transmission.pdf

8/11/2019 transmission.pdf

1/87


2/87

2 1 - 2 T R A N S M I S S I O N 3 - S P E E D

MANUAL

C o n d i t i o n

PossibleCause

C o r r e c t i o n

T R A N S M I S S I O N

SLIPS

(a)

L i n k a g e i n t e r f e r e n c e .

(a)

I n s p e c t

a n d r e m o v e a l l l i n k a g e i n t e r f e r e n c

O U T O F

G E A R

( b )

G e a r s h i f t r o d s o u t o f a d j u s t m e n t .

( b )

A d j u s t t h e g e a r s h i f t r o d s a s o u t l i n e d in G e a

s h i f t L i n k a g e A d j u s t m e n t s .

(c)

S e c o n d

o r d i r e c t s p e e d g e a r s y n c h r o n i z e r

(c)

D i s a s s e m b l e

t h e t ra n s m i s s i o n a n d r e p l a c e p a

c l u t c h teeth w o r n .

a s

n e c e s s a r y .

( d )

C l u t c h

h o u s i n g b o r e o r f a c e o u t o f a l i g n m e n t .

(d)

R e f er to t h e C l u t c h G r o u p f o r c o r r e c t i o n p

c e d u r e s .

T R A N S M I S S I O N

(a) E x c e s s i v e e n d p l a y i n t h e c o u n t e r s h a f t g e a r .

(a)

R e p l a c e t h e t h r u s t w a s h e r s .

N O I S E S

( b )

L o o s e s y n c h r o n i z e r h u b s p l i n e fi t o n m a i n s h a f t .

(b)

I n s p e c t t h e m a i n s h a f t a n d s y n c h r o n i z e r h

a n d r e p l a c e p a r t s a s n e c e s s a r y .

(c )

L o o s e s p l i n e f it o n l o w s p e e d s l i d i n g g e a r t o

(c )

I n s p e c t t h e l o w s p e e d s l id i n g g e a r a n d m a

m a i n s h a f t s p l i n e .

s h a f t . Re p l a c e p a r t s a s n e c e s s a r y .

(d)

L o o s e s p l i n e f i t o f r e a r m a i n s h a f t f l a n g e .

(d)

I n s p e c t t h e m a i n s h a f t a n d f l a n g e s p l i n e s . R

p l a c e

p a r ts a s n e c e s s a r y .

(e)

D a m a g e d , b r o k e n o r e x c e s s i v e l y w o r n g e a r

(e)

R e p l a c e

t h e w o r n g e a r s .

t e e t h .

(0

D r i v e p i n i o n b e a r i n g w o r n .

(f)

R e p l a c e

t h e w o r n b e a r i n g .

F / g . ?

A - 7 4 5 T h re e

S p e e d

Transmiss ion (Sect iona l View)

F / g .

2

A-833

Four

S p e e d

Transmiss ion (Sect iona l View)


3/87

T R A N S M I S S I O N 3 - S P E E D M A N U A L 2 1 - 3

PART 1

A-745

3-SPEED

M A N U A L T R A N S M I SS IO N

SERVICE

PROCEDURES

Gearshift

Linkage Ad jus tmen t

(1) With th e 2nd and 3 r d con t r o l r od d i s connec t ed

from

t h e l e v e r on t h e co l um n and t h e 1s t and r e v e r s e

con t r o l r od d i s connec t ed from t h e t r ans m i s s i on l e v e r ,

p os i t ion b o t h t r ans m i s s i on l e v e r s i n neu t r a l . (Th e

neu t r a l d e t en t b a l l s m us t b e engaged t o m ake t h i s

ad j u s t m en t co r r ec t l y .) To ch eck t h i s , s t a r t t h e eng i ne

(with c l u t ch d i s engaged ) t h en r e l eas e th e c l u t c hslow

ly.

(2) Insp ec t t he fore and a ft mov ement o f t he s h i f t

l e ve r s i n t he s teer i ng co lum n. I f t he mov ement a t

ou t e r end o f t h e l e v e r s e x ceed s

1

j

1Q

i nch , l oos en t h e

t wo u p p e r b u s h i n g s c r e w s (F ig . 3) androtate t h e b u s h

i ng ( d ow nw ar d ) un t i l a l l f r ee p l ay o f t h e l e v e r s h as

b een rem ov ed . R e t igh t en t h e b us h i ng

s c r e w s

s ecu r e l y .

, (3) Ins ta l l a wedge or sui tab le tool be tween the

c ross -ove r b l ad e and t h e 2nd and 3 r d l e v e r , s o that

t he c ros s -ov er b lade i s engaged withJ>oth lev er c ros s

ov e r p i n s .

( 4 ) A d j u s t t h e l eng t h o f t h e 2nd . and 3 r d . con t r o l

r od un t i l t h e s t ub s h a f t o f t h e con t r o l r od o r s w i v e l

en t e rs t h e h o l e i n t h e c o l um n l e v e r (F i g . 4 ). I n s t a l l

t h e w as h e r and c l i p t o s ecu r e and t i gh t en t h e s w i v e l

l ock nu t t o 70 inch - p oun d s t o r que . Du r i ng t h e ab ov e

s e t t i ng , t h e 2nd . and 3 r d . con t r o l rod s h ou l d b e ad

j u s t ed t o a l s o p os i t ion t h e s e l ec t o r l e v e r (on t h e col

um n) 5 degrees above ho r i zonta l l eve l .

(5) S l i de the c lamp and s w i v e l (on the end o f t he

1s t and r e v e r s e con t r o l r od ) e i th e r i n o r ou t , un t i l t h e

s w i v e l s t ub s h a f t en t er s t h e h o l e i n t h e t r ans m i s s i on

l e v e r (F i g . 4 ). In s t a l l w as h e r s and c l i p t o s e cu r e . De

t e r m i ne t h e m i d b ack - l a s h p os i ti on i n t h e l i nkag e ,

Fig . 3Gearsh i f t Lever Ad j us tm e n t

Fig . 4 A-745 Gearsh i f t Con tro ls

t h en t i gh t en t h e con t r o l r od l ock nu t .

(6) Remove the pos i t i on ing wedge ortool from t he

c ross -ove r b l ad e and l e v e r , t h en m ov e t h e s e l ec t o r

l e v e l t h r ough a l l p os i t ions to ch eck ad j u s t m en t s and

t o i n s u r e c r os s - ov e r s m oo t h nes s .

STEERING

C O L U M N A N D G E A R S H IF T

Remova l

(1) D i sc onn ect t he ba t te ry cab le at t he ba t te ry neg

a t i ve te rm ina l .

(2) D i s con nect t he sh i f t l i nkage rod s from th e s h i f t

t ub e l e v e r s a t t h e

bottom

o f t h e s t ee r ing co l u m n as

semb ly .

( 3 ) R em ov e t h e s t ee r i ng s h a f t coup l i ng t o w o r m -

s h a f t c l am p b o l t .

(4 ) D i s conn ec t th e d i r ec t i ona l s i gn a l , and h o r n

w i re s .

(5) C o m p r es s an d t u r n t h e h o r n button

k

t u r n

counterc lockw i se to re lease the

button from

t he re

ta iner .

(6)

R em ov e t h e h o r n s w i t ch r e t a i n i ng

sc rews .

(7) D i s conn ec t t h e h o r n w i r e c l i p and r em ov e t h e

h o r n s w i t c h as s e m b l y .

(8 ) R em ov e t h e s t ee ri ng w h ee l r e t a i n i ng nu t and

washer .

(9)

R em ov e t h e s t ee r i ng w h ee l , u s i ng p u l l e r T oo l

C-3428.

(10 ) D i s con nec t t h e s t ee r ing co l u m n a t t h e i n s t r u

m en t p ane l b r acke t b y r em ov i ng t h e r e t a in i ng s c r e w s

and c l am p .

(11) Remove the f loor p la te to toe board a t tach ing

sc rews .

(12) L i f t t h e s teer i ng co lu mn as semb ly up and o f f


4/87

21- 4

T R A N S M I S S I O N 3 - S P E E D

MANUAL

SWITCH R E T A I N I N G

SCREWS

3)

F i g .

5

S t e e r i n g

Column

Upper End

the end of the wormshaft, and remove the assembly

ou t

through the

passenger

compartment being care

fu l not tosoilor

damage

theheadlining.

Disassembly

Place the steering column assembly on a clean

padded bench to protect the paint finish.

(1) Remove the turn signal lever retaining screw

and remove the lever.

(2)

Remove the three

recessed

head

switch

retain

ing

screws

(Fig.

5) and

p u l l

the

turn

signal

switch

and

switch

plate up and out, feeding the wires and con

nectors through the steeringcolumnjacket.

(3) Disengage the column jacket lower seal

from

the lip on the jacket, and slide the seal down toward

the coupling.

(4) Exert an upward force on the steering shaft to

force

the steering column jacket upper bearing and

insulator up and out of the counterbore in the bearing

housing.

Remove the insulator

from

the bearing.

(5) Using

snap

ring pliersToolC-3128, remove the

F i g .

6Rem ov i ng Bear ing

U p p e r Snap R ing

F/g. 7

R e m o v i n g

Steering

Shaft Bearing

bearing upper retainer

snap

ring

from

the up

groove in the steering shaft

(Fig.

6).

(6) Using bearing puller Tool C-3891, remove

steeringcolumnupper bearing(Fig.7).

(7) Remove the lower

snap

ringand slide the

ste

ing

shaft and coupling assembly down, and out of

steering column jacket assembly.

(8) Remove the column jacket lower seal

from

steering shaft.

62x453

F i g .

8Removing Shift Leve r Pivot

Pin


5/87


MANUAL

21-5

SPACER

N Y L O N

LOWER SUPPORTCUP

WASHER

BUSHING RETAINING

SCREWS (2)

N U T (2)

CUP

ATTACHING

SCREWS (3)

Fig . 9

S t e e r i n g

Co l u m n

Lower End

N O T E :

The s t eer i ng s h a ft and c o u p l i n g

a s se m b l y

is se r v i c e d as an a s se m b l y , and is not to be

d i sas

s em b l ed .

(9)

While

supporting the gearshift housing in the

area around the shift lever

pivot

pin, drive out the

pivot

pin, using a

3

/

1 6

punch, an d remove the shift

lever (Fig. 8).

(10)

Remove the threelower support cup to jacket

attaching

screws(Fig.

9) and remove the cup.

(11)

Remove the nylon thrust

washer,

the low and

reverse

lever, and the

spacer.

(12) Remove the two lower shift tube bushing re

tainingscrewsat the slotted holes in the jacket.

(13)

Slide the shift tube

wi th

the 2nd and direct

lever, nylon bushing, spring and spring retainer out

of the jacket (Fig. 10).

N O T E : Thes h i ft tube a s se m b l y , wi th 2nd and di

rec t

l e v e r , s p r i n g ,

retainer

and

n y l o n b u s h i n g

are

se r v i c e d as an a s se m b l y , and are not to be

d i s a s

s em b l ed .

S E L E C T O R

S P R I N G

S H I F T T U B E

A N D

L E V E R

A S S E M B L Y

1

C O L U M N J A C K E T

N Y L O N B U S H I N G

6 2 x 5 3 0 A

S P R I N G W A S H E R

B O L T (2)

I N S U L A T O R

C O L U M N

C L A M P

Fig .

10Removing Shift

Tu be

Asse mb ly

B E A R I N G

H O U S I N G

G E A R S H I F T

H O U S I N G

J A C K E T A S S E M B L Y

6 2 x 5 5 2 ^

Fig. 11

Jacket Tube (Disassembled)

(14) Remove the floor plate

from

the column jack

et.

(15)

Remove the hexagon nuts from the twobear

ing

housing retaining bolts, and

lift

the steering

co

umn

upper bearing housing off the jacket assembl

(Fig.

11).

(16)

L i f t

the gearshift housing and spring washe

off the steering column jacket.

Inspec t ion

After cleaning, inspect allparts for wear or dam

age. Note the condition of the pins in the two lowe

shift levers, the shift lever socket at the top end o

the shift tube, and the inner end of the shift lever

Inspect the steering shaft upper bearing for smooth

operation, and lubricate

wi th

Multi-Purpose

Chassi

Lubricantor similar lubricant. If the bearing has any

signsofroughnessor wear, it should be replaced. Re

placement bearings are pre-lubricated.

Assemb ly

(1) Position the spring washer on the ledge pro

vided in the top end of the steering column jacke

(Fig.

11) and place the shift lever housing in position

at the top end of the column jacket.

(2) Place

the two bearing housing retaining bolt

in

position in the housing, and just start the nuts on

them.

(3) Stand the column assembly upright, and lowe

the bearing housing into position, engaging the bolt

headsin the slots in the column jacket.

(4) Tighten the two retainer bolt nuts alternately

and evenly in

steps

to prevent unseating the bol

heads

f rom

the slots. Tighten to 50 inch pounds.

(5) Position the floor plate isolator in the openin

in the plate. Lubricate the isolator

wi th

asoapsolu

t ion

or rubber lubricant, then slide the

floor

plate as

sembly on the steering columnwi ththe insulated sid

down.

(6) The floor plate assembly must be installed be

fore

installing the shift tube and levers, since thi

cannot be

done

after the shift tube and levers are in

place in the steering column.


6/87

2 1 - 6 T R A N S M I S S I O N 3 - S P E E D M A N U A L '

N O T E : M e t a l to m e t a l w o r k i ng

su r f a c e s

s h o u l dbe

l ubr i ca ted w i th Mu l t i- P u r p o s e l u b r i c an t tofac i l i ta te

ins ta l la t i on .

(7 ) Turn

the

n y l o n b u s h i n g

on the

sh i f t tub e , (F ig .

10) sothe twoho l e si n theb u s h i n gar ea l i gned

with

the cen te r l i ne of the 2nd and 3rds p e ed sh i f t l e v e r ,

t h e n s l i d ethesh i f t tu be a nd l e v e r a s se m b l y t h r ou g h

the jacke t tube and

into

t he be a r ing h ou s i ng .

(8 ) Ins ta l l

thes p a c er

a r ou nd

the

se l e c to r l e ve r

so

i t

res t s

a g a in s t t he 2nd a nd 3 r d

speed

sh i f t l e ve r .

(9) Insta l l the low andr e ve r s e l eve r . Th e n i n s ta l l

t he ny l on w a she r , c e n te r i ng it o ve r the end of the

sh i f t t u be .

(10) In s ta l l t he lower su pp or t -cup

in

the jacke t (F ig .

9) ,

w h i l e h o l d i n g p r e s s u r e a ga in s t

the cup to

o ve r

com ethe

se l e c to r s p r i ng l oa d , s t a r t

the

t h r e e s u p p o r t

cu p re ta in ing s c r e w s , an d

tighten

to 30 i n c h p o u n d s .

(11) Loose ly en te r

the

l ow e r bu sh i ng r e ta i n i ng

sc rews t h r o u g h thes l o t sin thej a c k e t , and

into

the

n y l o n b u s h i n g (F i g .

10).

(12) Rotate

the

n y lo n b u s h i n g

to

w h e r e

al l

p l a y

at

t he sh i f t l e ve r s and space rs is e l i m i na te d , but no

b i n d i n g occu r s . With the b u s h i n g in t h i s po s i t i on ,

tighten

the twob u s h i n gstoj a c k e t sc rews to 30i n c h

p o u n d s

to rque .

N O T E : T h e sh i f t tube must

be

f ree

to

s l ide

upand

d o w n

in

it s bush ing .N ob i n d i n g

is

pe r m i s sa b le .

(13) Theg e a r sh i f t l e v e r i n su l a to r shou l dbee xa m

i n e d , an d if any wear ordamage ise v i de n t , it s h o u l d

be p u l l e d offt he l e ve r a nd r e p l a c e d .

N O T E :

W

o r n g e a r s h i f t lever i n su l a to r w i l l r e s u l t

in

a

t h u m p i n g

or rattling

s o u n d

in the

s t e e r i ng

co lumn.

(14) Place a s c re w d r i ve r b l a de be tw e e n the 2nd

an d 3rds p e ed sh i f t l e ve r a ndthese l e c to r l e ve r , soit

wil l

h o l d the se l e c to r l e ve r at ne u t r a l p o s i t i on ha l f

w a y be tw e en t he tw o sh i f t l e ve r s ( F ig .12).

SELECTOR LEVER

IN NEUTRAL

COLUM N LOWER

SEAL

1

\ f. i SCREW

?

D IVEP

62x454

\

8 3 A R i f - ' G

F X 1

\ S N A P R I N G

I N S T A L L I N G

S L E E V E

# C

3879

i

62x52i

Pig 12Holding S e l e c to r l e v e r In Neutral

Pig 13Installing Steering Column Upper

Bearing

(15) Posi t ion

the

g ea r sh i f t l e ve r

in the

sh i f t l e v

h o u s i n g

s o

it

engages

the

ho l e

i n the

sh i f t t u be p l a

with

the pi nho le a l i gned .

(16) Suppor t the j a c k e t t u be ho u s i ng in the ar

a r o u n d the pi nho le (F ig .8) andd r i v e thep i v o tp

i n f l u s h

withthe

h o u s i n g .

NOTE: Be fo re s l i d ing

the

co lumn jacket lower se

on tothe steering s h a f t ,the seal

should

be

cated. F i l lthe

cavity

inthe ins ide d iameter of

seal ,between the twomouded sealbushing

short

f ibre whee lbe ring

lubricant.

(17) Slide the se a l onto the s t e e r i ng sha f t ,an

dow n a g a i n s tthec o u p l i n g ,

with

the lip at theou t s i

d i a m e te r f a c i ng u p w a r d , so thesea l c an bepo s i t ion

on

the lowerend of the column jacketduring

asse

bly.

(18) Slide the s t e e r i ng sha f t into the c o l u m na

s e m b l y , a n d i n s t a l ltheh o r s e s h o e s h a p e d l o w e r s n

r i ng i n t he l ow e r g r oove on t he s t e er i ng sha f t .

(19) Place the s t e e r i ng c o l u m n u p pe r b e a r ingo

t he s t e e r i ng sha f t .

(20) Posi t ion

the

w a vy u pp e r sna p r i ng a g a i n s t

th

to p of thebear ing .

Place

b e a r ing i n s ta l l i ng s l e e ve Too lC-3879an dth

s te e r i ng w he e l r e ta i n i ng w a she rand nut , on the t

o f t he s t e e r ing sh a f t i n

that

o r de r ( F i g .13).

N O T E : Never

p re s s the

be ring

into

po s i t i on

w

a

s l e e ve

that

e xe r t s

p r e s s u r e

aga ins t the ou te r r ac

s i n c e t h i s w ou l d da m a g e the

bearing.

Do notd r

th ebe ring

into

p l a c e w i t h ah a m m e r , s i n c e d a

ag eto thebe ring an dsteering s h a f tcoupling

o c c u r .

(21) Turn

the

s t e e r i ng w h e e l r e ta in i ng

nut to

exe

p r e s s u r e on the

i n s ta l l i ng s l e e ve , u p pe r sna p r i n

a n d b e a r i n g , p r e s s i n g the be a r i ng d ow n on to th

k n u r l e d s e c t i o nof thes t e e r i ng t u be andaga ins tth

l ow e r s na p r i ng .

(22) Exe r t su f f i c ien t p ressu re aga ins t

the

u p p

snap

r i n g

to

flatten

it

aga ins t

the

be a r i ng

so it ca

ente r the g roove in the s t e e r i ng t u be . Bes u r eth

snap

r i ng i s

firmly

s ea ted in the g roov e .


7/87

T R A N S M I S S I O N 3 - S P E I D MANUAL 21-7

(23)

Placethe insulator over the bearing, then slide

the steering shaft, bearing and insulator downward

intothe counterbore provided in the bearing housing.

(24)

Position the directional switch assembly in the

bearing housing, while feeding the turn signal and

horn wires through the steering column and out

through

the opening provided in the column jacket.

(25)Placethe switch plate over the switch, and in

stallthe threeswitch retaining

screws

(Fig. 5).Tight

en

screws

to 24 inch

pounds

torque.

(26)Position the turn signal lever in the assembly,

sightingdown through the hole in the switch to align

the screw hole, and install the lever attaching screw.

Tightenscrewsto 24 inchpoundstorque.

Installation

(In the

Vehic le)

(1) Insert the column and jacket tube assembly

through

the

floor

pan opening, being careful not to

soilor

damage

the headlining.

(2) Position the clamp on the coupling and

wi th

the

master

splines on the worn shaft and coupling

aligned,

engagethe column coupling

wi th

the steering

gearworm shaft.

(3) Loosely fasten the steering column jacket to the

instrument panel bracket wi th the clamp and the two

attaching screws. Besure the tab on the clamp is en

tered in the locating slot in the column jacket.

(4) Wi th the steering shaft coupling clamp in posi

t ion

on the coupling assembly, install the clamp bolt

so that itengagesthe groove in the wormshaft.Tight

en clamp bolt nut to 30 footpoundstorque.

(5) Position the steering jacket assembly so the

steering shaft coupling is centered at the midpoint

of its travel.

N O T E :

With thes teer i ng

c o l u m n

jacke t c lamp

b o l t s

loose,

f ree

t r a v e l in the s t eer i ng s h a ft cou p l i ng

along

with the

s lo t ted

bolt ho les in the c o l u m n

c l a m p ;

permits

the j acke t and s t ee r i ng s h a f tas

s em b l ytomoveup an d down(ax ia l l y ) .

(6) Move the column assembly up or down in the

G A U G E H O L E

Fig.

74Positioning

Steer ing

Sha f t

C o up l i n g

instrument panel bracket so the rear edge of th

coupling

boot aligns

wi th

the gaugehole in the shaf

(Fig.

14). Tighten the steering column bracket clam

screws

securely.

(7) W i th the coupling centered, tighten the column

jacket to instrument panel clamp bolts to 95 inch

pounds torque.

(8)

Push

the

floor

plate down to contact the to

board, and start the floor plate to toe board attach

ingbolts, leaving them just loose enough so the floo

plate can be shifted to align the lower end of the col

umn

jacket.

(9) Visuallyinspect to besurethe lower end of th

column

jacket and shifter tube assembly is concentri

wi th the steering shaft. If they are not concentric

shift the floor plate to a position where it holds th

column

jacket and shift tube assembly concentri

wi th

the steering shaft and tighten the floor plate t

toe board attaching

screws

to 90 inch pounds.

N O T E : If the co l um n j acket ands h i ft tube

a s s e m

blyare not

con cen t r ic

it isp o ss i b l efor the s t ee r i ng

s h a f t to rub on the i n s i d e s u r f a c e of the s h i f t e

tubeat the lowerend.'

(10)

Recheck the lower end of the column jacke

and shift tube assembly, toassurethat they

have

re

mained concentric wi th the steering shaft after tight

ening the attaching screws.

(11) Slide the steering column lowersealup to th

bottom

end of the column jacket, and force the oute

li pof the sealinto position around the flanged lowe

end of the column jacket and shift tube assembly

(Fig.12).

(12) W i th the

master

splines in the steering whee

hub and steering shaft aligned, place the steering

wheel

on the steering shaft.

(13)

Install the steering wheel retaining

washer

and

nut. Tighten the steering wheel nut to 24 footpound

torque.

(14) Install any horn switch parts previously re

moved from the steering wheel, and install the horn

button

or horn

ring.

REAR

OIL SEAL

R e m o v e /

(1) Disconnect the propeller shaft at the transmis

sionflange andsecurethe shaft to the frame membe

for

working

clearance.

(2)

Hold

the mainshaft

wi th Tool

C-3281, tKfen re

move the flange nut and

washer.

(3) Remove the transmission flange, using

Tool

C

452 i fnecessary.

(4) Remove the oilseal,using Tool C-748.

Installation

(1) Drive a new seal into the extension housing

using Tool C-3837.


8/87

21-8


M A N U A L -

(2) Install

the transmission flange, washer and nut. (3) Reconnect the propeller shaft and tighten t

Tighten

nut to 175 foot-pounds torque. flange nuts to 30 foot-pounds torque.

MAJOR SERWIC1NG 3-SPEED MANUAL A-745

Removal

I M P O R T A N T : To r e m ove the

t r a n s m i s s i o n ,

it will

be necessa ry to f i r s t r e m ove the t o r s i on bar rear

anch o r c r os s m em b e r a n d r u b b e r i so la tor s .

Refer

to

G r o u p

2, T o r s i o n

Bar

R ub b e r

I so la to r ,

then

re

m o v ethet rans m i s s i on

as f o l l ow s :

(1)

Drain

the

lubricant

from

the transmission.

(2)

Disconnect the propeller shaft,

speedometer

ca

ble and housing and the gearshift

control

rods.

Re

m ove spe e dom e te r cab le

(pinion

comes out

with

ca

b le )with

ha nd s o

thath o u s i ng

i s

notc r u s h e d .

(3)

Remove the back-up

light

switch

leads

(if so

equipped).

(4)

Install

engine support

fixture

C-3487, mounting

firmly into

the holes in the side frame members

wi th

the support

ends

up against the underside of the oil

pan flange.

(5)

Raise the engine

slightly w i t h

the support

fix

ture.

Disconnect transmission extension housing

from

the removable center crossmember.

(6)

Support the transmission

wi th

a suitable jack.

Tap out the

four long

bolts and remove the center

crossmember (Fig. 15). Remove the bolts that attach

the transmission to the clutch housing.

(7)

Slide the transmission rearward

u n t i l

the

pinion

shaft clears the clutch disc before

lowering

the trans

mission. (This precaution w i l l

avoid

damaging the

clutch

disc).

(8)

Lower the transmission and remove

from

under

the vehicle.

(9)

Remove the rear motor support and crossmem

ber, then mount the transmission in repair stand DD-

1014.

Fig.

15Removing

or Installing Center

C r o s s m e m b e r (Auto. Trans. Shown

DISASSEMBLY

To

disassemble the transmission for cleaning a

overhaul,

refer to (Fig. 16), then proceed as

follow

(1)

Using

Tool

C-3281, flange

holding

tool,

remo

the flange retaining nut and washer.

(2)

If

necessary,

attach puller

Tool

C-452, and

move the flange assembly.

(3)

Remove the bolts that attach the cover to t

case.

Remove the cover then discard the gasket.

(4) Using a pair of feeler

gauges, measure

the sy

chronizer

float.

The measurement of the

float

shou

be taken before any further disassembly of the tran

mission is attempted.

(5)

The synchronizer float should be betwe

.050 and .090

inch,

when measured between the sy

chronizer outer

ring

pin and the opposite synchron

er outer

ring

(Fig. 17). This measurement must

made

on two pins, 180

degrees

apart

wi th

equal g

on

both

ends

for float determination.

(6)

There should be a snug fit between the pi

and the outer rings,

similar

to that obtained wh

measuring

wi th

a micrometer.

Extension

Hous ing

(1)

Remove the bolts and one nut that

attaches

t

extension housing to the transmission

case.

Slide t

extension housing off the mainshaft. Discard the

g

ket.

Drive Pinion

(1)

Remove the bolts that attach the main dri

pinion

bearing retainer, then slide the retainer off t

pinion.

Discard the gasket and drive the seal out

the retainer, using a suitable

drift.

(2)

Grasp the pinion shaft and p u l l the assemb

out of the

case

slightly, then slide the synchroniz

front

inner stop

ring

from

the short splines on t

pinion

as the

pinion

assembly is being removed

fro

the

case,

(Fig. 18).

(3)

Remove the

snapring

(Fig.19),

which

locks t

main

drive

pinion

bearing on the

pinion

shaft, usi

snapring

pliers. Remove the

pinion

bearing wash

then carefully

press

the

pinion

shaft out of the

be

ing,

using an arbor

press.

Remove the oil slinger.

(4)

Remove

snapring

and 15 bearing rollers

fro

the

cavity

in the end of the

drivepinion.

Mainshaft

(1)

W i t h

the transmission in reverse, remove t

outer center bearing

snap

ring,using a hook or a

f

blade, then

partially

remove the mainshaft.


9/87

J

COVER BOLT

SYNCHRONIZER

UNIT

>

S T O P R I N G j

3 R D A N D 4 T H

C L U T C H S L E E V E 3 R D S P E E D G E A R ( 29 T E E T H )

Fig .

33M a i n s h a f t Gear

Identification

6 4 x 7 4 2

C L U T C H

G E A R

S H I F T

P L A T E S (3)

1 S T A N D 2 N D C L U T C H

S L E E V E G E A R

1 S T S P E E D G E A R

2 N D S P E E D

G E A R

1 S T

A N D 2 N D

S Y N C H R O N I Z E R

S N A P R I N G ,

C L U T C H

G E A R

E X T E N S I O N H O U S I N G

Fig. 35R e m o v i n g or

Installing Center

Bear ing

Snap

RingFron t

C A U T I O N :

Make s u r e the sh a f ts are

free

of

b u r r s

before

r em ov a l ; o t h e r w i s e ,the

bores

m ay bes c o re d

r e s u l t i ng in leakage after r e a sse m b l y .

(3)

Carefully push the gearshift lever shafts out of

the housing,

allowing

the detent balls to

fal l

free. Re

move the

seals

and discard.

(4) Slide the gearshift interlock sleeve, interlock

pin

and spring out of the housing.

E x t e n s i o n

H ous ing and Mainshaft

(1) Remove the bolts that attach the extension

housing to the transmission

case.

(2) Slide the

th i rd

and fourth synchronizer sleeve

slightly forward,

then using a soft hammer, tap on

the extension housing (in a rearwarddirection).Slide

the housing and mainshaft assembly out and away

from the case, (Fig. 32).

(3) Refer to Fig. 33 for location of the various

gears,

synchronizer sleeves and clutches before dis

assembling the mainshaft.

3 R D A N D 4 T H S P E E D

S Y N C H R O N I Z E R C L U T C H

G E A R

Fig .

34

Disassembl ing

Mainshaft

(4) Using a pair of

snap

ring pliers, remove th

snap

ring

(Fig. 34), that retains the 3rd and 4th syn

chronizer clutch

gear

and sleeve, slide 3rd and 4t

synchronizer assembly off the end of the mainshaft

(5) Slide the 3rdspeed gear and stop ring off th

mainshaft. (Do not separate the 3rd and 4th spee

synchronizer clutch gear, sleeve,

shift

plates o

springs unless inspection reveals a replacement par

is required.)

(6)

Using a suitable pair of long

nose

pliers, com

press

the

snap

ringthat retains the mainshaft cente

bearing in the extension housing,(Fig.35).

(7)

Holding

the

snap

ring compressed, p u l l th

mainshaft assembly and bearing out of the extension

housing, (Fig. 36). Remove the rear oilseal from th

extension housing.

(8) Remove the

snap

ring that retains the main

shaft bearing on the shaft (Fig. 37). Remove bear

ing

from the mainshaft by inserting steel plates o

the front side of the 1st speed gear, then using

S N A P R I N G

G R O O V E

M A I N S H A F T

6 4 x 7 4 5

E X T E N S I O N

H O U S I N G I

Fig .

36

Re m o v i n g

or

Installing Mainshaft


20/87

21-20


MANUAL-

P L I E R S

S E A R I N G

B E A R I N G

R E T A I N i N G

R . N G

64x746

S N A P

R I N G

F i g . 37-Removing or

Installing Center

Bearing

Snap R ing

Rear

press or hammer, press ordrive the rear bearing off

the mainshaft. (Be

careful

not to damage the gear

teeth.)

(9)

Remove the bearing, bearing retainer r ing , 1st

speed gear, andfirstspeed stopring.

(10)

Again

usingsnapringpliers,remove the snap

ring that retains the 1st and 2ndclutch sleeve gear

and

clutchto the mainshaft, (Fig. 38).

Slide

the 1st

and2nd

clutch

sleeve gear and

clutch from

themain-

shaft.

(Do

not separate theclutchsleeve gear and the

clutch, unless inspectionreveals a replacement part

is required.)

Fig.

39 shows the various mainshaft bearing sur

faces of the gears. Inspect these surfaces for signs

of

wear,scoring,or anycondition that

would

not al

lowthe shaft to be used at reassembly.

(11) Usingashimstock feeler gauge, measure the

end play

of the countershaft gear, by

inserting

the

gauge between the thrust washer and the gear, (Fig.

40).

This measurement should not exceed .0045 to

.028 .If measurement is greater than that specified,

newthrust washers must beinstalledat reassembly.

S N A P R I N G

L I E R S

S T O P R I N G

1 S T S P E E D G E A R

2 N D S P E E D

G E A R

R E T A I N I N G R I N G

/

C L U T C H

*

\

1 S T

A N D 2 N D

C L U T C H S L E E V E G E A R

64x747A

J

B E A R I N G

S N A P R I N G

G R O O V E

S N A P R I N

G R O O V E

S N A P

R I N G

G R O O V E

6 4

x 7 4

Fig . 39Mainshaft Bearing Surfaces

* ^

% V

\ F E E L E R G A U G

K

* * '

\ ^>

N

T H R U S T W A S H E

C O U N T E R S H A F T G E A

6 4

x

7 5 0

Fig .

40

Measuring Countershaft

Gear

End

Play

Reverse Gear, Lever and Fork

Fig. 41 shows the reverse gear

shift fork,

the

verse slidinggear, the reverse slidinggear shaft a

the cluster gear.

(1)

Using a suitable dr i f t , drive the reverse sli

R E V E R S E

G E A R

S H A F T

R E V E R S E S L I D I N G

G E A R

R E V E R S E S P E E D

G E A R S H I F T F O R K

R E V E R S E

S H I F T E R

*

.

S H A F T

A N D

D E T E

P L A T E

^ B A C K U P

L I G H

IT*

S W I T C H

P L U G

R E V E R S E L E V E

D E T E N T S P R I N

R E T A I N E R

R E V E R S E

G E A R

S H I F T E R

S H A F T

6 4

x 7 4

Fig .

38

Removing

orInstalling Clu tch

Gear Snap R ing F ig .

41Gear, Shaft

and

Leve r

Identification


21/87


MANUAL 21-21

gear

shaft

(from front

to rear) far enough out of the

ease

to remove the reverse slider

gear,

(Fig.42).

Remove the

woodruff

key from the shaft. Remove

the shaft

from

the

case.

(2) Remove the reverse gearshift lever detent

spring retainer, gasket, plug and detent ball spring

from

the rear of the

case,

(Fig.41).

Th e following s tep

need

only bedoneif oil

leakage

is v i s i b l e a round the

r e ve r se gea r s h i f t

l ever sha f t .

(3) Remove anyb u r r s from the s h a ft so as not to

damaget h ecasebore,then carefully push the reverse

gearshift lever shaft

inward

and remove it

from

the

case(Fig.43).

Lif t

out the detent ball

from

the bottom

of

the

case.

Remove the

shift

fo rk

from

the shaft and

detent plate.

Drive P in ion and Cou ntersh af t Gear

(1) Using countershaft arbor C-3938, and a plastic

hammer, drive the countershaft out of the

case,

al

lowing the countershaft

gear

to be lowered to the

bottomof the

case.

(This

wi l l

permit the removal of

the main drivepinion.)

(2)Remove the main drive

pinion

bearing retainer

attaching bolts, then slide the retainer and gasket

from

the main drive

pinion

shaft. Remove the

pinion

o il

seal.

(3) Using a pair of

snap

ring pliers, remove the

main drive

pinion

bearing outer

snap

ring, using a

plastic hammer, drive the main drive

pinion into

the

case

and remove.

(4)

Using

snap

ring

pliers, remove the main drive

pinionbearing inner

snap

ring.Using an arborpress,

remove the bearing

from

the main drive

pinion.

(5)

Remove the

snap

ring

and 16 bearing rollers

fromthecavityin the drivepinion.

(6) Remove the countershaft gear (cluster)

from

the bottom of the

case,

(Fig.44).

(7)

Remove the arbor and the 76 needle type

bear

ings,thrust

washers

and spacer,

from

the center of

the countershaft

gear.

F i g . 43

Re m o v i n g

or

Insta l l ing Reverse Shi f t

Fork

and

Lever

C L E A N I N G

AND I N S PECT I ON

Clean the transmission case thoroughly, using

suitable solvent, dry wi th compressed air. Inspect th

case for cracks, strippedthreads in the various bol

holes and the machined mating surfaces for burrs

nicks

or anyconditionthat

would

render thecaseun

fit for further service. The

front

mating surfac

should be smooth; if any burrs are present,

dres

them

off wi th a

fine mi l l file.

If

threads

are stripped

install Helicoilinserts.

Ba l l Bear ings

Wash the ball bearing, using a clean solvent an

blow

drywi th compressed air.

C A U T I O N : Do not

s p i n

the

bear ingswith

air

p re s

s u r e ;

turn s l ow l y

by h a n d .

S p i nn i ng

u n l u b r i c a te d

bear ings

mayca u s e damage to the races and the

bal ls .

' ;- x 5 3 A

Fig .

42 Re m o v i n g

or Insta l l ing Reverse Sl ider

Gear

Fig.

44

Re mov ing

or

Insta l l ing Coun te rsha f t

Gear

and

Arbor


22/87

2 1 - 2 2 T R A N S M I S S I O N 4 - S P E E D MANUAL

B e surethe ballbearings are clean, then lubricate

them wi th l ightgrade engine oi l .Inspect the bearings

fo r roughness. This canbestbe determined byslowly

turningthe outerraceby hand. Measure the fit of the

bearings on their respective shafts.

Needle Type Bear ing Ro l le rs

and Spacers

Inspect all bearing rollers for flat

spots

or brinel l-

ing. Inspect all bearing roller

spacers

for signs of

wear or

galling. Install

new parts as required.

Gears

Inspect the gear teeth on the synchronizer clutch

gears

and stop rings. If there is evidence of chipping

or excessively

worn

teeth,

install

new parts at

reas

sembly. Be

sure

the clutchsleeve slides easily on the

clutchgear.Inspect the countershaft gearand allslid

in g

gear

teeth for chipped or broken teeth, or show

in gsigns of excessive wear. Small nicks or burrs must

be stoned off.

Inspect the teeth on the main drive

pinion.

If ex

cessively

worn,

broken or chipped, a new

pinion

should

be installed.

Test the interlock sleeve and pin for free move

ment in the bore of the shift housing. Examine the

detent balls for signs of

brinelling.

If the lever de

tents show signs of excessive wear to the extent of

no t

locking in gear, install a new part. Inspect the

shiftforks for wear on theshanksandpads.

Synchron izer Stop R ings

Inspect the stop rings for cracks at the corners of

the

shift

plate indexing slots. If the rings are cracked

or show signs of extreme wear on the threaded bore,

install

new rings at reassembly.

Mainshaft

Inspect the mainshaft

gear

and bearing mating sur

faces. If the

gear

contact surfaces show signs of gall

in g or excessively

worn,

a new mainshaft should be

installed.

Inspect the

snap

ring

grooves for burred

edges.

If

roughor burred, remove the

condition

using a

fine

file

or

crocus

cloth.

Inspect the synchronizer

clutch

gear

teeth on the shaft for burrs.

A S S E M B L Y

Countershaf t Gear and

Drive

P in ion

(1) Using heavy

grease,

coat the inside of the bore

of

the

gear

at each end, then

install

the

roller

bearing

spacer; centered. Insert arbor Tool C-3938,

into

the

gearand through thespacer.Center the arbor.

(2) Coat the needle typerollerbearings w i t h heavy

grease,

then at each end of the gear, install 19

ro l l

ers,

followed

by a

spacer

ring and 19 more

roller

bearings and 1spacerr ing , (Fig.30).

T H R U S T W A S H E R

T A N G

C O U N T E R S H A F T

G E A R

A R B O R

l

- V \ t

S T H R U S T W A S H E R ,

A

T A N G

6 x 7 5

Fig. 45 Co un te r sh af t Gear and Arbor Assembly

(3) If the countershaft gear end play exceed

.028

when measured during disassembly of Exte

sion Housing and Mainshaft/'

Step

11,

install

ne

thrust washers. Coat thrustwashers wi thheavy

grea

and

install

them over the arbor wi ththe tang side

wardthecase

boss,

(Fig.45).

(4) Install the countershaft gear assembly into t

case,

(Fig.44).Allowthe

gear

assembly to rest on

bottomof the

case.

(Be

sure

the thrustwashers stay

position.)

(5) Slide the bearingo i lslinger over the main dr

pinion

shaft, then

press

the main drive

pinionbe

in gon the

pinion

shaft. Be

sure

the outer

snap

ri

groove is toward the

front

(Fig. 46).

Seat

the beari

ful lyagainst the shoulder on thegear.

(6)

Install a new inner

snap

ring into the groo

B E A R I N G

S N A P R I N G ( O U T E R )

T O W A R D THE F R O N T

M A I N D R I V E

P I N I O N

S N A P R I N

4 ^ 7 $ $ , / ' *

7 ' X ,

R O L L E R B E A R I N G S (16 )

6 4 x 7

Fig. 46Main Drive Pinion and Bearing Assembly


23/87


MANUAL 21-23

to

retain the bearing. Besurethe

snap

ringisseated.

(7) Place thepinionshaft in a vise (withsoft jaws),

then install

16 bearing rollers in the cavity of the

shaft. Coat the bearing rollers

w i t h

heavy

grease,

then

install

the bearing retaining

snap

ring in its groove.

(8)

Install

the main drive

pinion

and bearing in

thecaseandintoposition in thefront bore. Tap light

ly intoplace, using a plastic hammer. Installthe outer

snap

ring

in the bearing groove.

(9)

UsingToolC-3789,

install

a new oil seal in the

retainer bore.

Install

the main drive

pinion

bearing

retainer and gasket.

Install

the attaching bolts and

tightento 35 foot-pounds torque.

(10) Start the countershaft in its bore at the rear

of

the

case.

Raise the countershaft

gear u n t i l

the

teeth mesh wi ththe main drive

piniongear.

(Be

sure

the thrust

washers

remain in position on the

ends

of

the arbor and the

tangs

aligned wi ththe slots in the

case.)

(11)

Align the countershaft arbor

wi th

theboresin

the

case,

then drive or

press

the countershaft

into

the

gear.Install

the

woodruff

key. Continue to

press

the

shaft into the case

u n t i l

the end of the shaft is

flush

with the rear face of the

case.

Remove arbor Tool

C-3938.

R e v e r s e

Gear, Lever and Fork

The followingstepneed

only

be done if the reverse

shaft was removed

because

of an o illeak.

(1) Install a new oil seal on the reverse gearshift

lever shaft. Coat the lever shaft

wi th

multi-purpose

grease,

then carefully

install

the lever shaft

into

bore

in

the

case,

(Fig. 43).

Install

the reverse fo rk in the

lever.

Fil l

the recess next to the shaft wi th

mul t i

purpose

grease,

theninstallthe operating lever, (Fig.

29). Install

a flatwasher, lockwasher and nut.

Tight

en nut securely.

(2) Install

the reverse

shift

detent balland spring.

Install

the reverse detent ball spring retainer gasket

and retainer. Tighten securely.

(3)

Position the reverse slider gearshaft in posi

t ionin the end of the

case,

and drive in far enough

to position the reverse slider

gear

on the protruding

end of the shaft

w i t h

the

shift

slot toward the rear,

(Fig.42). At the

same

time, engage the slot

wi th

the

reverse shift fork.

(4) Wi th

the reverse slider

gear

correctly posi

tioned,drive the reverse

gearinto

thecasefar enough

tobe able to

install

the

woodruff

key.

Drive

the shaft

into position,

flush

wi ththe end of thecase(Fig.42).

(5) Install the back-up l ight switch and gasket (if

so equipped), and tighten securely.

Ex tens ion H ous ing

and Mainshaft

(1)Slide the secondspeed gearover the mainshaft

(synchronizer cone toward the rear) and down into

position against the shoulder on the shaft, (Fig. 38).

(2)Slide the first and second clutchsleeve gearas

semblyincluding 2ndgearstop ring) over the main

shaft (with the shift fo rk slot toward the front) an

down into

position against the second

speed gea

(Be

surethe stopringis indexed

wi th

theshift plates

Installa new

snap

ringtosecure(Fig.38).

(3)

Slide the low

gear

stop

ring

over the shaft an

down into

position and index wi th the

shift

plates

(4) Slide the first speed gear (synchronizer con

toward theclutchsleeve gearjust installed) over th

mainshaft and downinto position against the clutc

sleevegear.

(5) Install

the mainshaft bearing retaining ring

followed

by the mainshaft center bearing. Using an

arbor and a suitable tool ,drive or

press

the bearing

down

into

position.

Install

a new

snap

ring tosecur

(Fig.

37).

(6)

Slide the rear bearing over the mainshaft and

driveor

pressinto

position.

(7) Install the partially assembled mainshaft int

the extension housing far enough to engage the re

tainingringin the slot in the extension housing (Fig

36).Compress the retainingringand at the

same

tim

seatthe mainshaft in the extension housing (Fig.35

(Be

sureretainingring isseatedall around its slot

(8) Slide the th i rd speed gear over the mainshaf

(with

the synchronizer cone toward the

front) fol

lowed

by theth i r d

gear

stopring.

(9) Install the th i rd and fourth speedsynchronize

clutch

gear

assembly

(including

sleeve,

shift

plate

and springs) on the mainshaft

(shift

fork slot toward

the rear) down against the th i rdspeed gear.Besur

and index the rear stopring wi ththe

clutchgearshif

plates (Fig. 34).

(10)

Install

the retaining

snap

ring (Fig. 34), then

using heavy

grease,

position the

front

stop ringove

theclutchgear,again indexing theringslots

wi th

th

shift

plates (Fig.34).

C A U T I O N : It is v e r y important that the i n d e x i n g

of

all s t op r i ngsand the pos i t i on ing of the

gea rs

an d c l u t c he s

on the m a i n sha f t be co r r ec t , or the

mating of the ex t ens i on h ous i ng to the

case

wil

not

be

p o ss i b l ewithoutdam age.

(11) Coat a new extension housing to

case

gaske

wi th

grease

(both sides) then place in position on the

case.

(12) Center the reverse slider

gear

on its shaft and

move the 3rd and 4thspeedclutchsleeve

slightly

to

ward

the

front,

then carefully insert the mainshaf

into

the

case,

(Fig.32). Be

sure

the 3rd and 4th

speed

stop ring is indexed

wi th

the shifter plates, and a

the

same

time

align

and push in on the extension

housing tobottomit against the gasket and

case.

Rotate the extension housing backintoplace,align

gasket if

necessary,install

extension housing attach

ingbolts and tighten securely.


24/87

21-24


MANUAL

Gearshi f t Homing

and

Mechanism,

The following 4 steps need only be done if the

gearshift housing was disassembled previously be

cause

of leakingseals.

(1) Slide the interlocksleeve into position in the

housing, (Fig. 31).Installa new oil

seal

on

each

gear

shifter shaft. Coat one of the shafts wi thmulti-pur

pose

grease,

then

install

the operating lever, (Fig.

29). Install

a flatwasher, lockwasher and nut. Tighten

nut

securely.

(2)Place

a detent ball in the sleeve,

followed

by

the spring and

interlock

pin.

Coat the other

gear

shift

er shaft

wi th

multi-purposegreaseand start the shaft

intothe housing.Placeremaining detent ball on the

spring

and

compress

ball and spring wi th a small

screwdriver, then push shaft in u n t i lseated.

F i l l

the

recess

next to the shaft wi th multi-purpose

grease,

theninstallthe operating lever, flatwasher, lockwash

er and nut. Tighten nut securely.Install the gearshift

forks in the gear shifter shafts and position forks

and shifter shafts in neutralposition,(Fig.31).

(3) Position the 1st and 2nd, 3rd and 4th clutch

sleeve gears

in the neutral position, then using a

new

gasketinstall

the

shift

housing making

sure

the

shift forks align

wi th

grooves in the clutchsleeve

gears.

(4) Wi th shift

housing in place,

install

the retain

ing

bolts fingertight,thenshift transmission into re

verse. Tighten

the two end

center alignment

b o l t s

f i rst , then tighten the other retaining bolts. Test by

shifting

in and out of

reverse

several times making

sure

no interference occurs when

shifting

into re

verse.

(5)

Install

the gearshift control assembly and con

nect the

shift

rods, (Fig. 28).

(6) Install

the propeller shaft flange on end of the

mainshaft. Installwasher and nut, and tighten to 175

foot-pounds torque.

Installation

Place

a small amount of short

fibre

wheel bearing

lubricant

around the inner end of the main drive

pin

io nshaft pi lotbushing in theflywheeland on the pin

io nbearing retainerreleasebearing

sleeve

area.

N O T E :Do not

l u b r i c ate

the

en d

of thepinion s h a f t ,

the c l u t ch

d i s c

s p l i n e sor thec l u t ch re lease l e ve rs .

(1) Remove transmission

from

the repair stand.

Shift

the transmission into reverse, then slide the

sembly under the vehicle.

(2) Wi th

the

shift

lever side downward and usi

a suitable jack, raise the transmission u n t i lthe dri

pinion shaft is centered in the clutch housing bo

(3) Roll the transmission slowly forward u n t i l t

pinion

shaft enters the clutch disc. Turn the

pini

shaft u n t i l the splines are aligned, then

work

t

transmission

forward u n t i l

seated against the clut

housing.

N O T E : Do not

allow

the t r a n sm i s s i o n to

h a n

after

the

pinion s h a f t

has

entered

the

c l u t ch d i s

(4)Rotate the transmission into position,install

taching bolts and tighten to 50 foot-pounds torqu

(5) Install the center crossmember and the fo

long bolts, position the isolator assemblies over

bolts,

install and tighten the retaining nuts to

foot-pounds torque. Makesure the extension housi

insulator and/or spring is in place,

install

and tight

retainingbolts to 35 foot-pounds torque.

(6) Remove the engine support

fixture

and dise

gagethe hooks

from

the holes in the frame side rai

(7)

Refer to Group 2 and reinstall the torsionba

and parts as outlined in Torsion Bar Rubber Iso

tor.

(8) Install

the

speedometer

pinion

and cable. R

connect the parking brake cable, propeller shaft, a

back-up l ightswitch leads.

(9) Reconnect the exhaust pipes (if remove

Tightenbolts securely.

(10)

Fil l

the transmission

wi th

7Vfe pints of

Mu

purpose Gear

Oi l

SAE 140. If

shift effortbecomes

tremely

high

during

cold

weather, Multi-purposeG

Oil

SAE 80 should be used. Automatic Transmissi

F l u i d

Type A Suffix A may also be used in

tremely

coldclimates.

(11)

Attach the gearshift lever to the stub lever

the shift housing, tighten the two bolts secure

Carefully

slide the lower boot up over the two

b

heads.

(12) Slide the upper boot down the

shift

lever a

secure

in place wi th the screws.

Install

the cons

t r im

plate.

(13)Road

test

the vehicle to make

sure

the tra

mission

shifts smoothly andoperatesquietly.

(14)If the shift linkage requires adjustment, re

to

Page15.


25/87

T O R Q U E F L I T E T R A N S M I S S I O N ( T O R Q U E C O N V E R T E R ) 2 1 - 2 5

PART 2

T O R Q U E F L I T E

T R A N S M I S S I O N T O R Q U E C O N V E R T E R )

( A - 7 2 7

-B)

Descr ip t ion

T h e T o r queF l i t e T r ans m i s s i on m od e l i d en t if i cat i on

m ar k i ngs a r e cas t i n r ai s ed l et t er s ab ou t % i nch h i gh

on the lower lefts i d e o f t h e t r ans m i s s i on b e l l h ous i ng .

The A-727-B t ransm i ss ion (F ig . 1) us ed i n t he C h r y s

l e r m od e l v eh i c l e s , h as th e s l i d i ng s p l i ne t y p e

output

s h a f t T h e A - 727 -B t r ans m i s s i on (F ig . 2) u s ed i n t h e

I m p e r i a l m od e l s i s th e s am e as f o r t h e Ch r y s l e r m od

el s e x cep t that th e output s h a f t

u ses

t he de tachab le

t y p e u n i v e r s a ljoint f lange.

T h e T o r qu eF l i t e T r ans m i s s i on com b i nes a t o r que

conv e r t e r with a fu l ly-automat ic 3- speed gear sys tem.

T h e t o rque conv e r t e r h ous i ng and tr ans m i s s i on case

a r e an i n t eg r a l a l um i num cas t i ng . T h e t r ans m i s s i on

cons i s t s of two multiple d i s c c l u t ch es , an o v e r r un n i ng

c l u t c h , two s er vos and band s , and two p lanetary gear

sets to p rov i de th ree forw ard ra t ios and a rev er se

ra t i o . The comm on su n gear of t he p lanetary gear

sets i s connected to t he frontc l u t c h b y a d r i v i n g s h e l l

w h i ch i s s p l i ned t o t h e s u n gea r and t o t h e

front

c l u t ch r e ta i ne r . T h e h yd r au l i c s y s t em

cons i s t s

of a

front

and r ea r p um p , and a s i ng l e v a l v e b od y w h i ch

conta ins a l l o f the va l v es excep t t he go vernor va l v e .

V en t i ng o f t h e t r ans m i s s i on i s accom p l i s h ed b y a

d r i l l e d p as s age t h r ough t h e up p e r

part

o f t he

front

o i l p u m p h o u s i n g .

The torque co nv er te r is a t tached to t he c ranks ha f t

t h rou gh a f l ex i b le d r i v i n g p la te . Coo l i ng o f t he con

v e r t e r i s accom p l i s h ed b y c i r cu l a t i ng t h e t rans m i s s i on

fluid

t h rou gh an o il -to -water t ype coo le r , l oca ted i n

the rad ia tor lower tank . The torque conver te r

assem

b l y i s a s ea l ed un i t w h i ch canno t b e d i s a s s em b l ed .

T h e t r a n s m i s s i o n fluid is filtered b y an i n t e r na l

D a c r o n Ty p e

filter

a t tached to t he low er s i de o f t he

v a l v e b od y a s s em b l y .

E n g in e

to rque i s transm i t ted to t he torque conv er t

e r t h en , t h r ough t h e i np u t s h a f t t o t h e

multiple

d i s c

c lu t ches i n t h e t r ans m i s s i on . T h e p ow e r flowd e p e n d s

on the app l i ca t ion o f the c lu tches and bands . Refer to

C l u t c h Engagem en t and B and A p p l i ca t ion Ch a r t .

T h e T o r qu eF l i t e T r ans m i s s i on s e r v i c i ng p r oced

u re s a r e in gene r a l t h e s am e f o r a l l C h r y s l e r and Im

p e r i a l m od e l s . W h e r e v a r ia t ions i n p r oced u r es occu r ,

ap p l i ca ti on t o t h e Ch r y s l e r o r I m p e r i a l i s i nd i ca t ed .

How ev e r , w h en a

383

o r

413

c ub i c inch (H i- Per f o r m

ance) eng ine i s us ed , t he gov ernor s p r i ng i s l i gh te r to

p r ov i d e h i gh e r s h i f t s p eed s .

The s p ec ia l par t s a re l i s ted i n t he 1965 Par t s Cata

log ; t here fore , be s ure they a re us ed wh en rep lace

m en t i s neces s a r y .

SERVICE

DIAGNOSIS

T O R Q U E F L I T E T R A N S MI S S I ON

N O T E : T h e t r a n s m i s s i o n s h o u l d n o t b e r e m o v e d n o r d i s a s s e m b l e d until a c a r e f u l d i a g n o s i s is m a d e t h e

definite c a u s e d e t e r m i n e d a n d a l l p o s s i b l e e x t e r n a l c o r r e c t io n s p e r f o r m e d . In d i a g n o s i n g a n y a b n o r m a l s h i f t

c o n d i t i o n , a l w a y s m a k e t h e h y d r a u l i c p r e s s u r e t es t s b e f o r e d i s a s s e m b l y o r r ep l a c e m e n t o f p a r t s .

C o n d i t i o n

Possible

Cause

Correction

( a ) A d j u s t th e e n g i n e i d l e s p e e d t o 5 0 0 r p m . R e a d

j u s t

throttle

l i n k a g e .

( b ) I n s p e c t t h e

fluid

l e v e l , t h e n perform h y d r a u l i c

p r e s s u r e t e s ts a n d a d j u s t t o s p e c i f i c at i o n s .

( c ) A d j u s t t h e l o w -r e v e r s e b a n d .

( d ) P e r f o r m p r e s s u r e t e s t s t o d e t e r m i n e c a u s e a n d

c o r r e c t a s r e q u i r e d .

( e ) I n s p e c t th e a c c u m u l a t o r f o r s t i c k i n g , b r o k e n

r i ng s o r s p r i n g . R e p a i r a s r e q u i r e d .

( f ) L o w - r e v e r s e s e r v o , b a n d o r l i n k a g e m a l f u n c t i o n , ( f ) I n s p e c t t h e s e r v o f o r d a m a g e d s e a l s , b i n d i n g

l i n k a g e o r

faulty

b a n d l i n i n g . Re p a i r a s r e

q u i r e d .

( g ) D is a s s e m b l e a n d i n s p e c t c l u t c h . R ep a i r o r r e

p l a c e a s r e q u i r e d .

H A R S H E N G A G E M E N T ( a ) E n g i n e i d l e s p e e d t o o h i g h .

IN D , 1 ,2 A N D R

( b ) H y d r a u l i c p r e s s u r e s t o o h i g h o r l o w .

( c ) L o w - r e v e r s e b a n d o u t o f a d j u s t m e n t .

( d ) V a l v e b o d y m a lf u n c t io n o r l e a k a g e .

( e ) A c c u m u l a t o r s t i c k in g , b r o k e n r i n gs o r s p r i n g .

(g ) Worn o r faulty front a n d / o r r e a r c l u t c h .


26/87

2 1 - 2 6 T O R Q U E F L I T E T R A N S M I S S IO N ( T O R Q U E C O N V E R T E R )

Condition

Possible

Cause

C o r r e c t i o n

D E L A Y E D

E N G A G E -

(a ) L ow

fluid

l e v e l .

M EN T IN D ,

1 , 2

A N D R

( b ) In c o r r e c t c o n t r o l c a b l e a d j u s t m e n t .

( c ) O i l filter c l o g g e d .

( d ) H y d r a u l i c p r e s s u r e s t o o h i g h o r l o w .

( e ) V a l v e b o d y m a l fu n c t i o n o r l e a k a g e .

( f) A c c u m u l a t o r s t i c k i n g , b r o k e n r in g s o r s p r i n g .

( g ) C l u t c h e s o r s er v o s s t ic k i n g o r n o t o p e r a t i n g .

( h ) Fau l t y front p u m p .

(i )

Worn

o r

faulty front

a n d / o r r e a r c l u t c h .

(j )

Worn

o r b r o k e n in p u t s h a f t a n d / o r r e a c t i o n

s h a f t s u p p o r t s e a l r i n g s .

( k ) A e r a t e d f l u i d .

R U N A W A Y O R H A R S H ( a ) L o w fluid l e v e l .

U PSHIFT A N D 3 - 2

K I C K D O W N ( a ) I nc o r re c t

throttle

l i n k a g e a d j u s t m e n t .

( c ) H y d r a u l i c p r e s s u r e s t o o h i g h o r l o w .

( d ) K i c k d o w n b a n d o u t o f a d j u s t m e n t .

( e ) V a l v e b o d y m a l f u n c t i o n o r l e a k a g e .

( f ) G o v e r n o r m a l f u n c t i o n .

( g ) A c c u m u l a t o r s t i c k i n g , b r o k e n r i n g s o r s p r i n g .

( h ) C l u t c h e s o r s e r v o s s t i c k in g o r n o t o p e r a t i n g .

( i) K i c k d o w n s e r v o , b a n d o r l i n k a g e m a l f u n c t i o n .

(j )

Worn

o r faulty front c l u t c h .

(k ) Worn o r b r o k e n i n p u t s h a f t a n d / o r r e a c t i o n


N O U PSHIFT (a ) L ow

fluid

l e v e l .

( b ) I nco r rec t

throttle


( c ) K i c k d o w n b a n d o u t o f a d j u s t m e n t .


( e ) G o v e r n o r s t i c k i n g .

( f) V a l v e b o d y m al f u n c t io n o r l e a k a g e .


( h ) C l u t c h e s o r s e r v o s s t i c k in g o r n o t o p e r a t i n g .

(a ) R e f i l l t o co r r ec t l e ve l

with

A u t o m a t i c T r an s m

s i o n

F l u i d , T y p e A , S u ff i x A .

( b ) A d j u s t t h e c o n t r o l c a b l e .

( c ) R e p l a c e t h e o il filter.

( d ) P er f o rm t h e h y d r a u l i c p r e s s u r e t es t s a n d a d j u

t o s p e c i f i c a t io n s .

( e ) P e r f o r m p r e s s u r e t es t s t o d e t e r m i n e c a u s e a


( f ) I n s p e c t t h e a c c u m u l a t o r f o r s t i c k i n g , b r o k

r i n g s o r s p r i n g . R e p a i r a s r e q u i r e d .

( g ) R e m o v e th e v a l v e b o d y a s s e m b l y a n d perfo

a i r p r e s s u r e te s t s . R e p a i r a s r e q u i r e d .

( h ) P e r f o r m t h e h y d r a u l i c p r e s s u r e t e s t s . A d j u s t

r e p a i r a s r e q u i r e d .

( i ) D i s a s s e m b l e a n d i n s p e c t c l u t c h . R e p a i r o r r


( j) I n s p e c t a n d r e p l a c e s e a l r i n g s a s r e q u i r e d , a l

i n s p e c t r e s p e c t iv e b o r e s f o r w e a r . R e p l a c e t

p a r t s a s r e q u i r e d .

( k ) I n s p e c t f o r a i r l e a k a g e into t h e front p u m p

s

tion

p a s s a g e s .

( a ) R e f i l l t o co r r ec t l e ve l with A u t o m a t i c T r a n s m

s i o n F l u i d , T y p e A , S u ff i x A .

( b ) A d j u s t t h e throttle l i n k a g e .

( c ) P e rf o r m t h e h y d r a u l i c p r e s s u r e t es t s a n d a d j u

t o s p e c i f i c a t i o n s .

( d ) A d j u s t t h e k i c k d o w n b a n d .

( e ) P e r f o rm t h e h y d r a u l i c p r e s s u r e t es t s a n d a d j u


( f) I n s p e c t t h e g o v e r n o r a n d r e p a i r a s r e q u i r e d .

( g ) I n s p e c t t h e a c c u m u l a t o r f o r s t i c k i n g , b r o k


( h ) R e m o v e t h e v a l v e b o d y a s s e m b l y a n d

perfo

t h e a i r p r e s s u r e t e s t s . R e p a i r a s r e q u i r e d .

( i ) I n s p e c t t h e s e r v o f o r s t i c k i n g , b r o k e n s e a l r i n g

b i n d i n g l i n k a g e o r

faulty

b a n d l i n i n g . Re p

a s

r e q u i r e d .

( j) D i s a s s e m b l e a n d i n s p e c t t h e c l u t c h . R e p a i r

r e p l a c e a s r e q u i r e d ,

( k ) I n s p e c t a n d r e p l a c e s e a l r i n gs a s r e q u i r e d , al

i n s p e c t t h e r e s p e c t i v e b o r e s fo r w e a r . R e p l a

p a r t s a s r e q u i r e d .

(a ) R e f i l l t o co r rec t l e ve l with A u t o m a t i c T r an s m

s i on

F l u i d T y p e A , S u ff ix A .

( b ) A d j u s t t h e throttle l i n k a g e .

( c ) A d j u s t t h e k i c k d o w n b a n d .

( d ) P e rf o r m t h e h y d r a u l i c p r e s s u r e t es t s a n d a d j u


( e ) R e m o v e a n d c l e a n t h e g o v e r n o r . R e p l a c e p a

i f n e c e s s a r y .

( f) P e r f o r m p r e s s u r e t e s t s t o d e t e r m i n e c a u s e a


( g ) I n s p e c t a c c u m u l a t o r f o r s t i c k i n g , b r o k e n r i n

o r s p r i n g . R e p a i r a s r e q u i r e d .

( h ) R e m o v e t h e v a l v e b o d y a s s e m b l y a n d perfo

t h e a i r p r e s s u r e te s t s . R e p a i r a s r e q u i r e d .


27/87

TORQUEFLITE T R A N S M I S S I ON (T OR QU E CON V ER T ER )

2 1 - 2 7

Condit ion

P o s s i b l e

Cause

C o r r e c t i o n

N O U P S H I F T

C o n t i n u e d

I) F a u l t y r e a r o i l p u m p ,

( j) K i c k d o w n s e r v o , b a n d o r l i n k a g e m a l f u n c t i o n .

(k ) Worn o r faulty front c l u t c h .

(I) Worn o r b r o k e n i n p u t s h a f t a n d / o r r e a c ti o n


N O K I C K D O W N O R ( a ) I nc o r r ec t

throttle


N O R M A L D O W N S H I F T ( b ) I n c o r r e c t c o n t r o l c a b l e a d j u s t m e n t .

( c ) K i c k d o w n b a n d o u t o f a d j u s t m e n t .


( e ) G o v e r n o r s t i c k i n g .

( f ) V a l v e b o d y m a l f u n c t i o n o r l e a k a g e .


( h ) C l u t c h e s o r s e r v o s s t i c k i n g o r n o t o p e r a t i n g .

( i ) K i c k d o w n s e r v o , b a n d o r l i n k a g e m a l f u n c t i o n .

S HI F TS

ER R AT IC

SLIPS I N F O R W A R D

DR IVE

P O S I T I O N S

( j) O v e r r u n n i n g c l u t c h n o t h o l d i n g .

(a ) L ow fluid l e v e l .

( b ) A e r a t e d f l u i d .

( c ) I nco r rec t throttle l i n k a g e a d j u s t m e n t .

( d ) I n c o r r e c t c o n t r o l c a b l e a d j u s t m e n t .

( e ) H y d r a u l i c p r e s s u r e s t o o h i g h o r l o w .

( f ) G o v e r n o r s t i c k i n g .

(g ) O i l filter c l o g g e d .

( h ) V a l v e b o d y m a l f u n c ti o n o r l e a k a g e .

( i) C l u t c h e s o - s e r v o s s t i c k i n g o r n o t o p e r a t i n g .

( j) F a u l t y r e a r a n d / o r

front

o i l p u m p .

(k ) Worn o r b r o k e n i n p u t s h a f t a n d / o r r e a c ti o n


(a ) L ow fluid l e v e l .

( b ) A e r a t e d f l u id .

( c ) I nco r rec t

throttle


( d ) In c o r r e c t c o n t ro l c a b l e a d j u s t m e n t .

( e ) H y d r a u l i c p r e s s u r e s t o o l o w .

( i ) P e r fo r m t h e h y d r a u l i c p r e s s u r e t e s t s , a d j u s t o r

r e p a i r a s r e q u i r e d ,

( j) I n s p e c t t h e s e r v o f o r s t i c k in g , b r o k e n s e a l r i n g s ,


faulty

b a n d l i n i n g . R e p a i r a s

r e q u i r e d .

( k ) D i s a s s e m b l e a n d i n s p e c t c l u t c h . R e p a i r o r r e


( I) I n s p e c t a n d r e p l a c e t h e s e a l r i n g s a s r e q u i r e d ,

a l s o i n s p e c t t h e r e s p e c t i v e b o r e s f o r w e a r . R e

p l a c e p a r t s a s r e q u i r e d .

( a ) A d j u s t t h e throttle l i n k a g e .

( b ) A d j u s t t h e c o n t r o l c a b l e .

( c ) A d j u s t t h e k i c k d o w n b a n d .

( d ) P e r fo r m t h e h y d r a u l i c p r e s s u r e t es t s a n d a d j u s t


( e ) Re m o v e a n d c l e a n t h e g o v e r n o r . R e p l a c e p a r t s


( f ) P e r fo r m p r e s s u r e t es t s t o d e t e r m i n e c a u s e a n d


( g ) I n s p e c t t h e a c c u m u l a t o r f o r s t i c k i n g , b r o k e n

r i n gs o r s p r i n g . Re p a i r a s r e q u i r e d .

( h ) R em o v e th e v a l v e b o d y a s s e m b l y a n d perform

t h e a i r p r e s s u r e t e s t s . R e p a i r a s r e q u i r e d .

( i) I n s p e c t t h e s e r v o f o r s t i c k i n g , b r o k e n s e a l r i n g s ,


faulty

b a n d l i n i n g . R e p a i r

a s

r e q u i r e d .

( j) D i s a s s e m b l e t h e t r an s m i s s i o n a n d r e p a i r t h e

o v e r r u n n i n g c l u t c h a s r e q u i r e d .

(a ) R e f i l l t o t he co r rec t l e ve l with A u t o m a t i c T r a n s

m i s s i o n F l u i d , T y p e A , S u f f ix A .

( b ) I n s p e c t f o r a i r l e a k a g e

into

th e

front

p u m p

su c t i on p a s s a g e s .

( c ) A d j u s t t h e throttle l i n k a g e .

( d ) A d j u s t t h e c o n t r o l c a b l e .

( e ) P e rf o r m t h e h y d r a u l i c p r e s s u r e t e s t s a n d a d j u s t


( f ) R e m o v e a n d c l e a n th e g o v e r n o r . R e p l a c e p a r t s


( g ) R e p l a c e t h e o i l filter.

( h ) P e r f o r m p r e s s u r e t e s ts t o d e t e r m i n e c a u s e a n d


( i) R em o v e th e v a l v e b o d y a s s e m b l y a n d perform

a i r p r e s s u r e t e s t s . R e p a i r a s r e q u i r e d .

( j) P e r f o r m t h e h y d r a u l i c p r e s s u r e t e s t s , a d j u s t o r

r e p a i r a s r e q u i r e d ,

( k ) I n s p e c t a n d r e p l a c e t h e s e a l ri n g s a s r e q u i r e d ,

a l s o i n s p e c t r e s p e c t i v e b o r e s f o r w e a r . R e p l a c e

t h e p a r t s a s r e q u i r e d .

(a ) R e f i l l t o t he co r rec t l e ve l with A u t o m a t i c T r a n s

m i s s io n F l u i d , T y p e A , S u f f i x A .

( b ) I n s p e c t f o r a i r l e a k a g e into t h e front p u m p

s u c t i o n p a s s a g e s .

( c ) A d j u s t th e throttle l i n k a g e .

( d ) A d j u s t t h e c o n t r o l c a b l e .

( e ) P er f o r m t h e h y d r a u l i c p r e s s u r e t e s t s a n d a d j u s t



28/87

2 1 - 2 8 T O R Q U E F L I T E T R A N S M I S S I O N ( T O R Q U E C O N V E R T E R ) -

Condition Possible

Cause

C o r r e c t i o n

SLIPS

I N F O R W A R D

D R I V E

P O S I T I O N S

C o n t i n u e d

( f ) V a l v e b o d y m a l f u n c t i o n o r l e a k a g e .


( h ) C l u t c h e s o r s e r v o s s t i c k i n g o r n o t o p e r a t i n g .

(i ) Worn o r faulty a n d / o r r e a r c l u tc h .

( j) O v e r r u n n i n g c l u t c h n o t h o l d i n g .

(k )

Worn

o r b r o k e n i n p u t s h a f t a n d / o r r e a ct i o n


SLIPS

IN

RE V E RS E

O N L Y ( a ) L o w

fluid

l e v e l .

( b ) A e r a t e d f l u id .

( c ) In c o r r e c t c o n t r o l c a b l e a d j u s t m e n t .


( e ) L o w - r ev e r s e b a n d o u t o f a d j u s t m e n t .

( f) V a l v e b o d y m a lf u n c t i o n o r l e a k a g e .

( g ) F r o n t c l u t c h o r r e a r s e r v o , s t i c k i n g o r n o t o p e r a t

i n g .

( h ) L o w - r e v e r s e s e r v o , b a n d o r l i n k a g e m a l f u n c t i o n .

( i ) Fau l t y

front

o i l p u m p .

SLIPS I N A L L P O S I T I O N S ( a ) L o w fluid l e v e l .

( b ) H y d r a u l i c p r e s s u r e s t o o l o w .

( c ) V a l v e b o d y m a l f u n c t i o n o r l e a k a g e .

( d ) F a u l t y front oi l p u m p .

( e ) C l u t c h e s o r s e r v o s s t i c k i n g o r n o t o p e r a t i n g .

(f )

Worn

o r b r o k e n i n p u t s h a f t a n d / o r r e ac t i o n


(a ) L ow

fluid

l e v e l .


(c ) O i l filter c l o g g e d .

( d ) V a l v e b o d y m a l f u n c t io n o r l e a k a g e .

( e ) F a u l t y front o il p u m p .

( f ) C l u t c h e s o r s e r v o s s t i c k i n g o r n o t o p e r a t i n g .

N O D R I V E I N A N Y

P O S I T I O N

( f ) P e r fo r m p r e s s u r e t es t s t o d e t e r m i n e c a u s e a


( g ) I n s p e c t t h e a c c u m u l a t o r f o r s t i c k i n g , b r o k


( h ) R e m o v e t h e v a l v e b o d y a s s e m b l y perform

p r e s s u r e t e s t s . R e p a i r a s r e q u i r e d .

( i) D i s a s s e m b l e a n d i n s p e c t c l u t c h . R e p a i r o r


( j) D i s a s s e m b l e t h e t r an s m i s s i o n a n d r e p a i r t

o v e r r u n n i n g c l u t c h a s r e q u i r e d .

( k) I n s p e c t a n d r e p l a c e t h e s e a l r in g s a s r e q u i r e

a l s o

i n s p e c t t h e r e s p e c t i v e b o r e s f o r w e a r . R

p l a c e p a r t s a s r e q u i r e d .

(a ) R e f i l l t o co r rec t l e ve l with A u t o m a t i c T r a n s m

s i o n

F l u i d , T y p e A , S u ff i x A .

( b ) I n s p e c t f o r a i r l e a k a g e

into

front p u m p s u c t i

p a s s a g e s .

( c ) A d j u s t t h e c o n t r o l c a b l e .

( d ) P e rf o r m t h e h y d r a u l i c p r e s s u r e t e s t s a n d a d j u


( e ) A d j u s t th e l o w - r e v e r s e b a n d .

( f ) P e r f o r m p r e s s u r e t e s t s t o d e t e r m i n e c a u s e a


( g ) R e m o v e th e v a l v e b o d y a s s e m b l y a n d perfo


( h ) I n s p e c t t h e s e r v o fo r d a m a g e d s e a l s , b i n d i

l i n k a g e o r

faulty

b a n d l i n i n g . R e p a i r a s

q u i r e d .

( i ) P e r fo r m t h e h y d r a u l i c p r e s s u r e t e s t s , a d j u s t


(a ) R e f i l l t o t he co r rec t l e ve l with A u t o m a t i c T r a n

m i s s i o n F l u i d , T y p e A , S u f fi x A .

( b ) P e r f o r m t h e h y d r a u l i c p r e s s u r e t es t s a n d a d j u


( c ) P e r fo r m p r e s s u r e t es t s t o d e t e r m i n e c a u s e a n


( d ) P e r f o r m t h e h y d r a u l i c p r e s s u r e t e s t s , a d j u s t


( e ) Re m o v e th e v a l v e b o d y a s s e m b l y a n d perfo

a i r p r e s s u r e t es t s . R e p a i r a s r e q u i r e d .

( f ) I n s p e c t a n d r e p l a c e th e s e a l ri n g s a s r e q u i r e

a l s o

i n s p e c t r e s p e c t i v e b o r e s f o r w e a r . R e p l a

t h e p a r t s a s r e q u i r e d .

(a ) R e f i l l t o t he co r rec t l e ve l with A u t o m a t i c T r a n

m i s s i on F l u i d , T y p e A , S u ff ix A .

( b ) P e rf o r m t h e h y d r a u l i c p r e s s u r e t es t s a n d a

j u s t t o s p e c i f i c a t i o n s .

( c ) R e p l a c e th e o i l filter.

( d ) Pe r f o r m p r e s s u r e t e s t s t o d e t e r m i n e c a u s e a


( e ) P e r f o r m t h e h y d r a u l i c p r e s s u r e t e s t s , a d j u s t


( f) R e m o v e t h e v a l v e b o d y a s s e m b l y a n d perfo



29/87

C o n d i t i o n

- T O R Q U E F L I T E

T R A N S M I S S IO N ( T O R Q U E C O N V E R T E R ) 2 1 - 2 9

P o s s i b l e C a u s e C o r r e c t i o n

N O D R I V E I N F O R W A R D ( a ) H y d r a u l i c p r e s s u r e s t o o l o w .

D R I V E P O S I T I O N S

( b ) V a l v e b o d y m a l f u n c t io n o r l e a k a g e .

( c ) A c c u m u l a t o r s t i c k i n g , b r o k e n r i ng s o r s p r i n g .

( d ) C l u t c h e s o r s e r v o s , s t ic k i n g o r n o t o p e r a t i n g .

(e )

Worn

o r

faulty

r e a r c l u t c h .

( f) O v e r r u n n i n g c l u t c h n o t h o l d i n g .

(g ) Worn o r b r o k e n input s h a f t a n d / o r r e a c ti o n


N O D R I V E I N

REVERSE

( a ) I n c o r r e c t c o n t r o l c a b l e a d j u s t m e n t .


( c ) L o w - r e v e r s e b a n d o u t o f a d j u s t m e n t .

( d ) V a l v e b o d y m a l f u n c t io n o r l e a k a g e .

( e ) F r o n t c l u t c h o r r e a r s e r v o , s t i c k i n g o r n o t o p e r a t

i ng .

( f) L o w - r e v e r s e s e r v o , b a n d o r l i n k a g e m a l f u n c t i o n .

(g )

Worn

o r

faulty front

c l u t c h .

( a ) I n c o r r e c t c o n t r o l c a b l e a d j u s t m e n t .

( b ) V a l v e b o d y m a l f u n c ti o n o r l e a k a g e .

( c ) R e a r c l u t c h i n o p e r a t i v e .

( a ) K i c k d o w n b a n d o u t o f a d j u s t m e n t .

( b ) L o w - r e v e r s e b a n d o u t o f a d j u s t m e n t .

( c ) K i c k d o w n a n d / o r l o w - r e v e r s e s e r v o , b a n d , l i nk

a g e m a l f u n c t i o n .

( d ) F r o n t a n d / o r r e a r cl u t c h

faulty.

( e ) P l a n e t a r y g e a r se ts b r o k e n o r s e i z e d .

( f) O v e r r u n n i n g c l u t c h w o r n , b r o k e n o r s e i z e d .

G R A T I N G , S C R A P I N G O R ( a ) K i c k d o w n b a n d o u t o f a d j u s t m e n t .

G R O W L I N G N O I S E ( b ) L o w - r e v e r s e b a n d o u t o f a d j u s t m e n t .

(c )

Output

s h a f t b e ar i n g d a m a g e d .

( d ) G o v e r n o r s u p p o r t b i n d i n g o r b r o k e n s e a l r i n g s .

( e ) F r o n t a n d / o r r e

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