from control lever assembly and
check operation of control lever. Readjust a.s required.
8. Lower and remove car from hoist.

REVERSE

CONTROL LEVER
BRACKET

&-PIVOT

SHIFT LEVER
PIN

SHIFT LEVER
BRACKET

LEVER
INTERLOCK
PLATE
3RD 8 4TH
LEVER

I ST 8 2 N D
LEVER

Fig. 7B-29-Shift Control Assembly (Exploded View)

Fig. 7B-28-Shift Control Assern bly (Starfire)

SHIFT CONTROL ASSEMBLY (Figs. 7B-26, 7B-27 and

1. Remove control lever knob, lock nut, spring and

2. Remove boot retainer, boot and insulator.

3 . Pull back edge of carpeting and remove control
assembly attaching bolts.
4. Raise car on hoist. Remove retaining pins and
disconnect control rods from shift control levers. Remove
34 swivel from lever.
5. Disconnect speedometer cable and back-up lamp
Switch from transmission.
6. Push 1-2 and reverse control rods up t o floor pan.
Move control assembly l-eaMlard and t o left until it clears
extension, then tip rear of control downward and remove
Shift control lever from car.
Installation (Figs. 7B-26,7B-27 and 78-28)
1 . Position control lever with lower seal in floor pan
Opening and install bolts attaching control assembly to floor

2. Install insulator, upper seal and retainer.

3 - Install "T" handle, spring, lock nut and lever knob.
4. Install 3-4 swivel and control rorls to shift control

SHIFT CONTROL ASSEMBLY REPAIR (Fig. 7B-29)

1. Remove shift control lever pivot shaft retaining ring
and pivot shaft. Remove control lever assembly from control
housing.
2. Note position of spacers in relation to levers.
Remove spacers and levers from control housing.
3. Remove lever spring and retainer from control lever.
4.. Remove the lever pin retaining clip, pin and lever
from housing.
5. Clean and inspect all parts. Replace all worn,
cracked or broken Parts as necessary.
(NOTE: If necessary t o remove the reverse lever adjusting
screw, grind or chisel off the weld and remove screw from
housing.)

6. If removed, position control lever in lever housing

and install lever pin and retaining clip. Install reverse lever
adjusting SCrew but do not weld at this time(NOTE: Lubricate all levers and spacers with a water
repellant type of lubricant such as lubriplate or equivalent.)

7. Install s h f t levers and spacers in control housing.

8. Install shift lever spring and retainer in housing
making sure lever engages s h f t levers.
9. Install lever pivot shaft and retaining clip.
10. If removed, adjust reverse lever adjusting screw as
follows:
a. Position control lever in the first and second
shifter lever and touching the interlock plate spacer
between the 1-2 and reverse levers.
b . Hold the reverse release rod against the screw
tightening the screw to eliminate any contact of the
control finger as it travels across the neutral gate of the
spacer plate.
c. Weld the screw securely in place.

4-SPEED MANUAL TRANSMISSION 7B-19

3, Disconnect the speedometer cable and back-up lamp

4, Disconnect transmission control rod and lever
ssembfie~ from the shifter shafts. Tie rods up out of work

5.
6.
7.
remove

Remove crossmember-to-transmission mount bolts.

Remove catalytic converter support bracket.
Support engine with an appropriate jack stand and
crossmember-to-frame bolts. Remove crossmember

move transmission to clutch housing upper

retaining bolts and install guide pins in holes.

(NOTE: Guide pins must be used to support transmission to

prevent distortion of the clutch driven plate hub when
removing or installing transmission .)

9 . Remove lower bolts, then

rearward and remove from car.

slide transmission

ition transmission to clutch housing and slide

ting clutch gear into pilot bearing.
ke certain main drive gear splines are clean and

1. Clutch Gear

5. 4th Speed Blocker

13. 1-2 Speed Synch.

Snap Ring
14. 1st Speed Blocker

6. 4-3 Synch. Snap Ring 15. First Gear

7. 4-3 Synch. Hub
16. Reverse Gear Thrust
8. 3rd Speed Blocker
and Spring Washers
17*
Ring-Bearing to
Mainshaft
18. Extension
11. 2nd Speed Blocker
19. Vent

20SpeedometerDrive
Gear and Clip

2. Reverse removal procedure, using the following

specified torque ratings for the attaching parts:
Transmission to clutch housing bolts . .
Crossmember to frame bolts (exc. Starfire)
.
Crossmember to frame bolts (Starfire)
Crossmember to transmission mount bolts
Propeller shaft bolt (Exc. Starfire) . . .
.....
Propeller shaft bolt (Starfire)
. . . . . . . . .
Torque arm bracket
Torque arm to differential housing . . .

. .
.
. .
.
.
.
.

. 53 ft . lbs.
. 25 ft .lbs.
. 43 ft. lbs.

. . 35 ft. lbs.
. . 16 ft. lbs.
. . 13 ft. lbs.
. . 30 ft. lbs.
. . 113 ft. lbs.

C A U T I O N : Propeller shaft
attaching fasteners are an important
attaching part in that i t could affect
the performance of vital parts and
systems, and/or could result in
major repair expense. I t must be
replaced with one of the same part
number or with an equivalent part
i f replacement becomes necessary.
Do not use a replacement part of
lesser quality or substitute design.
Torque values must be used as
specified during reassembly to
assure proper retention of this part.

29. Snap Ring-Bearing to

Extension
30. Rear Bearing
31. Countergear Roller
Bea ri nq
21. Mainshaft
32. Magnet
22. Rear O i l Seal
33. 4-3 Synch. Sleeve
34. Cou nte rgea r
22a. Rear Extension
Housing Bushing
Assembly
23. Retainer Oil Seal
35. Counter Shaft
24, Snap Ring-Bearing
36. Reverse Idler Shaft
37. 1-2 Speed Synch.
to Gear
Sleeve and Reverse
25. Clutch Gear Bearing
Gear
26*
Ring-Bearing
38. Reverse Idler Gear
to Case
27. Thrust Washer-Front 39e (Sliding)
Clutch Key
2 8 . T h r u s t W a s h e r - R e a r 40,woodruffKey

Fig. 7B-32-Four Speed Manual Transmission

I
I

7B-20 4-SPEED MANUAL TRANSMISSION

DISASSEMBLY OF TRANSMISSION (Fig. 7B-32)

1. Remove side cover attaching bolts and remove side
cover assembly.
2. Remove clutch gear bearing retainer bolts, retainer

Fig. 7B-35-Removing Extension To Rear Bearing Snap Ring

Fig. 7B-33-Removing Clutch Gear Bearing

Fig. 7B-36-Removing Countershaft

Fig. 7B-34-Removing Clutch Gear and Mainshaft

Fig. 7 B-37-Removing Reverse Idler Gear Shaft

6 . Using snap ring pliers, expand the snap ring in the
extension w h c h retains the mainshaft rear bearing (Fig.
7B-35) and remove the extension.
7. Using 5-22246 a t the front of the countershaft, drive
the shaft and its woodruff key out the rear of the case, Tool
J-22246 will now hold the roller bearings in position within
the countergear bore. Remove the gear and bearings. (Fig.

case. (Fig. 7B-37)

DISASSEMBLY OF MAINSHAFT
1. Using snap ring pliers, remove the 3rd and 4th speed
sliding clutch hub snap ring from mainshaft and remove
clutch assembly, third gear blocker ring and third speed gear
from front of mainshaft. (Fig. 7B-38)

4-SPEED MANUAL TRANSMlSSlON 7B-21

Fig. 7B-38-Removing 3rd and 4th Synchronizer Snap Ring

Fig. 7B40-Removing Rear Bearing and I st Speed Gear

Fig. 7B41 -Removing I st and 2nd Synchronizer Snap Ring

Fig. 7 B-39-Removing Rear Bearing To Mainshaft Snap Ring
of mainshaft to remove first gear, thrust washer, spring
washer and rear bearing from rear of mainshaft. (Fig. 7B40)
5. Remove the 1st and second sliding clutch hub snap
ring from the mainshaft and remove the clutch assembly, 2nd
speed blocker ring and second speed gear from the rear of the
mainshaft. (Fig. 7 B 4 1)

CLEANING AND INSPECTION

Transmission Case
1. Wash the transmission thoroughly inside and outside
with cleaning solvent, then inspect the case for cracks.
2. Check the front and rear faces for burrs, and if
Present, dress them off with a fine mill fie.

Front and Rear Bearings

1. Wash the front and rear ball bearings thoroughly in a
cleaning solvent .

2. Blow out bearings with compressed air.

(NOTE: Do not allow the bearings to spin, turn them slowly
by hand. Spinning bearings will damage the race and balls.)
3 . Make sure bearings are clean, then lubricate with
light engine oil and check them for roughness by slowly
turning the race by hand.

Bearing Rollers
All clutch gear and countergear bearing rollers should be
inspected closely and replaced if they show wear. Inspect
counter shaft and reverse idler shaft at the same time, replace
if necessary. Replace all worn washers.
Gears

1. Inspect all gears for excessive wear, chips, or cracks

and replace any that are worn or damaged.
2. Check both clutch sleeves to see that they slide
freely on their hubs.

70-22 4-SPEED MANUAL TRANSMISSION

Reverse Idler Gear Bushings

The bushing used in the idler gear is pressed into the gear
and finish bored in place. Tlus insures the positive alignment
of the bushng and shaft as well as proper meshing of the
gears. Because of the high degree of accuracy to which these
parts are machined, the bushing is not serviced separately.
REPAIRS
$

Clutch Keys and Springs

(NOTE: The clutch hubs and sliding sleeves are a selected

assembly and should be kept together as originally
assembled, but the keys and two springs may be replaced if
worn or broken .)

1. Mark hub and sleeve so they can be matched upon

reassembly.
2. Push the hub from the sliding sleeve, the keys and
the springs may be easily removed.
3 . Place the three keys and two springs in position (one
on each side of hub), so all three keys are engaged by both
springs. (Fig, 7B42) The tanged end of each synchronizer
spring should be installed into different key cavities on either
side. Slide the sleeve onto the hub aligning the marks made
before disassembly.

Fig. 7B-43-Ex tension Bushing Replacement

(NOTE: A groove around the outside of the synchronizer

hub identifies the end that must be opposite the fork slot in
the sleeve when assembled. This groove indicates the end of
the hub with a greater recess depth.)

Fig. 7B-44-Installing Extension Oil Seal

Fig. 7 B42-Synchronizer Assembly

Extension Oil Seal or Bushing
If bushing in rear of extenison requires replacement,
remove seal and use Tool 5-5778 to drive bushing into
extension housing. (Fig. 7B43) Using the same tool, drive
new bushing in from the rear. Coat ID. of bushing and seal
with transmission lubricant, then install new oil seal using
Tool J-5154 or 5-21426. (Fig. 7 3 4 4 )

Clutch Gear Bearing Retainer Oil Seal

If the lip seal in the retainer needs replacement; pry the
oil seal out and replace with a new seal using Tool 5-23096
until seal seats in its bore. (Fig. 7B-45 and 7B-06)
(NOTE: Lip of seal must face rear of bearing retainer.)

Fig. 7 B-45-Removing Bearing Retainer Oil Seal

4-SPEED MANUAL TRANSMISSION 7B-23

3. Install the 3rd and 4th synchronizer assembly with

the fork slot downward on the mainshaft until it bottoms
out against flange.

(NOTE: Be sure the notches of the blocker ring align with

the keys of the synchronizer assembly.)
4. Install synchronizer hub to mainshaft snap ring.
(Fig. 7B48) Both synchronizer snap rings are identical. Turn
the rear of the mainshaft upward. Install the following parts
on the mainshaft:

Fig. 7 B-46-Installing Bearing Retainer Oil Seal

ASSEMBLY OF MAINSHAFT (Fig. 7B-47)
Turn the front of the mainshaft upward. Install the
following parts on the mainshaft :
1. Install the third speed gear with clutching teeth
upward; the rear face of the gear will butt against the flange
on the mainshaft.
2. Install a blocking ring with clutching teeth
downward over the synchronizing surface of the third speed
gear, All four blocker rings used in this transmission are
identical.

1. Drive Gear Bearing

2 . Drive Gear
3. Mainshaft Pilot
Bearings
4 . 3-4 Synchronizer
Assembly
5. Third Speed Gear
6. Second Speed Gear
7. 1-2 Synchronizer and
Reverse Gear Assembly

Fig. 7B-48-Installing 3rd and 4th Synchronizer Snap Ring

8. First Speed Gear

9. Thrust Washer
10. Spring Washer
11.
12.
13.
14.
15.

Rear Bearing
Speedo Drive Gear
Mainshaft
Snap Ring
Synchronizing
"Blocker" Ring

Fig. 7B47-Clutch Gears and Mainshaft

7 B-24 4-SPEED MANUAL TRANSMISSION

Fig. 7B-49-Installing 1st and 2nd Synchronizer Snap ling

Fig. 7 B-52-Installing Speedometer Drive Gear and Clip

,I 1

I"'

<

I
I

I ?

Fio 7R-Cn-Tnctallina R e a r R ~ a r i n o

ii

5. Install the second speed gear with clui;clung

upward; the front face of the gear will butt again:st the
on the mainshaft.
6. 1nstai ablocker ring with clutching teeth downward
over synchronizing surface of the second speed gear.
7. Install the first and second svnchronizer assemblv
with fork slot downwards.
8. Install synchronizer hub to mainshaft snap ring.
(Fin.
- 7B49)
9. 1nhall a blocker ring with notches downward so
they align with the keys of the 1-2 synchronizer assembly.
10. Install first gear with clutching teeth downward.
11. Install first gear thrust washer (steel).

I/

(NOTE: Be sure the notches of the blocker ring align with

the keys of the synchronizer assembly.)

12. Install first gear spring washer.

13. Install rear ball bearing with snap ring slot
downward; press onto mainshaft. (Fig. 7B-50)
14. Install rear bearing to mainshaft snap ring. (Fig.
7B-5 1)
15. Install speedometer drive gear and clip. (Fig. 7B-52)
This compleies the assembly ofthe mainshaft. -

MSEMBLY OF TRANSMISSION (Fig. 7B-56)

1. Using Tool 5-22246 load a row of roller bearings
(27) and a -bearing thrust as her at each end of the
countergear. Use heavy grease to hold them in place. (Fig.
7B-53)
2. Place countergear assembly through case rear
opening along with a tanged thrust washer (tang away from
gear) at each end and install countergear shaft and woodruff
key from rear of case.

(NOTE: Be sure countershaft picks up both thrust washers

and that the tangs are aligned with their notches in the case.)
3. Install reverse idler gear and shaft with its woodruff
key from the rear of case.

4-SPEED MANUAL TRANSMISSION 7B-25

i

M A I N DRIVE GEAR

Fig. 7B-53-Loading Countergear Bearings

Fig. 7B-5 5 -Loading Mainshaft Bearings

6. Pilot the clutch gear, pilot bearings and 4th speed
blocker ring assembly over the front of the mainshaft
assembly. Do not assembly bearing to gear at this time.
7. Place extension to case gasket at rear of case holding
in place with grease and, from the rear of the case, assemble
the clutch gear, mainshaft and extension to case as an
assembly.
8. Install extension to case retaining bolts. Using seal
cement on bottom bolt only.
9. Install front bearing outer snap ring to bearing and
position bearing over stem of drive gear and into front case
bore.
10. Install snap ring to drive gear stem, and drive gear
bearing retainer and gasket to case.

Fig. 7 B-54-Installing Extension to Rear Bearing Snap Ring

(NOTE: The retainer oil return hole should be at the bottom

and gasket positioned for free oil return .)
4. Using snap ring pliers, expand the snap ring in the
extension and assemble extension over rear of mainshaft and
onto rear bearing. Seat snap ring in rear bearing groove. (Fig.

7B-54)
5. Load the mainshaft pilot bearings (14) into the
clutch gear cavity and assemble the 4th speed blocker ring
onto the clutch gear clutching surface with its clutching teeth
toward the gear. (Fig. 7B-55)

11. Shift synchronizer sleeves to neutral positions and

install cover, gasket and fork assembly to case. Be sure forks
align with their synchronizer sleeve grooves.
12. Tighten all bolts t o specified torque.

TRANSMISSION ALIGNMENT (REFER TO THREE

SPEED SECTION)

7B-26 4-SPEED MANUAL TRANSMISSION

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Snap Ring, Hub to Shaft

Synch. Ring
3 4 Synch. Sleeve
Synch.KeySpring
Synch. Hub and Keys
Synch. Key Spring
Synch. Ring
Third Gear
Mainshaft
Second Gear
Synch. Ring
Synch. Key Spring

25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.

13.

Svnch- Hub and Kevs

36.
37.

14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.

inch. Key Spring -

1-2 Synch. Sleeve and

Reverse Gear
Snap Ring, Hub to Shaft
First Gear
Thrust Washer
Waved Washer
Ring Bearing
Snap Ring, Bearing to Shaft
Speedo Gear Clip
Speedo Drive Gear
Bearing Retainer Bolts and
Washers (4)

38.
39.
40.
41.
42.
43.
44.
45.
46.

Front Bearing Retainer

Bearing Retainer Gasket
Bearing Retainer Oil Seal
Snap Ring
BearingSnapRing
Front Bearing
Drive Gear
Pilot Bearings
Case
Extension to Case Gasket
Rear Bearing to Extension
Retaining Ring
Rear Extension
Extension to Case Retaining
Bolts and Washers
Rear Extension Bushing
Rear Seal
Thrust Washer
Spacer
Countergear Shaft Roller
Bearings
Countergear
Countergear Shaft Roller
Bearings
Spacer
Thrust Washer

47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.

Fig. 7B-%-Four Speed Transmission (Exploded View)

Countergear Shaft
Countergear Shaft Key
Reverse Idler Shaft
Idler Shaft Key
Reverse Idler Gear
Side Cover Gasket
3-4 Shift Fork
1-2 Shift Fork
3-4 Shifter Shaft
Retaining "E" Ring
1-2 Shifter Shaft With
"0" Rings
Reverse Shifter Shaft
3-4 Detent Cam
Detent Cam Spring
Reverse Detent Ball and
Spring
1-2 Detent Cam
Shift Cover
Plug and Gasket
Shifter Shaft Seal
Shifter Shaft Seal
Shift Cover Bolts and
Washers
Shift Cover Attaching Bolts
and Lock Washers

--

5-SPEED MANUAL TRANSMISSION 7B-27

*

FIVE SPEED MANUAL TRANSMISSION

INDEX
SUBJECT
Diagnosis

PAGE

. . . . . . . . . . . . . . . . . . 7B-3

TO tension Housing Oil Seal Replacement . . . . . 7B-27

ceneral Description . . . . . . . . . . . . . . 7B-27
Major Service Operations . . . . . . . . . . . . 7B-27
Minor (on Car) Adjustments
speedometer Driven Gear
Removal and Installation

. . . . . . . . . . 7B -27

. . . . . . . . . . . 7B-27

GENERAL DESCRIPTION
The five-speed manual transmission is a floor shift and
fully synchronized in all forward speeds. Fifth gear is an
overdrive which means that the transmission output shaft
turns faster than the input shaft when in fifth gear.
The transmission has a single shift rail with the shifting
mechanism totally enclosed inside the transmission. With this
design, the shift mechanism is unaffected by dirt, water and
corrosion.
All gears are in constant mesh with the countergear
(gears on counter shaft) including reverse (through the
reverse idler gear). When shifting gears, the selected gear is
locked to the output shaft through the synchronizer clutch
hub.
-

(NOTE: All gears are fully synchronized except Reverse

gear.)
Overdrive, fifth gear, is obtained by a gear on the output
shaft and one of the gears on the countergear inside the
transmission instead of a bolt-on overdrive as used with some
other transmissions.
When in overdrive, the car's engine turns about 20%
slower than direct drive. At 55 mph in overdrive, the car's
engine rpm is about 44 mph.
DEXRON@-11 automatic transmission fluid is used for
lubrication. The capacity of the transmission is 3.5 pints (1.6
litres). When checking the fluid level, remove the fill plug
from the right side of the transmission case, add fluid to
bring the level to the bottom of the fill hole.

MINOR (ON CAR) ADJUSTMENTS

SPEEDOMETERDRIVEN GEAR
Disconnect speedometer cable, remove retainer to
housing bolt and remove retainer and adapter. Insert
Screwdriver into retainer slot in sleeve and pry sleeve and
driven gear from housing.
Coat seal and speedometer gear shaft with automatic
transmission lubricant and insert gear. Push sleeve into
housing until the retainer can be inserted into the groove in
the sleeve and install the retainer.

m E ~ TRANSMISSION
m ~ ~
MOUNTS

Raise the car on a hoist. Push up and pull down on the

tmsmission tailshaft while observing the transmission
mount. If the rubber separates from the metal plate of the
mount Or if the tailshaft moves up but not down (mount

SUBJECT

PAGE

Tools . . . . . . . . .
Transmission
. . . . . .
Assembly
. . . . .
Disassembly
Removal and Installations
Specifications . . . . .

. . . . . . . . . .

.7~45

.
.
.
.

. 7B-38
. 7B-31
.7~.27
. 713-44

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

bottomed out) replace the mount. If there is relative

movement between a metal plate of the mount and its
attaching point, tighten the screws or nuts attaching the
mount to the transmission or crossmember.

EXTENSION OIL SEAL REPLACEMENT

1. Raise car on hoist then remove propeller shaft.
2. Pry seal out of extension.
3. Wash counterbore with cleaning solvent and inspect
for damage.
4. Prelubricate between sealing lips and coat new seal
O.D. with Permatex or equivalent and start straight in bore in
case extension. Using Tool 5-5154 or 5-2 1426, tap seal into
counterbore un ti1 flange bottoms against extension.
5 . Reinst all propeller shaft. Torque pr3peller shaft
bolts to 16 ft lbs. (exc. Starfire); 13 ft. lbs. on Starfire.

' i

C A U T I 0 N : Propeller shaft
attaching fasteners are an important
attachin partFin that i t could affect
the per ormance of vital parts and
systems, and/or could result in
major repair expense. It must be
replaced with one of the same part
number or with an equivalent part
if replacement becomes necessary.
Do not use a replacement part of
lesser quality or substitute design.
Torque values must be used as
specified during reassembly to
assure proper retention of this part.

11

I
i

1
I

1
1

/1

,I

'1

MAJOR SERVICE OPERATIONS

Removal
1. Remove shift control knob.
2. Remove boot retainer, boot and insulator.
3. Pull back edge of carpeting and remove shift control
assembly attaching bolts and shifter assembly.
4. Raise car on hoist.
5. Remove propeller shaft assembly.
6. Disconnect the speedometer cable and speedometer
driven gears.
7. Remove crossmember-to-transmission mount bolts.
8. Remove catalytic converter support bracket.
9. Support engine with an appropriate jack stand and
remove crossmember-to-frame bolts. Remove crossmember
from car.

5-SPEED MANUAL TRANSMISSION 7B-29

I8

Fig. 7B-58-Five Speed Overdrive Transmission (Exploded View)

O I L SEAL
BUSHING
PIN
S H I F T E R HEAD
THREADED PLUG
POPPET SPRING
MESH LOCK PLUNGER
BREATHER A S S ' Y
SELECTOR LEVER P I V O T
W I R I N G HARNESS C L I P
NAME PLATE
BACK-UP L I G H T BRACKET
CUP PLUG
EXTENSION HOUSING MITH BUSHING
3/8-16 X 3 1/4 HEX HD. BOLT
SWITCH
NEEDLE BEARING
S H I F T RAIL
SPRING PIN
R A I L SELECTOR END
F I R S T & REVERSE S H I F T FORK
S H I F T FORK PAD
F I R S T & REVERSE S H I F T L I N K
GASKET
9/16-18 PLUG
SPEEDOMETER GEAR
SPEEDOMETER GEAR R E T A I N I N G C L I P
OR BALL & SNAP RING
SNAP R I N G
THRUST WASHER
1 S T S P E E D GEAR
SNAP R I N G
BLOCKING R I N G
SYNCHRONIZER S P R I N G
S H I F T PLATE
CLUTCH HUB
CLUTCH S L E E V E
REVERSE GEAR & BUSHING A S S ' Y
BUSHING
SELECTOR ARM - OPTIONAL
SPRING PIN
INTERLOCK PAWL
S E L E C T O R ARM R E T A I N I N G PLATE
1 / 4 - 2 0 X 3/4 HEX. HD. S E L F T A P P I N G SCREW
REVERSE I D L E R GEAR & BUSHING
BUSHING
SPRING PIN
REVERSE I D L E R S H A F T
"0" R I N G
REVERSE I D L E R GEAR
REVERSE I D L E R SHAFT
BEARI NG SPACER
ROLLER BEARING
REVERSE I D L E R GEAR
DOWEL P I N

"
*

S T A R F I R E ONLY
MIXED PRODUCTION

CENTER SUPPORT
MAGNET
NEEDLE BEARING
S H I F T RAIL
PIN
RETAINING C L I P
SELECTOR LEVER
NEEDLE BEARING
THRUST WASHER
NEEDLE THRUST BEARING
NEEDLE THRUST RACE
OUTPUT SHAFT
3 R D S P E E D GEAR
BLOCKING R I N G
SYNCHRONIZER S P R I N G
SYNCHRONIZER S H I F T PLATE
CLUTCH HUB
CLUTCH SLEEVE
SNAP R I N G
SYNCHRONIZER BLOCKING R I N G
2ND S P E E D GEAR
THRUST WASHER
SNAP R I N G
SPACER
5 T H S P E E D GEAR
2ND & 3 R D S H I F T L I N K
2ND & 3 R D S H I F T FORK
4 T H & 5TH S H I F T L I N K
4 T H & 5 T H S H I F T FORK
NEEDLE ROLLERS
SPACER
SYNCHRONIZER BLOCKING RING
SYNCHRONIZER S P R I N G
S H I F T PLATE
CLUTCH HUB
CLUTCH SLEEVE
SYNCHRONIZER BLOCKING R I N G
NEEDLE THRUST BEARING
BEARING ROLLERS
I N P U T DRIVE GEAR
NEEDLE THRUST BEARING
THRUST WASHER
NEEDLE BEARI NG
O I L SEAL
CLUSTER GEAR
SPRING
SPRING PIN
GEAR DAMPER
SNAP R I N G
THRUST WASHER
NEEDLE BEARING
CLUSTER GEAR - V 8 ONLY
CLUSTER GEAR - V6 ONLY
1/2 INCH P I P E PLUG
TRANS CASE SLEEVE
TRANS CASE

"

'
1

5-SPEED MANUAL TRANSMISSION 7B-31

10. Remove transmission to clutch housing upper

retainingbolts and install guide pins in holes.

Poppet Spring and Plunger

2. Remove plug and poppet spring (Fig. 7B-60), turn
transmission upside down to remove plunger or use a magnet.

VOTE: Guide pins must be used to support transmission to

prevent &stortion of the clutch driven plate hub when
removingor installing the transmission .)
11. Remove lower bolts, then slide transmission
rearwardand remove from car.
12. Remove back-up lamp switch and fill plug, tip
on its side and drain the fluid.

installation of transmission
1. Position transmission to clutch housing and slide
forward,piloting clutch gear into pilot bearing.

@oTE: Make certain main drive gear splines are clean and

&Y -1
2. Reverse removal procedure, using the following
torque ratings for the attaching parts:
~~ansmission
to clutch housing bolts . .
Crossmember t o frame nuts . . . . . .
Crossmember to transmission mount bolts
propeller shaft bolts (exc. Starfire) . . .
propeller shaft bolts (Starfire) . . . . .

. . . 53 ft. lbs.

...
. .
. . .
. ..

35 ft. lbs.
35 ft. lbs.
16 ft. lbs.
13 ft. lbs.

Shifter Head Roll Pin

3. Drive roll pin from shifter head and shift rail. (Fig.
7B-61)
4. Remove six bolts that retain transmission case and
extension housing to center support.
5. Slide transmission case forward and remove thrust
bearing and races from input shaft or case.
6. Remove extension housing by sliding it rearward.
The shifter head, shift rail and selector lever are not fastened
to housing and should not be permitted t o drop out. Remove
from extension housing.
The selector lever may be removed from shift rail by
removing retaining ring and pin.

(NOTE: The needle rollers are not always retained in needle

case. Catch loose needles if they fall out during disassembly
so they can be replaced in mating race during assembly.)
Rail Selector
7. Remove rail selector pin and remove rail selector.
(Fig. 7B-62)
8. Remove snap ring behind speedometer gear, then
remove gear and ball.

C A U T I O N : Propeller shaft
attaching fasteners are an important
attaching part i n that it could affect
the performance of vital parts and
systems, and/or could result in
major repair expense. It must be
replaced with one o f the same part
number or with an equivalent part
i f replacement becomes necessary.
Do not use a replacement part o f
lesser quality or substitute design.
Torque values must be used as
specified during reassembly t o
assure proper retention o f this part.
TRANSMISSION DISASSEMBLY

Selector Lever Pivot

1. Remove selector lever pivot (Fig. 7B-59) from
extension housing.
Fig. 7B-60-Removing Poppet Spring and Plunger

Fig. 'iB-59-Removing Selector Lever Pivot

Fig. 7B-61-Removing Shifter Head Roll Pin

7
5-SPEED MANUAL TRANSMISSION 7B-33

~ and ~Fifth~Shiftt Linkh

16. Position interlock pawl to the outboard position to
permit the fourth and fifth shift link and shift fork to be
(Fig. 78-68)
17. Lift link from shift fork and slide link out. Remove
~

Center Support
18. Remove center support from output shaft and
countergear. (Fig. 7B-69)

(NOTE: Roller bearings could drop out of center support.)

Needle Thrust Bearinn
19. Remove neeze thrust bearing from output shaft or
center support. (Fig. 7B-70)
20. Remove countergear from gears on output shaft.

(NOTE: Roller bearings could drop out of input shaft .)

22. Remove thrust bearing from end of input shaft or
synchronizer hub.

Fig. 7B-67-Removing Second and Third Shift Rail

Fig. 7B-70-Removing Needle Bearing Thrust Bearing

Fig. 7B-71 -Removing Input Shaft

FGURTH AND FIFTH

Fig. 7B-69- ~ e m o v i nCenter

~
Support

Fig. 7B-72-Removing Fourth and Fifth Speed Synchronizer

!f

23. Remove the fourth and fifth synchronizer and

;s. (Fig. 73-72)

OUTPUT SHAFT
SECOND AND THIRD GEAR
SYNCHRONIZER ASSEMBLY

Fig. 78-75 -Removing Second and Third Gear S~nchronizer

OUTPUT SHAFT

Fig. 7 ~ - 7 6 - ~ e r n o v iThird
n ~ Speed Gear
Roller Bearings
All roller bearings in center support, case and extension
housing should be inspected and replaced if they are worn or
damaged .
Gears
1. Inspect all gears for excessive wear, chips or cracks
.
and replace any that are worn or damaged.
2. Check all three synchronizer clutch sleeves to see
that they slide freely on their hubs.
I

Fig. 7B-74-Removing Second Speed Gear

r Synchronizer Assembly
ring; then remove second and rhjrd

Replacing Synchronizer Keys and Springs

(NOTE: The clutch hubs and sliding sleeves are a selected
assembly and should be kept together as an assembly, but the
keys and two springs may be replaced if worn or broken.)
reassemblv .

Transmission Case
1. Wash the transmission case thoroughly inside and
outside with cleaning solvent; then inspect for cracks.
2. Check the front and rear faces for burrs and if

overlap slots in hub and opening in springs are not opposite

each other.
4. Place shift keys in slots of hub with radius side out
and springsin grooves of keys.
-

3. Check bearing bores in case and, if damaged, replace

I
I

'

case.

made before di&s;embly.

installation. (Fig. 7B-77)

-- -

- --0-----0

----

--

Depress keys for ease of

5-SPEED MANUAL TRANSMISSION 7B-35

CASEBEARING AND SEAL REPLACEMENT

~ ~ r n o vand
a l Installation of Input Shaft Bearing
1 . Install Tool J-26225 beneath bearing and expand
tool until a firm grip is obtained.
r

2. Use slide hammer 5-6125 and remove bearing. (Fig.

7B-78)
3. Apply Loctite 601 or equivalent on bearing to case
surface. Using Tool 5-26222-1-2 with driver handle 5-8092,
drive bearing into case until tool seats on case. (Fig. 7B-79)

Removal and Installa tion of Countergear Bearing

1 . Install Tool 5-26225 beneath bearing and expand
tool until a firm grip is obtained.
2. Use slide hammer 5-6125 and remove bearing. (Fig.
7 B-80)
3 . Apply Loctite 601 or equivalent on bearing to case
surface. Using Tool 5-26223 with driver handle 58092, drive
bearing into case un ti1 tool seats on case. (Fig. 7B-8 1)

ONE END OF EACH SPRING TO BE

ASSEMBLED IN STRUT SCOT AS
SHOWN IN OPPOS ITDIRECTION

Fig. 7 B-77 -Synchronizer Assembly

Fig. 7BSO-Removing Counter Gear Bearing From Case

Fig. 7B-78-Removing Input Shaft Bearing From Case

Fig. 7 B-8 1 -Installing Counter Gear Bearing In Case

I
Fig. 7B-79-Installing Input Shaft Bearing In Case

Removal and Installation of Seal

1. Remove input shaft bearing from case using Tool
5-26225.
2. Insert Tool 5-26243 through front of case and work
pointed end of tool behind seal ahd drive seal out of case.
(Fig. 7B-82)
3. Apply Loctite 601 or equivalent on seal to case

7B-36 5-SPEED MANUAL TRANSMISSION

CENTER SUPPORT BEARINGS REPLACEMENT

Removal and Installation of Output Shaft Bearing
1. Support center support on two wood blocks.
2. Use T o o l 5 - 2 2 4 0 7 (Pitman Shaft Bearing
Installer-variable ratio) with driver handle 5-8092 and drive
bearing out of center support. (Fig. 7B-84)

3. Using Tool 5-26222-1-3 with driver handle 5 4 0 9 2 ,

drive bearing from front to rear of center support until tool
seats on center support. (Fig. 7 B 8 5 )

Removal and Installation of Countergear Bearing

1. Support center support on two wood blocks.
2. Remove retaining plate and interlock pawl.

Fig. 7B-82-Removing Seal From Case

Fig. 7B-86-Removing Countergear Bearing

From Center Support
Fig. 7B-83-Installing Seal In Case

3. Using Tool 5-26222-1 with driver handle 5-80929

drive bearing out of center support. (Fig. 7B-86)

- - -

5-SPEED MANUAL TRANSMISSION 7B-37

2. For installation, prelubricale between sealing lips

and coat new seal OD. with Permatex or equivalent.
3. Using Tool 5-21426 or 5-5154, tap seal until it seats
on extension housing. (Fig. 7B-91)

Fig. 7B87 -Installing Countergear Bearing

In Center Support
4. Apply Loctite 601 or equivalent on bearing t o case
surface. Using Tool 5-26223 with driver handle 5-8092, drive
bearing until tool seats on center support. (Fig. 7B-87)
5. Install interlock pawl and retaining plate. Torque
screws to 10 ft . lbs.

Fig. 7B-89 -Installing Countergear Bearing

In Extension Housing

0 I L SEAL

EXTENSION HOUSING BEARING, BUSHING AND SEAL

REPLACEMENT
Removal and Installation of Countergear Bearing
1. Install Tool J-26225 beneath bearing and expand
tool until a firm grip is obtained.
2. Use slide hammer 5 8 125 and remove bearing. (Fig.
7B-88)
3 . Apply Loctite 601 or equivalent on bearing to case
surface. Using Tool 5-26222-1 with driver handle 543092,
drive bearing until tool seats on extension housing. (Fig.
7B-89)
Removal and Installation of Oil Seal
1. Pry oil seal from extension housing. (Fig. 7B-90)
Fig. 7B-90-Removing Oil Seal From Extension Housing

EXTENSION HOUSING

Fig. 7B-88-Removing Countergear Bearing

From Extension Housing

Fig. 7B-91 -Installing Oil Seal In Extension Housing

7%-38 5-SPEED MANUAL TRANSMISSION

Removal and Installa tion of Bushing

1 . Remove oil seal.
2. Observe depth location of bushing in bore of
extension housing.
3. Using Tool 5-5778 or 5-21424-9 and driver handle
5-8092, drive bushing out from rear of extension housing.
4. Drive new bushng in from rear of extension housing
to same depth, using Tool 5-5778 or 5-21424-9 and driver
handle J-8092. (Fig. 7B-92)

3 . Install synchronizer and blocker rings with chamfer

on sleeve toward front of shaft and position on face of third
speed gear.
4. Install snap ring in shaft groove ahead of
synchronizer hub. (Fig. 7B-94)

SNAP, G
N
. IR

Fig. 7B-94-Installing Second and Third Gear Synchronizer

Fig. 7B-92-Removing and Installing Extension Housing

TRANSMISSION ASSEMBLY

Second and Third Gear Synchronizer

(NOTE: Synchronizer assemblies are similar except hub

splines differ. Hub and sleeve are selective fit to obtain a free
sliding fit with .002" maximum backlash. Keep mated parts
together to insure correct sliding fit and backlash .)

Second Speed Gear

5. Install the second speed gear coned end into blocker
ring.
6. Install thrust washer on face of second speed gear
and install snap ring in shaft groove in front of thrust washer,
(Fig. 7B-95)
7 . Install two rows of 46 needle bearings inside of th
fifth speed gear with a spacer in between and on each end o
needle bearings. Retain with petroleum jelly as they ax
installed. (Fig. 7B-96)

CAUTION: Be sure to use the

needle bearings; other

correct

2. Assemble blocker rings with slots aligned with shift

keys of synchronizer assembly.

THRUST WASHE

THIRD SPEED GEAR

OUTPUT SHAFT

Fig. 7B-93-Installing Third Speed Gear

Fig. 7B-95-Installing Second Speed Gear

-7

SSPEED MANUAL TRANSMISSION 7B-39

10. Install on output shaft with chamfered edge of

sleeve toward front of transmission.

Input Shaft Thrust Bearing

11. Install thrust bearing on end of the fourth and fifth
synchronizer assembly. (Fig. 7B-99)
Input Shaft
12. Assemble 19 needle rollers into second step of input
shaft bore and retain with petroleum jelly. (Fig. 78-100)
13. Carefully install shaft with needles over end of
output shaft.

FIFTH SPEED GEAR

Fig. 7B-96-Installing Fifth Speed Gear Needle Bearing

bearings used in this transmission

are similar in length but have a
slightly differen r diameter.
Fifth Speed Gear
8. Carefully install fifth speed gear on output shaft
with coned end toward front of shaft. (Fig. 7B-97)

(NOTE: Be sure needle bearings and spacers do not drop

out .)

(NOTE: Be sure needle rollers do not drop out.)

Output Shaft to Center Support Needle Bearing
14. Install a needle thrust bearing and races with inner
race lip toward rear, over output shaft against shaft shoulder.
(Fig. 7B-101)
15. Be sure needle rollers are retained in center support
with petroleum jelly.
Output Shaft and Countergear to Center Support
16. Mesh countergear teeth with teeth of input shaft
gears assembled to output shaft.
17. Install center support over output shaft and
countergear. (Fig. 7B-102)

(NOTE: Be sure needle rollers do not fall out of center

support .)

Fourth and Fifth Speed Synchronizer Assembly

9. Assemble the blocker rings with slots aligned with
shift keys of the fourth and fifth synchronizer assembly.
(Fig. 7B-98)

Fig. 7B-99-Installing Input Shaft Thrust Bearing

Fig. 7B-97-Installing Fifth Speed Gear

Z

FOURTH AND FIFTH

SYNCHRONIZER ASSEMBLY
OUTPUT SHAFT

BLOCKER R l NGS

Fig. 7B-98--1nstalhg Fourth alrd Fifth Synchronizer

I
Fig. 7B-100-Installing Input Shaft

Fig. 7B-101-Installing Output Shaft To Center Support

Needle Bearing
Fig. 7B-103-Installing Reverse Gear and Reverse Idler Gear
*
FIRST AND REVERSE
SHIFT FORK

SECOND AND THIRD

SHIFT FORK

FOURTH AND Fl FTH

SHIFT FORK

SECOND AND THIRD

FOURTH AND FIFTH

SHIFT LINK
C

Fig. 7B-104-Installing Shift Forks and Links

(NOTE: Replace worn or damaged shift pads on all shift

forks if necessary.)

22. Assemble the second and third shift fork on second

and third sliding sleeve. Locate interlock pawl to permit shift
link to be installed through center slot in center support.
23. Install second and third shift link through slot and
engage in shift fork.
24. Locate interlock pawl to permit first and reverse
shift link to be installed in inboard slot of center support.
25. Install first and reverse shift link into shift fork.
26. If the selector arm was removed during disassembly,
install the selector arm over shift rail aligning hole in selector
arm with the hole near middle of rail. Drive roll pin into arm
and rail.

20. Assemble the fourth and fifth shift fork on the

fourth and fifth synchronizer sliding sleeve. Locate interlock
pawl to permit shift link to be installed through outboard
slot of center support.

First and Reverse Shift Fork to Shift Rail

27. Install shift rail through shift fork from front to rear
with poppet notches located to rear of transmission. (Fig.
7B-105)

(NOTE: The shift forks can be identified in Fig. 7B-104 by

the different angles of the holes in each fork.)

First and Reverse Synchronizer Shift Fork and Rail

28. Engage shift fork with first and reverse synchronizer
sleeve and install these parts by sliding synchronizer hub over
output shaft with chamfered edge of sleeve towards front,
(Fig. 7B-106)

Reverse Gear and Reverse Idler Gear

18. Install the reverse gear and bushing assembly on V-6
and bearing assembly on V-8 over output shaft and against
center support.
19. Install reverse idler gear and bushing assembly 09
V-6 and bearing assembly on V-8 over reverse idler shaft to
mesh with reverse gear. (Fig. 7B-103)
Shift Forks and Links (Fig. 7B-104)

21. Install fourth and fifth shift link through slot and
engage in shift fork.

-s*r%~%lq$t

5-SPEED MANUAL TRANSMISSION 7B-41

Fig. 7B-105-Installing First and Reverse Shift Fork

To Shift Rail

Fig. 7B-107-Installing Hub Snap Ring

Fig. 7B-106-Installing First and Reverse Synchronizer

Shift Fork and Rail
29. Guide shift rail through interlock pawl, second and
third h f t fork and fourth and fifth shift fork. Be sure
selector arm is aligned with notch in shift link.

Fig. 7B-108-Installing Blocking, First Gear Thrust Washer

and Snap Ring

Synchronizer Hub Snap Ring

30. Install snap ring in shaft groove. (Fig. 7B-107)
Blocker Ring, First Gear, Thrust Washer and Snap Ring
31. Install blocker ring and first speed gear over output
shaft behind first and reverse synchronizer assembly. Align
notches on blocker ring with notches in synchronizer hub.
32. Install thrust washer and snap ring behind first speed
gear. (Fig. 7B-108)
Speedometer Gear and Rail Selector
33. Install speedometer gear retainer in hole in output
shaft with retainer loop forward. Slide speedometer gear over
output shaft and retainer until retainer snaps up to lock gear.
34. Slide rail selector with hole in selector to rear of
transmission and ball facing inboard and retain with roll pin.
(Fig. 7B-109)
Selector Lever and Shift Rail
. 35. Install selector lever and shift rail into hole provided
extension housing. Install shifter head on rail as rail
becomes exposed in housing opening. Do not install roll pin
at this time. (Fig. 7B-110)

~ i g7~-109-1nstalling
.
Speedometer Gear and Rail Selector

7B42 5-SPEED MANUAL TRANSMISSION

Y
.*

LNPIIT SHAFT

SHlFTER HEAD

I
i

1
Fig. 7B-112-Installing Input Shaft Thrust Bearing and Case

Fig. 7B-I IO-Installing Shifter Lever and Shift Rail

Extension Housing
Be sure needle bearings in extension housing are retained
with petroleum jelly.

Shifter Head Roll Pin

40. Drive roll pin into shifter head and shift rail. (Fig,
7B-113)
Poppet Spring and Plunger

CAUTION: Be sure to use the

correct needle bearings. Other
bearings in this transmission are
similar in length but have a
different diameter.

(NOTE: Coat plug threads with sealer number 1052080,

Loctite number 92 or equivalent.)

36. Apply a continuous 1/32" bead of RTV (Room

Temperature Vulcanizing) sealer to transmission case and
extension housing.
37. Install extension housing over output shaft while
guiding selector lever to engage rail selector. (Fig. 7 -111)
Input Shaft Thrust Bearing and Case
38. Install lipped thrust race, except V-6 (not used),
with lip toward front, needle thrust bearing and flat thrust
washer over input shaft. (Fig. 7B-112)
39. Install case to front side of center support and retain
with six hex head bolts. Torque to 40 ft. lbs.

(NOTE: If a binding condition exists when installing case,

check to be sure that a fifth speed gear spacer for bearings
did not fall down between fifth gear and synchronizer .)

Fig. 7B-111 -Installing Extension Housing

%
!

Fig. 7B-113-Installing Shifter Head Roll Pin

7 B-44 SPECIFICATIONS

TRANSMISSION SPECIFICATIONS
CAPACITY
3Speed .
4-Speed .
5Speed .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- 3 112 Pints
- 2 112 Rnts
- 3 112 Pints

GEAR RATIO
*S9,RZ
First .
Second
Third
Fourth
Fifth .
Reverse

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.
.
.

*ZR,ZM,S4,RH

. .
. .
. .
. .
. .
. .

*Transmission Code Numbers

TORQUE SPECIFICATIONS-3 and 4 SPEED TRANSMISSIONS

Specified torque is for installation of parts only. Checking of torque during inspection may be 10%below that specified.

APPLICATION
Side Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Transmission to Clutch Housing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Cross Support Bar to Frame Bolts - Omega & Cutlass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cross Support Bar to Body Bolts - Starfire
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Transmission Mount to Transmission Bolts - Exc. Starfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Starfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Transinission Mount to Cross Support Bar - Omega & Cutlass Only . . . . . . . . . . . . . . . . . . . . . . . . 35
Propeller Shaft Strap Bolts - Omega & Cutlass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Propeller Shaft U-Bolt Nuts .Starfire
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Bearing Retainer to Transmission Case Bolts - Exc. Starfire . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Starfire . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rear Bearing Retainer to Transmission Bolts - Exc. Starfire . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Starfire . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
T.C.S.Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Transmission Filler Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

TORQUE SPECIFICATIONS-5 SPEED TRANSMISSION

APPLICATION

Crossmember to Frame Bolts - Exc. Starfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crossmember to Frame Bolts - Starfire
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crossmember to Mount Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *
Extension Housing to Center Support Case (6 Bolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fillplug
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hex Head Self Tapping Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Poppet Spring and Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Bolts - Exc. Starfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Bolts - Starfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selector Lever Pivot
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shifter to Extension Housing Bolts
...........................................
Torque Arm Bracket
Torque Arm to Differential Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission to Clutch Housing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

_
1
1

TOOLS 7 B 4 5

SLIDE HAMMER
EXTENS ION HOUS ING BUSHING REMOVER
REAR EXTENS ION SEAL INSTALLER
(ALTERNATE)
EXTENS ION HOUSING O I L SEAL INSTALLER
S N A P RING PLIERS
EXTENS ION HOUSING O I L SEAL INSTALLER
MTENS ION HOUSING BUSHING INSTALLER
ENGINE SUPPORT BAR
SEAL REMOVER
SEAL REMOVER
D I A L INDICATOR
DRIVE HANDLE
FRONT O I L SEAL61NSTALLER
EXTENS ION
Fig. 7B-117-Tools

REAR EXTENS ION SEAL INSTALLER

COUNTERGEAR LOAD ING TOOL
BEARING INSTALLER
CLUTCH GEAR BEARING RETAINER
SEAL INSTALLER
CLUTCH PLATE ALIGNMENT TOOL
BEAR ING INSTALLERS
BEARING INSTALLER
SEAL INSTALLER
BEARING REMOVER
SEAL REMOVER
ROD - SHIFT LINKAGE ADJUSTING
ROD - SHIFT LINKAGE ADJUSTING
HEADLESS BOLTS TO GU l DE TRANS.
ON TO BELL HOUS ING

CLUTCH 7C-1

CLUTCH
STARFIRE-OMEGA-CUTLASS
STARFIRE CLUTCH.

. . . . . . . . . . . . . . . . . . . 7C-3

OMEGA AND CUTLASS CLUTCH.

. .

7C-7

CLUTCH DIAGNOSIS
NOTE: Reset lash after any parts changes in the clutch area.
POSSIBLE CAUSE

CORRECTION

Fails to Release (Pedal Pressed to FloorShift Lever Does Not Move Freely In and Out of Reverse Gear)

a.
b.
c.
d.
e.
f.

Excessive clutch lash.

Improper pedal travel.
Loose linkage.
Faulty pilot bearing.
Faulty driven disc.
Fork off ball stud.

a.
b.
c.
d.
e.
f.

g.
h.

Clutch disc hub binding on clutch gear spline.

Clutch disc warped or bent.

g.
h.

Adjust linkage to specs.

Trimburnperstopandadjustlinkage.
Replace as necessary.
Replace bearing.
Replace disc.
Install properly and lubricate fingers at
throw-out bearing with wheel bearing grease.
Repair or replace clutch gear.
Replace disc (run-out should not exceed .025").

Slipping

a.
b.
c.

d.
e.
f.

g.

Improper adjustment (no lash).

Oil soaked driven disc.
Worn facing or facing torn from disc.
Warped pressure plate or flywheel.
Weak diaphragm spring.

a.
b.
c.
d.
e.

Driven plate not seated in.

Driven plate overheated.

f.
g.

Adjust linkage to spec.

Install new disc and correct oil leak at its source.
Replace disc.
Replace pressure plate or flywheel.
Replace pressure plate (Be sure lash is checked before
replacing plate).
Make 30 to 40 normal starts.
Allow to cool - check lash.

Grabbing (Chattering)

a.
b.
c.

d.

e.

Oil on facing.
Worn splines on clutch gear,
Loose engine mountings.
Warped pressure plate or flywheel.
Burned or smeared resin on flywheel or pressure plate.

a.
b.
c.
d.
e.

Install new disc and correct leak.

Replace transmission clutch gear.
Tighten or replace mountings.
Replace pressure plate or flywheel.
Sand off it superficial, replace burned or heat checked
parts.

CLUTCH DIAGNOSIS

STARFIRE CLUTCH 7C-3

STARFIRE C L U T C H
INDEX
PAGE

SUBJECT

.
Description
Dja~0sis . .
clutch Assembly
Removal . .

stallat at ion

. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .

7C-3
7C-1

. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .

7C-5
7C-6

SUBJECT
Maintenance and Adjustments
Clutch Linkage
. . . . . .
Maintenance Recommendations
. .
Specifications and Torque
Tools . . . . . . . . . . .

PAGE

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

. . . . 7C4
. . . . 7C -3
. . . . 7C-10
. . . . 7~-10

MAINTENANCE RECOMMENDATIONS

GENERAL DESCRIPTION
The clutch is a cable operated design (Fig. 7C-1). The
pedal lever pivots on a shaft common with the brake pedal
assembly and operates the release yoke through a sheathed
cable attached to the upper section of the pedal lever. The
lower end of the cable is threaded and is provided with a ball
stud that fits into a hole in the release lever.
The clutch pressure plate, driven disc and release bearing
are of a conventional design (Fig. 7C-2), with the fork
pivoting on a ball stud located opposite the control cable
attaching point. A single plate, dry friction disc,bent finger,
b p h r a f l s ~ r i n gtype clutch is used on the Starfire. The
m m b l ~consists of the clutch driven plate, Cover-Pressure
plate and clutch release mechanism,

provides the spring pressure required t o hold the friction disc

against the flywheel, but also acts as the release levers that
take up the spring pressure when the clutch is disengaged.
The diaphragm spring clutch features rate decreasing
pedal effort, which eliminates the need of an overcenter
spring assist. Pressure plate spring pressure forces the driven
plate against the flywheel, thereby coupling the engine to the
transmission.
The clutch release mechanism consists of a ball thrust
bearing, appropriate levers and cable linkage to manually
control the action of the bearing. The ball thrust bearing
(clutch release bearing) is piloted on the main drive gear
bearing retainer. When pressure is applied to the clutch pedal

M A I N DRIVE GEAR
IAPHRAGM SPRING

BALL STUD ADJUSTMENT

CLUTCH
FORK

BALL

CLUTCH
HOUSING

1 . P R I O R T O A T T A C H M E N T OF C A B L E ,
P L A C E G A U G E J-23644 SO F L A T E N D
IS A G A I N S T F R O N T F A C E O F T H E
CLUTCH HOUSING A N D THE H O O K E D
E N D IS L O C A T E D A T P O I N T OF C A B L E
ATTACHMENT ON FORK.
2. T U R N B A L L S T U D I N W A R D BY H A N D
U N T I L CLUTCH RELEASE BEARING
MAKES CONTACT WITH CLUTCH
SPRING F I N G E R S .
3. I N S T A L L L O C K N U T A N D T I G H T E N
(25 F T . LBS.) B E I N G C A R E F U L N O T
T O CHANGE B A L L STUD ADJUSTMENT.
4. I N S T A L L B A L L S T U D CAP.
5. R E M O V E G A U G E B Y P U L L I N G O U T W A R D A T HOUSING END.

HOUSING

GAUGE
J-23644

STARFIRE CLUTCH 7C-5

SERVICE OPERATIONS
CLUTCHCABLE REPLACEMENT
1. Remove clutch fork cover at side of housing.
2. Disconnect return spring and clutch cable at clutch
shift fork.
3. Remove clip and pin retaining cable to pedal arm.
4. Pull cable assembly through reinforcement and
disengage from fender skirt reinforcement.
5 . Push new cable through body reinforcement. Secure
cable end to pedal arm with pin, washer and clip.
(NOTE: Lubricate retaining pin with graphite type grease .)

6. Route cable over fender skirt reinforcement and

down to the clutch fork lever. Install cable end in fork lever
and install screw pin.
7. Push clutch fork forward until throwout bearing
contacts clutch spring fingers and tighten screw pin on cable
until it bottoms on fork. Turn 114 additional revolution
clockwise and drop pin into groove in fork.
8. Attach return spring.
9. Install clutch fork cover and tighten retaining screws
to 80 in. lbs.
CLUTCH REPLACEMENT (Fig. 7C4)
Removal
1 . Raise car on hoist.
2. Remove transmission as outlined in Section 7B.
3 . Remove clutch fork cover then disconnect clutch
return spring and control cable from clutch fork.
4. Remove flywheel housing lower cover.
5 . Remove flywheel housing from engine.

6. To remove release bearing form clutch fork, slide

lever off ball stud against spring action. If necessary t o
replace ball stud, remove cap, lock nut and stud from
housing.
7. If assembly marks on clutch assembly and flywheel
are not distinguishable, remark with paint or centerpunch.
8. Loosen clutch cover to flywheel, attaching bolts one
turn at a time until spring pressure is released, to avoid
bending clutch cover flange.
9. Support the pressure plate and cover assembly then
remove the bolts and clutch assembly.

(NOTE: Do not disassemble the clutch cover, spring and

pressure plate for repair. If defective replace complete
assembly.)

Inspection
1. Examine friction surfaces of flywheel and pressure
plate for scoring, roughness, or severe overheating. Slight
roughness may be smoothed with fine emery cloth, but if
surface is deeply scored or grooved, part should be replaced.
2. Inspect clutch driven plate for condition of facings,
or facing wear to rivets, loose rivets, broken or very loose
torsional springs. If oil is found on the driven plate facings,
examine the transmission drain back hole, pilot bushing,
engine rear main bearing, transmission input shaft seal, and
other local points for oil leakage.
3. Check fit of driven plate hub on transmission input
shaft gear for an easy sliding fit.
4. Inspect clutch release bearing for scoring or
excessive wear on front contact face. Check for roughness
and free fit on clutch drive gear bearing retainer.

CLUTCH DRIVEN

PRESSURE PLATE AND

COVER ASSEMBLY

BOLT

Fig. 7C4-Clutch and Clutch Housing

OMEGA AND CUTLASS CLUTCH 7C-7

OMEGA AND CUTLASS

CLUTCH
INDEX
PAGE

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
e

7C-7
7C-1
7C-9
7C-9

OMEGA AND CUTLASS CLUTCH

MAINTENANCE RECOMMENDATIONS
The clutch release bearing is a prepacked sealed unit
which requires no periodic lubrication. ~h~ clutch linkage
should be lubricated at each lubrication period with enane
oil. The clutch pedal free travel should be checked whenever
the car is in the service area. Free travel at the center of the
pedal pad is 718" to 1-112" for Omega and 1 1 / 1 6 ~to 518"
(17mm to 32mm) for the Cutlass.

CLUTCH PILOT

SUBJECT

PAGE

Maintenance and Adjustments

Clutch Linkage
. . . . .
Maintenance Recommendations
Specifications and Torque
.
Tools . . . . . . . . . .

. . . . . . . . . . 7C-7

. . . . . . . . .

7C-7

. . . . . . . . . . 7C-10

. . . . . . . . .

.7C-10

DESCRIPTION (Fig. 7C-7)

A single plate, dry disc-type clutch is used on cars with
manual transmissions. The driven plate incorporates a
damper assembly in the hub to prevent the transmitting of
vibration from the engine to the transmission. Grooves on
both sides of the clutch plate lining prevent the sticking of
the plate to the flywheel and pressure late due to vacuum
between the membersThe clutch pressure plate is of the disc spring type. There
is an overcenter effect inherent in the action of the disc
spring itself. This eliminates the need for an overcenter assist
spring.
Pressure plate spring pressure forces the driven plate
against the flywheel, thereby coupling the engine to the
transmission.
The clutch release mechanism consists of a ball thrust
bearing, appropriate levers and linkage to manually control
the action of the bearing. When pressure is applied to the
clutch pedal t o release the clutch, the clutch release fork
pivots on its ball socket. The inner end then pushes the
release bearing forward so that it presses against the inner
ends of the clutch release levers, releasing the clutch. Pedal
effort is transmitted by the pedal to the lever and shaft
assembly and then through the clutch release fork.
.
I

LEVER AND

RETURN

SHAFT ASSEMBLY

RETA l NER
PUSH ROD

ADJUSTING
ROD
b

Fig. 7C-7-Clutch Assembly

Fig. 7C-8-Lower Clutch Linkage (Omega)

7C-8 OMEGA AND CUTLASS CLUTCH

MAINTENANCE AND ADJUSTMEN'S

CLUTCH LINKAGE (Figs. 7C-8,7C-9,7C-10 & 7C-11)
1. Check for worn linkage, broken or disconnected
pedal return spring.
2. Lubricate with engine oil as required.
Clutch Pedal Free Travel Adjustment (Omega)
Check clutch free pedal travel in center of pedal pad,
718" to 1-112". If not within these specifications, adjust as

BRACKET ASSEMBLY

1. Loosen lower push rod swivel lock nut.

2. Disconnect pedal return spring.
3 , Rotate clutch lever and shaft assembly until ,,lut
pedal is firmly against rubber bumper on dash brace.
4. Push outer end of clutch fork rearward until rele
bearing lightly contacts clutch plate.
5. Remove lower push rod swivel retaining cli
inst all swivel in gauge hole (upper hole), reinstall re&&
clip.
6. Increase length of push rod until all lash is removed
7 . Install swivel in lower hole of lever and shrf;
assembly and install retaining clip.
8 . Tighten lock nut against swivel being careful not to
change rod length. Reinstall clutch return spring.
9. Recheck free pedal travel.

CLUTCH START SWITCH

SHAFT ASSEMBLY
UTCH RETURN SPRING
LOWER PUSH ROD
b

Fig. 7C-9-Upper Clutch Linkage (Omega)

Fig. 7C-11-Upper Clutch Linkage (Cutlass)

10 FT. LBS. (14 N

18 FT. LBS. (24 N.

FILL RECESS
WITH WHEEL
BEAR ING LUBE

BEARING LUBE

Fig. 7C-l O-Lower Clutch Linkage (Cutlass)

OMEGA AND CUTLASS CLUTCH 7C-9

Clutch pedal Free Travel Adjustment (Cutlass)

check clutch free pedal travel in center of pedal pad
11/16" to 518" (17mm to 32mm). If not w i t h n these
specifjcations,adjust as follows:
1. Remove clutch return spring.
2. Rotate clutch lever and shaft assembly until clutch
pedal is firmly against rubber bumper on bracket.
3. Push outer end of clutch fork rearward until release
bearing lightly contacts clutch plate.
4. Install lower push rod "A" in clutch fork and rod
"B" in gage hole (upper hole).
5. Increase length of push rod "A" until all lash is

9. Recheck free pedal travel.

1. Disconnect clutch return spring, then disconnect

lower push rod from clutch fork.
2. Disconnect clutch pedal push rod at pedal arm.
3. Disconnect and remove clutch start switch.
4. Remove pedal pivot bolt nut from right side of pivot
bolt. Slide pivot bolt and pedal arm from support housing
and remove from car. Insert dummy shaft into support
housing to hold brake pedal parts in place while sliding pivot

4. Slide pedal assembly from mounting bracket.

5. To install, reverse removal procedure.
CLUTCH ASSEMBLY, RELEASE BEARING,
RELEASE FORK, AND BALL STUD

Removal
1 . Remove transmission.
2. Disconnect the clutch return spring and clutch rod
assembly.
3 . Remave the clutch release bearing.
4. Remove flywheel housing leaving starter attached t o
engine. Release fork and ball stud will remain with housing.
The clutch release fork, boot and ball stud are accessible for
service. (Fig. 7C -12)
5. Scribe an "X" mark on the flywheel opposite the
"X" on the cover. The cover is marked "X" for balance
purposes. (Fig. 7C-13)
(NOTE: Loosen pressure plate attaching bolts evenly
approximately one turn at a time.)
(NOTE: DO NOT LUBRICATE splines as the lubricant will
be forced into the dampener friction surfaces by centrifugal
force and clutch rattle can occur.)

5. Clean and inspect all parts. Replace as necessary. Do

not clean nylon bushings with a cleaning agent, simply wipe
with a clean cloth. Relubricate all bushings and moving parts.
6. Reinstall bushings, spacer, pivot bolt and pedal arm
in support housing.
7. Install pivot nut.
8. Position clutch start switch on mounting post and
pedal arm. Install retaining nut and connect switch wiring.
9. Connect clutch push rod to pedal arm.
1. Disconnect clutch operating rod at the pedal.
2. Remove pedal pivot bolt nut.
3. Remove retainer at clutch start switch.

Fig. 7C-13-Clutch Cover Alignment

Fig. 7C-14-Clutch Disc

Installation
1. Inspect clutch pilot bearing and replace if necessary.
Fig. 7C-12-Clutch Release Bearing

2. Install, clutch disc (Fig. 7C-14) and clutch cover

assembly, being careful to ahgn "X" marks. Install attaching
bolts finger tight.

3. Place clutch disc alignment tool J-23720 or an old

drive gear in disc and into pilot bearing to align disc. Tighten
clutch cover assembly as follows:
a. Tighten 3 bolts in holes marked "L" until cover
assembly is within 114'' of flywheel. (Fig. 7C-13)
b. Tipten next 3 bolts until cover assembly is
within 114 of flywheel.

c. Tighten 3 bolts in holes marked -L- to 3o

Lbs.
d. Tighten remaining 3 bolts to 30 ft. lbs.
4. Remove alignment tool, lubricate the internal
of the release bearing and the release yoke ball stud
wheel bearing grease and install bearing.
5. Install flywheel housing and transmission. c
and adjust linkage.

CLUTCH SPECIFICATIONS
DISC FACINGS

Omega 3.8 Litre (231) V-6

Omega 5.0 Litre (305) V-8
Cutlass 3.8 Litre (231) V-6
Cutlass 4.3 Litre (260) V-8
Cutlass 5.0 Litre (305) V-8

.
.
.
.
.

.
.
.
.
.

.
.
.
.
.

.
.
.
.
.

.
.
.
.
.

. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.

THICKNESS
All

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
TORQUE SPECIFICATIONS
CLUTCH

Specified torque is for installation of parts only. Checking of torque during inspection may be 10% below that specified.

APPLICATION

. . . .
Clutch Cover .Exc. Starfire
Clutch Cover & Pressure Plate - Starfire
. .
Clutch Housing To Engine Block
Ball Stud to Engine - Omega &
Clutch Lever and Shaft Assy. t
Clutch Lever and Shaft Assy . t
Clutch Release Fork Ball Stud -

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

J-1448

J-1448

PI LOT BEARING REMOVER

Fig. 7C-15-Tools

14

r~mmt"a6ett~t~jtr
3v

ALL SERIES CHASSIS ELECTRICAL 8A1-1

CHASSIS ELECTRICAL
AND
INSTRUMENT PANELS
. . . . . . . . . 8 A 1.1
J N S T R U M E N T P A N E L .STARFJRE . . . . . . . . . . 8 A 2.1
I N S T R U M E N T P A N E L .O M E G A . . . . . . . . . . . 8 A 3.1
I N S T R U M E N T P A N E L . C U T L A S S . . . . . . . . . . . 8 A 4.1
I N S T R U M E N T P A N E L . 88.98 . . . . . . . . . . . . - 8 A 5 - 1
C H A S S I S ELECTRICAL .ALL SERIES

I N S T R U M E N T P A N E L .T O R O N A D O

C H A S S I S ELECTRICAL

. . . . . . . . 8 A 6.1

.ALL SERIES

INDEX
PAGE
Back-up Lamp Switch Adjustment
bttery
. . . . . . . . . . .
Buzzer. Horn Relay -Key Warning

. . . . . . . 8A144
. . . . . (Section 6D)
. . . . . . . 8A143

. . . . . . . . . . . . . . . 8A1-17
. . . . . . . . . . . . . . . (Section 6D)
. . . . . . . . . . . . . . . . . 8 A1.1

ring

SUBJECT

PAGE

Diagnosis Charts (Continued)

. . . . . . . . . . 8A 1-38
Stop Lamps (Toronado)
. . . . . . . . 8Al-34
Stop Lamp (Exc . Toronado)
Tail Lamps . . . . . . . . . . . . . . . . 8A 1-23
. . . . . . . . 8Al-37
Temperature Indicator Light
. . . . . . . . . . . 8A 1-26
Trunk Lamp (Cutlass)
Trunk Lamp (Cutlass. 88. 98) . . . . . . . . 8Al-27
. . . . . . . . . . 8A 1-29
Trunk Lamp (Toronado)
. . . . . . . . 8A I-39
Turn Signal (Exc .Toronado)
. . . . . . . . . . 8A 1-38
Turn Signal (Toronado)
Electrical Circuit Diagnosis . . . . . . . . . . 8A1-16
. . . . . . . . . . . . . . . 8A 1-43
Flasher Service
. . . . . . . . . . . . . . . . . 8A143
Fuel Gage
. . . . . . . . . . . . . . . . 8A 1-13
Fuse Panels
. . . . . . . . . . 8A1-16
Fusible Link Replacement
Headlamp k m i n g . . . . . . . . . . . . . . 8A 1 4 3
Headlamp Switch . . . . . . . . . . . . . . 8A 14 4
. . . . . . . . . . . . . . . . 8A 1 4 4
Horn Relay
. . . . . . . . . . . 8A 1-18
Instrument Panel Wiring
Key Warning Buzzer . . . . . . . . . . . . . 8A 14 3
. . . . . . . . 8A 14 5
Lamp Bulb Removal (Exterior)
. . . . . . . . 8A 1 4 6
Lamp Bulb Removal (Interior)
. . . . . . . . . . 8A 1 4 9
Lamp Bulb Specifications
Neutral Start Switch . . . . . . . . . . . . . 8A 1 4 4
Radio Dial Lamps . . . . . . . . . . . . . . 8 A 1 4 7
. . . . . . . . . . 8Al-43
Seat Belt Warning System
. . . . . . . . . . . . . . . . (Section 6D)
Starter
Wiper . . . . . . . . . (Refer to Body Service Manual)
. . . . . . . . . . . . . . . 8A1-3
Wiring Diagrams

"

I
I

DIAGNOSIS
The following information and illustrations on wiring
wiring harness location. fuse panel and fusible link
aid id electrical diagnosis . Refer to ELECTRICAL
C I R c u l ~DIAGNOSIS for procedures .
combination junction and fuse panel is mounted on
the
under the instrument panel . Each wire from the
fUepanel is color coded t o simplify servicing .

SHORT CIRCUIT TESTING

Do not use a circuit breaker in place of a fuse when
checking for a short circuit on cars equipped with the
E l e c t r o n i c Lamp Monitoring System without first
disconnecting the circuit boards at the front and rear body
connectors . Failure to disconnect the circuit boards will
result in damage to them .