21a - gianecri

21a - gianecri
TRANSMISSION AND TRANSFER CASE
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21 - 1
TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page
page
44RE AUTOMATIC TRANSMISSION . . . . . . . . . . . . 1
NV247 TRANSFER CASE . . . . . . . . . . . . . . . . . . 140
44RE AUTOMATIC TRANSMISSION
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
3-4 SHIFT SEQUENCE . . . . . . . . . . . . . . . . . . . . 8
44 RE TRANSMISSION . . . . . . . . . . . . . . . . . . . . 2
BRAKE TRANSMISSION SHIFT INTERLOCK
MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CAUSES OF BURNT FLUID . . . . . . . . . . . . . . . . 4
CONVERTER CLUTCH ENGAGEMENT . . . . . . . 8
CONVERTER DRAINBACK VALVE . . . . . . . . . . . 8
EFFECTS OF INCORRECT FLUID LEVEL . . . . . . 4
ELECTRONIC GOVERNOR . . . . . . . . . . . . . . . . . 5
ELECTRONIC LOCK-UP TORQUE
CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLUID CONTAMINATION . . . . . . . . . . . . . . . . . . . 4
GEARSHIFT MECHANISM . . . . . . . . . . . . . . . . . 5
GOVERNOR PRESSURE CURVES . . . . . . . . . . . 7
HYDRAULIC CONTROL SYSTEM . . . . . . . . . . . . 7
OVERDRIVE OFF SWITCH . . . . . . . . . . . . . . . . . 8
QUICK FILL VALVE . . . . . . . . . . . . . . . . . . . . . . . 8
RECOMMENDED FLUID . . . . . . . . . . . . . . . . . . . 4
SHIFT VALVE OPERATION . . . . . . . . . . . . . . . . . 7
TRANSMISSION GEAR RATIOS . . . . . . . . . . . . . 5
TRANSMISSION IDENTIFICATION . . . . . . . . . . . 4
DIAGNOSIS AND TESTING
AIR TESTING TRANSMISSION CLUTCH AND
BAND OPERATION . . . . . . . . . . . . . . . . . . . . . . 14
ANALYZING ROAD TEST . . . . . . . . . . . . . . . . . 11
AUTOMATIC TRANSMISSION DIAGNOSIS . . . . . 9
BRAKE TRANSMISSION SHIFT INTERLOCK . . 10
CONVERTER HOUSING FLUID LEAK
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS TABLES AND CHARTS—RE
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 16
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . 10
HYDRAULIC PRESSURE TEST . . . . . . . . . . . . . 12
OVERDRIVE ELECTRICAL CONTROLS . . . . . . 10
PARK/NEUTRAL POSITION SWITCH . . . . . . . . 10
PRELIMINARY DIAGNOSIS . . . . . . . . . . . . . . . . . 9
ROAD TESTING . . . . . . . . . . . . . . . . . . . . . . . . 11
THROTTLE VALVE CABLE . . . . . . . . . . . . . . . . 11
SERVICE PROCEDURES
ALUMINUM THREAD REPAIR . . . . . . . . . . . . . . 29
CONVERTER DRAINBACK CHECK VALVE
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FLUID AND FILTER REPLACEMENT . . . . . . . . . 26
FLUID LEVEL CHECK . . . . . . . . . . . . . . . . . . . . 26
FLUSHING COOLERS AND TUBES . . . . . . . . . . 28
OIL PUMP VOLUME CHECK . . . . . . . . . . . . . . . 28
TRANSMISSION FILL PROCEDURE . . . . . . . . . 27
REMOVAL AND INSTALLATION
BRAKE TRANSMISSION SHIFT INTERLOCK
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
FLOOR SHIFTER . . . . . . . . . . . . . . . . . . . . . . . 38
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . 36
GOVERNOR SOLENOID AND PRESSURE
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
OUTPUT SHAFT FRONT BEARING . . . . . . . . . . 48
OUTPUT SHAFT REAR BEARING . . . . . . . . . . . 48
OVERDRIVE HOUSING BUSHING . . . . . . . . . . 47
OVERDRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . 46
PARK/NEUTRAL POSITION SWITCH . . . . . . . . 36
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . 35
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 29
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . 44
YOKE SEAL REPLACEMENT . . . . . . . . . . . . . . 36
DISASSEMBLY AND ASSEMBLY
FRONT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 87
FRONT SERVO PISTON . . . . . . . . . . . . . . . . . . 83
OIL PUMP AND REACTION SHAFT SUPPORT . 83
OVERDRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . 97
OVERRUNNING CLUTCH CAM/OVERDRIVE
PISTON RETAINER . . . . . . . . . . . . . . . . . . . . . . 81
PLANETARY GEARTRAIN/OUTPUT SHAFT . . . 92
REAR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . 88
REAR SERVO PISTON . . . . . . . . . . . . . . . . . . . 83
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TRANSMISSION AND TRANSFER CASE
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TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . 69
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CLEANING AND INSPECTION
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . 114
FRONT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 115
FRONT SERVO . . . . . . . . . . . . . . . . . . . . . . . . . 114
OIL PUMP AND REACTION SHAFT SUPPORT . . 115
OVERDRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . 116
OVERRUNNING CLUTCH/LOW-REVERSE
DRUM/OVERDRIVE PISTON RETAINER . . . . . 114
PLANETARY GEARTRAIN . . . . . . . . . . . . . . . . . 116
REAR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . 116
REAR SERVO . . . . . . . . . . . . . . . . . . . . . . . . . . 114
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 113
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
ADJUSTMENTS
BAND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . 120
BRAKE TRANSMISSION SHIFT INTERLOCK . . . 117
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . 119
TRANSMISSION THROTTLE VALVE CABLE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 117
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . 122
SPECIFICATIONS
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . 135
SPECIAL TOOLS
RE TRANSMISSIONS. . . . . . . . . . . . . . . . . . . . . 136
DESCRIPTION AND OPERATION
ranges except fourth gear. The torque converter
clutch is controlled by the Powertrain Control Module (PCM). The torque converter clutch is hydraulically applied and is released when fluid is vented
from the hydraulic circuit by the torque converter
control (TCC) solenoid on the valve body. The torque
converter clutch engages in fourth gear, and in third
gear when the O/D switch is OFF. Engagement
occurs when the vehicle is moving at a steady speed
after the vehicle has warmed up. The torque converter clutch disengages when the accelerator is
applied. The 44 RE transmission is cooled by an integral fluid cooler inside the radiator.
44 RE TRANSMISSION
Vehicles equipped with the 3.1L turbo diesel engine
use the 44RE automatic transmission.
The 44RE is a four speed fully automatic transmission (Fig. 1) with an electronic governor. First
through third gear ranges are provided by the
clutches, bands, overrunning clutch, and planetary
gear sets in the transmission. Fourth gear range is
provided by the overdrive unit that contains an overdrive clutch, direct clutch, planetary gear set, and
overrunning clutch. The overdrive clutch is applied in
fourth gear only. The direct clutch is applied in all
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TRANSMISSION AND TRANSFER CASE
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Fig. 1 44 RE Transmission
DESCRIPTION AND OPERATION (Continued)
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TRANSMISSION AND TRANSFER CASE
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DESCRIPTION AND OPERATION (Continued)
1 – CONVERTER CLUTCH
2 – TORQUE CONVERTER
3 – OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY
4 – FRONT BAND
5 – FRONT CLUTCH
6 – DRIVING SHELL
7 – REAR BAND
8 – TRANSMISSION OVERRUNNING CLUTCH
9 – OVERDRIVE UNIT
10 – PISTON RETAINER
11 – OVERDRIVE CLUTCH
12 – DIRECT CLUTCH
13 – INTERMEDIATE SHAFT
14 – FRONT BEARING
15
16
17
18
19
20
21
22
23
24
25
26
27
28
–
–
–
–
–
–
–
–
–
–
–
–
–
–
HOUSING
REAR BEARING
OUTPUT SHAFT
SEAL
OVERDRIVE OVERRUNNING CLUTCH
OVERDRIVE PLANETARY GEAR
DIRECT CLUTCH SPRING
OVERDRIVE CLUTCH PISTON
VALVE BODY ASSEMBLY
FILTER
FRONT PLANETARY GEAR
REAR CLUTCH
TRANSMISSION
REAR PLANETARY GEAR
TRANSMISSION IDENTIFICATION
FLUID ADDITIVES
Transmission identification numbers are stamped
on the left side of the case just above the oil pan gasket surface (Fig. 2). Refer to this information when
ordering replacement parts.
Fluid additives other than Mopart approved fluorescent leak detection dyes are not to be used in this
transmission.
EFFECTS OF INCORRECT FLUID LEVEL
A low fluid level allows the pump to take in air
along with the fluid. Air in the fluid will cause fluid
pressures to be low and develop slower than normal.
If the transmission is overfilled, the gears churn the
fluid into foam. This aerates the fluid and causing
the same conditions occurring with a low level. In
either case, air bubbles cause fluid overheating, oxidation and varnish buildup which interferes with
valve, clutch and servo operation. Foaming also
causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid
overflow can easily be mistaken for a leak if inspection is not careful.
Fig. 2 Transmission Part And Serial Number
Location
1 – PART NUMBER
2 – BUILD DATE
3 – SERIAL NUMBER
RECOMMENDED FLUID
NOTE: Refer to the Service Procedures section of
this Group for fluid level checking procedures.
FLUID TYPE
Mopart ATF Plus 3, Type 7176 automatic transmission fluid is the recommended fluid for Chrysler
automatic transmissions.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
CAUSES OF BURNT FLUID
Burnt, discolored fluid is a result of overheating
which has two primary causes.
(1) A result of restricted fluid flow through the
main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed
drainback valve, a damaged main cooler, or severe
restrictions in the coolers and lines caused by debris
or kinked lines.
(2) Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the
transmission fluid if the vehicle is improperly
equipped. Such vehicles should have an auxiliary
transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to
handle heavy loads.
FLUID CONTAMINATION
Transmission fluid contamination is generally a
result of:
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DESCRIPTION AND OPERATION (Continued)
• adding incorrect fluid
• failure to clean dipstick and fill tube when
checking level
• engine coolant entering the fluid
• internal failure that generates debris
• overheat that generates sludge (fluid breakdown)
• failure to reverse flush cooler and lines after
repair
• failure to replace contaminated converter after
repair
The use of non recommended fluids can result in
transmission failure. The usual results are erratic
shifts, slippage, abnormal wear and eventual failure
due to fluid breakdown and sludge formation. Avoid
this condition by using recommended fluids only.
The dipstick cap and fill tube should be wiped
clean before checking fluid level. Dirt, grease and
other foreign material on the cap and tube could fall
into the tube if not removed beforehand. Take the
time to wipe the cap and tube clean before withdrawing the dipstick.
Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy
is to replace the radiator as the cooler in the radiator
is not a serviceable part. If coolant has circulated
through the transmission for some time, an overhaul
may also be necessary; especially if shift problems
had developed.
The transmission cooler and lines should be
reverse flushed whenever a malfunction generates
sludge and/or debris. The torque converter should
also be replaced at the same time.
Failure to flush the cooler and lines will result in
recontamination. Flushing applies to auxiliary coolers as well. The torque converter should also be
replaced whenever a failure generates sludge and
debris. This is necessary because normal converter
flushing procedures will not remove all contaminants.
ELECTRONIC LOCK-UP TORQUE CONVERTER
The torque converter is a hydraulic device that
couples the engine crankshaft to the transmission.
The torque converter consists of an outer shell with
an internal turbine, a stator, an overrunning clutch,
an impeller, and an electronically applied converter
clutch. Torque multiplication is created when the stator directs the hydraulic flow from the turbine to
rotate the impeller in the direction the engine crankshaft is turning. The turbine transfers power to the
planetary gear sets in the transmission. The transfer
of power into the impeller assists torque multiplication. At low vehicle-speed, the overrunning clutch
holds the stator stationary (during torque multiplication) and allows the stator to freewheel at high vehi-
cle speed. The converter clutch engagement reduces
engine speed. Clutch engagement also provides
reduced transmission fluid temperatures. The torque
converter hub drives the transmission oil (fluid)
pump.
The torque converter is a sealed, welded unit that
is not repairable and is serviced as an assembly.
CAUTION: The torque converter must be replaced if
a transmission failure results in large amounts of
metal or fiber contamination in the fluid.
TRANSMISSION GEAR RATIOS
Gear ratios are:
• 1st 2.74:1
• 2nd 1.54:1
• 3rd 1.00:1
• 4th 0.69:1
• Rev. 2.21
GEARSHIFT MECHANISM
The shift mechanism is cable operated and provides six shift positions. The shift positions are:
• Park (P)
• Reverse (R)
• Neutral (N)
• Drive (D)
• Manual Second (2)
• Manual Low (1)
Manual low (1) range provides first gear only.
Overrun braking is also provided in this range. Manual second (2) range provides first and second gear
only. Drive range provides first, second, third, and
overdrive fourth gear ranges. The shift into overdrive
fourth gear range occurs only after the transmission
has completed the shift into (D) third gear range. No
further movement of the shift mechanism is required
to complete the 3-4 shift.
ELECTRONIC GOVERNOR
Governor pressure is controlled electronically. Components used for governor pressure control include:
• Governor body
• Valve body transfer plate
• Governor pressure solenoid valve
• Governor pressure sensor
• Fluid temperature thermistor
• Throttle position sensor (TPS)
• Transmission speed sensor
• Powertrain control module (PCM)
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TRANSMISSION AND TRANSFER CASE
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DESCRIPTION AND OPERATION (Continued)
GOVERNOR PRESSURE SOLENOID VALVE
The solenoid valve is a duty-cycle solenoid which
regulates the governor pressure needed for upshifts
and downshifts. It is an electro-hydraulic device
located in the governor body on the valve body transfer plate (Fig. 3).
The inlet side of the solenoid valve is exposed to
normal transmission line pressure. The outlet side of
the valve leads to the valve body governor circuit.
The solenoid valve regulates line pressure to produce governor pressure. The average current supplied to the solenoid controls governor pressure. One
amp current produces zero kPa/psi governor pressure. Zero amps sets the maximum governor pressure.
The powertrain control module (PCM) turns on the
trans control relay which supplies electrical power to
the solenoid valve. Operating voltage is 12 volts
(DC). The PCM controls the ground side of the solenoid using the governor pressure solenoid control circuit.
Fig. 3 Governor Pressure Solenoid Valve
1 – SOLENOID FILTER
2 – GOVERNOR PRESSURE SOLENOID
GOVERNOR PRESSURE SENSOR
The governor pressure sensor measures output
pressure of the governor pressure solenoid valve (Fig.
4).
The sensor output signal provides the necessary
feedback to the PCM. This feedback is needed to adequately control governor pressure.
GOVERNOR BODY AND TRANSFER PLATE
The transfer plate is designed to supply transmission line pressure to the governor pressure solenoid
valve and to return governor pressure.
The governor pressure solenoid valve is mounted in
the governor body. The body is bolted to the lower
side of the transfer plate (Fig. 4). The transfer plate
channels line pressure to the solenoid valve through
the governor body. It also channels governor pressure
from the solenoid valve to the governor circuit. It is
the solenoid valve that develops the necessary governor pressure.
Fig. 4 Governor Pressure Sensor
1 – RETAINING CLIP
2 – GOVERNOR BODY
3 – GOVERNOR PRESSURE SENSOR/TRANSMISSION FLUID
TEMPERATURE THERMISTOR
TRANSMISSION FLUID TEMPERATURE
THERMISTOR
Transmission fluid temperature readings are supplied to the transmission control module by the thermistor. The temperature readings are used to control
engagement of the fourth gear overdrive clutch, the
converter clutch, and governor pressure. Normal
resistance value for the thermistor at room temperature is approximately 1000 ohms.
The PCM prevents engagement of the converter
clutch and overdrive clutch, when fluid temperature
is below approximately 10°C (50°F).
If fluid temperature exceeds 126°C (260°F), the
PCM causes a 4-3 downshift and engage the converter clutch. Engagement is according to the third
gear converter clutch engagement schedule.
The overdrive OFF lamp in the instrument panel
illuminates when the shift back to third occurs. The
transmission will not allow fourth gear operation
until fluid temperature decreases to approximately
110°C (230°F).
The thermistor is part of the governor pressure
sensor assembly and is immersed in transmission
fluid at all times.
TRANSMISSION SPEED SENSOR
The speed sensor (Fig. 5) is located in the overdrive gear case. The sensor is positioned over the
park gear and monitors transmission output shaft
rotating speed. Speed sensor signals are triggered by
the park gear lugs as they rotate past the sensor
pickup face. Input signals from the sensor are sent to
the transmission control module for processing. The
vehicle speed sensor also serves as a backup for the
TRANSMISSION AND TRANSFER CASE
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21 - 7
DESCRIPTION AND OPERATION (Continued)
transmission speed sensor. Signals from this sensor
are shared with the powertrain control module.
•
(50°
•
•
•
Transmission fluid temperature is below 10° C
F) or above 121° C (250° F)
Shift to third not yet completed
Vehicle speed too low for 3-4 shift to occur
Battery temperature below –5° F.
HYDRAULIC CONTROL SYSTEM
The hydraulic control system provides fully automatic operation. The system performs five basic functions which are: pressure supply, pressure regulation,
flow control, clutch/band application, and lubrication.
PRESSURE REGULATION
The TPS provides throttle position input signals to
the PCM. This input signal is used to determine
overdrive and converter clutch shift schedule and to
select the proper governor curve.
The pressure regulator valve maintains line pressure. The amount of pressure developed is controlled
by throttle pressure which is dependent on the
degree of throttle opening. The regulator valve is
located in the valve body.
The throttle valve determines line pressure and
shift speed. Governor pressure increases in proportion to vehicle speed. The throttle valve controls
upshift and downshift speeds by regulating pressure
according to throttle position.
POWERTRAIN CONTROL MODULE (PCM)
Shift Valve Flow Control
The PCM controls operation of the converter
clutch, overdrive clutch, and governor pressure solenoid.
The control module determines transmission shift
points based on input signals from the transmission
thermistor, transmission output shaft speed sensor,
crankshaft position sensor, vehicle speed sensor,
throttle position sensor, and battery temperature sensor.
The manual valve is operated by the gearshift linkage
and provides the operating range selected by the driver.
The 1-2 shift valve provides 1-2 or 2-1 shifts and
the 2-3 shift valve provides 2-3 or 3-2 shifts.
The kickdown valve provides forced 3-2 or 3-1
downshifts depending on vehicle speed. Downshifts
occur when the throttle is opened beyond downshift
detent position. Detent is reached just before wide
open throttle position.
The 2-3 valve throttle pressure plug provides 3-2
downshifts at varying throttle openings depending on
vehicle speed.
The 1-2 shift control valve transmits 1-2 shift pressure to the accumulator piston. This controls kickdown band capacity on 1-2 upshifts and 3-2
downshifts.
The 3-4 shift, quick fill, and timing valves plus the
3-4 accumulator, are only actuated when the overdrive solenoid is energized. The solenoid contains a
check ball that controls a vent port to the 3-4 valves.
The check ball either diverts line pressure away from
or directly to the 3-4 valves.
The limit valve determines maximum speed at
which a 3-2 part throttle kickdown can be made. On
transmissions without a limit valve, maximum speed
for a 3-2 kickdown is at detent position.
The 2-3 shuttle valve has two functions. The first
is fast front band release and smooth engagement
during lift-foot 2-3 upshifts. The second is to regulate
front clutch and band application during 3-2 downshifts.
Fig. 5 Transmission Output Speed Sensor
1 – TRANSMISSION OUTPUT SHAFT SPEED SENSOR
2 – SEAL
THROTTLE POSITION SENSOR (TPS)
GOVERNOR PRESSURE CURVES
There are four governor pressure curves programmed into the transmission control module. The
different curves allow the control module to adjust
governor pressure for varying conditions. One curve
is used for operation when fluid temperature is at, or
below, 1°C (30°F). A second curve is used when fluid
temperature is at, or above, 10°C (50°F) during normal city or highway driving. A third curve is used
during wide-open throttle operation. The fourth curve
is used when driving with the transfer case in low
range.
SHIFT VALVE OPERATION
The shift valves are moved by a combination of
throttle and governor pressure. The governor pressure is generated by electrical components.
The conditions under which a shift to fourth will
not occur are:
• Overdrive switch is Off
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TRANSMISSION AND TRANSFER CASE
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DESCRIPTION AND OPERATION (Continued)
The 3-4 timing valve is moved by line pressure
coming through the 3-4 shift valve. The timing valve
holds the 2-3 shift valve in an upshift position. The
purpose is to prevent the 2-3 valve from up or downshifting before the 3-4 valve.
The 3-4 accumulator is mounted on the overdrive
housing and performs the same function as the 2-3
accumulator; it is used to smooth engagement during
a 3-4 shift.
The switch valve directs fluid apply pressure to the
converter clutch in one position and releases it in the
opposite position. It also directs oil to the cooling and
lube circuits. The switch valve regulates oil pressure
to the torque converter by limiting maximum oil
pressure to 130 psi.
OVERDRIVE OFF SWITCH
The overdrive OFF (control) switch is located in
the instrument panel. The switch is a momentary
contact device that signals the PCM to toggle current
status of the overdrive function. At key-on, overdrive
operation is allowed. Pressing the switch once causes
the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing
the switch a second time causes normal overdrive
operation to be restored and the overdrive lamp to be
turned off. The overdrive OFF mode defaults to ON
after the ignition switch is cycled OFF and ON. The
normal position for the control switch is the ON position. The switch must be in this position to energize
the solenoid and allow a 3-4 upshift. The control
switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when
illuminated by the transmission control module.
3-4 SHIFT SEQUENCE
The overdrive clutch is applied in fourth gear only.
The direct clutch is applied in all ranges except
fourth gear. Fourth gear overdrive range is electronically controlled and hydraulically activated. Various
sensor inputs are supplied to the powertrain control
module to operate the overdrive solenoid on the valve
body. The solenoid contains a check ball that opens
and closes a vent port in the 3-4 shift valve feed passage. The overdrive solenoid (and check ball) are not
energized in first, second, third, or reverse gear. The
vent port remains open, diverting line pressure from
the 2-3 shift valve away from the 3-4 shift valve. The
overdrive control switch must be in the ON position
to transmit overdrive status to the PCM. A 3-4
upshift occurs only when the overdrive solenoid is
energized by the PCM. The PCM energizes the overdrive solenoid during the 3-4 upshift. This causes the
solenoid check ball to close the vent port allowing
line pressure from the 2-3 shift valve to act directly
on the 3-4 upshift valve. Line pressure on the 3-4
shift valve overcomes valve spring pressure moving
the valve to the upshift position. This action exposes
the feed passages to the 3-4 timing valve, 3-4 quick
fill valve, 3-4 accumulator, and ultimately to the
overdrive piston. Line pressure through the timing
valve moves the overdrive piston into contact with
the overdrive clutch. The direct clutch is disengaged
before the overdrive clutch is engaged. The boost
valve provides increased fluid for lubrication and
torque convertor clutch capacity. The 3-4 accumulator
cushions overdrive clutch engagement to smooth 3-4
upshifts. The accumulator is charged at the same
time as apply pressure acts against the overdrive piston.
CONVERTER CLUTCH ENGAGEMENT
Converter clutch engagement in third or fourth
gear range is controlled by sensor inputs to the powertrain control module. Inputs that determine clutch
engagement are: coolant temperature, engine rpm,
vehicle speed, throttle position, and manifold vacuum. The torque converter clutch is engaged by the
clutch solenoid on the valve body. The clutch can be
engaged in third and fourth gear ranges depending
on overdrive control switch position. If the overdrive
control switch is in the normal ON position, the
clutch will engage after the shift to fourth gear, and
above approximately 72 km/h (45 mph). If the control
switch is in the OFF position, the clutch will engage
after the shift to third gear, at approximately 56
km/h (35 mph) at light throttle.
QUICK FILL VALVE
The 3-4 quick fill valve provides faster engagement
of the overdrive clutch during 3-4 upshifts. The valve
temporarily bypasses the clutch piston feed orifice at
the start of a 3-4 upshift. This exposes a larger passage into the piston retainer resulting in a much
faster clutch fill and apply sequence. The quick fill
valve does not bypass the regular clutch feed orifice
throughout the 3-4 upshift. Instead, once a predetermined pressure develops within the clutch, the valve
closes the bypass. Clutch fill is then completed
through the regular feed orifice.
CONVERTER DRAINBACK VALVE
DESCRIPTION
The drainback valve is located in the transmission
cooler outlet (pressure) line.
OPERATION
The valve prevents fluid from draining from the
converter into the cooler and lines when the vehicle
is shut down for lengthy periods. Production valves
have a hose nipple at one end, while the opposite end
TRANSMISSION AND TRANSFER CASE
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21 - 9
DESCRIPTION AND OPERATION (Continued)
is threaded for a flare fitting. All valves have an
arrow (or similar mark) to indicate direction of flow
through the valve.
BRAKE TRANSMISSION SHIFT INTERLOCK
MECHANISM
The Brake Transmission Shifter/Ignition Interlock
(BTSI), is a cable and solenoid operated system. It
interconnects the automatic transmission floor
mounted shifter to the steering column ignition
switch (Fig. 6). The system locks the shifter into the
PARK position. The Interlock system is engaged
whenever the ignition switch is in the LOCK or
ACCESSORY position. An additional electrically activated feature will prevent shifting out of the PARK
position unless the brake pedal is depressed at least
one-half an inch. A magnetic holding device in line
with the park lock cable is energized when the ignition is in the RUN position. When the key is in the
RUN position and the brake pedal is depressed, the
shifter is unlocked and will move into any position.
The interlock system also prevents the ignition
switch from being turned to the LOCK or ACCESSORY position (Fig. 6), unless the shifter is fully
locked into the PARK position.
DIAGNOSIS AND TESTING
AUTOMATIC TRANSMISSION DIAGNOSIS
Automatic transmission problems can be a result of
poor engine performance, incorrect fluid level, incorrect linkage or cable adjustment, band or hydraulic
control pressure adjustments, hydraulic system malfunctions or electrical/mechanical component malfunctions. Begin diagnosis by checking the easily
accessible items such as: fluid level and condition,
linkage adjustments and electrical connections. A
road test will determine if further diagnosis is necessary.
PRELIMINARY DIAGNOSIS
Two basic procedures are required. One procedure
for vehicles that are drivable and an alternate procedure for disabled vehicles (will not back up or move
forward).
VEHICLE IS DRIVEABLE
(1) Check for transmission fault codes using DRB
scan tool.
(2) Check fluid level and condition.
Fig. 6 Ignition Interlock Cable
1 – SHIFT MECHANISM
2 – SHIFTER BTSI LEVER
3 – ADJUSTMENT CLIP
4 – STEERING COLUMN ASSEMBLY
5 – INTERLOCK CABLE
21 - 10
TRANSMISSION AND TRANSFER CASE
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DIAGNOSIS AND TESTING (Continued)
(3) Adjust throttle and gearshift linkage if complaint was based on delayed, erratic, or harsh shifts.
(4) Road test and note how transmission upshifts,
downshifts, and engages.
(5) Perform stall test if complaint is based on sluggish acceleration. Or, if abnormal throttle opening is
needed to maintain normal speeds with a properly
tuned engine.
(6) Perform hydraulic pressure test if shift problems were noted during road test.
(7) Perform air-pressure test to check clutch-band
operation.
VEHICLE IS DISABLED
(1) Check fluid level and condition.
(2) Check for broken or disconnected gearshift or
throttle linkage.
(3) Check for cracked, leaking cooler lines, or loose
or missing pressure-port plugs.
(4) Raise and support vehicle on safety stands,
start engine, shift transmission into gear, and note
following:
(a) If propeller shaft turns but wheels do not,
problem is with differential or axle shafts.
(b) If propeller shaft does not turn and transmission is noisy, stop engine. Remove oil pan, and
check for debris. If pan is clear, remove transmission and check for damaged drive plate, converter,
oil pump, or input shaft.
(c) If propeller shaft does not turn and transmission is not noisy, perform hydraulic-pressure test to
determine if problem is hydraulic or mechanical.
PARK/NEUTRAL POSITION SWITCH
The center terminal of the park/neutral position
switch is the sense/starter-circuit terminal. It provides the ground for the starter solenoid circuit when
the transmission selector lever is in PARK or NEUTRAL positions only. The outer terminals on the
switch are for the backup lamp circuit.
SWITCH TEST
To test the switch, remove the wiring connector.
Test for continuity between the center terminal and
the transmission case. Continuity should exist when
the transmission is in PARK or NEUTRAL only. Continuity should not exist any other time or with the
transmission in any other gear.
Shift the transmission into REVERSE and test
continuity at the switch outer terminals. Continuity
should exist when the transmission is in REVERSE
only. Continuity should not exist between the outer
terminals and the case.
Check gearshift linkage adjustment before replacing a switch that tests faulty.
OVERDRIVE ELECTRICAL CONTROLS
The overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12
volt test lamp or a volt/ohmmeter. Check continuity of
each component when diagnosis indicates this is necessary. Refer to Group 8W, Wiring Diagrams, for component
locations and circuit information.
Switch and solenoid continuity should be checked
whenever the transmission fails to shift into fourth
gear range.
BRAKE TRANSMISSION SHIFT INTERLOCK
(1) Verify that the key can only be removed in the
PARK position
(2) When the shift lever is in PARK And the shift
handle pushbutton is in the “OUT” position, the ignition key cylinder should rotate freely from OFF to
LOCK. When the shifter is in any other gear or neutral position, the ignition key cylinder should not
rotate to the LOCK position.
(3) Shifting out of PARK should be possible when
the ignition key cylinder is in the OFF position.
(4) Shifting out of PARK should not be possible
while applying 25 lb. maximum handle pushbutton
force and ignition key cylinder is in the RUN or
START positions unless the foot brake pedal is
depressed approximately 1/2 inch (12mm).
(5) Shifting out of PARK should not be possible
when the ignition key cylinder is in the ACCESSORY
or LOCK positions.
(6) Shifting between any gears, NEUTRAL or into
PARK may be done without depressing foot brake
pedal with ignition switch in RUN or START positions and vehicle stationary or in motion.
GEARSHIFT CABLE
(1) The floor shifter lever and gate positions
should be in alignment with all transmission PARK,
NEUTRAL, and gear detent positions.
(2) Engine starts must be possible with floor shift
lever in PARK or NEUTRAL gate positions only. Engine
starts must not be possible in any other gear position.
(3) With floor shift lever handle push-button not
depressed and lever in:
(a) PARK position—Apply forward force on center of handle and remove pressure. Engine starts
must be possible.
(b) PARK position—Apply rearward force on center of handle and remove pressure. Engine starts
must be possible.
(c) NEUTRAL position—Normal position. Engine
starts must be possible.
(d) NEUTRAL position—Engine running and
brakes applied, apply forward force on center of
shift handle. Transmission shall not be able to shift
from neutral to reverse.
TRANSMISSION AND TRANSFER CASE
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21 - 11
DIAGNOSIS AND TESTING (Continued)
THROTTLE VALVE CABLE
Transmission throttle valve cable adjustment is
extremely important to proper operation. This adjustment positions the throttle valve, which controls shift
speed, quality, and part-throttle downshift sensitivity.
If cable setting is too loose, early shifts and slippage between shifts may occur. If the setting is too
tight, shifts may be delayed and part throttle downshifts may be very sensitive. Refer to the Adjustments section for the proper adjustment procedure.
ROAD TESTING
Before road testing, be sure the fluid level and control cable adjustments have been checked and
adjusted if necessary. Verify that diagnostic trouble
codes have been resolved.
SHIFT
LEVER
POSITION
Reverse
Observe engine performance during the road test.
A poorly tuned engine will not allow accurate analysis of transmission operation.
Operate the transmission in all gear ranges. Check
for shift variations and engine flare which indicates
slippage. Note if shifts are harsh, spongy, delayed,
early, or if part throttle downshifts are sensitive.
Slippage indicated by engine flare, usually means
clutch, band or overrunning clutch problems. If the
condition is advanced, an overhaul will be necessary
to restore normal operation.
A slipping clutch or band can often be determined
by comparing which internal units are applied in the
various gear ranges. The Clutch and Band Application chart provides a basis for analyzing road test
results.
TRANSMISSION CLUTCHES AND BANDS
FRONT
CLUTCH
FRONT
BAND
REAR
CLUTCH
X
REAR
BAND
OVERRUN.
CLUTCH
OVERDRIVE CLUTCHES
OVERDRIVE DIRECT OVERRUN.
CLUTCH
CLUTCH
CLUTCH
X
X
Drive Range
First
X
Second
X
X
X
X
X
X
X
X
X
X
X
X
Third
X
X
Fourth
X
X
2-Range
(Manual
Second)
1-Range
(Manual Low)
X
X
X
X
X
X
X
X
CLUTCH AND BAND APPLICATION CHART
ANALYZING ROAD TEST
Refer to the Clutch and Band Application chart
and note which elements are in use in the various
gear ranges.
Note that the rear clutch is applied in all forward
ranges (D, 2, 1). The transmission overrunning clutch
is applied in first gear (D, 2 and 1 ranges) only. The
rear band is applied in 1 and R range only.
Note that the overdrive clutch is applied only in
fourth gear and the overdrive direct clutch and overrunning clutch are applied in all ranges except fourth
gear.
For example: If slippage occurs in first gear in D
and 2 range but not in 1 range, the transmission
overrunning clutch is faulty. Similarly, if slippage
occurs in any two forward gears, the rear clutch is
slipping.
Applying the same method of analysis, note that
the front and rear clutches are applied simulta-
neously only in D range third and fourth gear. If the
transmission slips in third gear, either the front
clutch or the rear clutch is slipping.
If the transmission slips in fourth gear but not in
third gear, the overdrive clutch is slipping. By selecting another gear which does not use these clutches,
the slipping unit can be determined. For example, if
the transmission also slips in Reverse, the front
clutch is slipping. If the transmission does not slip in
Reverse, the rear clutch is slipping.
If slippage occurs during the 3-4 shift or only in
fourth gear, the overdrive clutch is slipping. Similarly, if the direct clutch were to fail, the transmission would lose both reverse gear and overrun
braking in 2 position (manual second gear).
If the transmission will not shift to fourth gear, the
control switch, overdrive solenoid or related wiring
may also be the problem cause.
21 - 12
TRANSMISSION AND TRANSFER CASE
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DIAGNOSIS AND TESTING (Continued)
This process of elimination can be used to identify
a slipping unit and check operation. Proper use of
the Clutch and Band Application Chart is the key.
Although road test analysis will help determine the
slipping unit, the actual cause of a malfunction usually cannot be determined until hydraulic and air
pressure tests are performed. Practically any condition can be caused by leaking hydraulic circuits or
sticking valves.
Unless a malfunction is obvious, such as no drive
in D range first gear, do not disassemble the transmission. Perform the hydraulic and air pressure tests
to help determine the probable cause.
HYDRAULIC PRESSURE TEST
Hydraulic test pressures range from a low of one
psi (6.895 kPa) governor pressure, to 300 psi (2068
kPa) at the rear servo pressure port in reverse.
An accurate tachometer and pressure test gauges
are required. Test Gauge C-3292 has a 100 psi range.
Test Gauge C-3293-SP has a 300 psi range and is
used where pressures exceed 100 psi.
Pressure Test Port Locations
Test ports are located at both sides of the transmission case (Fig. 7).
Line pressure is checked at the accumulator port
on the right side of the case. The front servo pressure
port is at the right side of the case just behind the
filler tube opening.
The rear servo and governor pressure ports are at
the right rear of the transmission case. The overdrive
clutch pressure port is at the left rear of the case.
Test One - Transmission In Manual Low
NOTE: This test checks pump output, pressure regulation, and condition of the rear clutch and servo
circuit. Both test gauges are required for this test.
(1) Connect tachometer to engine. Position tachometer so it can be observed from driver seat if helper
will be operating engine. Raise vehicle on hoist that
will allow rear wheels to rotate freely.
(2) Connect 100 psi Gauge C-3292 to accumulator
port. Then connect 300 psi Gauge C-3293-SP to rear
servo port.
(3) Disconnect throttle and gearshift cables from
levers on transmission valve body manual shaft.
(4) Have helper start and run engine at 1000 rpm.
(5) Move transmission shift lever fully forward
into 1 range.
(6) Gradually move transmission throttle lever
from full forward to full rearward position and note
pressures on both gauges:
Fig. 7 Pressure Test Port Locations
1
2
3
4
5
–
–
–
–
–
OVERDRIVE CLUTCH TEST PORT
GOVERNOR TEST PORT
ACCUMULATOR TEST PORT
FRONT SERVO TEST PORT
REAR SERVO TEST PORT
• Line pressure at accumulator port should be
54-60 psi (372-414 kPa) with throttle lever forward
and gradually increase to 90-96 psi (621-662 kPa) as
throttle lever is moved rearward.
• Rear servo pressure should be same as line pressure within 3 psi (20.68 kPa).
Test Two—Transmission In 2 Range
NOTE: This test checks pump output, line pressure
and pressure regulation. Use 100 psi Test Gauge
C-3292 for this test.
(1) Leave vehicle in place on hoist and leave Test
Gauge C-3292 connected to accumulator port.
(2) Have helper start and run engine at 1000 rpm.
(3) Move transmission shift lever one detent rearward from full forward position. This is 2 range.
(4) Move transmission throttle lever from full forward to full rearward position and read pressure on
gauge.
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TRANSMISSION AND TRANSFER CASE
21 - 13
DIAGNOSIS AND TESTING (Continued)
(5) Line pressure should be 54-60 psi (372-414
kPa) with throttle lever forward and gradually
increase to 90-96 psi (621-662 kPa) as lever is moved
rearward.
Test Three—Transmission In D Range Third Gear
NOTE: This test checks pressure regulation and
condition of the clutch circuits. Both test gauges
are required for this test.
(1) Turn OD switch off.
(2) Leave vehicle on hoist and leave Gauge C-3292
in place at accumulator port.
(3) Move Gauge C-3293-SP over to front servo port
for this test.
(4) Have helper start and run engine at 1600 rpm
for this test.
(5) Move transmission shift lever two detents rearward from full forward position. This is D range.
(6) Read pressures on both gauges as transmission
throttle lever is gradually moved from full forward to
full rearward position:
• Line pressure at accumulator in D range third
gear, should be 54-60 psi (372-414 kPa) with throttle
lever forward and increase as lever is moved rearward. If the torque convertor is allowed to lock up
pressure can rise to 130 psi (900 kPa). Be certain to
maintain the correct RPM during testing.
• Front servo pressure in D range third gear,
should be within 3 psi (21 kPa) of line pressure up to
kickdown point.
Test Four—Transmission In Reverse
NOTE: This test checks pump output, pressure regulation and the front clutch and rear servo circuits.
Use 300 psi Test Gauge C-3293-SP for this test.
(1) Leave vehicle on hoist and leave gauge C3292
in place at accumulator port.
(2) Move 300 psi Gauge C-3293-SP back to rear
servo port.
(3) Have helper start and run engine at 1600 rpm
for test.
(4) Move transmission shift lever four detents
rearward from full forward position. This is Reverse
range.
(5) Move transmission throttle lever fully forward
then fully rearward and note reading at Gauge
C-3293-SP.
(6) Pressure should be 145 - 175 psi (1000-1207
kPa) with throttle lever forward and increase to 230 280 psi (1586-1931 kPa) as lever is gradually moved
rearward.
Test Five—Governor Pressure
NOTE: This test checks governor operation by
measuring governor pressure response to changes
in vehicle speed. It is usually not necessary to
check governor operation unless shift speeds are
incorrect or if the transmission will not downshift.
The test should be performed on the road or on a
hoist that will allow the rear wheels to rotate freely.
(1) Move 100 psi Test Gauge C-3292 to governor
pressure port.
(2) Move transmission shift lever two detents rearward from full forward position. This is D range.
(3) Have helper start and run engine at curb idle
speed. Then firmly apply service brakes so wheels
will not rotate.
(4) Note governor pressure:
• Governor pressure should be no more than 20.6
kPa (3 psi) at curb idle speed and wheels not rotating.
• If pressure exceeds 20.6 kPa (3 psi), a fault
exists in governor pressure control system.
(5) Release brakes, slowly increase engine speed,
and observe speedometer and pressure test gauge (do
not exceed 30 mph on speedometer). Governor pressure should increase in proportion to vehicle speed.
Or approximately 6.89 kPa (1 psi) for every 1 mph.
(6) Governor pressure rise should be smooth and
drop back to no more than 20.6 kPa (3 psi), after
engine returns to curb idle and brakes are applied to
prevent wheels from rotating.
(7) Compare results of pressure test with analysis
chart.
Test Six—Transmission In Overdrive Fourth Gear
NOTE: This test checks line pressure at the overdrive clutch in fourth gear range. Use 300 psi Test
Gauge C-3292 for this test. The test should be performed on the road or on a chassis dyno.
(1) Remove tachometer; it is not needed for this
test.
(2) Move 300 psi Gauge to overdrive clutch pressure test port. Then remove other gauge and reinstall
test port plug.
(3) Lower vehicle.
(4) Turn OD switch on.
(5) Secure test gauge so it can be viewed from
drivers seat.
(6) Start engine and shift into D range.
(7) Increase vehicle speed gradually until 3-4 shift
occurs and note gauge pressure.
(8) Pressure should be 469-496 kPa (68-72 psi)
with closed throttle and increase to 620-827 kPa (90120 psi) at 1/2 to 3/4 throttle. Note that pressure can
increase to around 896 kPa (130 psi) at full throttle.
21 - 14
TRANSMISSION AND TRANSFER CASE
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DIAGNOSIS AND TESTING (Continued)
(9) Return to shop or move vehicle off chassis
dyno.
PRESSURE TEST ANALYSIS CHART
TEST CONDITION
Air-pressure testing requires that the oil pan and
valve body be removed from the transmission. The
servo and clutch apply passages are shown (Fig. 8).
INDICATION
Line pressure OK during
any one test
Pump and regulator
valve OK
Line pressure OK in R
but low in D, 2, 1
Leakage in rear clutch
area (seal rings, clutch
seals)
Pressure low in D Fourth
Gear Range
Overdrive clutch piston
seal, or check ball
problem
Pressure OK in 1, 2 but
low in D3 and R
Leakage in front clutch
area
Pressure OK in 2 but low
in R and 1
Leakage in rear servo
Front servo pressure low
in 2
Leakage in servo; broken
servo ring or cracked
servo piston
Pressure low in all
positions
Clogged filter, stuck
regulator valve, worn or
faulty pump, low oil level
Governor pressure too
high at idle speed
Governor pressure
solenoid valve system
fault. Refer to diagnostic
book.
Governor pressure low at
all mph figures
Faulty governor pressure
solenoid, transmission
control module, or
governor pressure
sensor
Lubrication pressure low
at all throttle positions
Clogged fluid cooler or
lines, seal rings leaking,
worn pump bushings,
pump, clutch retainer, or
clogged filter.
Fig. 8 Air Pressure Test Passages
1 – REAR SERVO APPLY
2 – FRONT SERVO APPLY
3 – PUMP SUCTION
4 – FRONT CLUTCH APPLY
5 – FRONT SERVO RELEASE
6 – LINE PRESSURE TO ACCUMULATOR
7 – PUMP PRESSURE
8 – TO CONVERTER
9 – REAR CLUTCH APPLY
10 – FROM CONVERTER
11 – TO COOLER
Front Clutch Air Test
Line pressure high
Output shaft plugged,
sticky regulator valve
Place one or two fingers on the clutch housing and
apply air pressure through front clutch apply passage. Piston movement can be felt and a soft thump
heard as the clutch applies.
Line pressure low
Sticky regulator valve,
clogged filter, worn pump
Rear Clutch Air Test
AIR TESTING TRANSMISSION CLUTCH AND
BAND OPERATION
Air-pressure testing can be used to check transmission front/rear clutch and band operation. The test
can be conducted with the transmission either in the
vehicle or on the work bench, as a final check, after
overhaul.
Place one or two fingers on the clutch housing and
apply air pressure through rear clutch apply passage.
Piston movement can be felt and a soft thump heard
as the clutch applies.
Front Servo Apply Air Test
Apply air pressure to the front servo apply passage. The servo rod should extend and cause the
band to tighten around the drum. Spring pressure
should release the servo when air pressure is
removed.
TRANSMISSION AND TRANSFER CASE
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21 - 15
DIAGNOSIS AND TESTING (Continued)
Rear Servo Air Test
TORQUE CONVERTER LEAK POINTS
Apply air pressure to the rear servo apply passage.
The servo rod should extend and cause the band to
tighten around the drum. Spring pressure should
release the servo when air pressure is removed.
Possible sources of converter leaks are:
(1) Leaks at the weld joint around the outside
diameter weld (Fig. 10).
(2) Leaks at the converter hub weld (Fig. 10).
CONVERTER HOUSING FLUID LEAK
DIAGNOSIS
When diagnosing converter housing fluid leaks,
three items must be established before repair.
(1) Verify the correct fluid level in the transmission.
(2) Verify that a leak condition actually exists.
(3) Determined the true source of the leak.
Some suspected converter housing fluid leaks may
not be leaks at all. They may only be the result of
residual fluid in the converter housing, excessive
fluid fill or excess fluid spilled during factory fill or
fill after repair. Converter housing leaks have several
potential sources. Through careful observation, a leak
source can be identified before removing the transmission for repair. Pump seal leaks tend to move
along the drive hub and onto the rear of the converter. Pump O-ring or pump body leaks follow the
same path as a seal leak (Fig. 9). Pump vent or
pump attaching bolt leaks are generally deposited on
the inside of the converter housing and not on the
converter itself (Fig. 9). Pump seal or gasket leaks
usually travel down the inside of the converter housing. Front band lever pin plug leaks are generally
deposited on the housing and not on the converter.
Fig. 9 Converter Housing Leak Paths
1
2
3
4
5
6
7
–
–
–
–
–
–
–
PUMP SEAL
PUMP VENT
PUMP BOLT
PUMP GASKET
CONVERTER HOUSING
CONVERTER
REAR MAIN SEAL LEAK
Fig. 10 Converter Leak Points—Typical
1
2
3
4
–
–
–
–
OUTSIDE DIAMETER WELD
TORQUE CONVERTER HUB WELD
STARTER RING GEAR
LUG
CONVERTER HOUSING AREA LEAK CORRECTION
(1) Remove the transmission and torque converter.
Refer to the procedure in this group.
(2) Tighten front band adjusting screw until band
is tight around front clutch retainer. This prevents
front/rear clutches from coming out when oil pump is
removed.
(3) Remove oil pump and remove pump seal.
Inspect pump housing drainback and vent holes for
obstructions. Clear holes with solvent and wire.
(4) Inspect pump bushing and converter hub. If
bushing is scored, replace it. If converter hub is
scored, either polish it with crocus cloth or replace
converter.
(5) Install new pump seal, O-ring, and gasket.
Replace oil pump if cracked, porous or damaged in
any way. Be sure to loosen the front band before
installing the oil pump, damage to the oil pump seal
rings may occur if the band is still tightened to the
front clutch retainer.
(6) Loosen kickdown lever pin access plug three
turns. Apply Loctite 592, or Permatex No. 2 to plug
threads and tighten plug to 17 N·m (150 in. lbs.)
torque.
(7) Adjust front band.
(8) Lubricate pump seal and converter hub with
transmission fluid or petroleum jelly and install converter.
(9) Install transmission and converter housing
dust shield.
(10) Lower vehicle.
21 - 16
TRANSMISSION AND TRANSFER CASE
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DIAGNOSIS AND TESTING (Continued)
DIAGNOSIS TABLES AND CHARTS—RE
TRANSMISSION
The diagnosis charts provide additional reference
when diagnosing a transmission fault. The charts provide general information on a variety of transmission,
overdrive unit and converter clutch fault conditions.
The hydraulic flow charts in the Schematics and
Diagrams section of this group, outline fluid flow and
hydraulic circuitry. Circuit operation is provided for
neutral, third, fourth and reverse gear ranges. Normal working pressures are also supplied for each of
the gear ranges.
DIAGNOSIS CHARTS
CONDITION
HARSH ENGAGEMENT
(FROM NEUTRAL TO
DRIVE OR REVERSE)
POSSIBLE CAUSES
CORRECTION
1. Fluid Level Low
1. Add Fluid
2. Throttle Linkage Misadjusted
2. Adjust linkage - setting may be too long.
3. Mount and Driveline Bolts
Loose
3. Check engine mount, transmission mount,
propeller shaft, rear spring to body bolts, rear
control arms, crossmember and axle bolt
torque. Tighten loose bolts and replace
missing bolts.
4. U-Joint Worn/Broken
4. Remove propeller shaft and replace U-Joint.
5. Axle Backlash Incorrect
5. Check per Service Manual. Correct as
needed.
6. Hydraulic Pressure Incorrect
6. Check pressure. Remove, overhaul or
adjust valve body as needed.
7. Band Misadjusted.
7. Adjust rear band.
8. Valve Body Check Balls
Missing.
8. Inspect valve body for proper check ball
installation.
9. Axle Pinion Flange Loose.
9. Replace nut and check pinion threads
before installing new nut. Replace pinion gear
if threads are damaged.
10. Clutch, band or planetary
component damaged.
10. Remove, disassemble and repair
transmission as necessary.
11. Converter Clutch Faulty.
11. Replace converter and flush cooler and
line before installing new converter.
TRANSMISSION AND TRANSFER CASE
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21 - 17
DIAGNOSIS AND TESTING (Continued)
CONDITION
DELAYED ENGAGEMENT
(FROM NEUTRAL TO
DRIVE OR REVERSE)
NO DRIVE RANGE
(REVERSE OK)
POSSIBLE CAUSES
CORRECTION
1. Fluid Level Low.
1. Correct level and check for leaks.
2. Filter Clogged.
2. Change filter.
3. Gearshift Linkage Misadjusted.
3. Adjust linkage and repair linkage if worn or
damaged.
4. Torque Converter Drain Back
(Oil drains from torque converter
into transmission sump)
4. If vehicle moves normally after 5 seconds
after shifting into gear, no repair is necessary.
If longer, inspect pump bushing for wear.
Replace pump house.
5. Rear Band Misadjusted.
5. Adjust band.
6. Valve Body Filter Plugged.
6. Replace fluid and filter. If oil pan and old
fluid were full of clutch disc material and/or
metal particles, overhaul will be necessary.
7. Oil Pump Gears Worn/
Damaged.
7. Remove transmission and replace oil pump.
8. Governor Circuit and Solenoid
Valve Electrical Fault.
8. Test with DRB scan tool and repair as
required.
9. Hydraulic Pressure Incorrect.
9. Perform pressure test, remove transmission
and repair as needed.
10. Reaction Shaft Seal Rings
Worn/Broken.
10. Remove transmission, remove oil pump
and replace seal rings.
11. Rear Clutch/Input Shaft, Rear
Clutch Seal Rings Damaged.
11. Remove and disassemble transmission
and repair as necessary.
12. Regulator Valve Stuck.
12. Clean.
13. Cooler Plugged.
13. Transfer case failure can plug cooler.
1. Fluid Level Low.
1. Add fluid and check for leaks if drive is
restored.
2. Gearshift Linkage/Cable
Loose/Misadjusted.
2. Repair or replace linkage components.
3. Rear Clutch Burnt.
3. Remove and disassemble transmission and
rear clutch and seals. Repair/replace worn or
damaged parts as needed.
4. Valve Body Malfunction.
4. Remove and disassemble valve body.
Replace assembly if any valves or bores are
damaged.
5. Transmission Overrunning
Clutch Broken.
5. Remove and disassemble transmission.
Replace overrunning clutch.
6. Input Shaft Seal Rings
Worn/Damaged.
6. Remove and disassemble transmission.
Replace seal rings and any other worn or
damaged parts.
7. Front Planetary Failed Broken.
7. Remove and repair.
21 - 18
TRANSMISSION AND TRANSFER CASE
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DIAGNOSIS AND TESTING (Continued)
CONDITION
NO DRIVE OR REVERSE
(VEHICLE WILL NOT
MOVE)
SHIFTS DELAYED OR
ERRATIC (SHIFTS ALSO
HARSH AT TIMES)
POSSIBLE CAUSES
CORRECTION
1. Fluid Level Low.
1. Add fluid and check for leaks if drive is
restored.
2. Gearshift Linkage/Cable
Loose/Misadjusted.
2. Inspect, adjust and reassemble linkage as
needed. Replace worn/damaged parts.
3. U-Joint/Axle/Transfer Case
Broken.
3. Perform preliminary inspection procedure for
vehicle that will not move. Refer to procedure
in diagnosis section.
4. Filter Plugged.
4. Remove and disassemble transmission.
Repair or replace failed components as
needed. Replace filter. If filter and fluid
contained clutch material or metal particles, an
overhaul may be necessary. Perform lube flow
test. Flush oil. Replace cooler as necessary.
5. Oil Pump Damaged.
5. Perform pressure test to confirm low
pressure. Replace pump body assembly if
necessary.
6. Valve Body Malfunctioned.
6. Check and inspect valve body. Replace
valve body (as assembly) if any valve or bore
is damaged. Clean and reassemble correctly if
all parts are in good condition.
7. Transmission Internal
Component Damaged.
7. Remove and disassemble transmission.
Repair or replace failed components as
needed.
8. Park Sprag not Releasing Check Stall Speed, Worn/
Damaged/Stuck.
8. Remove, disassemble, repair.
9. Torque Converter Damage.
9. Inspect and replace as required.
1. Fluid Level Low/High.
1. Correct fluid level and check for leaks if low.
2. Fluid Filter Clogged.
2. Replace filter. If filter and fluid contained
clutch material or metal particles, an overhaul
may be necessary. Perform lube flow test.
3. Throttle Linkage Misadjusted.
3. Adjust linkage as described in service
section.
4. Throttle Linkage Binding.
4. Check cable for binding. Check for return to
closed throttle at transmission.
5. Gearshift Linkage/Cable
Misadjusted.
5. Adjust linkage/cable as described in service
section.
6. Clutch or Servo Failure.
6. Remove valve body and air test clutch, and
band servo operation. Disassemble and repair
transmission as needed.
7. Governor Circuit Electrical
Fault.
7. Test using DRB scan tool and repair as
required.
8. Front Band Misadjusted.
8. Adjust band.
9. Pump Suction Passage Leak.
9. Check for excessive foam on dipstick after
normal driving. Check for loose pump bolts,
defective gasket. Replace pump assembly if
needed.
TRANSMISSION AND TRANSFER CASE
WJ
21 - 19
DIAGNOSIS AND TESTING (Continued)
CONDITION
NO REVERSE (D
RANGES OK)
HAS FIRST/REVERSE
ONLY (NO 1-2 OR 2-3
UPSHIFT)
MOVES IN 2ND OR 3RD
GEAR, ABRUPTLY
DOWNSHIFTS TO LOW
NO LOW GEAR (MOVES
IN 2ND OR 3RD GEAR
ONLY)
POSSIBLE CAUSES
CORRECTION
1. Gearshift Linkage/Cable
Misadjusted/Damaged.
1. Repair or replace linkage parts as needed.
2. Park Sprag Sticking.
2. Replace overdrive annulus gear.
3. Rear Band Misadjusted/Worn.
3. Adjust band; replace.
4. Valve Body Malfunction.
4. Remove and service valve body. Replace
valve body if any valves or valve bores are
worn or damaged.
5. Rear Servo Malfunction.
5. Remove and disassemble transmission.
Replace worn/damaged servo parts as
necessary.
6. Direct Clutch in Overdrive Worn
6. Disassemble overdrive. Replace worn or
damaged parts.
7. Front Clutch Burnt.
7. Remove and disassemble transmission.
Replace worn, damaged clutch parts as
required.
1. Governor Circuit Electrical
Fault.
1. Test using DRB scan tool and repair as
required.
2. Valve Body Malfunction.
2. Repair stuck 1-2 shift valve or governor
plug.
3. Front Servo/Kickdown Band
Damaged/Burned.
3. Repair/replace.
1. Valve Body Malfunction.
1. Remove, clean and inspect. Look for stuck
1-2 valve or governor plug.
2. Governor Components Sticking.
2. Remove, clean and inspect. Replace faulty
parts.
1. Governor Components Sticking.
1. Remove clean, inspect and repair as
required.
2. Governor Circuit Electrical
Fault.
2. Test with DRB scan tool and repair as
required.
3. Valve Body Malfunction.
3. Remove, clean and inspect. Look for
sticking 1-2 shift valve, 2-3 shift valve,
governor plug or broken springs.
4. Front Servo Piston Cocked in
Bore.
4. Inspect servo and repair as required.
5. Front Band Linkage Malfunction
5. Inspect linkage and look for bind in linkage.
21 - 20
TRANSMISSION AND TRANSFER CASE
WJ
DIAGNOSIS AND TESTING (Continued)
CONDITION
NO KICKDOWN OR
NORMAL DOWNSHIFT
STUCK IN LOW GEAR
(WILL NOT UPSHIFT)
CREEPS IN NEUTRAL
BUZZING NOISE
POSSIBLE CAUSES
CORRECTION
1. Throttle Linkage Misadjusted.
1. Adjust linkage.
2. Accelerator Pedal Travel
Restricted.
2. Verify floor mat is not under pedal, repair
worn accelerator cable or bent brackets.
3. Valve Body Hydraulic Pressures
Too High or Too Low Due to Valve
Body Malfunction or Incorrect
Hydraulic Control Pressure
Adjustments.
3. Perform hydraulic pressure tests to
determine cause and repair as required.
Correct valve body pressure adjustments as
required.
4. Governor Circuit Electrical
Fault.
4. Test with DRB scan tool and repair as
required.
5. Valve Body Malfunction.
5. Perform hydraulic pressure tests to
determine cause and repair as required.
Correct valve body pressure adjustments as
required.
6. TPS Malfunction.
6. Replace sensor, check with DRB scan tool.
7. PCM Malfunction.
7. Check with DRB scan tool and replace if
required.
8. Valve Body Malfunction.
8. Repair sticking 1-2, 2-3 shift valves,
governor plugs, 3-4 solenoid, 3-4 shift valve,
3-4 timing valve.
1. Throttle Linkage Misadjusted/
Stuck.
1. Adjust linkage and repair linkage if worn or
damaged. Check for binding cable or missing
return spring.
2. Gearshift Linkage Misadjusted.
2. Adjust linkage and repair linkage if worn or
damaged.
3. Governor Component Electrical
Fault.
3. Check operating pressures and test with
DRB scan tool, repair faulty component.
4. Front Band Out of Adjustment.
4. Adjust Band.
5. Clutch or Servo Malfunction.
5. Air pressure check operation of clutches and
bands. Repair faulty component.
1. Gearshift Linkage Misadjusted.
1. Adjust linkage.
2. Rear Clutch Dragging/Warped.
2. Disassemble and repair.
3. Valve Body Malfunction.
3. Perform hydraulic pressure test to determine
cause and repair as required.
1. Fluid Level Low
1. Add fluid and check for leaks.
2. Shift Cable Misassembled.
2. Route cable away from engine and bell
housing.
3. Valve Body Misassembled.
3. Remove, disassemble, inspect valve body.
Reassemble correctly if necessary. Replace
assembly if valves or springs are damaged.
Check for loose bolts or screws.
4. Pump Passages Leaking
4. Check pump for porous casting, scores on
mating surfaces and excess rotor clearance.
Repair as required. Loose pump bolts.
5. Cooling System Cooler
Plugged.
5. Flow check cooler circuit. Repair as needed.
6. Overrunning Clutch Damaged.
6. Replace clutch.
TRANSMISSION AND TRANSFER CASE
WJ
21 - 21
DIAGNOSIS AND TESTING (Continued)
CONDITION
SLIPS IN REVERSE
ONLY
POSSIBLE CAUSES
CORRECTION
1. Fluid Level Low.
1. Add fluid and check for leaks.
2. Gearshift Linkage Misadjusted.
2. Adjust linkage.
3. Rear Band Misadjusted.
3. Adjust band.
4. Rear Band Worn.
4. Replace as required.
5. Overdrive Direct Clutch Worn.
5. Disassemble overdrive. Repair as needed.
6. Hydraulic Pressure Too Low.
6. Perform hydraulic pressure tests to
determine cause.
7. Rear Servo Leaking.
7. Air pressure check clutch-servo operation
and repair as required.
8. Band Linkage Binding.
8. Inspect and repair as required.
1. Fluid Level Low.
1. Add fluid and check for leaks.
2. Fluid Foaming.
2. Check for high oil level, bad pump gasket or
seals, dirt between pump halves and loose
pump bolts. Replace pump if necessary.
3. Throttle Linkage Misadjusted.
3. Adjust linkage.
4. Gearshift Linkage Misadjusted.
4. Adjust linkage.
5. Rear Clutch Worn.
5. Inspect and replace as needed.
6. Low Hydraulic Pressure Due to
Worn Pump, Incorrect Control
Pressure Adjustments, Valve Body
Warpage or Malfunction, Sticking,
Leaking Seal Rings, Clutch Seals
Leaking, Servo Leaks, Clogged
Filter or Cooler Lines
6. Perform hydraulic and air pressure tests to
determine cause.
7. Rear Clutch Malfunction,
Leaking Seals or Worn Plates.
7. Air pressure check clutch-servo operation
and repair as required.
8. Overrunning Clutch Worn, Not
Holding (Slips in 1 Only).
8. Replace Clutch.
SLIPS IN LOW GEAR “D”
ONLY, BUT NO IN 1
POSITION
Overrunning Clutch Faulty.
Replace overrunning clutch.
GROWLING, GRATING
OR SCRAPING NOISES
1. Drive Plate Broken.
1. Replace.
2. Torque Converter Bolts Hitting
Dust Shield.
2. Dust shield bent. Replace or repair.
3. Planetary Gear Set Broken/
Seized.
3. Check for debris in oil pan and repair as
required.
4. Overrunning Clutch Worn/
Broken.
4. Inspect and check for debris in oil pan.
Repair as required.
5. Oil Pump Components
Scored/Binding.
5. Remove, inspect and repair as required.
6. Output Shaft Bearing or
Bushing Damaged.
6. Remove, inspect and repair as required.
7. Clutch Operation Faulty.
7. Perform air pressure check and repair as
required.
8. Front and Rear Bands
Misadjusted.
8. Adjust bands.
SLIPS IN FORWARD
DRIVE RANGES
21 - 22
TRANSMISSION AND TRANSFER CASE
WJ
DIAGNOSIS AND TESTING (Continued)
CONDITION
DRAGS OR LOCKS UP
NO 4-3 DOWNSHIFT
NO 4-3 DOWNSHIFT
WHEN CONTROL
SWITCH IS TURNED OFF
CLUNK NOISE FROM
DRIVELINE ON CLOSED
THROTTLE 4-3
DOWNSHIFT
POSSIBLE CAUSES
CORRECTION
1. Fluid Level Low.
1. Check and adjust level.
2. Clutch Dragging/Failed
2. Air pressure check clutch operation and
repair as required.
3. Front or Rear Band
Misadjusted.
3. Adjust bands.
4. Case Leaks Internally.
4. Check for leakage between passages in
case.
5. Servo Band or Linkage
Malfunction.
5. Air pressure check servo operation and
repair as required.
6. Overrunning Clutch Worn.
6. Remove and inspect clutch. Repair as
required.
7. Planetary Gears Broken.
7. Remove, inspect and repair as required
(look for debris in oil pan).
1. Circuit Wiring and/or
Connectors Shorted.
1. Test wiring and connectors with test lamp
and volt/ohmmeter. Repair wiring as
necessary. Replace connectors and/or
harnesses as required.
2. PCM Malfunction.
2. Check PCM operation with DRB scan tool.
Replace PCM only if faulty.
3. TPS Malfunction
3. Check TPS with DRB scan tool at PCM.
4. Lockup Solenoid Not Venting.
4. Remove valve body and replace solenoid
assembly if plugged or shorted.
5. Overdrive Solenoid Not Venting.
5. Remove valve body and replace solenoid if
plugged or shorted.
6. Valve Body Valve Sticking.
6. Repair stuck 3-4 shift valve or lockup timing
valve.
1. Control Switch Open/Shorted.
1. Test and replace switch if faulty.
2. Overdrive Solenoid Connector
Shorted.
2. Test solenoids and replace if seized or
shorted.
3. PCM Malfunction.
3. Test with DRB scan tool. Replace PCM if
faulty.
4. Valve Body Stuck Valves.
4. Repair stuck 3-4, lockup or lockup timing
valve.
1. Transmission Fluid Low.
1. Add Fluid.
2. Throttle Cable Misadjusted.
2. Adjust cable.
3. Overdrive Clutch Select Spacer
Wrong Spacer.
3. Replace overdrive piston thrust plate spacer.
TRANSMISSION AND TRANSFER CASE
WJ
21 - 23
DIAGNOSIS AND TESTING (Continued)
CONDITION
3-4 UPSHIFT OCCURS
IMMEDIATELY AFTER 2-3
SHIFT
POSSIBLE CAUSES
CORRECTION
1. Overdrive Solenoid Connector
or Wiring Shorted.
1. Test connector and wiring for loose
connections, shorts or ground and repair as
needed.
2. TPS Malfunction.
2. Test TPS and replace as necessary. Check
with DRB scan tool.
3. PCM Malfunction.
3. Test PCM with DRB scan tool and replace
controller if faulty.
4. Overdrive Solenoid Malfunction.
4. Replace solenoid.
5. Valve Body Malfunction.
5. Remove, disassemble, clean and inspect
valve body components. Make sure all valves
and plugs slide freely in bores. Polish valves
with crocus cloth if needed.
WHINE/NOISE RELATED
TO ENGINE SPEED
1. Fluid Level Low.
1. Add fluid and check for leaks.
2. Shift Cable Incorrect Routing.
2. Check shift cable for correct routing. Should
not touch engine or bell housing.
NO 3-4 UPSHIFT
1. O/D Switch In OFF Position.
1. Turn control switch to ON position.
2. Overdrive Circuit Fuse Blown.
2. Replace fuse. Determine why fuse failed
and repair as necessary (i.e., shorts or
grounds in circuit).
3. O/D Switch Wire Shorted/Open
Cut.
3. Check wires/connections with 12V test lamp
and voltmeter. Repair damaged or loose
wire/connection as necessary.
4. Distance or Coolant Sensor
Malfunction.
4. Test both sensors with test lamp or
volt/ohmmeter and replace faulty sensor.
5. TPS Malfunction.
5. Check with DRB scan tool and replace if
necessary.
6. Neutral Switch to PCM Wire
Shorted/Cut.
6. Test switch as described in service section
and replace if necessary. Engine no start.
7. PCM Malfunction.
7. Check with DRB scan tool and replace if
necessary.
8. Overdrive Solenoid Shorted/
Open.
8. Replace solenoid if shorted or open and
repair loose or damaged wires (DRB scan
tool).
9. Solenoid Feed Orifice in Valve
Body Blocked.
9. Remove, disassemble, and clean valve
body thoroughly. Check feed orifice.
10. Overdrive Clutch Failed.
10. Disassemble overdrive and repair as
needed.
11. Hydraulic Pressure Low.
11. Pressure test transmission to determine
cause.
12. Valve Body Valve Stuck.
12. Repair stuck 3-4 shift valve, 3-4 timing
valve.
13. O/D Piston Incorrect Spacer.
13. Remove unit, check end play and install
correct spacer.
14. Overdrive Piston Seal Failure.
14. Replace both seals.
15. O/D Check Valve/Orifice
Failed.
15. Check for free movement and secure
assembly (in piston retainer). Check ball bleed
orifice.
21 - 24
TRANSMISSION AND TRANSFER CASE
WJ
DIAGNOSIS AND TESTING (Continued)
CONDITION
SLIPS IN OVERDRIVE
FOURTH GEAR
POSSIBLE CAUSES
CORRECTION
1. Fluid Level Low.
1. Add fluid and check for leaks.
2. Overdrive Clutch Pack Worn.
2. Remove overdrive unit and rebuild clutch
pack.
3. Overdrive Piston Retainer
Bleed Orifice Blown Out.
3. Disassemble transmission, remove retainer
and replace orifice.
4. Overdrive Piston or Seal
Malfunction.
4. Remove overdrive unit. Replace seals if
worn. Replace piston if damaged. If piston
retainer is damaged, remove and disassemble
the transmission.
5. 3-4 Shift Valve, Timing Valve or
Accumulator Malfunction.
5. Remove and overhaul valve body. Replace
accumulator seals. Make sure all valves
operate freely in bores and do not bind or
stick. Make sure valve body screws are
correctly tightened and separator plates are
properly positioned.
6. Overdrive Unit Thrust Bearing
Failure.
6. Disassemble overdrive unit and replace
thrust bearing (NO. 1 thrust bearing is between
overdrive piston and clutch hub; NO. 2 thrust
bearing is between the planetary gear and the
direct clutch spring plate; NO. 3 thrust bearing
is between overrunning clutch hub and output
shaft).
7. O/D Check Valve/Bleed Orifice
Failure.
7. Check for function/secure orifice insert in
O/D piston retainer.
1. Fluid Level Low.
1. Add fluid and check for leaks.
2. Throttle Valve Cable
Misadjusted.
2. Adjust throttle valve cable.
3. Overdrive Clutch Pack
Worn/Burnt.
3. Remove unit and rebuild clutch pack.
4. TPS Faulty.
4. Test with DRB scan tool and replace TPS.
5. Overdrive Clutch Bleed Orifice
Plugged.
5. Disassemble transmission and replace
orifice.
6. Overdrive Solenoid or Wiring
Shorted/Open.
6. Test solenoid and check wiring for
loose/corroded connections or shorts/grounds.
Replace solenoid if faulty and repair wiring if
necessary.
7. Overdrive Excess Clearance
7. Remove unit. Measure end play and select
proper spacer.
8. O/D Check Valve Missing or
Stuck.
8. Check for presence of check valve. Repair
or replace as required.
TORQUE CONVERTER
LOCKS UP IN SECOND
AND/OR THIRD GEAR
Lockup Solenoid, Relay or Wiring
Shorted/Open.
Test solenoid, relay and wiring for continuity,
shorts or grounds. Replace solenoid and relay
if faulty. Repair wiring and connectors as
necessary.
HARSH 1-2, 2-3, 3-4 OR
3-2 SHIFTS
Lockup Solenoid Malfunction.
Remove valve body and replace solenoid
assembly.
DELAYED 3-4 UPSHIFT
(SLOW TO ENGAGE)
TRANSMISSION AND TRANSFER CASE
WJ
21 - 25
DIAGNOSIS AND TESTING (Continued)
CONDITION
NO START IN PARK OR
NEUTRAL
NO REVERSE (OR SLIPS
IN REVERSE)
OIL LEAKS.
POSSIBLE CAUSES
CORRECTION
1. Gearshift Linkage/Cable
Misadjusted.
1. Adjust linkage/cable.
2. Neutral Switch Wire Open/Cut.
2. Check continuity with test lamp. Repair as
required.
3. Neutral Switch Faulty.
3. Refer to service section for test and
replacement procedure.
4. Neutral Switch Connect Faulty.
4. Connectors spread open. Repair.
5. Valve Body Manual Lever
Assembly Bent/Worn/Broken.
5. Inspect lever assembly and replace if
damaged.
1. Direct Clutch Pack (front clutch)
Worn.
1. Disassemble unit and rebuild clutch pack.
2. Rear Band Misadjusted.
2. Adjust band.
3. Front Clutch Malfunctioned/
Burned.
3. Air-pressure test clutch operation. Remove
and rebuild if necessary.
4. Overdrive Thrust Bearing
Failure.
4. Disassemble geartrain and replace
bearings.
5. Direct Clutch Spring Collapsed/
Broken.
5. Remove and disassemble unit. Check clutch
position and replace spring.
1. Fluid Lines and Fittings
Loose/Leaks/Damaged.
1. Tighten fittings. If leaks persist, replace
fittings and lines if necessary.
2. Fill Tube (where tube enters
case) Leaks/Damaged.
2. Replace O-ring seal. Inspect tube for cracks
in fill tube.
3. Pressure Port Plug Loose
Loose/Damaged.
3. Tighten to correct torque. Replace plug or
reseal if leak persists.
4. Pan Gasket Leaks.
4. Tighten pan screws (150 in. lbs.). If leaks
persist, replace gasket.
5. Valve Body Manual Lever Shaft
Seal Leaks/Worn.
5. Replace shaft seal.
6. Rear Bearing Access Plate
Leaks.
6. Replace gasket. Tighten screws.
7. Gasket Damaged or Bolts are
Loose.
7. Replace bolts or gasket or tighten both.
8. Adapter/Extension Gasket
Damaged Leaks/Damaged.
8. Replace gasket.
9. Neutral Switch Leaks/Damaged.
9. Replace switch and gasket.
10. Converter Housing Area
Leaks.
10. Check for leaks at seal caused by worn
seal or burr on converter hub (cutting seal),
worn bushing, missing oil return hole in front
pump housing or hole plugged. Check for
leaks past O-ring seal on pump or past
pump-to-case bolts; pump housing porous, oil
coming out vent due to overfill or leak past
front band shaft access plug.
11. Pump Seal Leaks/Worn/
Damaged.
11. Replace seal.
12. Torque Converter Weld
Leak/Cracked Hub.
12. Replace converter.
13. Case Porosity Leaks.
13. Replace case.
21 - 26
TRANSMISSION AND TRANSFER CASE
WJ
DIAGNOSIS AND TESTING (Continued)
CONDITION
NOISY OPERATION IN
FOURTH GEAR ONLY
POSSIBLE CAUSES
CORRECTION
1. Overdrive Clutch Discs, Plates
or Snap Rings Damaged.
1. Remove unit and rebuild clutch pack.
2. Overdrive Piston or Planetary
Thrust Bearing Damaged.
2. Remove and disassemble unit. Replace
either thrust bearing if damaged.
3. Output Shaft Bearings
Scored/Damaged.
3. Remove and disassemble unit. Replace
either bearing if damaged.
4. Planetary Gears Worn/Chipped.
4. Remove and overhaul overdrive unit.
5. Overdrive Unit Overrunning
Clutch Rollers Worn/Scored.
5. Remove and overhaul overdrive unit.
SERVICE PROCEDURES
FLUID LEVEL CHECK
Transmission fluid level should be checked monthly
under normal operation. If the vehicle is used for
trailer towing or similar heavy load hauling, check
fluid level and condition weekly. Fluid level is
checked with the engine running at curb idle speed,
the transmission in NEUTRAL and the transmission
fluid at normal operating temperature.
FLUID LEVEL CHECK PROCEDURE
(1) Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive
vehicle if necessary to bring fluid temperature up to
normal hot operating temperature of 82°C (180°F).
(2) Position vehicle on level surface.
(3) Start and run engine at curb idle speed.
(4) Apply parking brakes.
(5) Shift transmission momentarily into all gear
ranges. Then shift transmission back to Neutral.
(6) Clean top of filler tube and dipstick to keep
dirt from entering tube.
(7) Remove dipstick (Fig. 11) and check fluid level
as follows:
(a) Correct acceptable level is in crosshatch area.
(b) Correct maximum level is to MAX arrow
mark.
(c) Incorrect level is at or below MIN line.
(d) If fluid is low, add only enough Mopart ATF
Plus 3 to restore correct level. Do not overfill.
CAUTION: Do not overfill the transmission. Overfilling may cause leakage out the pump vent which
can be mistaken for a pump seal leak. Overfilling
will also cause fluid aeration and foaming as the
excess fluid is picked up and churned by the gear
train. This will significantly reduce fluid life.
Fig. 11 Dipstick Fluid Level Marks—Typical
1 – DIPSTICK
2 – MAXIMUM CORRECT FLUID LEVEL
3 – ACCEPTABLE FLUID LEVEL
FLUID AND FILTER REPLACEMENT
Refer to the Maintenance Schedules in Group 0,
Lubrication and Maintenance, for proper service
intervals. The service fluid fill after a filter change is
approximately 3.8 liters (4.0 quarts).
REMOVAL
(1) Hoist and support vehicle on safety stands.
(2) Place a large diameter shallow drain pan
beneath the transmission pan.
(3) Remove bolts holding front and sides of pan to
transmission (Fig. 12).
(4) Loosen bolts holding rear of pan to transmission.
(5) Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan.
(6) Hold up pan and remove remaining bolt holding pan to transmission.
(7) While holding pan level, lower pan away from
transmission.
(8) Pour remaining fluid in pan into drain pan.
(9) Remove screws holding filter to valve body
(Fig. 13).
(10) Separate filter from valve body and pour fluid
in filter into drain pan.
(11) Dispose of used trans fluid and filter properly.
TRANSMISSION AND TRANSFER CASE
WJ
21 - 27
SERVICE PROCEDURES (Continued)
CLEANING
(1) Using a suitable solvent, clean pan and magnet.
(2) Using a suitable gasket scraper, clean gasket
material from gasket surface of transmission case
and the gasket flange around the pan.
INSTALLATION
Fig. 12 Transmission Pan—Typical
1 – GASKET
2 – PAN
3 – TRANSMISSION
(1) Place replacement filter in position on valve
body.
(2) Install screws to hold filter to valve body (Fig.
13). Tighten screws to 4 N·m (35 in. lbs.) torque.
(3) Place new gasket in position on pan and install
pan on transmission.
(4) Place pan in position on transmission.
(5) Install screws to hold pan to transmission (Fig.
12). Tighten bolts to 17 N·m (150 in. lbs.) torque.
(6) Lower vehicle and fill transmission with
Mopart ATF Plus 3, type 7176 fluid.
TRANSMISSION FILL PROCEDURE
INSPECTION
Fig. 13 Transmission Filter—Typical
1 – TRANSMISSION
2 – FILTER
Inspect bottom of pan and magnet for excessive
amounts of metal. A light coating of clutch or band
material on the bottom of the pan does not indicate a
problem unless accompanied by slipping condition or
shift lag. If fluid and pan are contaminated with
excessive amounts or debris, refer to the diagnosis
section of this group.
Check the adjustment of the front and rear bands,
adjust if necessary.
To avoid overfilling transmission after a fluid
change or overhaul, perform the following procedure:
(1) Remove dipstick and insert clean funnel in
transmission fill tube.
(2) Add following initial quantity of Mopart ATF
Plus 3 to transmission:
(a) If only fluid and filter were changed, add 6
pints (3 quarts) of ATF Plus 3 to transmission.
(b) If transmission was completely overhauled,
torque converter was replaced or drained, and
cooler was flushed, add 16 pints (8 quarts) of ATF
Plus 3 to transmission.
(3) Apply parking brakes.
(4) Start and run engine at normal curb idle
speed.
(5) Apply service brakes, shift transmission
through all gear ranges then back to NEUTRAL, set
parking brake, and leave engine running at curb idle
speed.
(6) Remove funnel, insert dipstick and check fluid
level. If level is low, add fluid to bring level to
MIN mark on dipstick. Check to see if the oil level
is equal on both sides of the dipstick. If one side is
noticeable higher than the other, the dipstick has
picked up some oil from the dipstick tube. Allow the
oil to drain down the dipstick tube and re-check.
(7) Drive vehicle until transmission fluid is at normal operating temperature.
(8) With the engine running at curb idle speed, the
gear selector in NEUTRAL, and the parking brake
applied, check the transmission fluid level.
CAUTION: Do not overfill transmission, fluid leaks,
foaming and shifting problems can result.
21 - 28
TRANSMISSION AND TRANSFER CASE
WJ
SERVICE PROCEDURES (Continued)
(9) Add fluid to bring level up to MAX arrow
mark.
When fluid level is correct, shut engine off, release
park brake, remove funnel, and install dipstick in fill
tube.
CONVERTER DRAINBACK CHECK VALVE
SERVICE
The converter drainback check valve is located in
the cooler outlet (pressure) line near the radiator
tank. The valve prevents fluid drainback when the
vehicle is parked for lengthy periods. The valve check
ball is spring loaded and has an opening pressure of
approximately 2 psi.
The valve is serviced as an assembly; it is not
repairable. Do not clean the valve if restricted, or
contaminated by sludge, or debris. If the valve fails,
or if a transmission malfunction occurs that generates significant amounts of sludge and/or clutch particles and metal shavings, the valve must be
replaced.
The valve must be removed whenever the cooler
and lines are reverse flushed. The valve can be flow
tested when necessary. The procedure is exactly the
same as for flow testing a cooler.
If the valve is restricted, installed backwards, or in
the wrong line, it will cause an overheating condition
and possible transmission failure.
CAUTION: The drainback valve is a one-way flow
device. It must be properly oriented in terms of flow
direction for the cooler to function properly. The
valve must be installed in the pressure line. Otherwise flow will be blocked and would cause an overheating condition and eventual transmission failure.
OIL PUMP VOLUME CHECK
After the new or repaired transmission has been
installed, fill to the proper level with Mopart ATF
PLUS 3 (Type 7176) automatic transmission fluid.
The volume should be checked using the following
procedure:
(1) Disconnect the cooler outlet line at the rear
of the transmission and place a drainpan under the
disconnected line.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or internal damage to the transmission may occur.
(2) Run the engine at curb idle speed, with the
shift selector in neutral.
(3) If fluid flow is intermittent or it takes more
than 20 seconds to collect one quart of ATF PLUS 3,
disconnect the cooler inlet line at the front of the
transmission.
(4) Refill the transmission to the proper level and
recheck pump volume.
(5) If flow is found to be within acceptable limits,
replace the cooler. Then fill transmission to the
proper level, using Mopart ATF PLUS 3 (Type 7176)
automatic transmission fluid.
(6) If fluid flow is still found to be inadequate,
check the line pressure using the Transaxle Hydraulic Pressure Test procedure.
FLUSHING COOLERS AND TUBES
When a transmission failure has contaminated the
fluid, the oil cooler(s) must be flushed. The torque
converter must also be replaced. This will insure that
metal particles or sludged oil are not later transferred back into the reconditioned (or replaced) transmission.
The only recommended procedure for flushing coolers and lines is to use Tool 6906 Cooler Flusher.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1–1968. WEAR STANDARD INDUSTRIAL RUBBER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTIBLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CONTACT WITH YOUR EYES OR SKIN: IF EYE CONTAMINATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906
(1) Remove cover plate filler plug on Tool 6906.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions generally used to clean automatic transmission components. DO NOT use solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906.
(3) Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
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TRANSMISSION AND TRANSFER CASE
21 - 29
SERVICE PROCEDURES (Continued)
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmission cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system.
(5) Connect the BLUE pressure line to the OUTLET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Turn pump ON for two to three minutes to
flush cooler(s) and lines. Monitor pressure readings
and clear return lines. Pressure readings should stabilize below 20 psi. for vehicles equipped with a single cooler and 30 psi. for vehicles equipped with dual
coolers. If flow is intermittent or exceeds these pressures, replace cooler.
(8) Turn pump OFF.
(9) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(10) Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF.
(11) Place CLEAR suction line into a one quart
container of Mopart ATF Plus 3, type 7176 automatic
transmission fluid.
(12) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the transmission cooler and lines. Turn pump OFF.
(13) Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
REMOVAL AND INSTALLATION
TRANSMISSION
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid component damage. The converter drive plate, pump
bushing, or oil seal can be damaged if the converter is left attached to the driveplate during
removal. Be sure to remove the transmission and
torque converter as an assembly.
REMOVAL
(1) Open the hood and disconnect the negative battery cable.
(2) Remove the (2) upper fan shroud retaining
bolts.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum transmission case and valve body can be repaired by the
use of Heli-Coils, or equivalent. This repair consists
of drilling out the worn-out damaged threads. Then
tap the hole with a special Heli-Coil tap, or equivalent, and installing a Heli-Coil insert, or equivalent,
into the hole. This brings the hole back to its original
thread size.
Heli-Coil, or equivalent, tools and inserts are
readily available from most automotive parts suppliers.
Fig. 14 Transmission Dipstick Tube Support Bracket
Position & Orientation
1 – TRANSMISSION DIPSTICK TUBE
2 – TURBOCHARGER EXHAUST MANIFOLD HEATSHIELD
3 – TRANSMISSION DIPSTICK TUBE SUPPORT BRACKET
RETAINING NUT
(3) Remove the transmission dipstick tube support
bracket nut from the turbocharger heatshield (Fig.
14).
(4) Position a drainpan under the transmission.
(5) Pull the transmission dipstick tube from the
transmission housing.
(6) Raise the vehicle on a hoist.
(7) Remove the (2) lower fan shroud retaining
bolts.
21 - 30
TRANSMISSION AND TRANSFER CASE
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REMOVAL AND INSTALLATION (Continued)
CAUTION: Mark the position of the driveshaft in
relation to its companion flange prior to disassembly. Driveshaft must be reinstalled in the same position it was in prior to disassembly.
Fig. 16 Rear Driveshaft - Supported
1 – REAR DRIVESHAFT
Fig. 15 Front Driveshaft Retaining Bolts
1 – TRANSFER CASE
2 – FRONT DRIVESHAFT RETAINING BOLTS
3 – REFERENCE MARK
(8) Remove the front driveshaft retaining bolts
(Fig. 15) and remove the driveshaft from the transfer
case companion flange. Support the driveshaft with
mechanics wire.
(9) Remove the rear driveshaft retaining bolts and
remove the driveshaft from the transfer case companion flange. Support the driveshaft with mechanics
wire (Fig. 16).
(10) Disconnect the transfer case shift cable from
the shifter arm (Fig. 17).
(11) Disconnect the vent tube from the transfer
case (Fig. 17).
(12) Remove the transmission oil pan and drain
the transmission fluid. Reinstall the transmission oil
pan.
(13) Remove the drainpan.
(14) Remove the (4) exhaust system support
bracket retaining bolts from the transmission support crossmember (Fig. 18).
(15) Unclip the wire harness from the transmission support crossmember.
(16) Position a jack under the transmission support crossmember.
(17) Remove the (8) transmission support crossmember retaining bolts (Fig. 18).
Fig. 17 Disconnecting Transfer Case Shift Linkage
1
2
3
4
5
6
–
–
–
–
–
–
TRANSFER CASE RETAINING NUTS
TRANSFER CASE SHIFTER CABLE
TRANSFER CASE VENT HOSE
FLAT BLADED TOOL
TRANSFER CASE
TRANSMISSION ELECTRICAL CONNECTOR
TRANSMISSION AND TRANSFER CASE
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21 - 31
REMOVAL AND INSTALLATION (Continued)
Fig. 18 Transmission Support Crossmember
Position & Orientation
1
2
3
4
5
6
–
–
–
–
–
–
TRANSFER CASE
TRANSMISSION MOUNT RETAINING BOLTS (2 OF 4)
EXHAUST SYSTEM SUPPORT BRACKET RETAINING BOLTS
CROSSMEMBER RETAINING BOLTS
TRANSMISSION
CROSSMEMBER RETAINING BOLTS
(18) Position a transmission jack under the transfer case.
(19) Lower the transmission assembly enough to
gain access and remove the transfer case to transmission retaining nuts.
(20) Remove the transfer case from the vehicle.
(21) Remove the jack from the transmission support crossmember.
(22) Remove the (4) transmission mount retaining
bolts (Fig. 18) and remove the transmission support
crossmember and mount from the vehicle.
(23) Remove the transfer case shift cable bracket
from the transmission housing (Fig. 19).
(24) Disconnect the throttle valve cable at the ball
and socket connection by gently pulling straight
apart (Fig. 19).
(25) Remove the throttle valve cable bracket
retaining fasteners and position the cable assembly
out of the way (Fig. 19).
(26) Remove the spring from the shift lever arm
(Fig. 19).
(27) Disconnect the shifter cable at the ball and
socket connection by gently pulling straight apart
(Fig. 19).
(28) Remove the shifter cable bracket retaining
bolt from the transmission housing (Fig. 19).
Fig. 19 Transmission Control Cables & Fluid Lines
1
2
3
4
–
–
–
–
TRANSMISSION SHIFTER CABLE
THROTTLE VALVE CABLE
TRANSFER CASE SHIFTER CABLE
TRANSFER CASE SHIFTER CABLE BRACKET RETAINING
BOLT (1 OF 2)
5 – THROTTLE VALVE CABLE BRACKET RETAINING BOLT
6 – ELECTRICAL CONNECTORS
7 – TRANSMISSION FLUID LINES
(29) Remove the transmission fluid cooler lines
from the transmission (Fig. 19).
(30) Disconnect all the transmission electrical connectors and unclip the wire harness from the transmission housing (Fig. 19).
(31) Remove the exhaust system inlet pipe retaining bolts from the turbocharger down pipe (Fig. 20).
Support the front portion of the exhaust system with
mechanics wire. Be certain to position the pipe out of
the way of the torque converter bolt access hole.
Located in the transmission bellhousing.
(32) Disconnect the engine speed sensor. Located
on the upper right side of the transmission bellhousing.
(33) Remove the starter motor from the vehicle.
Refer to Group 8B, Starting Systems for the procedure.
NOTE: Mark the position of the torque convertor in
relation to the driveplate so they can be reassembled in there original position.
(34) Working through the torque convertor bolt
access hole (Fig. 21), remove the (4) torque convertor
to driveplate retaining bolts. Rotate the engine in a
clockwise direction to access the converter bolts.
(35) Place a jack under the transmission.
21 - 32
TRANSMISSION AND TRANSFER CASE
WJ
REMOVAL AND INSTALLATION (Continued)
(36) Remove the (10) engine to transmission bellhousing retaining bolts.
(37) Remove the transmission and torque converter from the vehicle.
INSTALLATION
CAUTION: This engine is equipped with a engine
speed sensor. Located in the top of the bellhousing.
Care must be taken not to damage the sensor or
corresponding wires during transmission removal
and installation.
CAUTION: Check the torque converter hub and hub
drive notches for sharp edges, burrs, scratches or
nicks. Polish the hub and notches with 320 / 400
grit sandpaper, if necessary. The hub must be
smooth to avoid damaging the pump seal at torque
converter installation.
Fig. 20 Exhaust System Inlet Pipe Retaining Bolts
1 – EXHAUST SYSTEM INLET PIPE RETAINING BOLTS
2 – ENGINE OIL PAN
CAUTION: Lubricate the front pump seal and install
at least one quart of the approved transmission
fluid directly into the torque converter prior to its
installation.
(1) Install the torque converter in the transmission. Refer to the procedure in this group for detailed
instructions.
(2) Lubricate the rear of the crankshaft or the converter pilot hub with lithium grease.
(3) Position the transmission / converter assembly
on a transmission jack and secure with chains.
NOTE: Be sure the engine block mounted dowel
pins are installed and protrude far enough to hold
the transmission in alignment.
(4) Using the transmission jack, position the transmission assembly so the engine block mounted dowel
pins are perfectly aligned with the corresponding
holes in the transmission bellhousing.
Fig. 21 Torque Converter Bolt Access Hole
1 – TORQUE CONVERTER BOLT ACCESS HOLE
2 – ENGINE OIL PAN
3 – TOP DEAD CENTER ALIGNMENT TOOL ACCESS HOLE
CAUTION: Be certain the engine speed sensor has
been disconnected before proceeding.
CAUTION: Be certain the torque convertor is properly installed in the transmission. If the torque convertor is not installed correctly the engine will not
rotate upon installation. Refer to the Torque Converter removal and installation procedure in this
group for the procedure.
(5) Install the (10) engine to transmission bellhousing retaining bolts. Torque the bolts to 102 N·m
(75 ft. lbs.).
(6) Connect the engine speed sensor. Located on
the upper right side of the transmission bellhousing.
TRANSMISSION AND TRANSFER CASE
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21 - 33
REMOVAL AND INSTALLATION (Continued)
NOTE: When installing the torque convertor to
driveplate retaining bolts, the torque convertor can
be rotated into position with a flat-bladed screwdriver through the starter motor access hole. Then
working through the torque convertor bolt access
hole, thread a longer than original bolt into the convertor and pull the convertor up against the driveplate by hand. Remove the longer bolt and install
the original bolts one by one until all bolts are
installed. Then go back and torque all bolts to specification.
(7) Rotate the converter so the previously scribed
alignment mark is aligned with the mark on the
driveplate.
Fig. 23 Exhaust System Inlet Pipe Retaining Bolts
1 – EXHAUST SYSTEM INLET PIPE RETAINING BOLTS
2 – ENGINE OIL PAN
Fig. 22 Torque Converter Bolt Access Hole
1 – TORQUE CONVERTER BOLT ACCESS HOLE
2 – ENGINE OIL PAN
3 – TOP DEAD CENTER ALIGNMENT TOOL ACCESS HOLE
(8) Working through the torque convertor bolt
access hole (Fig. 22), install the (4) torque convertor
to driveplate retaining bolts. Torque the bolts to 32
N·m (24 ft. lbs.) after all bolts are installed.
(9) Install the starter motor in the vehicle. Refer
to Group 8B, Starting Systems for the procedure.
(10) Install the exhaust system inlet pipe and
retaining bolts (Fig. 23). Torque the bolts to 41 N·m
(30 ft. lbs.).
(11) Connect the transmission electrical connectors
and clip the wire harness on the transmission housing.
Fig. 24 Transmission Control Cables & Fluid Lines
1
2
3
4
–
–
–
–
TRANSMISSION SHIFTER CABLE
THROTTLE VALVE CABLE
TRANSFER CASE SHIFTER CABLE
TRANSFER CASE SHIFTER CABLE BRACKET RETAINING
BOLT (1 OR 2)
5 – THROTTLE VALVE CABLE BRACKET RETAINING BOLT
6 – ELECTRICAL CONNECTORS
7 – TRANSMISSION FLUID LINES
21 - 34
TRANSMISSION AND TRANSFER CASE
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REMOVAL AND INSTALLATION (Continued)
(12) Install the transmission fluid cooler lines on
the transmission (Fig. 24). Torque the nuts to 18 N·m
(13 ft. lbs.).
(13) Install the shifter cable bracket and retaining
bolt (Fig. 24).
(14) Connect the shifter cable (Fig. 24).
(15) Install the spring on the shift lever arm (Fig.
24).
(16) Install the throttle valve cable bracket and
retaining fasteners (Fig. 24).
(17) Connect the throttle valve cable (Fig. 24).
(18) Install the transfer case shift cable bracket on
the transmission housing (Fig. 24).
(19) Position the transmission support crossmember/mount assembly and install the (4) transmission
mount retaining bolts (Fig. 25). Torque the bolts to
75 N·m (55 ft. lbs.).
(20) Install a jack under the transmission support
crossmember and raise slightly.
(23) Unclip the wire harness from the transmission support crossmember.
(24) Position the exhaust system support brackets
and install the retaining bolts. Torque the bolts to 41
N·m (30 ft. lbs.) (Fig. 25).
(25) Install the vent tube on the transfer case.
(26) Connect the transfer case shift cable on the
shifter arm.
(27) Install the rear driveshaft. Torque the bolts to
32 N·m (24 ft. lbs.). Be certain to install the driveshaft in the same position as before removal.
Fig. 26 Front Driveshaft Retaining Bolts
1 – TRANSFER CASE
2 – FRONT DRIVESHAFT RETAINING BOLTS
3 – REFERENCE MARK
Fig. 25 Transmission Support Crossmember
Position & Orientation
1
2
3
4
5
6
–
–
–
–
–
–
TRANSFER CASE
TRANSMISSION MOUNT RETAINING BOLTS (2 OF 4)
EXHAUST SYSTEM SUPPORT BRACKET RETAINING BOLTS
CROSSMEMBER RETAINING BOLTS
TRANSMISSION
CROSSMEMBER RETAINING BOLTS
(21) Install the transfer case on the transmission.
Torque the transfer case retaining nuts to 75 N·m (55
ft. lbs.).
(22) Using the jack, raise the transmission assembly into position and install the (8) transmission support crossmember retaining bolts (Fig. 25). Torque
the bolts to 41 N·m (30 ft. lbs.).
(28) Install the front driveshaft. Torque the bolts
to 32 N·m (24 ft. lbs.) (Fig. 26). Be certain to install
the driveshaft in the same position as before
removal.
(29) Install the (2) lower fan shroud retaining
bolts. Torque the bolts to 15 N·m (132 in. lbs.).
(30) Lower the vehicle on the hoist.
(31) Install the transmission dipstick tube in the
transmission housing.
(32) Install the transmission dipstick tube support
bracket retaining nut (Fig. 27). Torque the nut to 25
N·m (221 in. lbs.).
(33) Install the (2) upper fan shroud retaining
bolts. Torque the bolts to 15 N·m (132 in. lbs.).
(34) Connect the negative battery cable.
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TRANSMISSION AND TRANSFER CASE
21 - 35
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
Check converter hub and drive notches for sharp
edges, burrs, scratches, or nicks. Polish the hub and
notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid damaging
the pump seal at installation.
(1) Lubricate converter hub and oil pump seal lip
with transmission fluid.
(2) Place torque converter in position on transmission.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
Fig. 27 Transmission Dipstick Tube Support Bracket
Position & Orientation
1 – TRANSMISSION DIPSTICK TUBE
2 – TURBOCHARGER EXHAUST MANIFOLD HEATSHIELD
3 – TRANSMISSION DIPSTICK TUBE SUPPORT BRACKET
RETAINING NUT
TORQUE CONVERTER
(3) Align torque converter to oil pump seal opening.
(4) Insert torque converter hub into oil pump.
(5) While pushing torque converter inward, rotate
converter until converter is fully seated in the oil
pump gears.
(6) Check converter seating with a scale and
straightedge (Fig. 28). Surface of converter lugs
should be 1/2 in. to rear of straightedge when converter is fully seated.
(7) If necessary, temporarily secure converter with
C-clamp attached to the converter housing.
(8) Install the transmission in the vehicle.
(9) Fill the transmission with the recommended
fluid.
REMOVAL
(1) Remove transmission and torque converter
from vehicle.
(2) Place a suitable drain pan under the converter
housing end of the transmission.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque converter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pull the torque converter forward until the center hub clears the oil pump seal.
(4) Separate the torque converter from the transmission.
Fig. 28 Checking Torque Converter Seating
1 – SCALE
2 – STRAIGHTEDGE
21 - 36
TRANSMISSION AND TRANSFER CASE
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REMOVAL AND INSTALLATION (Continued)
YOKE SEAL REPLACEMENT
PARK/NEUTRAL POSITION SWITCH
REMOVAL
REMOVAL
(1) Raise vehicle.
(2) Mark propeller shaft and axle yoke for alignment reference.
(3) Disconnect and remove propeller shaft.
(4) Remove old seal with Seal Remover C-3985-B
(Fig. 29) from overdrive housing.
(1) Raise vehicle and position drain pan under
switch.
(2) Disconnect switch wires.
(3) Remove switch from case.
INSTALLATION
(1) Place seal in position on overdrive housing.
(2) Drive seal into overdrive housing with Seal
Installer C-3995-A (Fig. 30).
(3) Carefully guide propeller shaft slip yoke into
housing and onto output shaft splines. Align marks
made at removal and connect propeller shaft to rear
axle pinion yoke.
INSTALLATION
(1) Move shift lever to Park and Neutral positions.
Verify that switch operating lever fingers are centered in switch opening in case (Fig. 31).
Fig. 31 Park/Neutral Position Switch
Fig. 29 Removing Overdrive Housing Yoke Seal
1 – SPECIAL TOOL C-3985–B
2 – SEAL
1 – NEUTRAL CONTACT
2 – MANUAL LEVER AND SWITCH PLUNGER IN REVERSE
POSITION
3 – PARK CONTACT
4 – SWITCH
(2) Install new seal on switch and install switch in
case. Tighten switch to 34 N·m (25 ft. lbs.) torque.
(3) Test continuity of new switch with 12V test
lamp.
(4) Connect switch wires and lower vehicle.
(5) Top off transmission fluid level.
GEARSHIFT CABLE
REMOVAL
Fig. 30 Installing Overdrive Housing Yoke Seal
1 – SPECIAL TOOL C-3995–A OR C-3972–A
2 – SPECIAL TOOL C-4471
(1) Place the transmission gear selector in the
“PARK” position.
(2) Raise the vehicle on a hoist.
(3) Disconnect the shift cable eyelet from the
transmission shift lever (Fig. 32).
TRANSMISSION AND TRANSFER CASE
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21 - 37
REMOVAL AND INSTALLATION (Continued)
(7) Disconnect the shift cable from the shifter
assembly (Fig. 33).
(8) Remove the shift cable seal plate retaining
nuts from the floor pan studs (Fig. 34).
Fig. 32 Shift Cable at Transmission
1
2
3
4
–
–
–
–
TRANSMISSION SHIFTER CABLE
THROTTLE VALVE CABLE
TRANSFER CASE SHIFTER CABLE
TRANSFER CASE SHIFTER CABLE BRACKET RETAINING
BOLT (1 OF 2)
5 – THROTTLE VALVE CABLE BRACKET RETAINING BOLT
6 – ELECTRICAL CONNECTORS
7 – TRANSMISSION FLUID LINES
(4) Remove the shift cable from the shift cable support bracket.
(5) Lower the vehicle from the hoist.
(6) Remove shift lever bezel and necessary console
parts for access to shifter and cable assembly.
Fig. 34 Shift Cables at Floor Pan
1 – SEAL PLATES
2 – TRANSMISSION SHIFT CABLE
3 – TRANSFER CASE SHIFT CABLE
(9) Remove the shifter cable through the floor pan
opening.
INSTALLATION
(1) Route the shift cable through hole in floor pan.
(2) Install the shift cable seal plate retaining nuts
on the floor pan studs. (Fig. 35). Torque the nuts to 7
N·m (65 in. lbs.).
Fig. 35 Shift Cables at Floor Pan
Fig. 33 Transmission Shift Cable at Shifter
1
2
3
4
–
–
–
–
SHIFT LEVER PIN
ADJUSTMENT SCREW
SHIFT CABLE
SHIFTER ASSEMBLY BRACKET
1 – SEAL PLATES
2 – TRANSMISSION SHIFT CABLE
3 – TRANSFER CASE SHIFT CABLE
(3) Install the shift cable in the shifter bracket
assembly.
21 - 38
TRANSMISSION AND TRANSFER CASE
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REMOVAL AND INSTALLATION (Continued)
(4) Place the floor shifter in the “PARK” position.
(5) Loosen the adjustment screw on the shifter
cable (Fig. 36).
Fig. 36 Transmission Shift Cable at Shifter
1
2
3
4
–
–
–
–
SHIFT LEVER PIN
ADJUSTMENT SCREW
SHIFT CABLE
SHIFTER ASSEMBLY BRACKET
(6) Snap the shift cable onto the shift lever pin.
Located on the shifter assembly (Fig. 36).
(7) Raise the vehicle on a hoist.
(8) Install the shift cable on the shift cable support
bracket (Fig. 37).
(9) Place the transmission shift lever in the
“PARK” position. Park is the rearmost detent position on the transmission manual shift lever (Fig. 37).
(10) Snap the shifter cable on the shift control
lever (Fig. 37).
Fig. 37 Shift Cable at Transmission
1
2
3
4
–
–
–
–
TRANSMISSION SHIFTER CABLE
THROTTLE VALVE CABLE
TRANSFER CASE SHIFTER CABLE
TRANSFER CASE SHIFTER CABLE BRACKET RETAINING
BOLT (1 OF 2)
5 – THROTTLE VALVE CABLE BRACKET RETAINING BOLT
6 – ELECTRICAL CONNECTORS
7 – TRANSMISSION FLUID LINES
(2) Remove the shift lever bezel and any necessary
console parts for access to the shift lever assembly
and shift cables.
(3) Disconnect the shift cable from the shifter and
support bracket assembly (Fig. 38).
CAUTION: Be certain shift cable is routed correctly,
free of binding, sharp edges and hot exhaust system components.
(11) Lower the vehicle from the hoist.
(12) Verify the transmission and shifter are in the
“PARK” position.
(13) Torque the adjustment screw to 7 N·m (65 in.
lbs.) (Fig. 36).
(14) Verify correct shifter operation.
(15) Install the shift lever bezel and any console
parts removed to access the shift control cable
FLOOR SHIFTER
Fig. 38 Shift Cable at Shifter
REMOVAL
(1) Shift the transmission into the “PARK” position.
1
2
3
4
–
–
–
–
SHIFT LEVER PIN
ADJUSTMENT SCREW
SHIFT CABLE
SHIFTER ASSEMBLY BRACKET
TRANSMISSION AND TRANSFER CASE
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21 - 39
REMOVAL AND INSTALLATION (Continued)
(4) Disconnect the brake transmission shift interlock cable from the shifter BTSI lever and the shifter
bracket assembly.
(5) Disconnect the transfer case shift cable from
the transfer case shift lever pin (Fig. 39).
(10) the shifter from the vehicle.
INSTALLATION
(1) Install the shifter in the vehicle.
(2) Install the shifter assembly retaining nuts on
the floor pan mounted studs (Fig. 41). Torque to 28
N·m (250 in. lbs.).
Fig. 39 Transfer Case Shift Cable
1
2
3
4
–
–
–
–
CLIP
SHIFTER
TRANSFER CASE SHIFT LEVER PIN
TRANSFER CASE SHIFT CABLE
(6) Remove the clip retaining the transfer case
shift cable to the shifter bracket assembly.
(7) Remove the transfer case shift cable from the
shifter assembly.
(8) Disconnect all wiring connectors from the
shifter assembly.
(9) Remove the shifter assembly retaining nuts
from the floor pan (Fig. 40).
Fig. 41 Shifter Assembly
1 – FLOOR PAN
2 – SHIFTER ASSEMBLY
(3) Connect all wiring on the shifter assembly.
(4) Install the transfer case shift cable on the
shifter bracket assembly and secure with clip (Fig.
42).
Fig. 42 Transfer Case Shift Cable
Fig. 40 Shifter Assembly
1 – FLOOR PAN
2 – SHIFTER ASSEMBLY
1
2
3
4
–
–
–
–
CLIP
SHIFTER
TRANSFER CASE SHIFT LEVER PIN
TRANSFER CASE SHIFT CABLE
21 - 40
TRANSMISSION AND TRANSFER CASE
WJ
REMOVAL AND INSTALLATION (Continued)
(5) Snap the transfer case shift cable onto the shift
lever pin (Fig. 42).
(6) Install the brake transmission interlock cable
into the shifter assembly bracket and connect on the
BTSI lever.
(7) Install the shift cable on the shifter bracket
and snap in place (Fig. 43).
Fig. 43 Transmission Shift Cable at Shifter
1
2
3
4
–
–
–
–
SHIFT LEVER PIN
ADJUSTMENT SCREW
SHIFT CABLE
SHIFTER ASSEMBLY BRACKET
(8) With the shifter in the “PARK” position, loosen
the shift cable adjustment screw.
(9) Snap the shift cable on the shift lever pin (Fig.
43).
(10) Torque the adjustment screw to 7 N·m (65 in.
lbs.).
(11) Verify correct shifter operation.
(12) Install the shift lever bezel and any console
parts removed for access to the shift lever assembly
and shift cables.
BRAKE TRANSMISSION SHIFT INTERLOCK
CABLE
REMOVAL
(1) Remove the steering column opening cover.
Refer to Group 8E, Instrument Panel Systems for the
procedure.
(2) Remove the lower steering column shroud from
the vehicle.
(3) Disconnect the brake transmission shift interlock (B. T. S. I.) cable solenoid electrical connector
(Fig. 44).
Fig. 44 B. T. S. I. Solenoid Connector Location
1
2
3
4
5
6
7
–
–
–
–
–
–
–
LEFT MULTIFUNCTION SWITCH CONNECTOR
LOWER CLOCKSPRING CONNECTORS
RIGHT MULTIFUNCTION SWITCH CONNECTOR
SHIFTER INTERLOCK CABLE CONNECTOR
SHIFTER INTERLOCK SOLENOID CONNECTOR
IGNITION SWITCH CONNECTOR RECEPTACLES
SKIM CONNECTOR
(4) With the ignition switch in the “RUN” position
depress the B. T. S. I. cable locking tab, located on
top of the cable connector (Fig. 44) at the steering
column and pull the B. T. S. I. cable straight out.
(5) Remove the center console from the vehicle.
Refer to Group 23, Body for the procedure.
(6) Disconnect the B. T. S. I. cable from the shifter
B. T. S. I. lever and remove the cable from the shifter
bracket (Fig. 45).
(7) Disconnect the B. T. S. I. cable from any routing clips.
(8) Remove the B. T. S. I. cable from the vehicle.
TRANSMISSION AND TRANSFER CASE
WJ
REMOVAL AND INSTALLATION (Continued)
Fig. 45 Brake Transmission Interlock Cable
1 – SHIFT MECHANISM
2 – SHIFTER BTSI LEVER
3 – ADJUSTMENT CLIP
4 – STEERING COLUMN ASSEMBLY
5 – INTERLOCK CABLE
21 - 41
21 - 42
TRANSMISSION AND TRANSFER CASE
WJ
REMOVAL AND INSTALLATION (Continued)
Fig. 46 Brake Transmission Shift Interlock
1 – SHIFT MECHANISM
2 – SHIFTER BTSI LEVER
3 – ADJUSTMENT CLIP
INSTALLATION
(1) Position the cable in the vehicle and secure in
the original position with appropriate retaining clips.
(2) Install the B. T. S. I. cable on the shifter
bracket and connect at the shifter B. T. S. I. lever
(Fig. 46).
(3) Install the center console in the vehicle. Refer
to Group 23, Body for the procedure.
(4) Push the B. T. S. I. cable straight into the
square mounting hole in the steering column until
cable snaps in place (Fig. 47).
(5) Connect the brake transmission shift interlock
(B. T. S. I.) cable solenoid electrical connector (Fig.
47).
(6) Install the lower steering column shroud in the
vehicle.
(7) Install the steering column opening cover.
Refer to Group 8E, Instrument Panel Systems for the
procedure.
(8) Verify correct B. T. S. I. cable operation.
4 – STEERING COLUMN ASSEMBLY
5 – INTERLOCK CABLE
GOVERNOR SOLENOID AND PRESSURE
SENSOR
REMOVAL
(1) Hoist and support vehicle on safety stands.
(2) Remove transmission fluid pan and filter.
(3) Disengage wire connectors from pressure sensor and solenoid (Fig. 48).
(4) Remove screws holding pressure solenoid
retainer to governor body.
(5) Separate solenoid retainer from governor (Fig.
49).
(6) Pull solenoid from governor body (Fig. 50).
(7) Remove bolts holding governor body to valve
body.
(8) Separate governor body from valve body (Fig.
51).
(9) Remove governor body gasket.
(10) Remove retainer holding pressure sensor to
governor body.
(11) Pull pressure sensor from governor body (Fig.
52).
TRANSMISSION AND TRANSFER CASE
WJ
21 - 43
REMOVAL AND INSTALLATION (Continued)
(9) Align pressure solenoid to bore in governor
body (Fig. 50).
(10) Push solenoid into governor body.
(11) Place solenoid retainer in position on governor
(Fig. 49).
(12) Install screws to hold pressure solenoid
retainer to governor body.
(13) Engage wire connectors into pressure sensor
and solenoid (Fig. 48).
(14) Install transmission fluid pan and (new) filter.
(15) Lower vehicle and road test to verify repair.
Fig. 47 B. T. S. I. Solenoid Connector Location
1
2
3
4
5
6
7
–
–
–
–
–
–
–
LEFT MULTIFUNCTION SWITCH CONNECTOR
LOWER CLOCKSPRING CONNECTORS
RIGHT MULTIFUNCTION SWITCH CONNECTOR
SHIFTER INTERLOCK CABLE CONNECTOR
SHIFTER INTERLOCK SOLENOID CONNECTOR
IGNITION SWITCH CONNECTOR RECEPTACLES
SKIM CONNECTOR
Fig. 48 Governor Solenoid And Pressure Sensor
1 – PRESSURE SENSOR
2 – PRESSURE SOLENOID
3 – GOVERNOR
INSTALLATION
Before installing the pressure sensor and solenoid
in the governor body, replace O-ring seals, clean the
gasket surfaces and replace gasket.
(1) Lubricate O-ring on pressure sensor with
transmission fluid.
(2) Align pressure sensor to bore in governor body
(Fig. 52).
(3) Push pressure sensor into governor body.
(4) Install retainer to hold pressure sensor to governor body.
(5) Place gasket in position on back of governor
body (Fig. 51).
(6) Place governor body in position on valve body.
(7) Install bolts to hold governor body to valve
body.
(8) Lubricate O-ring, on pressure solenoid, with
transmission fluid.
Fig. 49 Pressure Solenoid Retainer
1 – PRESSURE SOLENOID RETAINER
2 – GOVERNOR
21 - 44
TRANSMISSION AND TRANSFER CASE
WJ
REMOVAL AND INSTALLATION (Continued)
Fig. 50 Pressure Solenoid and O-ring
1 – PRESSURE SOLENOID
2 – O-RING
3 – GOVERNOR
Fig. 52 Pressure Sensor and Retainer
1 – RETAINING CLIP
2 – GOVERNOR BODY
3 – GOVERNOR PRESSURE SENSOR/TRANSMISSION FLUID
TEMPERATURE THERMISTOR
• Governor pressure solenoid.
• Governor pressure sensor.
• Converter clutch/overdrive solenoid assembly
and harness (includes sump temperature thermistor).
• Governor housing gasket.
• Solenoid case connector O-rings.
The remaining valve body components are serviced
only as part of a complete valve body assembly.
REMOVAL
Fig. 51 Governor Body and Gasket
1 – GOVERNOR BODY
2 – GASKET
VALVE BODY
The valve body can be removed for service without
having to remove the transmission assembly.
The valve body can be disassembled for cleaning
and inspection of the individual components. Refer to
Disassembly and Assembly section for proper procedures.
The only replaceable valve body components are:
• Manual lever.
• Manual lever washer, seal, E-clip, and shaft
seal.
• Manual lever detent ball.
• Throttle lever.
• Fluid filter.
• Pressure adjusting screw bracket.
(1) Shift transmission into NEUTRAL.
(2) Raise vehicle.
(3) Remove gearshift and throttle levers from shaft
of valve body manual lever.
(4) Disconnect wires at solenoid case connector
(Fig. 53).
(5) Position drain pan under transmission oil pan.
(6) Remove transmission oil pan and gasket.
(7) Remove fluid filter from valve body.
(8) Remove bolts attaching valve body to transmission case.
(9) Lower valve body enough to remove accumulator piston and springs.
(10) Work manual lever shaft and electrical connector out of transmission case.
(11) Lower valve body, rotate valve body away
from case, pull park rod out of sprag, and remove
valve body (Fig. 54).
INSTALLATION
(1) Check condition of O-ring seals on valve body
harness connector (Fig. 55). Replace seals on connector body if cut or worn.
(2) Check condition of manual lever shaft seal in
transmission case. Replace seal if lip is cut or worn.
Install new seal with 15/16 deep well socket (Fig. 56).
TRANSMISSION AND TRANSFER CASE
WJ
21 - 45
REMOVAL AND INSTALLATION (Continued)
(7) Position valve body in case and work end of
park lock rod into and through pawl sprag. Turn propeller shaft to align sprag and park lock teeth if necessary. The rod will click as it enters pawl. Move rod
to check engagement.
CAUTION: It is possible for the park rod to displace
into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged
in the pawl and has not displaced into this cavity.
Fig. 53 Transmission Case Connector
1 – SOLENOID CASE CONNECTOR
2 – PARK/NEUTRAL POSITION SWITCH CONNECTOR
TERMINAL
(8) Install accumulator springs and piston into
case. Then swing valve body over piston and outer
spring to hold it in place.
(9) Align accumulator piston and outer spring,
manual lever shaft and electrical connector in case.
(10) Then seat valve body in case and install one
or two bolts to hold valve body in place.
(11) Tighten valve body bolts alternately and
evenly to 11 N·m (100 in. lbs.) torque.
(12) Install new fluid filter on valve body. Tighten
filter screws to 4 N·m (35 in. lbs.) torque.
(13) Install throttle and gearshift levers on valve
body manual lever shaft.
(14) Check and adjust front and rear bands if necessary.
(15) Connect solenoid case connector wires.
(16) Install oil pan and new gasket. Tighten pan
bolts to 17 N·m (13 ft. lbs.) torque.
(17) Lower vehicle and fill transmission with
Mopart ATF Plus 3, type 7176 fluid.
(18) Check and adjust gearshift and throttle valve
cables, if necessary.
Fig. 54 Valve Body
1
2
3
4
5
–
–
–
–
–
VALVE BODY
WIRE HARNESS
GOVERNOR PRESSURE SOLENOID
PARK ROD
GOVERNOR PRESSURE SENSOR
(3) Check condition of seals on accumulator piston
(Fig. 57). Install new piston seals, if necessary.
(4) Place valve body manual lever in low (1 position) so ball on park lock rod will be easier to install
in sprag.
(5) Lubricate shaft of manual lever with petroleum
jelly. This will ease inserting shaft through seal in
case.
(6) Lubricate seal rings on valve body harness connector with petroleum jelly.
Fig. 55 Valve Body Harness Connector O-Ring Seal
1 – CONNECTOR O-RINGS
2 – VALVE BODY HARNESS CONNECTOR
3 – HARNESS
21 - 46
TRANSMISSION AND TRANSFER CASE
WJ
REMOVAL AND INSTALLATION (Continued)
CAUTION: Support the overdrive unit with a jack
before moving it rearward. This is necessary to prevent damaging the intermediate shaft. Do not allow
the shaft to support the entire weight of the overdrive unit.
Fig. 56 Manual Lever Shaft Seal
1 – 15/1688 SOCKET
2 – SEAL
Fig. 58 Overdrive Unit Bolts
1 – OVERDRIVE UNIT
2 – ATTACHING BOLTS (7)
Fig. 57 Accumulator Piston Components
1
2
3
4
–
–
–
–
INNER SPRING
ACCUMULATOR PISTON
OUTER SPRING
SEAL RINGS
OVERDRIVE UNIT
REMOVAL
(1) Shift transmission into Park.
(2) Raise vehicle.
(3) Mark propeller shaft universal joint(s) and axle
pinion yoke for alignment reference at installation.
(4) Disconnect and remove propeller shaft(s).
(5) Remove transmission oil pan, remove gasket,
drain oil and reinstall pan.
(6) If overdrive unit had malfunctioned, or if fluid
is contaminated, remove entire transmission. If diagnosis indicated overdrive problems only, remove just
the overdrive unit.
(7) Support transmission with transmission jack.
(8) Remove vehicle speed sensor.
(9) Remove bolts attaching overdrive unit to transmission (Fig. 58).
(10) Carefully work overdrive unit off intermediate
shaft. Do not tilt unit during removal. Keep it as
level as possible.
(11) If overdrive unit does not require service,
immediately insert Alignment Tool 6227-2 in splines
of planetary gear and overrunning clutch to prevent
splines from rotating out of alignment. If misalignment occurs, overdrive unit will have to be disassembled in order to realign splines.
(12) Remove and retain overdrive piston thrust
bearing. Bearing may remain on piston or in clutch
hub during removal.
(13) Position drain pan on workbench.
(14) Place overdrive unit over drain pan. Tilt unit
to drain residual fluid from case.
(15) Examine fluid for clutch material or metal
fragments. If fluid contains these items, overhaul will
be necessary.
(16) If overdrive unit does not require any service,
leave alignment tool in position. Tool will prevent
accidental misalignment of planetary gear and overrunning clutch splines.
INSTALLATION
(1) Be sure overdrive unit Alignment Tool 6227-2
is fully seated before moving unit. If tool is not
seated and gear splines rotate out of alignment, overdrive unit will have to be disassembled in order to
realign splines.
TRANSMISSION AND TRANSFER CASE
WJ
21 - 47
REMOVAL AND INSTALLATION (Continued)
(2) If overdrive piston retainer was not removed
during service and original case gasket is no longer
reusable, prepare new gasket by trimming it.
(3) Cut out old case gasket around piston retainer
with razor knife (Fig. 59).
(4) Use old gasket as template and trim new gasket to fit.
(5) Position new gasket over piston retainer and
on transmission case. Use petroleum jelly to hold
gasket in place if necessary. Do not use any type of
sealer to secure gasket. Use petroleum jelly only.
(8) Verify that splines in overdrive planetary gear
and overrunning clutch hub are aligned with Alignment Tool 6227-2. Overdrive unit cannot be installed
if splines are not aligned. If splines have rotated out
of alignment, unit will have to be disassembled to
realign splines.
(9) Carefully slide Alignment Tool 6227-2 out of
overdrive planetary gear and overrunning clutch
splines.
(10) Raise overdrive unit and carefully slide it
straight onto intermediate shaft. Insert park rod into
park lock reaction plug at same time. Avoid tilting
overdrive during installation as this could cause
planetary gear and overrunning clutch splines to
rotate out of alignment. If this occurs, it will be necessary to remove and disassemble overdrive unit to
realign splines.
(11) Work overdrive unit forward on intermediate
shaft until seated against transmission case.
(12) Install bolts attaching overdrive unit to transmission unit. Tighten bolts in diagonal pattern to 34
N·m (25 ft-lbs).
(13) Install speed sensor.
(14) Connect speed sensor and overdrive wires.
(15) Align and install propeller shaft.
OVERDRIVE HOUSING BUSHING
Fig. 59 Trimming Overdrive Case Gasket
1 – GASKET
2 – SHARP KNIFE
(6) Install selective spacer on intermediate shaft, if
removed. Spacer goes in groove just rearward of
shaft rear splines (Fig. 60).
REMOVAL
(1) Remove overdrive housing yoke seal.
(2) Insert Remover 6957 into overdrive housing.
Tighten tool to bushing and remove bushing (Fig.
61).
Fig. 60 Intermediate Shaft Selective Spacer Location
1 – SELECTIVE SPACER
2 – SPACER GROOVE
3 – INTERMEDIATE SHAFT
(7) Install thrust bearing in overdrive unit sliding
hub. Use petroleum jelly to hold bearing in position.
CAUTION: Be sure the shoulder on the inside diameter of the bearing is facing forward.
Fig. 61 Bushing Removal—Typical
1 – REMOVER 6957
2 – EXTENSION HOUSING BUSHING
21 - 48
TRANSMISSION AND TRANSFER CASE
WJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Align bushing oil hole with oil slot in overdrive
housing.
(2) Tap bushing into place with Installer 6951 and
Handle C-4171.
(3) Install new oil seal in housing using Seal
Installer C-3995–A (Fig. 62).
Fig. 63 Output Shaft Rear Bearing
Fig. 62 Overdrive Housing Seal Installation
1 – SPECIAL TOOL C-3995–A OR C-3972–A
2 – SPECIAL TOOL C-4471
OUTPUT SHAFT REAR BEARING
REMOVAL
(1) Remove overdrive unit from the vehicle.
(2) Remove overdrive geartrain from housing.
(3) Remove snap ring holding output shaft rear
bearing into overdrive housing (Fig. 63).
(4) Using a suitable driver inserted through the
rear end of housing, drive bearing from housing.
1 – OUTPUT SHAFT REAR BEARING
2 – OVERDRIVE HOUSING
3 – SNAP RING
INSTALLATION
(1) Place replacement bearing in position on
geartrain with locating retainer groove toward the
rear.
(2) Push bearing onto shaft until the snap ring
groove is visible.
(3) Install snap ring to hold bearing onto output
shaft (Fig. 64).
(4) Install overdrive geartrain into housing.
(5) Install overdrive unit in vehicle.
INSTALLATION
(1) Place replacement bearing in position in housing.
(2) Using a suitable driver, drive bearing into
housing until the snap ring groove is visible.
(3) Install snap ring to hold bearing into housing
(Fig. 63).
(4) Install overdrive geartrain into housing.
(5) Install overdrive unit in vehicle.
OUTPUT SHAFT FRONT BEARING
REMOVAL
(1) Remove overdrive unit from the vehicle.
(2) Remove overdrive geartrain from housing.
(3) Remove snap ring holding output shaft front
bearing to overdrive geartrain. (Fig. 64).
(4) Pull bearing from output shaft.
Fig. 64 Output Shaft Front Bearing
1
2
3
4
5
–
–
–
–
–
OUTPUT SHAFT FRONT BEARING
SNAP RING
OUTPUT SHAFT
GROOVE TO REAR
OVERDRIVE GEARTRAIN
WJ
TRANSMISSION AND TRANSFER CASE
21 - 49
DISASSEMBLY AND ASSEMBLY
VALVE BODY
Remove the valve body from the transmission,
refer to Removal and Installation procedures section
in this group.
DISASSEMBLY
CAUTION: Do not clamp any valve body component in a vise. This practice can damage the component resulting in unsatisfactory operation after
assembly and installation. Do not use pliers to
remove any of the valves, plugs or springs and do
not force any of the components out or into place.
The valves and valve body housings will be damaged if force is used. Tag or mark the valve body
springs for reference as they are removed. Do not
allow them to become intermixed.
(1) Remove fluid filter.
(2) Disconnect wires from governor pressure sensor and solenoid.
(3) Remove screws attaching governor body and
retainer plate to transfer plate.
(4) Remove retainer plate, governor body and gasket from transfer plate.
(5) Disconnect wires from governor pressure sensor, if not done previously.
(6) Remove governor pressure sensor from governor body. Sensor is retained in body with M-shaped
spring clip. Remove clip with small pointed tool and
slide sensor out of body.
(7) Remove governor pressure solenoid by pulling
it straight out of bore in governor body. Remove and
discard solenoid O-rings if worn, cut, or torn.
(8) Remove small shoulder bolt that secures solenoid harness case connector to 3-4 accumulator housing (Fig. 65). Retain shoulder bolt. Either tape it
to harness or thread it back into accumulator
housing after connector removal.
(9) Unhook overdrive/converter solenoid harness
from 3-4 accumulator cover plate (Fig. 66).
(10) Turn valve body over and remove screws that
attach overdrive/converter solenoid assembly to valve
body (Fig. 67).
(11) Remove solenoid and harness assembly from
valve body (Fig. 68).
(12) Remove boost valve cover (Fig. 69).
(13) Remove boost valve retainer, valve spring and
boost valve (Fig. 70).
Fig. 65 Solenoid Harness Case Connector Shoulder
Bolt
1 – SOLENOID HARNESS CASE CONNECTOR
2 – 3–4 ACCUMULATOR HOUSING
Fig. 66 Unhooking Solenoid Harness From
Accumulator Cover Plate
1 – OVERDRIVE/CONVERTER SOLENOID WIRE HARNESS
2 – 3–4 ACCUMULATOR COVER PLATE
21 - 50
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 69 Boost Valve Cover Location
1 – BOOST VALVE HOUSING AND COVER
2 – BOOST VALVE TUBE
Fig. 67 Solenoid Assembly Screws
1 – OVERDRIVE/CONVERTER CLUTCH SOLENOID ASSEMBLY
2 – HARNESS
Fig. 70 Boost Valve Components
1
2
3
4
5
6
Fig. 68 Solenoid Assembly
1
2
3
4
5
6
7
–
–
–
–
–
–
–
CASE CONNECTOR
GOVERNOR SOLENOID WIRES
CONVERTER CLUTCH SOLENOID
SOLENOID SCREWS
OVERDRIVE SOLENOID
GOVERNOR SENSOR WIRES
HARNESS
–
–
–
–
–
–
SPRING AND VALVE RETAINER
COVER SCREWS
BOOST VALVE COVER
BOOST VALVE PLUG
BOOST VALVE
BOOST VALVE SPRING
(14) Secure detent ball and spring with Retainer
Tool 6583 (Fig. 71).
(15) Remove park rod E-clip and separate rod from
manual lever (Fig. 72).
(16) Remove E-clip and washer that retains throttle lever shaft in manual lever (Fig. 73).
(17) Remove manual lever and throttle lever (Fig.
74). Rotate and lift manual lever off valve body and
throttle lever shaft. Then slide throttle lever out of
valve body.
(18) Position pencil magnet next to detent housing
to catch detent ball and spring. Then carefully
remove Retainer Tool 6583 and remove detent ball
and spring (Fig. 75).
TRANSMISSION AND TRANSFER CASE
WJ
21 - 51
DISASSEMBLY AND ASSEMBLY (Continued)
(19) Remove screws attaching pressure adjusting
screw bracket to valve body and transfer plate (Fig.
76). Hold bracket firmly against spring tension while
removing last screw.
Fig. 73 Throttle Lever E-Clip And Washer
1 – THROTTLE LEVER SHAFT
2 – E-CLIP AND WASHER
3 – MANUAL SHAFT
Fig. 71 Detent Ball And Spring
1 – SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING
Fig. 74 Manual And Throttle Lever
Fig. 72 Park Rod
1 – MANUAL LEVER
2 – E-CLIP
3 – PARK ROD
1 – PARK ROD
2 – MANUAL LEVER ASSEMBLY
3 – THROTTLE LEVER
21 - 52
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 75 Detent Ball And Spring
1
2
3
4
–
–
–
–
DETENT HOUSING
DETENT SPRING
DETENT BALL
PENCIL MAGNET
(20) Remove adjusting screw bracket, line pressure
adjusting screw, pressure regulator valve spring and
switch valve spring (Fig. 77). Do not remove throttle pressure adjusting screw from bracket and
do not disturb setting of either adjusting screw
during removal.
(21) Turn upper housing over and remove switch
valve, regulator valve and spring, and manual valve
(Fig. 78).
(22) Remove kickdown detent, kickdown valve, and
throttle valve and spring (Fig. 78).
(23) Loosen left-side 3-4 accumulator housing
attaching screw about 2-3 threads. Then remove center and right-side housing attaching screws (Fig. 79).
(24) Carefully rotate 3-4 accumulator housing
upward and remove 3-4 shift valve spring and converter clutch valve plug and spring (Fig. 80).
(25) Remove left-side screw and remove 3-4 accumulator housing from valve body (Fig. 81).
(26) Bend back tabs on boost valve tube brace (Fig.
82).
Fig. 77 Adjusting Screw Bracket And Spring
1
2
3
4
5
Fig. 76 Adjusting Screw Bracket Fastener
1
2
3
4
5
–
–
–
–
–
T25 TORX BIT
REMOVE THESE SCREWS FIRST
BRACKET
BRACKET
REMOVE THIS SCREW LAST
–
–
–
–
–
SWITCH VALVE SPRING
LINE PRESSURE SCREW
THROTTLE PRESSURE ADJUSTING SCREW
ADJUSTING SCREW BRACKET
PRESSURE REGULATOR VALVE SPRING
TRANSMISSION AND TRANSFER CASE
WJ
21 - 53
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 78 Upper Housing Control Valve Locations
1
2
3
4
5
6
7
–
–
–
–
–
–
–
UPPER HOUSING
REGULATOR VALVE
SWITCH VALVE
REGULATOR VALVE SPRING
KICKDOWN VALVE
KICKDOWN DETENT
THROTTLE VALVE AND SPRING
8 – MANUAL VALVE
9 – 1–2 GOVERNOR PLUG
10 – GOVERNOR PLUG COVER
11 – THROTTLE PLUG
12 – 2–3 GOVERNOR PLUG
13 – SHUTTLE VALVE PRIMARY SPRING
Fig. 79 Accumulator Housing Screw Locations
1 – LOOSEN THIS SCREW
2 – REMOVE THESE SCREWS
3 – 3–4 ACCUMULATOR HOUSING
Fig. 80 3-4 Shift And Converter Clutch Valve
Springs And Plug
1
2
3
4
–
–
–
–
ACCUMULATOR HOUSING
CONVERTER CLUTCH VALVE SPRING
CLUTCH VALVE PLUG
3–4 SHIFT VALVE SPRING
21 - 54
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
84). Note position of boost valve tube brace for
assembly reference.
(30) Remove lower housing and overdrive separator plate from transfer plate (Fig. 84).
(31) Remove the ECE check ball from the transfer
plate (Fig. 85). The ECE check ball is approximately
4.8 mm (3/16 in.) in diameter.
(32) Remove transfer plate from upper housing
(Fig. 86).
(33) Turn transfer plate over so upper housing separator plate is facing upward.
(34) Remove upper housing separator plate from
transfer plate (Fig. 87). Note position of filter in separator plate for assembly reference.
(35) Remove rear clutch and rear servo check balls
from transfer plate. Note check ball location for
assembly reference (Fig. 88).
Fig. 81 Accumulator Housing, Valve Springs And
Plug
1 – 3–4 SHIFT VALVE SPRING
2 – CONVERTER CLUTCH VALVE SPRING AND PLUG
3 – 3–4 ACCUMULATOR HOUSING
Fig. 83 Boost Valve Tube
Fig. 82 Boost Valve Tube Brace
1
2
3
4
–
–
–
–
BOOST VALVE TUBE
LOWER HOUSING
DISENGAGE THIS END OF TUBE FIRST
UPPER HOUSING
1 – BOOST VALVE TUBE
2 – TUBE BRACE (DOUBLE TAB)
(27) Remove boost valve connecting tube (Fig. 83).
Disengage tube from upper housing port first. Then
rock opposite end of tube back and forth to work it
out of lower housing.
CAUTION: Do not use tools to loosen or pry the
connecting tube out of the valve body housings.
Loosen and remove the tube by hand only.
(28) Turn valve body over so lower housing is facing upward (Fig. 84). In this position, the two check
balls in upper housing will remain in place and not
fall out when lower housing and separator plate are
removed.
(29) Remove screws attaching valve body lower
housing to upper housing and transfer plate (Fig.
Fig. 84 Lower Housing
1 – LOWER HOUSING
2 – OVERDRIVE SEPARATOR PLATE
3 – TRANSFER PLATE AND UPPER HOUSING
TRANSMISSION AND TRANSFER CASE
WJ
21 - 55
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 87 Upper Housing Separator Plate
1
2
3
4
–
–
–
–
TRANSFER PLATE
UPPER HOUSING SEPARATOR PLATE
FILTER SCREEN
BRACE
Fig. 85 ECE Check Ball
1 – ECE CHECK BALL (3/16”)
Fig. 88 Rear Clutch And Rear Servo Check Ball
Locations
Fig. 86 Transfer Plate
1 – UPPER HOUSING
2 – TRANSFER PLATE
1 – REAR CLUTCH CHECK BALL
2 – REAR SERVO CHECK BALL
3 – TRANSFER PLATE
21 - 56
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
VALVE BODY UPPER HOUSING
(1) Note location of check balls in valve body upper
housing (Fig. 89). Then remove the one large diameter and the six smaller diameter check balls.
(2) Remove governor plug and shuttle valve covers
(Fig. 91).
(3) Remove E-clip that secures shuttle valve secondary spring on valve stem (Fig. 90).
(4) Remove throttle plug, primary spring, shuttle
valve, secondary spring, and spring guides (Fig. 91).
(5) Remove boost valve retainer, spring and valve
if not previously removed.
(6) Remove throttle plug and 1-2 and 2-3 governor
plugs (Fig. 78).
(7) Turn upper housing around and remove limit
valve and shift valve covers (Fig. 92).
(8) Remove limit valve housing. Then remove
retainer, spring, limit valve, and 2-3 throttle plug
from limit valve housing (Fig. 92).
(9) Remove 1-2 shift control valve and spring (Fig.
92).
(10) Remove 1-2 shift valve and spring (Fig. 92).
(11) Remove 2-3 shift valve and spring from valve
body (Fig. 92).
(12) Remove pressure plug cover (Fig. 92).
(13) Remove line pressure plug, sleeve, throttle
pressure plug and spring (Fig. 92).
Fig. 89 Check Ball Locations In Upper Housing
1 – SMALL DIAMETER CHECK BALLS (6)
2 – LARGE DIAMETER CHECK BALL (1)
Fig. 90 Shuttle Valve E-Clip And Secondary Spring
Location
1 – E-CLIP
2 – SECONDARY SPRING AND GUIDES
3 – SHUTTLE VALVE
TRANSMISSION AND TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 91 Shuttle And Boost Valve Components
1
2
3
4
5
6
7
–
–
–
–
–
–
–
SPRING
RETAINER
BOOST VALVE
BOOST VALVE PLUG
SPRING GUIDES
E-CLIP
SHUTTLE VALVE SECONDARY SPRING
8 – SHUTTLE VALVE COVER
9 – SHUTTLE VALVE
10 – SHUTTLE VALVE PRIMARY SPRING
11 – GOVERNOR PLUG COVER
12 – THROTTLE PLUG
13 – UPPER HOUSING
14 – BOOST VALVE COVER
21 - 57
21 - 58
TRANSMISSION AND TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 92 Upper Housing Shift Valve And Pressure Plug Locations
1
2
3
4
5
6
7
–
–
–
–
–
–
–
UPPER HOUSING
1–2 SHIFT VALVE AND SPRING
2–3 SHIFT VALVE AND SPRING
2–3 THROTTLE PLUG
LIMIT VALVE HOUSING
LIMIT VALVE COVER
LIMIT VALVE AND SPRING
8 – RETAINER
9 – 1–2 SHIFT CONTROL VALVE AND SPRING
10 – PRESSURE PLUG COVER
11 – LINE PRESSURE PLUG
12 – PLUG SLEEVE
13 – THROTTLE PRESSURE SPRING AND PLUG
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
VALVE BODY LOWER HOUSING
(1) Remove timing valve cover.
(2) Remove 3-4 timing valve and spring.
(3) Remove 3-4 quick fill valve, spring and plug.
(4) Remove 3-4 shift valve and spring.
(5) Remove converter clutch valve, spring and plug
(Fig. 93).
(6) Remove converter clutch timing valve, retainer
and valve spring.
Fig. 93 Lower Housing Shift Valves And Springs
1 – LOWER HOUSING
2 – E-CLIP
3 – ACCUMULATOR END PLATE
4 – 3–4 ACCUMULATOR PISTON AND SPRING
5 – 3–4 ACCUMULATOR HOUSING
6 – 3–4 SHIFT VALVE AND SPRING
7 – PLUG
8 – SPRING RETAINER
9 – CONVERTER CLUTCH VALVE AND SPRING
10 – CONVERTER CLUTCH TIMING VALVE AND SPRING
11
12
13
14
15
16
17
18
19
20
–
–
–
–
–
–
–
–
–
–
OVERDRIVE SEPARATOR PLATE
3–4 QUICK FILL SPRING AND VALVE
HARNESS
CASE CONNECTOR
SOLENOID GASKET
CONVERTER CLUTCH SOLENOID
OVERDRIVE SOLENOID
TIMING VALVE COVER
PLUG
3–4 TIMING VALVE AND SPRING
21 - 59
21 - 60
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
3-4 ACCUMULATOR HOUSING
(1) Remove end plate from housing.
(2) Remove piston spring.
(3) Remove piston. Remove and discard piston
seals (Fig. 94).
LOWER HOUSING
(1) Lubricate valves, springs, and the housing
valve and plug bores with clean transmission fluid
(Fig. 93).
(2) Install 3-4 timing valve spring and valve in
lower housing.
(3) Install 3-4 quick fill valve in lower housing.
(4) Install 3-4 quick fill valve spring and plug in
housing.
(5) Install timing valve end plate. Tighten end
plate screws to 4 N·m (35 in. lbs.) torque.
3-4 ACCUMULATOR
(1) Lubricate accumulator piston, seals and housing piston bore with clean transmission fluid (Fig.
94).
(2) Install new seal rings on accumulator piston.
(3) Install piston and spring in housing.
(4) Install end plate on housing.
Fig. 94 Accumulator Housing Components
1
2
3
4
5
–
–
–
–
–
ACCUMULATOR PISTON
3–4 ACCUMULATOR HOUSING
TEFLON SEALS
PISTON SPRING
COVER PLATE AND SCREWS
TRANSFER PLATE
(1) Install rear clutch and rear servo check balls in
transfer plate (Fig. 95).
(2) Install filter screen in upper housing separator
plate (Fig. 96).
(3) Align and position upper housing separator
plate on transfer plate (Fig. 97).
(4) Install brace plate (Fig. 97). Tighten brace
attaching screws to 4 N·m (35 in. lbs.) torque.
(5) Install remaining separator plate attaching
screws. Tighten screws to 4 N·m (35 in. lbs.) torque.
ASSEMBLY
CAUTION: Do not force valves or plugs into place
during reassembly. If the valve body bores, valves
and plugs are free of distortion or burrs, the valve
body components should all slide into place easily.
In addition, do not overtighten the transfer plate
and valve body screws during reassembly. Overtightening can distort the housings resulting in
valve sticking, cross leakage and unsatisfactory
operation. Tighten valve body screws to recommended torque only.
Fig. 95 Rear Clutch And Rear Servo Check Ball
Locations
1 – REAR CLUTCH CHECK BALL
2 – REAR SERVO CHECK BALL
3 – TRANSFER PLATE
TRANSMISSION AND TRANSFER CASE
WJ
21 - 61
DISASSEMBLY AND ASSEMBLY (Continued)
(6) Install and start all valve body screws by hand
except for the screws to hold the boost valve tube
brace. Save those screws for later installation. Then
tighten screws evenly to 4 N·m (35 in. lbs.) torque.
Start at center and work out to sides when tightening screws (Fig. 101).
Fig. 96 Separator Plate Filter Screen Installation
1 – UPPER HOUSING SEPARATOR PLATE
2 – FILTER SCREEN
Fig. 98 Check Ball Locations In Upper Housing
1 – SMALL DIAMETER CHECK BALLS (6)
2 – LARGE DIAMETER CHECK BALL (1)
Fig. 97 Brace Plate
1 – BRACE
2 – TRANSFER PLATE
3 – SEPARATOR PLATE
UPPER AND LOWER HOUSING
(1) Position upper housing so internal passages
and check ball seats are facing upward. Then install
check balls in housing (Fig. 98). Seven check balls
are used. The single large check ball is approximately 8.7 mm (11/32 in.) diameter. The single small
check ball is approximately 4.8 mm (3/16 in.) in
diameter. The remaining 6 check balls are approximately 6.3 mm (1/4 in.) in diameter.
(2) Position assembled transfer plate and upper
housing separator plate on upper housing (Fig. 99).
Be sure filter screen is seated in proper housing
recess.
(3) Install the ECE check ball into the transfer
plate (Fig. 85). The ECE check ball is approximately
4.8 mm (3/16 in.) in diameter.
(4) Position lower housing separator plate on
transfer plate (Fig. 100).
(5) Install lower housing on assembled transfer
plate and upper housing (Fig. 101).
Fig. 99 Installing Transfer Plate On Upper Housing
1 – FILTER SCREEN
2 – TRANSFER PLATE/SEPARATOR PLATE ASSEMBLY
3 – UPPER HOUSING
21 - 62
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 100 Lower Housing Separator Plate
1 – BE SURE TO ALIGN BORES
2 – TRANSFER PLATE
3 – LOWER HOUSING (OVERDRIVE) SEPARATOR PLATE
Fig. 101 Installing Lower Housing On Transfer Plate
And Upper Housing
1
2
3
4
–
–
–
–
VALVE BODY SCREWS (13)
LOWER HOUSING
UPPER HOUSING
TRANSFER PLATE
UPPER HOUSING VALVE AND PLUG
Refer to (Fig. 102), (Fig. 103) and (Fig. 104) to perform the following steps.
(1) Lubricate valves, plugs, springs with clean
transmission fluid.
(2) Assemble regulator valve line pressure plug,
sleeve, throttle plug and spring. Insert assembly in
upper housing and install cover plate. Tighten cover
plate screws to 4 N·m (35 in. lbs.) torque.
(3) Install 1-2 and 2-3 shift valves and springs.
(4) Install 1-2 shift control valve and spring.
(5) Install retainer, spring, limit valve, and 2-3
throttle plug from limit valve housing.
(6) Install limit valve housing and cover plate.
Tighten screws to 4 N·m (35 in. lbs.).
(7) Install shuttle valve as follows:
(a) Insert plastic guides in shuttle valve secondary spring and install spring on end of valve.
(b) Install shuttle valve into housing.
(c) Hold shuttle valve in place.
(d) Compress secondary spring and install E-clip
in groove at end of shuttle valve.
(e) Verify that spring and E-clip are properly
seated before proceeding.
(8) Install shuttle valve cover plate. Tighten cover
plate screws to 4 N·m (35 in. lbs.) torque.
(9) Install 1-2 and 2-3 valve governor plugs in
valve body.
(10) Install shuttle valve primary spring and
throttle plug.
(11) Align and install governor plug cover. Tighten
cover screws to 4 N·m (35 in. lbs.) torque.
TRANSMISSION AND TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 102 Shuttle And Boost Valve Components
1
2
3
4
5
6
7
–
–
–
–
–
–
–
SPRING
RETAINER
BOOST VALVE
BOOST VALVE PLUG
SPRING GUIDES
E-CLIP
SHUTTLE VALVE SECONDARY SPRING
8 – SHUTTLE VALVE COVER
9 – SHUTTLE VALVE
10 – SHUTTLE VALVE PRIMARY SPRING
11 – GOVERNOR PLUG COVER
12 – THROTTLE PLUG
13 – UPPER HOUSING
14 – BOOST VALVE COVER
21 - 63
21 - 64
TRANSMISSION AND TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 103 Upper Housing Control Valve Locations
1
2
3
4
5
6
7
–
–
–
–
–
–
–
UPPER HOUSING
REGULATOR VALVE
SWITCH VALVE
REGULATOR VALVE SPRING
KICKDOWN VALVE
KICKDOWN DETENT
THROTTLE VALVE AND SPRING
8 – MANUAL VALVE
9 – 1–2 GOVERNOR PLUG
10 – GOVERNOR PLUG COVER
11 – THROTTLE PLUG
12 – 2–3 GOVERNOR PLUG
13 – SHUTTLE VALVE PRIMARY SPRING
TRANSMISSION AND TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 104 Upper Housing Shift Valve And Pressure Plug Locations
1
2
3
4
5
6
7
–
–
–
–
–
–
–
UPPER HOUSING
1–2 SHIFT VALVE AND SPRING
2–3 SHIFT VALVE AND SPRING
2–3 THROTTLE PLUG
LIMIT VALVE HOUSING
LIMIT VALVE COVER
LIMIT VALVE AND SPRING
8 – RETAINER
9 – 1–2 SHIFT CONTROL VALVE AND SPRING
10 – PRESSURE PLUG COVER
11 – LINE PRESSURE PLUG
12 – PLUG SLEEVE
13 – THROTTLE PRESSURE SPRING AND PLUG
21 - 65
21 - 66
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
BOOST VALVE TUBE AND BRACE
(1) Position valve body assembly so lower housing
is facing upward (Fig. 105).
(2) Lubricate tube ends and housing ports with
transmission fluid or petroleum jelly.
(3) Start tube in lower housing port first. Then
swing tube downward and work opposite end of tube
into upper housing port (Fig. 105).
(4) Insert and seat each end of tube in housings.
(5) Slide tube brace under tube and into alignment
with valve body screw holes (Fig. 106).
(6) Install and finger tighten three screws that
secure tube brace to valve body housings (Fig. 106).
(7) Bend tube brace tabs up and against tube to
hold it in position (Fig. 107).
(8) Tighten all valve body housing screws to 4 N·m
(35 in. lbs.) torque after tube and brace are installed.
Tighten screws in diagonal pattern starting at center
and working outward.
Fig. 106 Boost Valve Tube And Brace
1 – BOOST VALVE TUBE
2 – TUBE BRACE
Fig. 105 Boost Valve Tube
1
2
3
4
–
–
–
–
BOOST VALVE TUBE
LOWER HOUSING
DISENGAGE THIS END OF TUBE FIRST
UPPER HOUSING
3-4 ACCUMULATOR
(1) Position converter clutch valve and 3-4 shift
valve springs in housing (Fig. 108).
(2) Loosely attach accumulator housing with rightside screw (Fig. 108). Install only one screw at this
time as accumulator must be free to pivot upward for
ease of installation.
(3) Install 3-4 shift valve and spring.
(4) Install converter clutch timing valve and
spring.
(5) Position plug on end of converter clutch valve
spring. Then compress and hold springs and plug in
place with fingers of one hand.
(6) Swing accumulator housing upward over valve
springs and plug.
Fig. 107 Securing Boost Valve Tube With Brace
Tabs
1 – BEND TABS UP AGAINST TUBE AS SHOWN
(7) Hold accumulator housing firmly in place and
install remaining two attaching screws. Be sure
springs and clutch valve plug are properly seated
(Fig. 109). Tighten screws to 4 N·m (35 in. lbs.).
VALVE BODY FINAL
(1) Install boost valve, valve spring, retainer and
cover plate. Tighten cover plate screws to 4 N·m (35
in. lbs.) torque.
(2) Insert manual lever detent spring in upper
housing.
(3) Position detent ball on end of spring. Then hold
detent ball and spring in detent housing with
Retainer Tool 6583 (Fig. 110).
TRANSMISSION AND TRANSFER CASE
WJ
21 - 67
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 108 Converter Clutch And 3-4 Shift Valve
Springs
1
2
3
4
–
–
–
–
RIGHT-SIDE SCREW
3–4 ACCUMULATOR
3–4 SHIFT VALVE SPRING
CONVERTER CLUTCH VALVE SPRING
Fig. 109 Seating 3-4 Accumulator On Lower
Housing
1 – ACCUMULATOR BOX
2 – CONVERTER CLUTCH VALVE PLUG
(4) Install throttle lever in upper housing. Then
install manual lever over throttle lever and start
manual lever into housing.
(5) Align manual lever with detent ball and manual valve. Hold throttle lever upward. Then press
down on manual lever until fully seated. Remove
detent ball retainer tool after lever is seated.
(6) Then install manual lever seal, washer and
E-clip.
(7) Verify that throttle lever is aligned with end of
kickdown valve stem and that manual lever arm is
engaged in manual valve (Fig. 111).
(8) Position line pressure adjusting screw in
adjusting screw bracket.
(9) Install spring on end of line pressure regulator
valve.
(10) Install switch valve spring on tang at end of
adjusting screw bracket.
(11) Install manual valve.
(12) Install throttle valve and spring.
(13) Install kickdown valve and detent.
(14) Install pressure regulator valve.
(15) Install switch valve.
(16) Position adjusting screw bracket on valve
body. Align valve springs and press bracket into
place. Install short, upper bracket screws first and
long bottom screw last. Verify that valve springs and
bracket are properly aligned. Then tighten all three
bracket screws to 4 N·m (35 in. lbs.) torque.
(17) Lubricate solenoid case connector O-rings and
shaft of manual lever with light coat of petroleum
jelly.
(18) Obtain new fluid filter for valve body but do
not install filter at this time.
(19) If line pressure and/or throttle pressure
adjustment screw settings were not disturbed, continue with overhaul or reassembly. However, if
adjustment screw settings were moved or changed,
readjust as described in Valve Body Control Pressure
Adjustment procedure.
(20) Attach solenoid case connector to 3-4 accumulator with shoulder-type screw. Connector has small
locating tang that fits in dimple at top of accumulator housing (Fig. 112). Seat tang in dimple before
tightening connector screw.
(21) Install solenoid assembly and gasket. Tighten
solenoid attaching screws to 8 N·m (72 in. lbs.)
torque.
(22) Verify that solenoid wire harness is properly
routed (Fig. 113). Solenoid harness must be clear
of manual lever and park rod and not be
pinched between accumulator housing and
cover.
GOVERNOR BODY, SENSOR AND SOLENOID
(1) Turn valve body assembly over so accumulator
side of transfer plate is facing down.
(2) Install new O-rings on governor pressure solenoid and sensor.
(3) Lubricate solenoid and sensor O-rings with
clean transmission fluid.
(4) Install governor pressure sensor in governor
body. Then secure sensor with M-shaped retaining
clip.
21 - 68
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 110 Detent Ball Spring
1 – SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING
Fig. 112 Solenoid Harness Case Connector
Shoulder Bolt
1 – SOLENOID HARNESS CASE CONNECTOR
2 – 3–4 ACCUMULATOR HOUSING
Fig. 111 Manual And Throttle Lever Alignment
1
2
3
4
–
–
–
–
THROTTLE LEVER
MANUAL LEVER VALVE ARM
MANUAL VALVE
KICKDOWN VALVE
(5) Install governor pressure solenoid in governor
body. Push solenoid in until it snaps into place in
body.
(6) Position governor body gasket on transfer
plate.
(7) Install retainer plate on governor body and
around solenoid. Be sure solenoid connector is positioned in retainer cutout.
(8) Align screw holes in governor body and transfer plate. Then install and tighten governor body
screws to 4 N·m (35 in. lbs.) torque.
(9) Connect harness wires to governor pressure
solenoid and governor pressure sensor.
Fig. 113 Solenoid Harness Routing
1 – OVERDRIVE/CONVERTER SOLENOID WIRE HARNESS
2 – 3–4 ACCUMULATOR COVER PLATE
(10) Perform Line Pressure and Throttle Pressure
adjustments. Refer to adjustment section of this
group for proper procedures.
(11) Install fluid filter and pan.
(12) Lower vehicle.
(13) Fill transmission with recommended fluid and
road test vehicle to verify repair.
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
TRANSMISSION
DISASSEMBLY
(1) Clean transmission exterior with steam gun or
with solvent. Wear eye protection during cleaning
operations.
(2) Place transmission in a vertical position.
(3) Measure and record input shaft end play readings.
(4) Remove shift and throttle levers from valve
body manual lever shaft.
(5) Place transmission in horizontal position.
(6) Remove transmission oil pan and gasket.
(7) Remove filter from valve body (Fig. 114). Keep
filter screws separate from other valve body screws.
Filter screws are longer and should be kept with filter.
Fig. 115 Valve Body Bolt Locations
1 – VALVE BODY BOLTS
2 – VALVE BODY BOLTS
Fig. 114 Oil Filter Removal
1 – OIL FILTER
2 – VALVE BODY
3 – FILTER SCREWS (2)
(8) Remove park/neutral position switch.
(9) Remove hex head bolts attaching valve body to
transmission case (Fig. 115). A total of 10 bolts are
used. Note different bolt lengths for assembly reference.
(10) Remove valve body assembly. Push valve body
harness connector out of case. Then work park rod
and valve body out of case (Fig. 116).
(11) Remove accumulator piston and inner and
outer springs (Fig. 117).
(12) Remove pump oil seal with suitable pry tool
or slide-hammer mounted screw.
Fig. 116 Valve Body Removal
1
2
3
4
5
–
–
–
–
–
GOVERNOR PRESSURE SENSOR
GOVERNOR PRESSURE SOLENOID
VALVE BODY
PARK ROD
ACCUMULATOR PISTON
21 - 69
21 - 70
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
(17) Loosen front band adjusting screw until band
is completely loose.
(18) Squeeze front band together and remove band
strut (Fig. 119).
(19) Remove front band lever (Fig. 120).
(20) Remove front band lever shaft plug, if necessary, from converter housing.
(21) Remove front band lever shaft.
Fig. 117 Accumulator Piston And Springs
1 – ACCUMULATOR PISTON
2 – OUTER SPRING
3 – INNER SPRING
(13) Loosen front band adjusting screw locknut 4-5
turns. Then tighten band adjusting screw until band
is tight around front clutch retainer. This prevents
front/rear clutches from coming out with pump and
possibly damaging clutch or pump components.
(14) Remove oil pump bolts.
(15) Thread bolts of Slide Hammer Tools C-3752
into threaded holes in pump body flange (Fig. 118).
(16) Bump slide hammer weights outward to
remove pump and reaction shaft support assembly
from case (Fig. 118).
Fig. 118 Removing Oil Pump And Reaction Shaft
Support Assembly
1 – OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY
2 – SLIDE HAMMER TOOLS C-3752
Fig. 119 Removing/Installing Front Band Strut
1 – BAND LEVER
2 – BAND STRUT
3 – FRONT BAND
Fig. 120 Removing/Installing Front Band Lever
1 – FRONT BAND LEVER
WJ
TRANSMISSION AND TRANSFER CASE
21 - 71
DISASSEMBLY AND ASSEMBLY (Continued)
(22) Remove front and rear clutch units as assembly. Grasp input shaft, hold clutch units together and
remove them from case (Fig. 121).
(23) Lift front clutch off rear clutch (Fig. 122). Set
clutch units aside for overhaul.
Fig. 122 Separating Front/Rear Clutch Assemblies
1 – FRONT CLUTCH
2 – REAR CLUTCH
Fig. 121 Removing Front/Rear Clutch Assemblies
1 – INPUT SHAFT
2 – FRONT CLUTCH
3 – REAR CLUTCH
(24) Remove intermediate shaft thrust washer
from front end of shaft or from rear clutch hub (Fig.
123).
(25) Remove output shaft thrust plate from intermediate shaft hub (Fig. 124).
(26) Slide front band off driving shell (Fig. 125)
and remove band from case.
(27) Remove planetary geartrain as assembly (Fig.
126). Support geartrain with both hands during
removal. Do not allow machined surfaces on intermediate shaft or overdrive piston retainer to become
nicked or scratched.
(28) If overdrive unit is not to be serviced, install
Alignment Shaft 6227-2 into the overdrive unit to
prevent misalignment of the overdrive clutches during service of main transmission components.
(29) Loosen rear band adjusting screw 4-5 turns.
(30) Remove low-reverse drum snap ring (Fig.
127).
Fig. 123 Removing Intermediate Shaft Thrust
Washer
1 – INTERMEDIATE SHAFT THRUST WASHER
2 – INPUT SHAFT
3 – REAR CLUTCH RETAINER HUB
21 - 72
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 124 Removing Intermediate Shaft Thrust Plate
1 – INTERMEDIATE SHAFT HUB
2 – INTERMEDIATE SHAFT THRUST PLATE
Fig. 126 Removing Planetary Geartrain And
Intermediate Shaft Assembly
1 – PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT
ASSEMBLY
Fig. 125 Front Band Removal/Installation
1 – DRIVING SHELL
2 – FRONT BAND
(31) Remove low-reverse drum and reverse band.
(32) Remove overrunning clutch roller and spring
assembly as a unit (Fig. 128).
Fig. 127 Removing Low-Reverse Drum Snap Ring
1 – LOW-REVERSE DRUM
2 – HUB OF OVERDRIVE PISTON RETAINER
3 – LOW-REVERSE DRUM SNAP RING
WJ
TRANSMISSION AND TRANSFER CASE
21 - 73
DISASSEMBLY AND ASSEMBLY (Continued)
(33) Compress front servo rod guide about 1/8 inch
with Valve Spring Compressor C-3422-B (Fig. 129).
(34) Remove front servo rod guide snap ring.
Exercise caution when removing snap ring.
Servo bore can be scratched or nicked if care is
not exercised.
(35) Remove compressor tools and remove front
servo rod guide, spring and servo piston.
(36) Compress rear servo spring retainer about
1/16 inch with Valve Spring Compressor C-3422-B
(Fig. 130).
(37) Remove rear servo spring retainer snap ring.
Then remove compressor tools and remove rear servo
spring and piston.
(38) Inspect transmission components.
NOTE: TO SERVICE THE OVERRUNNING CLUTCH
CAM OR OVERDRIVE PISTON RETAINER, REFER
TO OVERRUNNING CLUTCH CAM SERVICE IN THIS
SECTION.
Fig. 128 Overrunning Clutch Assembly Removal
1 – OVERRUNNING CLUTCH CAM
2 – REAR BAND REACTION PIN
3 – OVERRUNNING CLUTCH ASSEMBLY
Fig. 130 Compressing Rear Servo Spring
1 – FRONT SERVO SNAP RING
2 – REAR SERVO SNAP RING
3 – SPECIAL TOOL
ASSEMBLY
Fig. 129 Compressing Front Servo Rod Guide
1 – SPRING COMPRESSOR TOOL C-3422–B
2 – ROD GUIDE SNAP RING
Do not allow dirt, grease, or foreign material to
enter the case or transmission components during
assembly. Keep the transmission case and components clean. Also make sure the tools and workbench
area used for assembly operations are equally clean.
Shop towels used for wiping off tools and hands
must be made from lint free material. Lint will stick
to transmission parts and could interfere with valve
operation, or even restrict fluid passages.
21 - 74
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
Lubricate the transmission components with
Mopart transmission fluid during reassembly. Use
Mopart Door Ease, or Ru-Glyde on seals and O-rings
to ease installation.
Petroleum jelly can also be used to hold thrust
washers, thrust plates and gaskets in position during
assembly. However, do not use chassis grease, bearing grease, white grease, or similar lubricants on any
transmission part. These types of lubricants can
eventually block or restrict fluid passages and interfere with valve operation. Use petroleum jelly only.
Do not force parts into place. The transmission
components and subassemblies are easily installed by
hand when properly aligned.
If a part seems extremely difficult to install, it is
either misaligned or incorrectly assembled. Also verify that thrust washers, thrust plates and seal rings
are correctly positioned before assembly. These parts
can interfere with proper assembly if mis-positioned.
The planetary geartrain, front/rear clutch assemblies and oil pump are all much easier to install
when the transmission case is upright.
(1) Install rear servo piston, spring and retainer
(Fig. 131). Install spring on top of servo piston and
install retainer on top of spring.
(2) Install front servo piston assembly, servo
spring and rod guide (Fig. 132).
(3) Compress front/rear servo springs with Valve
Spring Compressor C-3422-B and install each servo
snap ring (Fig. 133).
Fig. 132 Front Servo Components
1
2
3
4
5
6
–
–
–
–
–
–
PISTON SEAL RINGS
SERVO PISTON
SNAP RING
ROD GUIDE
SPRING
ROD
Fig. 133 Compressing Front/Rear Servo Springs
1 – SPRING COMPRESSOR TOOL C-3422–B
2 – ROD GUIDE SNAP RING
Fig. 131 Rear Servo Components
1
2
3
4
5
–
–
–
–
–
SERVO PISTON
PISTON SPRING
SNAP RING
RETAINER
PISTON SEAL
TRANSMISSION AND TRANSFER CASE
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21 - 75
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Lubricate clutch cam rollers with transmission
fluid.
(5) Install rear band in case (Fig. 134). Be sure
twin lugs on band are seated against reaction pin.
Fig. 135 Installing Low-Reverse Drum
1 – REAR BAND
2 – LOW-REVERSE DRUM
Fig. 134 Rear Band Installation
1 – REAR BAND
(6) Install low-reverse drum and check overrunning clutch operation as follows:
(a) Lubricate overrunning clutch race (on drum
hub) with transmission fluid.
(b) Guide drum through rear band.
(c) Tilt drum slightly and start race (on drum
hub) into overrunning clutch rollers.
(d) Press drum rearward and turn it in clockwise direction until drum seats in overrunning
clutch (Fig. 135).
(e) Turn drum back and forth. Drum should
rotate freely in clockwise direction and lock
in counterclockwise direction (as viewed
from front of case).
(7) Install snap ring that secures low-reverse drum
to hub of overdrive piston retainer (Fig. 136).
(8) Install rear band lever and pivot pin (Fig. 137).
Align lever with pin bores in case and push pivot pin
into place.
(9) Install planetary geartrain assembly (Fig. 138).
Fig. 136 Installing Low-Reverse Drum Retaining
Snap Ring
1 – LOW-REVERSE DRUM
2 – HUB OF OVERDRIVE PISTON RETAINER
3 – LOW-REVERSE DRUM SNAP RING
21 - 76
TRANSMISSION AND TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
(10) Install thrust plate on intermediate shaft hub
Fig. 137 Rear Band Lever And Pivot Pin Installation
1 – REAR BAND LEVER
2 – LEVER PIVOT PIN
Fig. 139 Installing Intermediate Shaft Thrust Plate
1 – INTERMEDIATE SHAFT HUB
2 – INTERMEDIATE SHAFT THRUST PLATE
Fig. 140 Input Shaft Seal Ring Location
Fig. 138 Installing Planetary Geartrain
1 – PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT
ASSEMBLY
(Fig. 139). Use petroleum jelly to hold thrust plate in
place.
(11) Check seal ring on rear clutch retainer hub
and seal rings on input shaft (Fig. 140). Also verify
that shaft seal rings are installed in sequence shown.
(12) Install rear clutch thrust washer (Fig. 141).
Use additional petroleum jelly to hold washer in
place if necessary.
1
2
3
4
–
–
–
–
INPUT SHAFT
TEFLON SEAL RING
METAL SEAL RING
REAR CLUTCH RETAINER
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TRANSMISSION AND TRANSFER CASE
21 - 77
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 141 Installing Rear Clutch Thrust Washer
1 – REAR CLUTCH RETAINER
2 – REAR CLUTCH THRUST WASHER (FIBER)
(13) Align clutch discs in front clutch and install
front clutch on rear clutch (Fig. 142). Rotate front
clutch retainer back and forth until completely
seated on rear clutch retainer.
(14) Coat intermediate shaft thrust washer with
petroleum jelly. Then install washer in rear clutch
hub (Fig. 143). Use enough petroleum jelly to hold
washer in place. Be sure grooved side of washer
faces rearward (toward output shaft) as shown.
Also note that washer only fits one way in
clutch hub. Note thickness of this washer. It is a
select fit part and is used to control transmission end
play.
Fig. 142 Assembling Front And Rear Clutch Units
1 – TURN FRONT CLUTCH BACK & FORTH UNTIL SEATED
2 – REAR CLUTCH ASSEMBLY
Fig. 143 Installing Intermediate Shaft Thrust Plate
1 – INTERMEDIATE SHAFT THRUST WASHER
2 – INPUT SHAFT
3 – REAR CLUTCH RETAINER HUB
(15) Align drive teeth on rear clutch discs with
small screwdriver (Fig. 144). This makes installation
on front planetary easier.
(16) Raise front end of transmission upward as far
as possible and support case with wood blocks. Front/
rear clutch and oil pump assemblies are easier to
install if transmission is as close to upright position
as possible.
(17) Slide front band into case.
(18) Install front and rear clutch units as assembly
(Fig. 145). Align rear clutch with front annulus gear
and install assembly in driving shell. Be sure output shaft thrust washer and thrust plate are
not displaced during installation.
(19) Carefully work assembled clutches back and
forth to engage and seat rear clutch discs on front
annulus gear. Also be sure front clutch drive lugs are
fully engaged in slots of driving shell after installation.
21 - 78
TRANSMISSION AND TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 144 Aligning Rear Clutch Disc Lugs
1 – REAR CLUTCH DISCS
2 – USE SMALL SCREWDRIVER TO ALIGN CLUTCH DISC
TEETH
Fig. 146 Front Band Linkage Installation
1 – BAND LEVER
2 – BAND STRUT
3 – FRONT BAND
that front clutch thrust washer is properly positioned
(Fig. 147). Use petroleum jelly to hold thrust washer
in place if necessary.
(24) Lubricate oil pump body seal with petroleum
jelly. Lubricate pump shaft seal lip with petroleum
jelly.
(25) Thread two Pilot Stud Tools C-3288-B into
bolt holes in oil pump bore flange (Fig. 148).
(26) Align and install oil pump gasket (Fig. 148).
Fig. 145 Installing Front/Rear Clutch Assemblies
1 – INPUT SHAFT
2 – FRONT CLUTCH
3 – REAR CLUTCH
(20) Assemble front band strut.
(21) Install front band adjuster, strut and adjusting screw (Fig. 146).
(22) Tighten band adjusting screw until band just
grips clutch retainer. Verify that front/rear clutches
are still seated before continuing.
(23) Check seal rings on reaction shaft support
hub. Verify that seal rings are hooked together and
Fig. 147 Reaction Shaft Support Seal Rings And
Front Clutch Thrust Washer
1 – REACTION SHAFT SUPPORT HUB
2 – FRONT CLUTCH THRUST WASHER
3 – SEAL RINGS
(27) Install oil pump (Fig. 149). Align and position
pump on pilot studs. Slide pump down studs and
work it into front clutch hub and case by hand. Then
install 2 or 3 pump bolts to hold pump in place.
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TRANSMISSION AND TRANSFER CASE
21 - 79
DISASSEMBLY AND ASSEMBLY (Continued)
(29) Measure input shaft end play (Fig. 150).
NOTE: If end play is incorrect, transmission is
incorrectly assembled, or output shaft thrust
washer and/or thrust plate are worn and need to be
changed.
Fig. 148 Installing Pilot Studs And Oil Pump Gasket
(a) Attach Adapter 8266–7 to Handle 8266–8.
(b) Attach dial indicator C-3339 to Handle
8266–8.
(c) Install the assembled tool onto the input
shaft of the transmission and tighten the retaining
screw on Adapter 8266–7 to secure it to the input
shaft.
(d) Position the dial indicator plunger against a
flat spot on the oil pump and zero the dial indicator.
(e) Move input shaft in and out and record reading. End play should be 0.56 - 2.31 mm (0.022 0.091 in.).
1 – OIL PUMP GASKET
2 – PILOT STUD TOOLS C-3288–B
(28) Remove pilot stud tools and install remaining
oil pump bolts. Tighten bolts alternately in diagonal
pattern to 20 N·m (15 ft. lbs.).
Fig. 150 Checking Input Shaft End Play
1 – TOOL 8266-B
2 – TOOL 8266-6
3 – TOOL C-3339
Fig. 149 Installing Oil Pump Assembly In Case
1 – OIL PUMP
2 – PILOT STUD TOOL
3 – PILOT STUD TOOL
21 - 80
TRANSMISSION AND TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
(30) Install accumulator piston and inner and
outer springs (Fig. 151).
(31) Verify that valve body solenoid harness is
secured in 3-4 accumulator housing cover plate.
(35) Install seal on park/neutral position switch
(Fig. 152). Then install and tighten switch to 34 N·m
(25 ft. lbs.).
Fig. 152 Park/Neutral Position Switch Seal Position
1 – NEUTRAL SWITCH
2 – SWITCH SEAL
Fig. 151 Accumulator Piston And Springs
1
2
3
4
5
–
–
–
–
–
GOVERNOR PRESSURE SENSOR
GOVERNOR PRESSURE SOLENOID
VALVE BODY
PARK ROD
ACCUMULATOR PISTON
(32) Install valve body as follows:
(a) Align and carefully insert park rod into pawl.
Rod will make click noise as it enters pawl. Move
rod slightly to check engagement.
(b) Align and seat valve body on case. Be sure
manual lever shaft and overdrive connector are
fully seated in case. Also be sure valve body wiring
is not pinched or kinked.
(c) Install and start all valve body attaching
bolts by hand. Then tighten bolts evenly, in a diagonal pattern to 12 N·m (105 in. lbs.) torque. Do
not overtighten valve body bolts. This could
result in distortion and cross leakage after
installation..
CAUTION: It is possible for the park rod to displace
into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged
in the pawl and has not displaced into the cavity.
(33) Install new filter on valve body. Tighten filter
screws to 4 N·m (35 in. lbs.).
(34) Adjust front and rear bands.
(36) Install magnet in oil pan. Magnet goes on
small protrusion at corner of pan.
(37) Position new oil pan gasket on case and
install oil pan. Tighten pan bolts to 17 N·m (13 ft.
lbs.).
(38) Install new valve body manual shaft seal in
case (Fig. 153). Lubricate seal lip and manual shaft
with petroleum jelly. Start seal over shaft and into
case. Seat seal with 15/16 inch, deep well socket.
Fig. 153 Installing Manual Lever Shaft Seal
1 – 15/1688 SOCKET
2 – SEAL
(39) Install throttle valve and shift selector levers
on valve body manual lever shaft.
TRANSMISSION AND TRANSFER CASE
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21 - 81
DISASSEMBLY AND ASSEMBLY (Continued)
OVERRUNNING CLUTCH CAM/OVERDRIVE
PISTON RETAINER
DISASSEMBLY
NOTE: TO SERVICE THE OVERRUNNING CLUTCH
CAM AND THE OVERDRIVE PISTON RETAINER,
THE TRANSMISSION GEARTRAIN AND OVERDRIVE
UNIT MUST BE REMOVED FROM THE TRANSMISSION.
(1) Remove the overdrive piston (Fig. 154).
(2) Remove the overdrive piston retainer bolts.
(3) Remove overdrive piston retainer.
(4) Remove case gasket.
(5) Mark the position of the overrunning clutch
cam in the case (Fig. 155).
(6) Remove the overrunning clutch cam bolts.
(7) Remove the overrunning clutch cam.
Fig. 155 Overrunning Clutch Cam Removal
1 – ALIGN MARKS IDENTIFYING NON-THREADED HOLE IN
CAM AND CASE
2 – OVERRUNNING CLUTCH ASSEMBLY
Fig. 154 Overdrive Piston Removal
1
2
3
4
–
–
–
–
OVERDRIVE CLUTCH PISTON
INTERMEDIATE SHAFT
SELECTIVE SPACER
PISTON RETAINER
Fig. 156 Location Of Non-Threaded Hole In Clutch
Cam
1 – NON-THREADED HOLE
2 – OVERRUNNING CLUTCH CAM
ASSEMBLY
(1) Examine bolt holes in overrunning clutch cam.
Note that one hole is not threaded (Fig. 156). This
hole must align with blank area in clutch cam bolt
circle (Fig. 157). Mark hole location on clutch cam
and blank area in case with grease pencil, paint
stripe, or scribe mark for assembly reference.
(2) Mark location of non-threaded hole in clutch
cam and blank area in bolt circle with grease pencil.
(3) Align and install overrunning clutch and cam
in case (Fig. 158). Be sure cam is correctly
installed. Bolt holes in cam are slightly countersunk on one side. Be sure this side of cam faces
rearward (toward piston retainer).
(4) Verify that non-threaded hole in clutch cam is
properly aligned. Check alignment by threading a
bolt into each bolt hole. Adjust clutch cam position if
necessary.
(5) Install and tighten overrunning clutch cam
bolts to 17 N·m (13 ft. lbs.) torque. Note that clutch
cam bolts are shorter than piston retainer bolts.
(6) Install new gasket at rear of transmission case.
Use petroleum jelly to hold gasket in place. Be sure
to align governor feed holes in gasket with feed passages in case (Fig. 159). Also install gasket before
overdrive piston retainer. Center hole in gasket is
smaller than retainer and cannot be installed over
retainer.
21 - 82
TRANSMISSION AND TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 157 Location Of Blank Area In Clutch Cam Bolt
Circle
1 – OVERRUNNING CLUTCH CAM SEAT IN CASE
2 – NON-THREADED HOLE IN CLUTCH CAM ALIGNS HERE
(BLANK AREA) OF SEAT
Fig. 159 Installing/Aligning Case Gasket
1 – CASE GASKET
2 – BE SURE GOVERNOR TUBE FEED HOLES IN CASE AND
GASKET ARE ALIGNED
Fig. 158 Overrunning Clutch Installation
1 – ALIGN MARKS IDENTIFYING NON-THREADED HOLE IN
CAM AND CASE
2 – OVERRUNNING CLUTCH ASSEMBLY
(7) Position overdrive piston retainer on transmission case and align bolt holes in retainer, gasket and
case (Fig. 160). Then install and tighten retainer
bolts to 17 N·m (13 ft. lbs.) torque.
(8) Install new seals on over drive piston.
(9) Stand transmission case upright on bellhousing.
(10) Position Guide Ring 8114-1 on outer edge of
overdrive piston retainer.
(11) Position Seal Guide 8114-2 on inner edge of
overdrive piston retainer.
(12) Install overdrive piston in overdrive piston
retainer by: aligning locating lugs on overdrive piston
to the two mating holes in retainer.
Fig. 160 Aligning Overdrive Piston Retainer
1 – PISTON RETAINER
2 – GASKET
3 – RETAINER BOLTS
(a) Aligning locating lugs on overdrive piston to
the two mating holes in retainer.
TRANSMISSION AND TRANSFER CASE
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21 - 83
DISASSEMBLY AND ASSEMBLY (Continued)
(b) Lubricate overdrive piston seals with Mopart
Door Ease, or equivalent.
(c) Install piston over Seal Guide 8114–2 and
inside Guide Ring 8114–1.
(d) Push overdrive piston into position in
retainer.
(e) Verify that the locating lugs entered the lug
bores in the retainer.
NOTE: INSTALL THE REMAINING TRANSMISSION
COMPONENTS AND OVERDRIVE UNIT.
FRONT SERVO PISTON
DISASSEMBLY
(1) Remove seal ring from rod guide (Fig. 161).
(2) Remove small snap ring from servo piston rod.
Then remove piston rod, spring and washer from piston.
(3) Remove and discard servo component O-ring
and seal rings.
ASSEMBLY
Clean and inspect front servo components.
(1) Lubricate new O-ring and seal rings with
petroleum jelly and install them on piston, guide and
rod.
(2) Install rod in piston. Install spring and washer
on rod. Compress spring and install snap ring (Fig.
161).
(3) Set servo components aside for installation during transmission reassembly.
Fig. 161 Front Servo
1 – PISTON RINGS
2 – SERVO PISTON
3 – O-RING
4 – SNAP RING
5 – PISTON ROD GUIDE
6 – SEAL RING
7 – SNAP RING
8 – SERVO SPRING
9 – WASHER
10 – SPRING
11 – PISTON ROD
REAR SERVO PISTON
DISASSEMBLY
(1) Remove small snap ring and remove plug and
spring from servo piston (Fig. 162).
(2) Remove and discard servo piston seal ring.
ASSEMBLY
(1) Lubricate piston and guide seals with petroleum jelly. Lubricate other servo parts with Mopart
ATF Plus 3, Type 7176, transmission fluid.
(2) Install new seal ring on servo piston.
(3) Assemble piston, plug, spring and new snap
ring.
(4) Lubricate piston seal lip with petroleum jelly.
Fig. 162 Rear Servo Components
1
2
3
4
5
6
7
8
–
–
–
–
–
–
–
–
SNAP RING
PISTON SEAL
PISTON PLUG
SPRING RETAINER
SNAP RING
PISTON SPRING
CUSHION SPRING
PISTON
OIL PUMP AND REACTION SHAFT SUPPORT
DISASSEMBLY
(1) Remove seal ring from housing and reaction
shaft support (Fig. 163).
(2) Mark pump housing and support assembly for
alignment reference.
21 - 84
TRANSMISSION AND TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
(3) Remove bolts attaching pump body to support
(Fig. 164).
Fig. 165 Separating Pump Housing From Reaction
Shaft Support
Fig. 163 Removing Pump Seal Ring
1 – REACTION SHAFT SUPPORT
2 – PUMP HOUSING
1 – PUMP HOUSING SEAL RING
Fig. 166 Pump Gear Removal
1 – REACTION SHAFT SUPPORT
2 – INNER GEAR
3 – OUTER GEAR
Fig. 164 Pump Support Bolts
1 – REACTION SHAFT SUPPORT
2 – PUMP
(4) Separate support from pump housing (Fig.
165).
(5) Remove inner and outer gears from reaction
shaft support (Fig. 166).
(6) If pump seal was not removed during transmission disassembly, remove seal with punch and hammer.
(7) Remove front clutch thrust washer from support hub (Fig. 167).
OIL PUMP BUSHING REPLACEMENT
(1) Remove pump bushing with Tool Handle
C-4171 and Bushing Remover SP-3551 from Tool Set
C-3887-J (Fig. 168).
(2) Install new pump bushing with Tool Handle
C-4171 and Bushing Installer SP-5117 (Fig. 168).
Bushing should be flush with pump housing bore.
Fig. 167 Support Hub Thrust Washer
1
2
3
4
–
–
–
–
BUSHING
REACTION SHAFT SUPPORT
THRUST WASHER
HUB
TRANSMISSION AND TRANSFER CASE
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21 - 85
DISASSEMBLY AND ASSEMBLY (Continued)
(3) Stake new pump bushing in two places with
blunt punch (Fig. 169). Remove burrs from stake
points with knife blade afterward.
REACTION SHAFT SUPPORT BUSHING REMOVAL
(1) Assemble Bushing Remover Tools SP-1191,
3633 and 5324 (Fig. 170). Do not clamp any part
of reaction shaft or support in vise.
(2) Hold Cup Tool SP-3633 firmly against reaction
shaft and thread remover SP-5324 into bushing as
far as possible by hand. Then thread remover tool 3-4
additional turns into bushing with a wrench.
(3) Turn remover tool hex nut down against
remover cup to pull bushing from shaft. Clean all
chips from shaft after bushing removal.
(4) Lightly grip old bushing in vise or with pliers
and back remover tool out of bushing.
(5) Assemble Bushing Installer Tools C-4171 and
SP-5325 (Fig. 170).
(6) Slide new bushing onto Installer Tool SP-5325.
(7) Position reaction shaft support upright on a
clean smooth surface.
(8) Align bushing in bore. Then tap bushing into
place until Bushing Installer SP-5325 bottoms.
(9) Clean reaction shaft support thoroughly after
installing bushing.
Fig. 168 Removing Oil Pump Bushing
1
2
3
4
5
6
7
–
–
–
–
–
–
–
SPECIAL TOOL C-4171
SPECIAL TOOL SP-3551
BUSHING
SPECIAL TOOL SP-5117
BUSHING
SPECIAL TOOL C-4171
PUMP HOUSING
Fig. 170 Replacing Reaction Shaft Support Bushing
1
2
3
4
5
6
7
–
–
–
–
–
–
–
SPECIAL TOOL SP-1191
SPECIAL TOOL SP-3633
SPECIAL TOOL C-4171
SPECIAL TOOL SP-5325
REACTION SHAFT
SPECIAL TOOL SP-5324
BUSHING
ASSEMBLY
Fig. 169 Staking Oil Pump Bushing
1 – NARROW BLADE
2 – BLUNT PUNCH
3 – TWO STAKES
(1) Lubricate gear bore in pump housing with
transmission fluid.
(2) Lubricate pump gears with transmission fluid.
(3) Support pump housing on wood blocks (Fig.
171).
(4) Install outer gear in pump housing (Fig. 171).
Gear can be installed either way (it is not a one-way
fit).
21 - 86
TRANSMISSION AND TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
(5) Install pump inner gear (Fig. 172).
CAUTION: The pump inner gear is a one way fit.
The bore on one side of the gear inside diameter (I.
D.) is chamfered. Be sure the chamfered side faces
forward (to front of pump).
CAUTION: The reaction shaft support seal rings
will break if overspread, or twisted. If new rings are
being installed, spread them only enough for installation. Also be very sure the ring ends are securely
hooked together after installation. Otherwise, the
rings will either prevent pump installation, or break
during installation.
Fig. 173 Hub Seal Ring Position
Fig. 171 Supporting Pump And Installing Outer Gear
1 – OUTER GEAR
2 – PUMP HOUSING
3 – WOOD BLOCKS
Fig. 172 Pump Inner Gear Installation
1 – OUTER GEAR
2 – INNER GEAR
(6) Install new thrust washer on hub of reaction
shaft support. Lubricate washer with transmission
fluid or petroleum jelly.
(7) If reaction shaft seal rings are being replaced,
install new seal rings on support hub (Fig. 173).
Lubricate seal rings with transmission fluid or petroleum jelly after installation. Squeeze each ring until
ring ends are securely hooked together.
1 – SEAL RINGS
2 – SUPPORT HUB
(8) Install reaction shaft support on pump housing
(Fig. 174).
(9) Align reaction support on pump housing. Use
alignment marks made at disassembly. Or, rotate
support until bolt holes in support and pump housing
are all aligned (holes are offset for one-way fit).
Fig. 174 Assembling Reaction Shaft Support And
Pump Housing
1 – PUMP HOUSING
2 – REACTION SHAFT SUPPORT
TRANSMISSION AND TRANSFER CASE
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21 - 87
DISASSEMBLY AND ASSEMBLY (Continued)
(10) Install all bolts that attach support to pump
housing. Then tighten bolts finger tight.
(11) Tighten support-to-pump bolts to required
torque as follows:
(a) Reverse pump assembly and install it in
transmission case. Position pump so bolts are facing out and are accessible.
(b) Secure pump assembly in case with 2 or 3
bolts, or with pilot studs.
(c) Tighten support-to-pump bolts to 20 N·m (15
ft. lbs.).
(d) Remove pump assembly from transmission
case.
(12) Install new oil seal in pump with Special Tool
C-4193 and Tool Handle C-4171 (Fig. 175). Be sure
seal lip faces inward.
(13) Install new seal ring around pump housing.
Be sure seal is properly seated in groove.
(14) Lubricate lip of pump oil seal and O-ring seal
with transmission fluid.
DISASSEMBLY
(1) Remove waved snap ring and remove pressure
plate, clutch plates and clutch discs.
(2) Compress clutch piston spring with Compressor
Tool C-3575-A (Fig. 176). Be sure legs of tool are
seated squarely on spring retainer before compressing spring.
(3) Remove retainer snap ring and remove compressor tool.
(4) Remove spring retainer and clutch spring. Note
position of retainer on spring for assembly reference.
(5) Remove clutch piston from clutch retainer.
Remove piston by rotating it up and out of retainer.
(6) Remove seals from clutch piston and clutch
retainer hub. Discard both seals as they are not reusable.
Fig. 175 Pump Oil Seal Installation
1 – PUMP BODY
2 – PUMP SEAL
3 – SPECIAL TOOL C-4193
Fig. 176 Compressing Front Clutch Piston Spring
FRONT CLUTCH
NOTE: The 44RE uses five plates and discs for the
front clutch.
1
2
3
4
–
–
–
–
FRONT CLUTCH SPRING
COMPRESSOR TOOL C-3575–A
RETAINER SNAP RING
SPRING RETAINER
21 - 88
TRANSMISSION AND TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
(1) Soak clutch discs in transmission fluid while
assembling other clutch parts.
(2) Install new seals on piston and in hub of
retainer. Be sure lip of each seal faces interior of
clutch retainer.
(3) Lubricate lips of piston and retainer seals with
liberal quantity of Mopart Door Ease. Then lubricate
retainer hub, bore and piston with light coat of transmission fluid.
(4) Install clutch piston in retainer (Fig. 177). Use
twisting motion to seat piston in bottom of retainer.
CAUTION: Never push the clutch piston straight in.
This will fold the seals over causing leakage and
clutch slip.
Fig. 178 Clutch Piston Spring Installation
1 – RETAINER
2 – CLUTCH SPRING
3 – PISTON
(5) Position spring in clutch piston (Fig. 178).
(6) Position spring retainer on top of piston spring
(Fig. 179). Make sure retainer is properly
installed. Small raised tabs should be facing
upward. Semicircular lugs on underside of
retainer are for positioning retainer in spring.
Fig. 179 Correct Spring Retainer Installed Position
1 – SMALL TABS ON RETAINER FACE UPWARD
REAR CLUTCH
DISASSEMBLY
Fig. 177 Front Clutch Piston Installation
1 – CLUTCH PISTON
2 – FRONT CLUTCH RETAINER
(7) Compress piston spring and retainer with Compressor Tool C-3575-A (Fig. 176). Then install new
snap ring to secure spring retainer and spring.
(8) Install clutch plates and discs. Install steel
plate then disc until all plates and discs are
installed. The front clutch uses 5 clutch discs and
plates.
(9) Install pressure plate and waved snap ring.
Front clutch clearance should be 1.70 to 3.40 mm
(0.067 to 0.134 in.). If clearance is incorrect, clutch
discs, plates, pressure plates and snap ring may have
to be changed.
(1) Remove fiber thrust washer from forward side
of clutch retainer.
(2) Remove input shaft front/rear seal rings.
(3) Remove selective clutch pack snap ring (Fig.
180).
(4) Remove top pressure plate, clutch discs, steel
plates, bottom pressure plate and wave snap ring
and wave spring (Fig. 180).
(5) Remove clutch piston with rotating motion.
(6) Remove and discard piston seals.
(7) Remove input shaft snap-ring (Fig. 181). It
may be necessary to press the input shaft in slightly
to relieve tension on the snap-ring
(8) Press input shaft out of retainer with shop
press and suitable size press tool. Use a suitably
sized press tool to support the retainer as close to the
input shaft as possible.
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 180 Rear Clutch Components
1
2
3
4
5
6
7
8
9
–
–
–
–
–
–
–
–
–
PISTON SPRING
REAR CLUTCH PISTON
CLUTCH PISTON SEALS
OUTPUT SHAFT THRUST WASHER (METAL)
INPUT SHAFT SNAP RING
REAR CLUTCH RETAINER
INPUT SHAFT
REAR CLUTCH THRUST WASHER (FIBER)
SHAFT FRONT SEAL RING (TEFLON)
10
11
12
13
14
15
16
17
–
–
–
–
–
–
–
–
SHAFT REAR SEAL RING (METAL)
CLUTCH PACK SNAP RING (SELECTIVE)
RETAINER SEAL RING
CLUTCH PLATES (3)
TOP PRESSURE PLATE
CLUTCH DISCS (4)
BOTTOM PRESSURE PLATE
WAVE SPRING
21 - 89
21 - 90
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
(10) Install wave spring in retainer (Fig. 185). Be
sure spring is completely seated in retainer groove.
Fig. 181 Removing/Installing Input Shaft Snap-Ring
1 – REAR CLUTCH RETAINER
2 – INPUT SHAFT SNAP RING
3 – SNAP RING PLIERS
ASSEMBLY
(1) Soak clutch discs in transmission fluid while
assembling other clutch parts.
(2) Install new seal rings on clutch retainer hub
and input shaft if necessary (Fig. 182).
(a) Be sure clutch hub seal ring is fully seated in
groove and is not twisted.
(3) Lubricate splined end of input shaft and clutch
retainer with transmission fluid. Then press input
shaft into retainer. Use a suitably sized press tool to
support retainer as close to input shaft as possible.
(4) Install input shaft snap-ring (Fig. 181).
(5) Invert retainer and press input shaft in opposite direction until snap-ring is seated.
(6) Install new seals on clutch piston. Be sure lip
of each seal faces interior of clutch retainer.
(7) Lubricate lip of piston seals with generous
quantity of Mopart Door Ease. Then lubricate
retainer hub and bore with light coat of transmission
fluid.
(8) Install clutch piston in retainer. Use twisting
motion to seat piston in bottom of retainer. A thin
strip of plastic (about 0.020” thick), can be used to
guide seals into place if necessary.
CAUTION: Never push the clutch piston straight in.
This will fold the seals over causing leakage and
clutch slip. In addition, never use any type of metal
tool to help ease the piston seals into place. Metal
tools will cut, shave, or score the seals.
(9) Install piston spring in retainer and on top of
piston (Fig. 185). Concave side of spring faces downward (toward piston).
Fig. 182 Rear Clutch Retainer And Input Shaft Seal
Ring Installation
1 – REAR CLUTCH RETAINER HUB SEAL RING
2 – INPUT SHAFT SEAL RINGS
Fig. 183 Input Shaft Seal Ring Identification
1 – BE SURE RING ENDS ARE HOOKED TOGETHER AFTER
INSTALLATION
2 – METAL REAR SEAL RING
3 – TEFLON FRONT SEAL RING (SQUEEZE RING TOGETHER
SLIGHTLY BEFORE INSTALLATION FOR BETTER FIT)
TRANSMISSION AND TRANSFER CASE
WJ
21 - 91
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 184 Pressing Input Shaft Into Rear Clutch
Retainer
1 – INPUT SHAFT
2 – REAR CLUTCH RETAINER
3 – PRESS RAM
Fig. 185 Piston Spring/Wave Spring Position
1
2
3
4
–
–
–
–
REAR CLUTCH RETAINER
PISTON SPRING
WAVE SPRING
CLUTCH PISTON
(11) Install bottom pressure plate (Fig. 180).
Ridged side of plate faces downward (toward piston)
and flat side toward clutch pack.
(12) Install first clutch disc in retainer on top of
bottom pressure plate. Then install a clutch plate followed by a clutch disc until entire clutch pack is
installed (4 discs and 3 plates are required) (Fig.
180).
(13) Install top pressure plate.
(14) Install selective snap ring. Be sure snap ring
is fully seated in retainer groove.
(15) Using a suitable gauge bar and dial indicator,
measure clutch pack clearance (Fig. 186).
(a) Position gauge bar across the clutch drum
with the dial indicator pointer on the pressure
plate (Fig. 186).
(b) Using two small screw drivers, lift the pressure plate and release it.
(c) Zero the dial indicator.
(d) Lift the pressure plate until it contacts the
snap-ring and record the dial indicator reading.
Clearance should be 0.64 - 1.14 mm (0.025 - 0.045
in.). If clearance is incorrect, steel plates, discs, selective snap ring and pressure plates may have to be
changed.
The selective snap ring thicknesses are:
• .107–.109 in.
• .098–.100 in.
• .095–.097 in.
• .083–.085 in.
• .076–.078 in.
• .071–.073 in.
• .060–.062 in.
(16) Coat rear clutch thrust washer with petroleum jelly and install washer over input shaft and
into clutch retainer (Fig. 187). Use enough petroleum
jelly to hold washer in place.
(17) Set rear clutch aside for installation during
final assembly.
21 - 92
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
(6) Remove front planetary gear front thrust
washer from annulus gear hub.
(7) Separate and remove driving shell, rear planetary and rear annulus from output shaft (Fig. 191).
(8) Remove front planetary rear thrust washer
from driving shell.
(9) Remove tabbed thrust washers from rear planetary gear.
(10) Remove lock ring that retains sun gear in
driving shell. Then remove sun gear, spacer and
thrust plates.
Fig. 186 Checking Rear Clutch Pack Clearance
1
2
3
4
5
6
–
–
–
–
–
–
DIAL INDICATOR
PRESSURE PLATE
SNAP RING
STAND
REAR CLUTCH
GAUGE BAR
Fig. 188 Front Annulus And Planetary Assembly
Removal
1 – DRIVING SHELL
2 – FRONT ANNULUS AND PLANETARY ASSEMBLY
3 – PLANETARY SNAP RING
Fig. 187 Installing Rear Clutch Thrust Washer
1 – REAR CLUTCH RETAINER
2 – REAR CLUTCH THRUST WASHER
PLANETARY GEARTRAIN/OUTPUT SHAFT
Fig. 189 Front Planetary Snap Ring Removal
1 – FRONT ANNULUS GEAR
2 – PLANETARY SNAP RING
DISASSEMBLY
ASSEMBLY
(1) Remove planetary snap ring (Fig. 188).
(2) Remove front annulus and planetary assembly
from driving shell (Fig. 188).
(3) Remove snap ring that retains front planetary
gear in annulus gear (Fig. 189).
(4) Remove tabbed thrust washer and tabbed
thrust plate from hub of front annulus (Fig. 190).
(5) Separate front annulus and planetary gears
(Fig. 190).
(1) Lubricate output shaft and planetary components with transmission fluid. Use petroleum jelly to
lubricate and hold thrust washers and plates in position.
(2) Assemble rear annulus gear and support if disassembled. Be sure support snap ring is seated and
that shoulder-side of support faces rearward (Fig.
192).
TRANSMISSION AND TRANSFER CASE
WJ
21 - 93
DISASSEMBLY AND ASSEMBLY (Continued)
(5) Install assembled rear planetary and annulus
gear on output shaft (Fig. 193). Verify that assembly
is fully seated on shaft.
(6) Install front thrust washer on rear planetary
gear (Fig. 194). Use enough petroleum jelly to hold
washer on gear. Be sure all four washer tabs are
seated in slots.
(7) Install spacer on sun gear (Fig. 195).
(8) Install thrust plate on sun gear (Fig. 196). Note
that driving shell thrust plates are interchangeable.
Use either plate on sun gear and at front/rear of
shell.
Fig. 190 Front Planetary And Annulus Gear
Disassembly
1
2
3
4
5
–
–
–
–
–
FRONT ANNULUS
THRUST WASHER
THRUST PLATE
FRONT THRUST WASHER
FRONT PLANETARY
Fig. 192 Assembling Rear Annulus And Planetary
Gear
1 – REAR ANNULUS GEAR
2 – TABBED THRUST WASHER
3 – REAR PLANETARY
Fig. 191 Removing Driving Shell, Rear Planetary
And Rear Annulus
1
2
3
4
–
–
–
–
REAR ANNULUS
REAR PLANETARY
DRIVING SHELL
OUTPUT SHAFT
(3) Install rear thrust washer on rear planetary
gear. Use enough petroleum jelly to hold washer in
place. Also be sure all four washer tabs are properly
engaged in gear slots.
(4) Install rear annulus over and onto rear planetary gear (Fig. 192).
Fig. 193 Installing Rear Annulus And Planetary On
Output Shaft
1 – REAR ANNULUS AND PLANETARY GEAR ASSEMBLY
2 – OUTPUT SHAFT
21 - 94
TRANSMISSION AND TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 194 Installing Rear Planetary Front Thrust
Washer
1 – FRONT TABBED THRUST WASHER
2 – REAR PLANETARY GEAR
Fig. 196 Installing Driving Shell Front Thrust Plate
On Sun Gear
1 – SPACER
2 – SUN GEAR
3 – THRUST PLATE
(11) Align rear thrust plate on driving shell and
install sun gear lock ring. Be sure ring is fully seated
in sun gear ring groove (Fig. 199).
(12) Install assembled driving shell and sun gear
on output shaft (Fig. 200).
(13) Install rear thrust washer on front planetary
gear (Fig. 201). Use enough petroleum jelly to hold
washer in place and be sure all four washer tabs are
seated.
Fig. 195 Installing Spacer On Sun Gear
1 – SUN GEAR
2 – SUN GEAR SPACER
(9) Hold sun gear in place and install thrust plate
over sun gear at rear of driving shell (Fig. 197).
(10) Position wood block on bench and support sun
gear on block (Fig. 198). This makes it easier to align
and install sun gear lock ring. Keep wood block
handy as it will also be used for geartrain end play
check.
Fig. 197 Installing Driving Shell Rear Thrust Plate
1 – DRIVING SHELL
2 – SUN GEAR
3 – REAR THRUST PLATE
TRANSMISSION AND TRANSFER CASE
WJ
21 - 95
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 198 Supporting Sun Gear On Wood Block
1 – SUN GEAR
2 – DRIVING SHELL
3 – WOOD BLOCK
Fig. 199 Installing Sun Gear Lock Ring
1
2
3
4
–
–
–
–
LOCK RING GROOVE
SUN GEAR LOCK RING
DRIVING SHELL
REAR THRUST PLATE
(14) Install front planetary gear on output shaft
and in driving shell (Fig. 202).
(15) Install front thrust washer on front planetary
gear. Use enough petroleum jelly to hold washer in
place and be sure all four washer tabs are seated.
(16) Assemble front annulus gear and support, if
necessary. Be sure support snap ring is seated.
(17) Install front annulus on front planetary (Fig.
202).
(18) Position thrust plate on front annulus gear
support (Fig. 203). Note that plate has two tabs
on it. These tabs fit in notches of annulus hub.
Fig. 200 Installing Assembled Sun Gear And Driving
Shell On Output Shaft
1 – SUN GEAR/DRIVING SHELL ASSEMBLY
2 – OUTPUT SHAFT
Fig. 201 Installing Rear Thrust Washer On Front
Planetary Gear
1 – FRONT PLANETARY GEAR
2 – REAR TABBED THRUST WASHER
(19) Install thrust washer in front annulus (Fig.
204). Align flat on washer with flat on planetary
hub. Also be sure washer tab is facing up.
(20) Install front annulus snap ring (Fig. 205). Use
snap ring pliers to avoid distorting ring during
installation. Also be sure ring is fully seated.
(21) Install planetary selective snap ring with
snap ring pliers (Fig. 206). Be sure ring is fully
seated.
(22) Turn planetary geartrain assembly over so
driving shell is facing workbench. Then support
geartrain on wood block positioned under forward
end of output shaft. This allows geartrain components to move forward for accurate end play check.
21 - 96
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
(23) Check planetary geartrain end play with
feeler gauge (Fig. 207). Gauge goes between shoulder
on output shaft and end of rear annulus support.
(24) Geartrain end play should be 0.12 to 1.22 mm
(0.005 to 0.048 in.). If end play is incorrect, snap ring
(or thrust washers) may have to be replaced. Snap
ring is available in three different thicknesses for
adjustment purposes.
Fig. 204 Installing Front Annulus Thrust Washer
1 – WASHER FLAT ALIGNS WITH FLAT ON PLANETARY HUB
2 – FRONT ANNULUS THRUST WASHER
3 – TAB FACES FRONT
Fig. 202 Installing Front Planetary And Annulus
Gears
1 – FRONT PLANETARY GEAR
2 – FRONT THRUST WASHER
3 – FRONT ANNULUS GEAR
Fig. 205 Installing Front Annulus Snap Ring
1 – SNAP RING PLIERS
2 – FRONT ANNULUS SNAP RING
Fig. 203 Positioning Thrust Plate On Front Annulus
Support
1 – FRONT ANNULUS
2 – THRUST PLATE
WJ
TRANSMISSION AND TRANSFER CASE
21 - 97
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 206 Installing Planetary Selective Snap Ring
1 – SELECTIVE SNAP RING
2 – SNAP RING PLIERS
Fig. 208 Transmission Speed Sensor Removal/
Installation
1 – SOCKET AND WRENCH
2 – SPEED SENSOR
3 – O-RING
Fig. 207 Checking Planetary Geartrain End Play
1 – OUTPUT SHAFT
2 – REAR ANNULUS GEAR
3 – FEELER GAUGE
OVERDRIVE UNIT
DISASSEMBLY
(1) Remove transmission speed sensor and O-ring
seal from overdrive case (Fig. 208).
(2) Remove overdrive piston thrust bearing (Fig.
209).
Fig. 209 Overdrive Piston Thrust Bearing Removal/
Installation
1 – THRUST BEARING
2 – OVERDRIVE PISTON
3 – THRUST PLATE
OVERDRIVE PISTON DISASSEMBLY
(1) Remove overdrive piston thrust plate (Fig.
210). Retain thrust plate. It is a select fit part and
may possibly be reused.
21 - 98
TRANSMISSION AND TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 210 Overdrive Piston Thrust Plate Removal/
Installation
1 – OVERDRIVE PISTON
2 – OVERDRIVE PISTON SPACER (SELECT FIT)
(2) Remove intermediate shaft spacer (Fig. 211).
Retain spacer. It is a select fit part and may possibly
be reused.
Fig. 212 Overdrive Piston Removal
1 – PISTON RETAINER
2 – OVERDRIVE PISTON
OVERDRIVE CLUTCH PACK DISASSEMBLY
(1) Remove overdrive clutch pack wire retaining
ring (Fig. 213).
(2) Remove overdrive clutch pack (Fig. 214).
NOTE: The 44RE transmission utilizes four clutch
discs and three clutch plates.
(3) Note position of clutch pack components for
assembly reference.
Fig. 211 Intermediate Shaft Spacer Location
1 – INTERMEDIATE SHAFT
2 – INTERMEDIATE SHAFT SPACER (SELECT FIT)
(3) Remove overdrive piston from retainer (Fig.
212).
Fig. 213 Removing Overdrive Clutch Pack Retaining
Ring
1 – OVERDRIVE CLUTCH PACK RETAINING RING
TRANSMISSION AND TRANSFER CASE
WJ
21 - 99
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 214 Overdrive Clutch Pack Removal
1 – OVERDRIVE CLUTCH PACK
Fig. 217 Access Cover Screw Removal/Installation
1 – TORX SCREWDRIVER (T25)
2 – ACCESS COVER SCREWS
OVERDRIVE GEARTRAIN DISASSEMBLY
(1) Remove overdrive clutch wave spring (Fig.
215).
Fig. 218 Access Cover And Gasket Removal/
Installation
1 – ACCESS COVER AND GASKET
Fig. 215 Overdrive Clutch Wave Spring Removal/
Installation
1 – WAVE SPRING
(2) Remove overdrive clutch reaction snap ring
(Fig. 216). Note that snap ring is located in same
groove as wave spring.
(5) Expand output shaft bearing snap ring with
expanding-type snap ring pliers. Then push output
shaft forward to release shaft bearing from locating
ring (Fig. 219).
Fig. 216 Overdrive Clutch Reaction Snap Ring
Removal/Installation
1 – REACTION RING
2 – CLUTCH HUB
(3) Remove Torx head screws that attach access
cover and gasket to overdrive case (Fig. 217).
(4) Remove access cover and gasket (Fig. 218).
Fig. 219 Releasing Bearing From Locating Ring
1 – EXPAND BEARING LOCATING RING WITH SNAP RING
PLIERS
2 – ACCESS HOLE
21 - 100
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
(6) Lift gear case up and off geartrain assembly
(Fig. 220).
Fig. 220 Removing Gear Case From Geartrain
Assembly
1 – GEARTRAIN ASSEMBLY
2 – GEAR CASE
TOOL 6227-1 AND A HYDRAULIC SHOP PRESS
WITH A MINIMUM RAM TRAVEL OF 5-6 INCHES.
THE PRESS MUST ALSO HAVE A BED THAT CAN
BE ADJUSTED UP OR DOWN AS REQUIRED.
RELEASE CLUTCH SPRING TENSION SLOWLY AND
COMPLETELY TO AVOID PERSONAL INJURY.
(1) Mount geartrain assembly in shop press (Fig. 222).
(2) Position Compressor Tool 6227-1 on clutch hub
(Fig. 222). Support output shaft flange with steel press
plates as shown and center assembly under press ram.
(3) Apply press pressure slowly. Compress hub and
spring far enough to expose clutch hub retaining ring
and relieve spring pressure on clutch pack snap ring
(Fig. 222).
(4) Remove direct clutch pack snap ring (Fig. 223).
(5) Remove direct clutch hub retaining ring (Fig.
224).
(6) Release press load slowly and completely (Fig.
225).
(7) Remove Special Tool 6227-1. Then remove
clutch pack from hub (Fig. 225).
(7) Remove snap ring that retains rear bearing on
output shaft.
(8) Remove rear bearing from output shaft (Fig.
221).
Fig. 221 Rear Bearing Removal
1 – OUTPUT SHAFT
2 – REAR BEARING
3 – SNAP RING
DIRECT CLUTCH, HUB AND SPRING DISASSEMBLY
Fig. 222 Geartrain Mounted In Shop Press
WARNING: THE NEXT STEP IN DISASSEMBLY
INVOLVES COMPRESSING THE DIRECT CLUTCH
SPRING. IT IS EXTREMELY IMPORTANT THAT
PROPER EQUIPMENT BE USED TO COMPRESS
THE SPRING AS SPRING FORCE IS APPROXIMATELY 830 POUNDS. USE SPRING COMPRESSOR
1
2
3
4
5
6
–
–
–
–
–
–
PRESS RAM
SPECIAL TOOL C-3995–A (OR SIMILAR TOOL)
CLUTCH HUB
PLATES
PRESS BED
SPECIAL TOOL 6227–1
TRANSMISSION AND TRANSFER CASE
WJ
21 - 101
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 223 Direct Clutch Pack Snap Ring Removal
1
2
3
4
5
–
–
–
–
–
CLUTCH HUB
SPECIAL TOOL 6227–1
DIRECT CLUTCH PACK SNAP RING
PRESS PLATES
CLUTCH DRUM
Fig. 225 Direct Clutch Pack Removal
1 – SPECIAL TOOL 6227–1
2 – DIRECT CLUTCH HUB
3 – DIRECT CLUTCH PACK
Geartrain Disassembly
(1) Remove direct clutch hub and spring (Fig. 226).
(2) Remove sun gear and spring plate. Then
remove planetary thrust bearing and planetary gear
(Fig. 227).
Fig. 226 Direct Clutch Hub And Spring Removal
Fig. 224 Direct Clutch Hub Retaining Ring Removal
1
2
3
4
–
–
–
–
SPECIAL TOOL 6227–1
CLUTCH HUB RETAINING RING
PRESS BED
PRESS PLATES
1 – DIRECT CLUTCH SPRING
2 – DIRECT CLUTCH HUB
(3) Remove overrunning clutch assembly with
expanding type snap ring pliers (Fig. 228). Insert pliers into clutch hub. Expand pliers to grip hub splines
and remove clutch with counterclockwise, twisting
motion.
21 - 102
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 227 Removing Sun Gear, Thrust Bearing And
Planetary Gear
1
2
3
4
5
–
–
–
–
–
PLANETARY GEAR
PLANETARY THRUST BEARING
CLUTCH SPRING PLATE
SPRING PLATE SNAP RING
SUN GEAR
(4) Remove thrust bearing from overrunning
clutch hub.
(5) Remove overrunning clutch from hub.
(6) Mark position of annulus gear and direct clutch
drum for assembly alignment reference (Fig. 229).
Use small center punch or scriber to make alignment
marks.
Fig. 229 Marking Direct Clutch Drum And Annulus
Gear For Assembly Alignment
1 – DIRECT CLUTCH DRUM
2 – HAMMER
3 – PUNCH
(7) Remove direct clutch drum rear retaining ring
(Fig. 230).
(8) Remove direct clutch drum outer retaining ring
(Fig. 231).
(9) Mark annulus gear and output shaft for assembly alignment reference (Fig. 232). Use punch or
scriber to mark gear and shaft.
Fig. 230 Clutch Drum Inner Retaining Ring Removal
Fig. 228 Overrunning Clutch Assembly Removal/
Installation
1 – OVERRUNNING CLUTCH
2 – NEEDLE BEARING
1 – INNER RETAINING RING
2 – DIRECT CLUTCH DRUM
3 – ANNULUS GEAR
WJ
TRANSMISSION AND TRANSFER CASE
21 - 103
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 231 Clutch Drum Outer Retaining Ring Removal
1 – OUTER RETAINING RING
Fig. 232 Marking Annulus Gear And Output Shaft
For Assembly Alignment
1 – OUTPUT SHAFT
2 – HAMMER
3 – PUNCH
(10) Remove snap ring that secures annulus gear
on output shaft (Fig. 233). Use two screwdrivers to
unseat and work snap ring out of groove as shown.
(11) Remove annulus gear from output shaft (Fig.
234). Use rawhide or plastic mallet to tap gear off
shaft.
Fig. 233 Annulus Gear Snap Ring Removal
1 – OUTPUT SHAFT
2 – ANNULUS GEAR
3 – SNAP RING
Fig. 234 Annulus Gear Removal
1 – OUTPUT SHAFT
2 – ANNULUS GEAR
GEAR CASE AND PARK LOCK DISASSEMBLY
(1) Remove locating ring from gear case.
(2) Remove park pawl shaft retaining bolt and
remove shaft, pawl and spring.
(3) Remove reaction plug snap ring and remove
reaction plug.
(4) Remove output shaft seal.
21 - 104
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
GEARTRAIN AND DIRECT CLUTCH ASSEMBLY
(1) Soak direct clutch and overdrive clutch discs in
Mopart ATF Plus 3, type 7176, transmission fluid.
Allow discs to soak for 10-20 minutes.
(2) Install new pilot bushing and clutch hub bushing in output shaft if necessary (Fig. 235). Lubricate
bushings with petroleum jelly, or transmission fluid.
Fig. 236 Annulus Gear Installation
1 – SNAP RING
2 – OUTPUT SHAFT FRONT BEARING
3 – ANNULUS GEAR
Fig. 235 Output Shaft Pilot Bushing
1 – OUTPUT SHAFT HUB
2 – OVERRUNNING CLUTCH HUB BUSHING
3 – INTERMEDIATE SHAFT PILOT BUSHING
(3) Install annulus gear on output shaft, if
removed. Then install annulus gear retaining snap
ring (Fig. 236).
(4) Align and install clutch drum on annulus gear
(Fig. 237). Be sure drum is engaged in annulus gear
lugs.
(5) Install clutch drum outer retaining ring (Fig.
237).
(6) Slide clutch drum forward and install inner
retaining ring (Fig. 238).
(7) Install rear bearing and snap ring on output
shaft (Fig. 239). Be sure locating ring groove in bearing is toward rear.
(8) Install overrunning clutch on hub (Fig. 240).
Note that clutch only fits one way. Shoulder on
clutch should seat in small recess at edge of
hub.
(9) Install thrust bearing on overrunning clutch
hub. Use generous amount of petroleum jelly to hold
bearing in place for installation. Bearing fits one
way only. Be sure bearing is seated squarely
against hub. Reinstall bearing if it does not
seat squarely.
Fig. 237 Clutch Drum And Outer Retaining Ring
Installation
1 – ANNULUS GEAR
2 – OUTER SNAP RING
3 – CLUTCH DRUM
(10) Install overrunning clutch in output shaft
(Fig. 241). Insert snap ring pliers in hub splines.
Expand pliers to grip hub. Then install assembly
with counterclockwise, twisting motion.
(11) Install planetary gear in annulus gear (Fig.
242). Be sure planetary pinions are fully seated
in annulus gear before proceeding.
TRANSMISSION AND TRANSFER CASE
WJ
21 - 105
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 238 Clutch Drum Inner Retaining Ring
Installation
1 – ANNULUS GEAR
2 – INNER SNAP RING
3 – CLUTCH DRUM
Fig. 241 Overrunning Clutch Installation
Fig. 239 Rear Bearing And Snap Ring Installation
1 – REAR BEARING
2 – SNAP RING
Fig. 240 Assembling Overrunning Clutch And Hub
1 – CLUTCH HUB
2 – OVERRUNNING CLUTCH
1
2
3
4
5
6
–
–
–
–
–
–
CLUTCH DRUM
OVERRUNNING CLUTCH ASSEMBLY
EXPANDING-TYPE SNAP RING PLIERS
CLUTCH DRUM
ANNULUS GEAR
OVERRUNNING CLUTCH ASSEMBLY SEATED IN OUTPUT
SHAFT
Fig. 242 Planetary Gear Installation
1 – PLANETARY GEAR
2 – ANNULUS GEAR
21 - 106
TRANSMISSION AND TRANSFER CASE
WJ
DISASSEMBLY AND ASSEMBLY (Continued)
(12) Coat planetary thrust bearing and bearing
contact surface of spring plate with generous amount
of petroleum jelly. This will help hold bearing in
place during installation.
(13) Install planetary thrust bearing on sun gear
(Fig. 243). Slide bearing onto gear and seat it against
spring plate as shown. Bearing fits one way only.
If it does not seat squarely against spring plate,
remove and reposition bearing.
(14) Install assembled sun gear, spring plate and
thrust bearing (Fig. 244). Be sure sun gear and
thrust bearing are fully seated before proceeding.
(15) Mount assembled output shaft, annulus gear,
and clutch drum in shop press. Direct clutch spring,
hub and clutch pack are easier to install with assembly mounted in press.
(16) Align splines in hubs of planetary gear and
overrunning clutch with Alignment tool 6227-2 (Fig.
245). Insert tool through sun gear and into splines of
both hubs. Be sure alignment tool is fully seated
before proceeding.
(17) Install direct clutch spring (Fig. 246). Be sure
spring is properly seated on spring plate.
Fig. 243 Planetary Thrust Bearing Installation
1 – SPRING PLATE
2 – PLANETARY THRUST BEARING
3 – SUN GEAR
Fig. 245 Alignment Tool Installation
1
2
3
4
–
–
–
–
SPECIAL TOOL 6227–2
PRESS PLATES
ASSEMBLED DRUM AND ANNULUS GEAR
SUN GEAR
NOTE: The 44RE transmission has 8 direct clutch
discs and 7 clutch plates.
Fig. 244 Sun Gear Installation
1 – SUN GEAR AND SPRING PLATE ASSEMBLY
(18) Assemble and install direct clutch pack on
hub as follows:
(a) Assemble clutch pack components or (Fig.
247).
(b) Install direct clutch reaction plate on clutch
hub first. Note that one side of reaction plate
is counterbored. Be sure this side faces rearward. Splines at rear of hub are raised
slightly. Counterbore in plate fits over raised
splines. Plate should be flush with this end of
hub (Fig. 248).
(c) Install first clutch disc followed by a steel
plate until all discs and plates have been installed.
TRANSMISSION AND TRANSFER CASE
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21 - 107
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 246 Direct Clutch Spring Installation
1
2
3
4
–
–
–
–
SPECIAL TOOL 6227–2
DIRECT CLUTCH SPRING
CLUTCH HUB
PRESS PLATES
(d) Install pressure plate. This is last clutch
pack item to be installed. Be sure plate is
installed with shoulder side facing upward
(Fig. 249).
(19) Install clutch hub and clutch pack on direct
clutch spring (Fig. 250). Be sure hub is started on
sun gear splines before proceeding.
Fig. 248 Correct Position Of Direct Clutch Reaction
Plate
1 – REACTION PLATE COUNTERBORE
2 – DIRECT CLUTCH REACTION PLATE (FLUSH WITH END OF
HUB)
3 – CLUTCH HUB
Fig. 247 44RE Direct Clutch Pack Components
1 – CLUTCH DISCS (8)
2 – PRESSURE PLATE
3 – CLUTCH PLATES (7)
4 – REACTION PLATE
21 - 108
TRANSMISSION AND TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
WARNING: THE NEXT STEP IN GEARTRAIN
ASSEMBLY INVOLVES COMPRESSING THE DIRECT
CLUTCH HUB AND SPRING. IT IS EXTREMELY
IMPORTANT THAT PROPER EQUIPMENT BE USED
TO COMPRESS THE SPRING AS SPRING FORCE IS
APPROXIMATELY 830 POUNDS. USE COMPRESSOR TOOL C-6227-1 AND A HYDRAULIC-TYPE
SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 6
INCHES. THE PRESS MUST ALSO HAVE A BED
THAT CAN BE ADJUSTED UP OR DOWN AS
REQUIRED. RELEASE CLUTCH SPRING TENSION
SLOWLY AND COMPLETELY TO AVOID PERSONAL
INJURY.
Fig. 249 Correct Position Of Direct Clutch Pressure
Plate
1 – DIRECT CLUTCH PRESSURE PLATE
2 – CLUTCH PACK
3 – BE SURE SHOULDER SIDE OF PLATE FACES UPWARD
(20) Position Compressor Tool 6227-1 on clutch
hub.
(21) Compress clutch hub and spring just enough
to place tension on hub and hold it in place.
(22) Slowly compress clutch hub and spring. Compress spring and hub only enough to expose ring
grooves for clutch pack snap ring and clutch hub
retaining ring.
(23) Realign clutch pack on hub and seat clutch
discs and plates in clutch drum.
(24) Install direct clutch pack snap ring (Fig. 251).
Be very sure snap ring is fully seated in clutch
drum ring groove.
(25) Install clutch hub retaining ring (Fig. 252).
Be very sure retaining ring is fully seated in
sun gear ring groove.
(26) Slowly release press ram, remove compressor
tools and remove geartrain assembly.
Fig. 250 Direct Clutch Pack And Clutch Hub
Installation
1 – CLUTCH HUB
2 – DIRECT CLUTCH PACK
3 – CLUTCH DRUM
Fig. 251 Direct Clutch Pack Snap Ring Installation
1 – SPECIAL TOOL 6227–1
2 – DIRECT CLUTCH PACK SNAP RING
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TRANSMISSION AND TRANSFER CASE
21 - 109
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 252 Clutch Hub Retaining Ring Installation
1 – SPECIAL TOOL 6227–1
2 – CLUTCH HUB RETAINING RING
GEAR CASE ASSEMBLY
(1) Position park pawl and spring in case and
install park pawl shaft. Verify that end of spring
with 90° bend is hooked to pawl and straight end of
spring is seated against case.
(2) Install pawl shaft retaining bolt. Tighten bolt
to 27 N·m (20 ft. lbs.) torque.
(3) Install park lock reaction plug. Note that plug
has locating pin at rear (Fig. 253). Be sure pin
is seated in hole in case before installing snap
ring.
(4) Install reaction plug snap-ring (Fig. 254). Compress snap ring only enough for installation; do
not distort it.
Fig. 254 Reaction Plug And Snap-Ring Installation
1 – REACTION PLUG SNAP RING
2 – SNAP RING PLIERS
(7) Support geartrain on Tool 6227-1 (Fig. 256). Be
sure tool is securely seated in clutch hub.
(8) Install overdrive gear case on geartrain (Fig.
256).
Fig. 255 Correct Rear Bearing Locating Ring
Position
1 – CASE ACCESS HOLE
2 – TAB ENDS OF LOCATING RING
Fig. 253 Reaction Plug Locating Pin And Snap-Ring
1 – REACTION PLUG SNAP RING (DO NOT OVERCOMPRESS
TO INSTALL)
2 – LOCATING PIN
3 – PARK LOCK REACTION PLUG
(5) Install new seal in gear case. On 4x4 gear case,
use Tool Handle C-4171 and Installer C-3860-A to
seat seal in case. On 4 x 2 gear case, use same Handle C-4171 and Installer C-3995-A to seat seal in
case.
(6) Verify that tab ends of rear bearing locating
ring extend into access hole in gear case (Fig. 255).
(9) Expand front bearing locating ring with snap
ring pliers (Fig. 257). Then slide case downward until
locating ring locks in bearing groove and release
snap ring.
(10) Install locating ring access cover and gasket
in overdrive unit case (Fig. 258).
OVERDRIVE CLUTCH ASSEMBLY
(1) Install overdrive clutch reaction ring first.
Reaction ring is flat with notched ends (Fig. 259).
21 - 110
TRANSMISSION AND TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 258 Locating Ring Access Cover And Gasket
Installation
1 – TORX SCREWDRIVER (T25)
2 – ACCESS COVER SCREWS
Fig. 256 Overdrive Gear Case Installation
1 – GEARTRAIN ASSEMBLY
2 – GEAR CASE
Fig. 259 Overdrive Clutch Reaction Ring Installation
1 – REACTION RING
2 – CLUTCH HUB
Fig. 257 Seating Locating Ring In Rear Bearing
1 – EXPAND BEARING LOCATING RING WITH SNAP RING
PLIERS
2 – ACCESS HOLE
(2) Install wave spring on top of reaction ring (Fig.
260). Reaction ring and wave ring both fit in
same ring groove. Use screwdriver to seat each
ring securely in groove. Also ensure that the ends of
the two rings are offset from each other.
NOTE: The 44RE transmission has 4 overdrive
clutch discs and 3 plates
(3) Assemble overdrive clutch pack.
(4) Install overdrive clutch reaction plate first.
(5) Install first clutch disc followed by first clutch
plate. Then install remaining clutch discs and plates
in same order.
(6) Install clutch pack pressure plate.
Fig. 260 Overdrive Clutch Wave Spring Installation
1 – WAVE SPRING
(7) Install clutch pack wire-type retaining ring
(Fig. 261).
INTERMEDIATE SHAFT SPACER SELECTION
(1) Place overdrive unit in vertical position. Mount
it on blocks, or in workbench with appropriate size
mounting hole cut into it. Be sure unit is facing
upward for access to direct clutch hub. Also be sure
output shaft is not loaded and internal components
are moved rearward for accurate measurement.
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TRANSMISSION AND TRANSFER CASE
21 - 111
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 261 Overdrive Clutch Pack Retaining Ring
Installation
1 – OVERDRIVE CLUTCH PACK RETAINING RING
(2) Determine correct thickness intermediate shaft
spacer as follows:
(a) Insert Special Tool 6312 through sun gear,
planetary gear and into pilot bushing in output
shaft. Be sure tool bottoms against planetary
shoulder.
(b) Position Gauge Tool 6311 across face of overdrive case (Fig. 262). Then position Dial Caliper
C-4962 over gauge tool.
(c) Extend sliding scale of dial caliper downward
through gauge tool slot until scale contacts end of
Gauge Alignment Tool 6312. Lock scale in place.
Remove dial caliper tool and note distance measured (Fig. 262).
(d) Select proper thickness end play spacer from
spacer chart based on distance measured (Fig.
263).
(e) Remove Gauge Alignment Tool 6312.
OD THRUST PLATE SELECTION
(1) Place overdrive unit in vertical position. Mount
it on blocks, or in workbench with appropriate size
mounting hole cut into it. Be sure unit is facing
upward for access to direct clutch hub. Also be sure
output shaft is not loaded and internal components
are moved rearward for accurate measurement.
(2) Determine correct thickness overdrive piston
thrust plate as follows:
(a) Position Gauge Tool 6311 across face of overdrive case. Then position Dial Caliper C-4962 over
gauge tool (Fig. 264).
(b) Measure distance to clutch hub thrust bearing seat at four points 90° apart. Then average
measurements by adding them and dividing by 4.
(c) Select and install required thrust plate from
information in thrust plate chart (Fig. 265).
Fig. 262 Shaft End Play Measurement
1 – SPECIAL TOOL 6312
2 – SPECIAL TOOL 6311
3 – SPECIAL TOOL C-4962
Fig. 263 Intermediate Shaft End Play Spacer
Selection
(3) Leave Alignment Tool 6227-2 in place. Tool will
keep planetary and clutch hub splines in alignment
until overdrive unit is ready for installation on transmission.
(4) Transmission speed sensor can be installed at
this time if desired. However, it is recommended that
sensor not be installed until after overdrive unit is
secured to transmission.
OVERDRIVE PISTON ASSEMBLY
(1) Install new seals on over drive piston.
(2) Stand transmission case upright on bellhousing.
(3) Position Guide Ring 8114-1 on outer edge of
overdrive piston retainer.
(4) Position Seal Guide 8114-2 on inner edge of
overdrive piston retainer.
(5) Install overdrive piston in overdrive piston
retainer by: aligning locating lugs on overdrive piston
to the two mating holes in retainer.
(a) Aligning locating lugs on overdrive piston to
the two mating holes in retainer.
21 - 112
TRANSMISSION AND TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
CLEANING AND INSPECTION
VALVE BODY
Fig. 264 Overdrive Piston Thrust Plate Measurement
1 – SPECIAL TOOL 6311
2 – DIRECT CLUTCH HUB THRUST BEARING SEAT
3 – SPECIAL TOOL C-4962
Clean the valve housings, valves, plugs, springs,
and separator plates with a standard parts cleaning
solution only. Do not use gasoline, kerosene, or any
type of caustic solution.
Do not immerse any of the electrical components in
cleaning solution. Clean the governor solenoid and
sensor and the dual solenoid and harness assembly
by wiping them off with dry shop towels only.
Dry all except the electrical parts with compressed
air. Make sure all passages are clean and free from
obstructions. Do not use rags or shop towels to
dry or wipe off valve body components. Lint
from these materials can stick to valve body
parts, interfere with valve operation, and clog
filters and fluid passages.
Wipe the governor pressure sensor and solenoid
valve with dry, lint free shop towels only. The O-rings
on the sensor and solenoid valve are the only serviceable components. Be sure the vent ports in the solenoid valve are open and not blocked by dirt or debris.
Replace the valve and/or sensor only when DRB scan
tool diagnosis indicates this is necessary. Or, if either
part has sustained physical damage (dented,
deformed, broken, etc.).
CAUTION: Do not turn the small screw at the end
of the solenoid valve for any reason. Turning the
screw in either direction will ruin solenoid calibration and result in solenoid failure. In addition, the
filter on the solenoid valve is NOT serviceable. Do
not try to remove the filter as this will damage the
valve housing.
Fig. 265 Overdrive Piston Thrust Plate Selection
(b) Lubricate overdrive piston seals with Mopart
Door Ease, or equivalent.
(c) Install piston over Seal Guide 8114–2 and
inside Guide Ring 8114–1.
(d) Push overdrive piston into position in
retainer.
(e) Verify that the locating lugs entered the lug
bores in the retainer.
(6) Install intermediate shaft spacer on intermediate shaft.
(7) Install overdrive piston thrust plate on overdrive piston.
(8) Install overdrive piston thrust bearing on overdrive piston.
(9) Install transmission speed sensor and O-ring
seal in overdrive case (Fig. 208).
Inspect the throttle and manual valve levers and
shafts. Do not attempt to straighten a bent shaft or
correct a loose lever. Replace these components if
worn, bent, loose or damaged in any way.
Inspect all of the valve body mating surfaces for
scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may
be removed with crocus cloth using only very light
pressure.
Minor distortion of a valve body mating surface
may be corrected by smoothing the surface with a
sheet of crocus cloth. Position the crocus cloth on a
surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are
heavily scored, the valve body will have to be
replaced.
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TRANSMISSION AND TRANSFER CASE
21 - 113
CLEANING AND INSPECTION (Continued)
CAUTION: Many of the valves and plugs, such as
the throttle valve, shuttle valve plug, 1-2 shift valve
and 1-2 governor plug, are made of coated aluminum. Aluminum components are identified by the
dark color of the special coating applied to the surface (or by testing with a magnet). Do not sand aluminum valves or plugs under any circumstances.
This practice could damage the special coating
causing the valves/plugs to stick and bind.
Inspect the valves and plugs for scratches, burrs,
nicks, or scores. Minor surface scratches on steel
valves and plugs can be removed with crocus cloth
but do not round off the edges of the valve or
plug lands. Maintaining sharpness of these edges is
vitally important. The edges prevent foreign matter
from lodging between the valves and plugs and the
bore.
Inspect all the valve and plug bores in the valve
body. Use a penlight to view the bore interiors.
Replace the valve body if any bores are distorted or
scored. Inspect all of the valve body springs. The
springs must be free of distortion, warpage or broken
coils.
Check the two separator plates for distortion or
damage of any kind. Inspect the upper housing,
lower housing, 3-4 accumulator housing, and transfer
plate carefully. Be sure all fluid passages are clean
and clear. Check condition of the upper housing and
transfer plate check balls as well. The check balls
and ball seats must not be worn or damaged.
Trial fit each valve and plug in its bore to check
freedom of operation. When clean and dry, the valves
and plugs should drop freely into the bores.
Valve body bores do not change dimensionally with
use. If the valve body functioned correctly when new,
it will continue to operate properly after cleaning and
inspection. It should not be necessary to replace a
valve body assembly unless it is damaged in handling.
The only serviceable valve body components are
listed below. The remaining valve body components
are serviced only as part of a complete valve body
assembly. Serviceable parts are:
• dual solenoid and harness assembly
• solenoid gasket
• solenoid case connector O-rings and shoulder
bolt
• switch valve and spring
• pressure adjusting screw and bracket assembly
• throttle lever
• manual lever and shaft seal
• throttle lever shaft seal, washer, and E-clip
• fluid filter and screws
• detent ball and spring
•
•
•
•
valve body screws
governor pressure solenoid
governor pressure sensor and retaining clip
park lock rod and E-clip
TRANSMISSION
GENERAL INFORMATION
Inspect the transmission bushings during overhaul.
Bushing condition is important as worn, scored bushings contribute to low pressures, clutch slip and
accelerated wear of other components. However, do
not replace bushings as a matter of course. Replace
bushings only when they are actually worn, or
scored.
Use recommended tools to replace bushings. The
tools are sized and designed to remove, install, and
seat bushings correctly. The bushing replacement
tools are included in Bushing Tool Set C-3887-B.
Pre-sized service bushings are available for
replacement purposes. Only the sun gear bushings
are not serviced. Low cost of the sun gear assembly
makes it easier to simply replace the gear and bushings as an assembly.
Heli-Coil inserts can be used to repair damaged,
stripped or worn threads in aluminum parts. These
inserts are available from most automotive parts
suppliers. Stainless steel inserts are recommended.
The use of crocus cloth is permissible where necessary, providing it is used carefully. When used on
shafts, or valves, use extreme care to avoid rounding
off sharp edges. Sharp edges are vital as they prevent foreign matter from getting between the valve
and valve bore.
Do not reuse oil seals, gaskets, seal rings, or
O-rings during overhaul. Replace these parts as a
matter of course. Also do not reuse snap rings or
E-clips that are bent or distorted. Replace these parts
as well.
Lubricate transmission parts with Mopart ATF
Plus 3, Type 7176, transmission fluid during overhaul and assembly. Use petroleum jelly, Mopart Door
Ease, or Ru-Glyde to prelubricate seals, O-rings, and
thrust washers. Petroleum jelly can also be used to
hold parts in place during reassembly.
TRANSMISSION CASE CLEANING AND
INSPECTION
Clean the case in a solvent tank. Flush the case
bores and fluid passages thoroughly with solvent.
Dry the case and all fluid passages with compressed
air. Be sure all solvent is removed from the case and
that all fluid passages are clear.
21 - 114
TRANSMISSION AND TRANSFER CASE
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CLEANING AND INSPECTION (Continued)
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components and
circulate throughout the transmission after assembly. A sufficient quantity of lint can block fluid passages and interfere with valve body operation.
Inspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repaired with Helicoil thread inserts. However, the
case will have to be replaced if it exhibits any type of
damage or wear.
Lubricate the front band adjusting screw threads
with petroleum jelly and thread the screw part-way
into the case. Be sure the screw turns freely.
OVERRUNNING CLUTCH/LOW-REVERSE
DRUM/OVERDRIVE PISTON RETAINER
Clean the overrunning clutch assembly, clutch cam,
low-reverse drum, and overdrive piston retainer in
solvent. Dry them with compressed air after cleaning.
Inspect condition of each clutch part after cleaning.
Replace the overrunning clutch roller and spring
assembly if any rollers or springs are worn or damaged, or if the roller cage is distorted, or damaged.
Replace the cam if worn, cracked or damaged.
Replace the low-reverse drum if the clutch race,
roller surface or inside diameter is scored, worn or
damaged. Do not remove the clutch race from
the low-reverse drum under any circumstances.
Replace the drum and race as an assembly if
either component is damaged.
Examine the overdrive piston retainer carefully for
wear, cracks, scoring or other damage. Be sure the
retainer hub is a snug fit in the case and drum.
Replace the retainer if worn or damaged.
Fig. 266 Accumulator Components
1
2
3
4
–
–
–
–
INNER SPRING
ACCUMULATOR PISTON
OUTER SPRING
SEAL RINGS
rod and piston if cracked, bent, or worn. Discard the
servo snap ring if distorted or warped.
Check the servo piston bore for wear. If the bore is
severely scored, or damaged, it will be necessary to
replace the case.
Replace any servo component if doubt exists about
condition. Do not reuse suspect parts.
REAR SERVO
Remove and discard the servo piston seal ring (Fig.
267). Then clean the servo components with solvent
and dry with compressed air. Replace either spring if
collapsed, distorted or broken. Replace the plug and
piston if cracked, bent, or worn. Discard the servo
snap rings and use a new ones at assembly.
ACCUMULATOR
Inspect the accumulator piston and seal rings (Fig.
266). Replace the seal rings if worn or cut. Replace
the piston if chipped or cracked.
Check condition of the accumulator inner and
outer springs (Fig. 266). Replace the springs if the
coils are cracked, distorted or collapsed.
FRONT SERVO
Clean the servo piston components with solvent
and dry them with compressed air. Wipe the band
clean with lint free shop towels.
Replace the front band if distorted, lining is
burned, flaking off, or worn to the point where the
grooves in the lining material are no longer visible.
Inspect the servo components. Replace the springs
if collapsed, distorted or broken. Replace the guide,
Fig. 267 Rear Servo Components
1
2
3
4
5
6
7
8
–
–
–
–
–
–
–
–
SNAP RING
PISTON SEAL
PISTON PLUG
SPRING RETAINER
SNAP RING
PISTON SPRING
CUSHION SPRING
PISTON
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TRANSMISSION AND TRANSFER CASE
21 - 115
CLEANING AND INSPECTION (Continued)
OIL PUMP AND REACTION SHAFT SUPPORT
(1) Clean pump and support components with solvent and dry them with compressed air.
(2) Check condition of the seal rings and thrust
washer on the reaction shaft support. The seal rings
do not need to be replaced unless cracked, broken, or
severely worn.
(3) Inspect the pump and support components.
Replace the pump or support if the seal ring grooves
or machined surfaces are worn, scored, pitted, or
damaged. Replace the pump gears if pitted, worn
chipped, or damaged.
(4) Inspect the pump bushing. Then check the
reaction shaft support bushing. Replace either bushing only if heavily worn, scored or damaged. It is not
necessary to replace the bushings unless they are
actually damaged.
(5) Install the gears in the pump body and measure pump component clearances as follows:
(a) Clearance between outer gear and reaction
shaft housing should be 0.010 to 0.063 mm (0.0004
to 0.0025 in.). Clearance between inner gear and
reaction shaft housing should be 0.010 to 0.063
mm (0.0004 to 0.0025 in.). Both clearances can be
measured at the same time by:
(I) Installing the pump gears in the pump
housing.
(II) Position an appropriate piece of Plastigagey across both gears.
(III) Align the plastigage to a flat area on the
reaction shaft housing.
(IV) Install the reaction shaft to the pump
housing.
(V) Separate the reaction shaft housing from
the pump housing and measure the Plastigagey
following the instructions supplied with it.
(b) Clearance between inner gear tooth and
outer gear should be 0.08 to 0.19 mm (0.0035 to
0.0075 in.). Measure clearance with an appropriate
feeler gauge.
(c) Clearance between outer gear and pump
housing should also be 0.010 to 0.19 mm (0.0035 to
0.0075 in.). Measure clearance with an appropriate
feeler gauge.
Check the lug grooves in the clutch retainer. The
steel plates should slide freely in the slots. Replace
the retainer if the grooves are worn or damaged.
Check action of the check ball in the retainer (Fig.
268). The ball must move freely and not stick.
NOTE: Inspect the clutch retainer bushings carefully (Fig. 269). The retainer bushings are NOT serviceable. It will be necessary to replace the retainer
if either bushing is scored, or worn.
Inspect the piston and retainer seal surfaces for
nicks or scratches. Minor scratches can be removed
with crocus cloth. However, replace the piston and/or
retainer if the seal surfaces are seriously scored.
Fig. 268 Front Clutch Piston Retainer Check Ball
Location
1 – RETAINER CHECK BALL
FRONT CLUTCH
Clean and inspect the front clutch components.
Replace the clutch discs if warped, worn, scored,
burned or charred, or if the facing is flaking off.
Replace the steel plates if heavily scored, warped, or
broken. Be sure the driving lugs on the plates are in
good condition. The lugs must not be bent, cracked or
damaged in any way.
Replace the clutch spring and spring retainer if
either is distorted, warped or broken.
Fig. 269 Retainer Bushing Location/Inspection
1 – FRONT CLUTCH RETAINER BUSHINGS (NONSERVICEABLE)
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TRANSMISSION AND TRANSFER CASE
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CLEANING AND INSPECTION (Continued)
REAR CLUTCH
Clean the clutch components with solvent and dry
them with compressed air. Do not use rags or shop
towels to dry any of the clutch parts. Lint from such
materials will adhere to component surfaces and
could restrict or block fluid passages after assembly.
Replace the clutch discs if warped, worn, scored,
burned/charred, the lugs are damaged, or if the facing is flaking off. Replace the top and bottom pressure plates if scored, warped, or cracked. Be sure the
driving lugs on the pressure and clutch plates are
also in good condition. The lugs must not be bent,
cracked or damaged in any way.
Replace the piston spring and wave spring if either
part is distorted, warped or broken.
Check the lug grooves in the clutch retainer. The
clutch and pressure plates should slide freely in the
slots. Replace the retainer if the grooves are worn or
damaged. Also check action of the check balls in the
retainer and piston. Each check ball must move
freely and not stick.
Replace the retainer bushing if worn, scored, or
doubt exists about bushing condition.
Inspect the piston and retainer seal surfaces for
nicks or scratches. Minor scratches can be removed
with crocus cloth. However, replace the piston and/or
retainer if the seal surfaces are seriously scored.
Check condition of the fiber thrust washer and
metal output shaft thrust washer. Replace either
washer if worn or damaged.
Check condition of the seal rings on the input shaft
and clutch retainer hub. Replace the seal rings only
if worn, distorted, or damaged. The input shaft front
seal ring is teflon with chamfered ends. The rear ring
is metal with interlocking ends.
Check the input shaft for wear, or damage. Replace
the shaft if worn, scored or damaged in any way.
PLANETARY GEARTRAIN
Clean the planetary components in solvent and dry
them with compressed air.
Check sun gear and driving shell condition.
Replace the gear if damaged or if the bushings are
scored or worn. The bushings are not serviceable.
Replace the driving shell if worn, cracked or damaged.
Replace planetary gear sets if gears, pinion pins, or
carrier are damaged in any way. Replace the annulus
gears and supports if either component is worn or
damaged.
Inspect the geartrain spacers, thrust plates, snap
rings, and thrust washers. Replace any of these parts
that are worn, distorted or damaged. Do not attempt
to reuse these parts.
The planetary gear thrust washers are different
sizes. The large diameter washers go on the front
planetary and the smaller washers go on the rear
planetary. All the washers have four locating tabs on
them. These tabs fit in the holes or slots provided in
each planetary gear.
Inspect the output shaft carefully. Pay particular
attention to the machined bushing/bearing surfaces
on the shaft and the governor valve shaft bore at the
shaft rear.
Replace the output shaft if the machined surfaces
are scored, pitted, or damaged in any way. Also
replace the shaft if the splines are damaged, or
exhibits cracks at any location (especially at the governor valve shaft bore).
The annulus gears can be removed from their supports if necessary. Just remove the snap rings and
separate the two parts when replacement is necessary. In addition, the annulus gear bushings can be
replaced if severely worn, or scored. However it is not
necessary to replace the bushings if they only exhibit
normal wear. Check bushing fit on the output shaft
to be sure.
OVERDRIVE UNIT
Clean the geartrain and case components with solvent. Dry all parts except the bearings with compressed air. Allow bearings to air dry.
Do not use shop towels for wiping parts dry unless
the towels are made from a lint-free material. A sufficient quantity of lint (from shop towels, cloths, rags,
etc.) could plug the transmission filter and fluid passages.
Discard the old case gasket and seals. Do not
attempt to salvage these parts. They are not reusable. Replace any of the overdrive unit snap rings if
distorted or damaged.
Minor nicks or scratches on components can be
smoothed with crocus cloth. However, do not attempt
to reduce severe scoring on any components with
abrasive materials. Replace severely scored components; do not try to salvage them.
Check condition of the park lock components and
the overdrive case.
Replace the case if cracked, scored, or damaged.
Replace the park lock pawl, plug, or spring if worn or
damaged. Be sure the bullet at the end of the park
lock rod is in good condition. Replace the rod if the
bullet is worn or the rod itself is bent or distorted.
Do not attempt to straighten the rod.
Check the bushings in the overdrive case. Replace
the bushings if severely scored or worn. Also replace
the case seal if loose, distorted, or damaged.
Examine the overdrive and direct clutch discs and
plates. Replace the discs if the facing is worn,
severely scored, or burned and flaking off. Replace
the clutch plates if worn, heavily scored, or cracked.
Check the lugs on the clutch plates for wear. The
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TRANSMISSION AND TRANSFER CASE
21 - 117
CLEANING AND INSPECTION (Continued)
plates should slide freely in the drum. Replace the
plates or drum if binding occurs.
Check condition of the annulus gear, direct clutch
hub, clutch drum and clutch spring. Replace the gear,
hub and drum if worn or damaged. Replace the
spring if collapsed, distorted, or cracked.
Be sure the splines and lugs on the gear, drum and
hub are in good condition. The clutch plates and
discs should slide freely in these components.
Inspect the thrust bearings and spring plate.
Replace the plate if worn or scored. Replace the bearings if rough, noisy, brinnelled, or worn.
Inspect the planetary gear assembly and the sun
gear and bushings. If either the sun gear or the
bushings are damaged, replace the gear and bushings as an assembly. The gear and bushings are not
serviced separately.
The planetary carrier and pinions must be in good
condition. Also be sure the pinion pins are secure and
in good condition. Replace the carrier if worn or damaged.
Inspect the overrunning clutch and race. The race
surface should be smooth and free of scores. Replace
the overrunning clutch assembly or the race if either
assembly is worn or damaged in any way.
Inspect the output shaft and governor components.
Replace the shaft pilot bushing and inner bushing if
damaged. Replace either shaft bearing if rough or
noisy. Replace the bearing snap rings if distorted or
cracked.
Check the machined surfaces on the output shaft.
These surfaces should clean and smooth. Very minor
nicks or scratches can be smoothed with crocus cloth.
Replace the shaft if worn, scored or damaged in any
way.
Inspect the output shaft bushings. The small bushing is the intermediate shaft pilot bushing. The large
bushing is the overrunning clutch hub bushing.
Replace either bushing if scored, pitted, cracked, or
worn.
ADJUSTMENTS
BRAKE TRANSMISSION SHIFT INTERLOCK
The park interlock cable is part of the brake/shift
lever interlock system. Correct cable adjustment is
important to proper interlock operation. The gear
shift and park interlock cables must both be correctly
adjusted in order to shift out of Park.
Park Interlock Cable Adjustment Procedure
(1) Shift the transmission into the Park position.
(2) Rotate the ignition switch to the LOCK position. Be sure ignition key cylinder is in LOCK
position. Cable will not adjust correctly in any
other position.
(3)
bly.
(4)
(5)
press
Remove shift lever bezel and/or console assemPull the cable lock button up to release cable.
Pull cable rearward. Then release cable and
lock button down until it snaps in place.
BTSI FUNCTION CHECK
(1) Verify removal of ignition key allowed in park
position only.
(2) When the shift lever is in park, and the shift
handle push-button is in the out position, the ignition key cylinder should rotate freely from off to lock.
When the shifter is in any other position, the ignition
key should not rotate from off to lock.
(3) Shifting out of park should be possible when
the ignition key cylinder is in the off position.
(4) Shifting out of park should not be possible
while applying 25 lb. max. handle push-button force,
and ignition key cylinder is in the run or start positions, unless the foot brake pedal is depressed
approximately 1/2 inch (12mm).
(5) Shifting out of park should not be possible
when the ignition key cylinder is in the accessory or
lock position.
(6) Shifting between any gears neutral or park
may be done without depressing foot brake with ignition switch in run or start positions and vehicle stationary or in motion.
(7) The floor shifter lever and gate positions
should be in alignment with all transmission detent
positions.
(8) Engine starts must be possible with floor shift
lever in park or neutral positions only. Engine starts
must not be possible in any other gate positions
other than park or neutral.
(9) With floor shift lever handle push-button not
depressed and lever detent in:
• PARK POSITION- apply forward force on center
of handle and remove pressure. Engine start must be
possible.
• PARK POSITION- apply rearward force on center of handle and remove pressure. Engine start
must be possible.
• NEUTRAL POSITION- engine start must be
possible.
• NEUTRAL POSITION, ENGINE RUNNING
AND BRAKES APPLIED- Apply forward force on
center of shift handle. Transmission should not be
able to shift into reverse detent.
TRANSMISSION THROTTLE VALVE CABLE
ADJUSTMENT
The transmission throttle valve is controlled by a
cable attached to the throttle linkage on one end and
the transmission throttle valve control lever on the
transmission end (Fig. 271).
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TRANSMISSION AND TRANSFER CASE
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ADJUSTMENTS (Continued)
Fig. 270 Brake Transmission Shift Interlock Cable
1
2
3
4
5
–
–
–
–
–
SHIFT MECHANISM
SHIFTER BTSI LEVER
ADJUSTMENT CLIP
STEERING COLUMN ASSEMBLY
INTERLOCK CABLE
A correctly adjusted throttle valve cable will cause
the throttle valve control lever on the transmission to
move simultaneously with the throttle linkage from
the idle position. Proper adjustment will allow simultaneous movement without causing the transmission
throttle valve lever to either move ahead of, or lag
behind the throttle linkage bell crank lever.
Checking Throttle Valve Cable Adjustment
(1) Disconnect the negative battery cable.
(2) Remove the intercooler outlet hose from the
engine and position it out of the way.
(3) Raise the vehicle on a hoist and verify that the
transmission throttle valve control lever is at the idle
position (Fig. 272). This position can be verified by
observing the throttle valve lever tension spring.
Control lever should be at its stop in the direction
being pulled by the tension spring.
(4) Lower the vehicle on the hoist.
(5) Disconnect the throttle valve cable end (B)
from the throttle bell crank lever (C). Carefully
slide cable off stud. Do not pry or pull cable off.
(6) Compare the position of cable end (B) to throttle bell crank lever (C) (Fig. 273).
• T. V. cable end (B) and throttle bell crank lever
(C) should be aligned (or centered on one another) to
within 1 mm (0.039 in.) in either direction (Fig. 273).
• If cable end and attachment stud are misaligned, the cable will have to be adjusted as
described in Throttle Valve Cable Adjustment procedure.
(7) Reconnect the cable end (B) on the throttle bell
crank lever (C). Then with aid of a helper, observe
movement of transmission throttle lever and lever on
throttle linkage.
• If the transmission throttle valve lever moves
ahead of, or lags behind the throttle lever, cable
adjustment will be necessary. Or, if the throttle lever
prevents the transmission lever from returning to
closed position, cable adjustment will be necessary.
(8) Install the intercooler outlet hose on the
engine.
(9) Connect the negative battery cable.
Throttle Valve Cable Adjustment Procedure
(1) Disconnect the negative battery cable.
(2) Remove the intercooler outlet hose from the
engine and position it out of the way.
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TRANSMISSION AND TRANSFER CASE
21 - 119
ADJUSTMENTS (Continued)
Fig. 271 Throttle Valve Cable at Transmission
1
2
3
4
–
–
–
–
TRANSMISSION SHIFTER CABLE
THROTTLE VALVE CABLE
TRANSFER CASE SHIFTER CABLE
TRANSFER CASE SHIFTER CABLE BRACKET RETAINING
BOLT (1 OF 2)
5 – THROTTLE VALVE CABLE BRACKET RETAINING BOLT
6 – ELECTRICAL CONNECTORS
7 – TRANSMISSION FLUID LINES
(3) Disconnect the throttle valve cable end (B)
from the throttle bell crank lever (C). Carefully
slide cable off stud. Do not pry or pull cable off.
(4) Pry the T. V. cable lock (A) into the UP position
(Fig. 274). This will unlock the cable and allow for
readjustment.
(5) Apply just enough tension on the T. V. cable (B)
to remove any slack in the braided cable. Pulling to
tight will cause the T. V. lever on the transmission to move out of its idle position, which will
result in an incorrect T. V. cable adjustment.
Slide the sheath of the T. V. cable (D) back and forth
until the centerlines of the T. V. cable end (B) and
the throttle bell crank lever (C) are aligned within
one millimeter (1mm) (Fig. 274).
(6) While holding the T. V. cable in the set position
push the T. V. cable lock (A) into the down position
(Fig. 274). This will lock the present T. V. cable
adjustment.
(7) Reconnect the T. V. cable (B) to the throttle bell
crank lever (C) (Fig. 274).
(8) Double check cable operation and adjustment.
Verify the transmission throttle valve lever and the
throttle bell crank lever move simultaneously.
(9) Install the intercooler outlet hose on the
engine.
Fig. 272 Throttle Valve Cable at Transmission
1
2
3
4
–
–
–
–
TRANSMISSION SHIFTER CABLE
THROTTLE VALVE CABLE
TRANSFER CASE SHIFTER CABLE
TRANSFER CASE SHIFTER CABLE BRACKET RETAINING
BOLT (1 OF 2)
5 – THROTTLE VALVE CABLE BRACKET RETAINING BOLT
6 – ELECTRICAL CONNECTORS
7 – TRANSMISSION FLUID LINES
(10) Connect the negative battery cable.
GEARSHIFT CABLE
Check adjustment by starting the engine in Park
and Neutral. Gearshift cable adjustment is CORRECT if the engine starts only in the Park and Neutral positions. Adjustment is INCORRECT if the
engine starts in one but not both positions. If the
engine starts in any position other than Park or Neutral, or if the engine will not start at all, the park/
neutral position switch or transmission range sensor
may be faulty.
Gearshift Adjustment Procedure
(1) Shift the transmission into the “Park” position.
(2) Remove the shift lever bezel and floor console
as necessary for access to the shift cable adjustment
screw (Fig. 275). Located near the shifter assembly.
(3) Loosen the shift cable adjustment screw (Fig.
275).
(4) Raise the vehicle on a hoist.
(5) Unsnap the cable eyelet from the transmission
shift lever (Fig. 276).
(6) Verify the transmission shift lever is in Park
position by moving lever fully rearward. Last rearward detent is Park position (Fig. 276).
21 - 120
TRANSMISSION AND TRANSFER CASE
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ADJUSTMENTS (Continued)
Fig. 273 Throttle Valve Cable at Throttle Linkage
1 – THROTTLE LINKAGE
2 – THROTTLE VALVE CABLE LOCKING CLIP
3 – THROTTLE VALVE CABLE
Fig. 274 Throttle Valve Cable at Throttle Linkage
1 – THROTTLE LINKAGE
2 – THROTTLE VALVE CABLE LOCKING CLIP
3 – THROTTLE VALVE CABLE
(7) Verify positive engagement of transmission
park lock by attempting to rotate propeller shaft.
Shaft will not rotate when park lock is engaged.
(8) Snap the shift cable eyelet onto the transmission shift lever (Fig. 276).
(9) Lower the vehicle on the hoist.
(10) Tighten the shift cable adjustment screw to 7
N·m (65 in. lbs.).
(11) Verify correct cable operation. Engine should
start only in the Park and Neutral positions.
(12) Install the shifter bezel and floor console components removed for access.
BAND ADJUSTMENTS
FRONT BAND ADJUSTMENT
The front (kickdown) band adjusting screw is
located on the left side of the transmission case
above the manual valve and throttle valve levers.
(1) Raise vehicle.
(2) Loosen band adjusting screw locknut 3-5 turns
(Fig. 277). Be certain the center adjusting screw
turns freely in case. Apply lubricant to screw threads
if necessary.
Fig. 275 Shift Cable at Shifter
1
2
3
4
–
–
–
–
SHIFT LEVER PIN
ADJUSTMENT SCREW
SHIFT CABLE
SHIFTER ASSEMBLY BRACKET
TRANSMISSION AND TRANSFER CASE
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21 - 121
ADJUSTMENTS (Continued)
Fig. 277 Front Band Adjustment Screw Location
1 – LOCK-NUT
2 – FRONT BAND ADJUSTER
Fig. 276 Transmission Control Cables at
Transmission
1
2
3
4
–
–
–
–
TRANSMISSION SHIFTER CABLE
THROTTLE VALVE CABLE
TRANSFER CASE SHIFTER CABLE
TRANSFER CASE SHIFTER CABLE BRACKET RETAINING
BOLT (1 OF 2)
5 – THROTTLE VALVE CABLE BRACKET RETAINING BOLT
6 – ELECTRICAL CONNECTORS
7 – TRANSMISSION FLUID LINES
(3) Tighten the band adjusting screw to 8 N·m (72
in. lbs.) torque with Inch Pound Torque Wrench
C-3380-A, a 3-in. extension and 5/16 socket.
CAUTION: If Adapter C-3705 is needed to reach the
adjusting screw (Fig. 278), tighten the screw to only
5 N·m (47-50 in. lbs.) torque.
44RE TRANSMISSION
• Back off front band adjusting screw 1- 7/8 turns.
• Hold the center adjusting screw in position and
torque the locknut to 41 N·m (30 ft. lbs.) torque.
(4) Lower vehicle.
REAR BAND ADJUSTMENT
The transmission oil pan must be removed for
access to the rear band adjusting screw.
(1) Raise vehicle.
(2) Remove transmission oil pan and drain fluid.
(3) Loosen band adjusting screw locknut 5-6 turns
(Fig. 279). Be sure adjusting screw turns freely in
lever.
(4) Tighten adjusting screw to 8 N·m (72 in. lbs.)
torque.
Fig. 278 Band Adjustment Adapter Tool
1 – INCH-POUND TORQUE WRENCH
2 – 5/16 SOCKET
3 – ADAPTER C-3705 (TIGHTEN ADJUSTING SCREW TO ONLY
5 N·m/50 IN-LBS IF ADAPTER IS USED)
44RE TRANSMISSION
• Back off adjusting screw 4 turns.
• Hold adjusting screw in place and tighten locknut to 34 N·m (25 ft. lbs.) torque.
(5) Position new gasket on oil pan and install pan
on transmission. Tighten pan bolts to 17 N·m (13 ft.
lbs.) torque.
(6) Lower vehicle and refill transmission with
Mopart ATF Plus 3, Type 7176 fluid.
VALVE BODY
CONTROL PRESSURE ADJUSTMENTS
There are two control pressure adjustments on the
valve body;
• Line Pressure
• Throttle Pressure
Line and throttle pressures are interdependent
because each affects shift quality and timing. As a
21 - 122
TRANSMISSION AND TRANSFER CASE
WJ
ADJUSTMENTS (Continued)
Fig. 279 Rear Band Adjusting Screw Location
1 – ADJUSTING SCREW
2 – REAR BAND LEVER
3 – LOCKNUT
result, both adjustments must be performed properly
and in the correct sequence. Adjust line pressure first
and throttle pressure last.
LINE PRESSURE ADJUSTMENT
Measure distance from the valve body to the inner
edge of the adjusting screw with an accurate steel
scale (Fig. 280).
Distance should be 33.4 mm (1-5/16 in.).
If adjustment is required, turn the adjusting screw
in, or out, to obtain required distance setting.
Fig. 280 Line Pressure Adjustment
1 – WRENCH
2 – 1–5/16 INCH
touches throttle lever tang and the throttle lever cam
touches gauge tool.
NOTE: The kickdown valve spring must be fully
compressed and the kickdown valve completely
bottomed to obtain correct adjustment.
NOTE: The 33.4 mm (1-5/16 in.) setting is an
approximate setting. Manufacturing tolerances may
make it necessary to vary from this dimension to
obtain desired pressure.
One complete turn of the adjusting screw changes
line pressure approximately 1-2/3 psi (9 kPa).
Turning the adjusting screw counterclockwise
increases pressure while turning the screw clockwise
decreases pressure.
THROTTLE PRESSURE ADJUSTMENT
Insert Gauge Tool C-3763 between the throttle
lever cam and the kickdown valve stem (Fig. 281).
Push the gauge tool inward to compress the kickdown valve against the spring and bottom the throttle valve.
Maintain pressure against kickdown valve spring.
Turn throttle lever stop screw until the screw head
Fig. 281 Throttle Pressure Adjustment
1 – HEX WRENCH (IN THROTTLE LEVER ADJUSTING SCREW)
2 – SPECIAL TOOL C-3763 (POSITIONED BETWEEN THROTTLE
LEVER AND KICKDOWN VALVE)
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS
WJ
TRANSMISSION AND TRANSFER CASE
21 - 123
HYDRAULIC FLOW IN PARK
SCHEMATICS AND DIAGRAMS (Continued)
21 - 124
TRANSMISSION AND TRANSFER CASE
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HYDRAULIC FLOW IN NEUTRAL
SCHEMATICS AND DIAGRAMS (Continued)
WJ
TRANSMISSION AND TRANSFER CASE
21 - 125
HYDRAULIC FLOW IN REVERSE
SCHEMATICS AND DIAGRAMS (Continued)
21 - 126
TRANSMISSION AND TRANSFER CASE
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HYDRAULIC FLOW IN DRIVE FIRST GEAR
SCHEMATICS AND DIAGRAMS (Continued)
WJ
TRANSMISSION AND TRANSFER CASE
21 - 127
HYDRAULIC FLOW IN DRIVE SECOND GEAR
SCHEMATICS AND DIAGRAMS (Continued)
21 - 128
TRANSMISSION AND TRANSFER CASE
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HYDRAULIC FLOW IN DRIVE THIRD GEAR (CONVERTER CLUTCH NOT APPLIED)
SCHEMATICS AND DIAGRAMS (Continued)
WJ
TRANSMISSION AND TRANSFER CASE
21 - 129
HYDRAULIC FLOW IN DRIVE THIRD GEAR (CONVERTER CLUTCH APPLIED)
SCHEMATICS AND DIAGRAMS (Continued)
21 - 130
TRANSMISSION AND TRANSFER CASE
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HYDRAULIC FLOW IN DRIVE FOURTH GEAR (CONVERTER CLUTCH NOT APPLIED)
SCHEMATICS AND DIAGRAMS (Continued)
WJ
TRANSMISSION AND TRANSFER CASE
21 - 131
HYDRAULIC FLOW IN DRIVE FOURTH GEAR (CONVERTER CLUTCH APPLIED)
SCHEMATICS AND DIAGRAMS (Continued)
21 - 132
TRANSMISSION AND TRANSFER CASE
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HYDRAULIC FLOW IN MANUAL LOW (1)
SCHEMATICS AND DIAGRAMS (Continued)
WJ
TRANSMISSION AND TRANSFER CASE
21 - 133
HYDRAULIC FLOW IN MANUAL SECOND (2)
SCHEMATICS AND DIAGRAMS (Continued)
21 - 134
TRANSMISSION AND TRANSFER CASE
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HYDRAULIC FLOW DURING FULL THROTTLE 3–2 DOWNSHIFT (PASSING GEAR)
SCHEMATICS AND DIAGRAMS (Continued)
TRANSMISSION AND TRANSFER CASE
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21 - 135
GEAR RATIOS
SPECIFICATIONS
TRANSMISSION
GENERAL
Component
Metric
Inch
Planetary end play
0.127-1.22
mm
0.005-0.048
in.
Input shaft end play
0.56-2.31
mm
0.022-0.091
in.
Clutch pack clearance/
Front.
1.703.40mm
0.067-0.134
in.
Clutch pack clearance/
Rear.
0.81-1.40
mm
0.022-0.037
in.
Front Clutch
44RE-5 discs
Rear Clutch
44RE-4 discs
Overdrive clutch disc
usage
44RE-4 discs
Direct clutch disc
usage
44RE-8 discs
44RE Band adjustment
from 72 in. lbs.
Front band
Back off 1-7/8 turns
Rear band
Back off 4 turns
Recommended fluid
MoparT ATF Plus 3, type
7176
•
•
•
•
•
1ST GEAR-2.74
2ND GEAR-1.54
3RD GEAR-1.00
4TH GEAR-0.69
REV. GEAR-2.21
TORQUE
DESCRIPTION
TORQUE
Fitting, cooler line at trans . . . . 18 N·m (13 ft. lbs.)
Bolt, torque convertor . . . . . . . . 31 N·m (23 ft. lbs.)
Bolt/nut, crossmember . . . . . . . . 68 N·m (50 ft. lbs.)
Bolt, driveplate to crankshaft . . 75 N·m (55 ft. lbs.)
Plug, front band reaction . . . . . 17 N·m (13 ft. lbs.)
Locknut, front band adj. . . . . . . 34 N·m (25 ft. lbs.)
Switch, park/neutral . . . . . . . . . 34 N·m (25 ft. lbs.)
Bolt, fluid pan . . . . . . . . . . . . . . 17 N·m (13 ft. lbs.)
Screws, fluid filter . . . . . . . . . . . 4 N·m (35 in. lbs.)
Bolt, oil pump . . . . . . . . . . . . . . 20 N·m (15 ft. lbs.)
Bolt, overrunning clutch cam . . 17 N·m (13 ft. lbs.)
Bolt, O/D to trans. . . . . . . . . . . . 34 N·m (25 ft. lbs.)
Bolt, O/D piston retainer . . . . . . 17 N·m (13 ft. lbs.)
Plug, pressure test port . . . . . . . 14 N·m (10 ft. lbs.)
Bolt, reaction shaft support . . . . 20 N·m (15 ft. lbs.)
Locknut, rear band . . . . . . . . . . 41 N·m (30 ft. lbs.)
Bolt, valve body to case . . . . . 12 N·m (100 in. lbs.)
Screw, solenoid wiring connector . . . . . . . . . . 4 N·m
(35 in. lbs.)
Screw, solenoid to transfer plate . 4 N·m (35 in. lbs.)
21 - 136
TRANSMISSION AND TRANSFER CASE
WJ
SPECIFICATIONS (Continued)
THRUST WASHER/SPACER/SNAP RING DIMENSIONS
Component
Metric
Inch
Front clutch thrust washer (reaction shaft
support hub)
1.55 mm
0.061 in.
Rear clutch thrust washer (clutch retainer)
1.55 mm
0.061 in.
Intermediate shaft thrust plate (shaft hub pilot)
1.5-1.6 mm
0.060-0.063 in.
Output shaft thrust washer (rear clutch hub)
Select fit to set end play
Rear clutch pack snap ring
1.5 mm
0.060 in.
1.95 mm
0.076 in.
2.45 mm
0.098 in.
Planetary geartrain snap ring (at front of output shaft)
Select fit (three thicknesses available)
Overdrive piston thrust plate
Thrust plate and spacer are select fit. Refer to
size charts and selection procedures in
Overdrive Unit D&A procedures
Intermediate shaft spacer
PRESSURE TEST
Overdrive clutch
Fourth gear only
Pressure should be 469-496 kPa (68-72 psi) with
closed throttle and increase to 620-896 kPa (90-130
psi) at 1/2 to 3/4 throttle.
Line pressure (at
accumulator)
Closed throttle
372-414 kPa (54-60 psi).
Front servo
Third gear only
No more than 21 kPa (3 psi) lower than line pressure.
Rear servo
1 range
No more than 21 kPa (3 psi) lower than line pressure.
R range
1103 kPa (160 psi) at idle, builds to 1862 kPa (270 psi)
at 1600 rpm.
D range closed throttle
Pressure should respond smoothly to changes in mph
and return to 0-7 kPa (0-1.5 psi) when stopped with
transmission in D, 1, 2. Pressure above 7 kPa (1.5 psi)
at stand still will prevent transmission from
downshifting.
Governor
SPECIAL TOOLS
RE TRANSMISSIONS
Gauge Bar—6311
Spring Compressor and Alignment Shaft—6227
TRANSMISSION AND TRANSFER CASE
WJ
SPECIAL TOOLS (Continued)
Extension Housing Pilot—C-3288-B
Puller, Slide Hammer—C-3752
Pressure Gauge—C-3292
Gauge, Throttle Setting—C-3763
Pressure Gauge—C-3293SP
Seal Installer—C-3860–A
Dial Indicator—C-3339
Seal Remover—C-3985-B
Spring Compressor—C-3422-B
21 - 137
21 - 138
TRANSMISSION AND TRANSFER CASE
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SPECIAL TOOLS (Continued)
Installer—C-3995-A
Bushing Remover/Installer Set—C-3887-J
Nut, Bushing Remover—SP-1191, From kit C-3887-J
Universal Handle—C-4171
Cup, Bushing Remover—SP-3633, From kit C-3887-J
Seal Installer—C-4193-A
Remover, Bushing—SP-3551
Dial Caliper—C-4962
Installer, Bushing—SP-5117
TRANSMISSION AND TRANSFER CASE
WJ
SPECIAL TOOLS (Continued)
Remover, Bushing—SP-5324
Flusher—6906
Installer, Bushing—SP-5325
Compressor, Spring—C-3575-A
Installer—8114
Remover—6957
Gauge—6312
Installer—6951
Adapter—C-3705
Retainer—6583
21 - 139
21 - 140
TRANSMISSION AND TRANSFER CASE
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NV247 TRANSFER CASE
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
NV247 TRANSFER CASE. . . . . . . . . . . . . . . . . . 140
REMOVAL AND INSTALLATION
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . 140
DESCRIPTION AND OPERATION
NV247 TRANSFER CASE
The NV247 transfer case is used with the 3.1L
turbo diesel engine. Refer to Group 21, Transmission
/ Transfer Case of the gasoline engine manual for
additional information.
Fig. 2 Front Driveshaft Retaining Bolts
Fig. 1 NV247 Transfer Case
REMOVAL AND INSTALLATION
TRANSFER CASE
REMOVAL
(1) Open the hood and disconnect the negative battery cable.
(2) Remove the (2) upper fan shroud retaining
bolts.
(3) Raise the vehicle on a hoist.
(4) Remove the (2) lower fan shroud retaining
bolts.
CAUTION: Mark the position of the driveshaft in
relation to its companion flange prior to disassembly. Driveshaft must be reinstalled in the same position it was in prior to disassembly.
(5) Remove the front driveshaft retaining bolts
(Fig. 2) and remove the driveshaft from the transfer
1 – TRANSFER CASE
2 – FRONT DRIVESHAFT RETAINING BOLTS
3 – REFERENCE MARK
case companion flange. Support the driveshaft with
mechanics wire.
(6) Remove the rear driveshaft retaining bolts and
remove the driveshaft from the transfer case companion flange. Support the driveshaft with mechanics
wire (Fig. 3).
(7) Disconnect the transfer case shift cable from
the shifter arm (Fig. 4).
(8) Disconnect the vent tube from the transfer case
(Fig. 4).
(9) Remove the transmission oil pan and drain the
transmission fluid. Reinstall the transmission oil
pan.
(10) Position a jack under the transmission support crossmember and support the transmission and
transfer case assembly.
(11) Remove the (8) transmission support crossmember retaining bolts (Fig. 5).
TRANSMISSION AND TRANSFER CASE
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21 - 141
REMOVAL AND INSTALLATION (Continued)
Fig. 3 Rear Driveshaft - Supported
1 – REAR DRIVESHAFT
Fig. 5 Transmission Support Crossmember Position
& Orientation
1
2
3
4
5
6
–
–
–
–
–
–
TRANSFER CASE
TRANSMISSION MOUNT RETAINING BOLTS (2 OF 4)
EXHAUST SYSTEM SUPPORT BRACKET RETAINING BOLTS
CROSSMEMBER RETAINING BOLTS
TRANSMISSION
CROSSMEMBER RETAINING BOLTS
(12) Position a transmission jack under the transfer case.
(13) Lower the transmission assembly enough to
gain access and remove the transfer case to transmission retaining nuts.
(14) Remove the transfer case from the vehicle.
INSTALLATION
NOTE: If a replacement transfer case is being
installed, be certain the counter weight is installed
on the transfer case housing prior to installation.
Fig. 4 Disconnecting Transfer Case Shift Linkage
1
2
3
4
5
6
–
–
–
–
–
–
TRANSFER CASE RETRAINING NUTS
TRANSFER CASE SHIFTER CABLE
TRANSFER CASE VENT HOSE
FLAT BLADED TOOL
TRANSFER CASE
TRANSMISSION ELECTRICAL CONNECTOR
(1) Install the transfer case on the transmission.
Torque the transfer case retaining nuts to 75 N·m (55
ft. lbs.) (Fig. 6).
(2) Install the vent tube on the transfer case (Fig.
6).
(3) Connect the transfer case shift cable on the
shifter arm (Fig. 6).
(4) Using the jack, raise the transmission assembly into position and install the (8) transmission support crossmember retaining bolts (Fig. 7). Torque the
bolts to 41 N·m (30 ft. lbs.).
(5) Install the rear driveshaft. Torque the bolts to
32 N·m (24 ft. lbs.). Be certain to install the driveshaft in the same position as before removal.
21 - 142
TRANSMISSION AND TRANSFER CASE
WJ
REMOVAL AND INSTALLATION (Continued)
Fig. 7 Transmission Support Crossmember Position
& Orientation
Fig. 6 Transfer Case Position & Orientation
1
2
3
4
5
6
–
–
–
–
–
–
TRANSFER CASE RETRAINING NUTS
TRANSFER CASE SHIFTER CABLE
TRANSFER CASE VENT HOSE
FLAT BLADED TOOL
TRANSFER CASE
TRANSMISSION ELECTRICAL CONNECTOR
1
2
3
4
5
6
–
–
–
–
–
–
TRANSFER CASE
TRANSMISSION MOUNT RETAINING BOLTS (2 OF 4)
EXHAUST SYSTEM SUPPORT BRACKET RETAINING BOLTS
CROSSMEMBER RETAINING BOLTS
TRANSMISSION
CROSSMEMBER RETAINING BOLTS
(6) Install the front driveshaft. Torque the bolts to
32 N·m (24 ft. lbs.) (Fig. 8). Be certain to install the
driveshaft in the same position as before removal.
(7) Install the (2) lower fan shroud retaining bolts.
Torque the bolts to 15 N·m (132 in. lbs.).
(8) Lower the vehicle on the hoist.
(9) Install the (2) upper fan shroud retaining bolts.
Torque the bolts to 15 N·m (132 in. lbs.).
(10) Fill the transmission fluid to specification.
(11) Connect the negative battery cable.
Fig. 8 Front Driveshaft Retaining Bolts
1 – TRANSFER CASE
2 – FRONT DRIVESHAFT RETAINING BOLTS
3 – REFERENCE MARK
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