Part 1
Disassembly-Subassembly Removal
Prior to removing any transmission subassemblies, plug all openings and thoroughly clean exterior of the unit, preferably by steam. Cleanliness through entire disassembly and assembly cannot be over-emphasized. When disassembling, each part should be washed in a suitable solvent, then dried by compressed air. Do not wipe parts with shop towels. All mating surfaces in the transmission are accurately machined; therefore, careful handling of parts must be exercised to avoid nicks or burrs.
Oil Pan
(1) Place transmission assembly in repair stand, Tool C-3750-A (Fig. 6).
(2) Unscrew oil pan bolts and remove oil pan and gasket. Fluid and Filter Change
Valve Body Assembly
(1) Loosen clamp bolts and remove throttle and gearshift levers from the transmission.
(2) Remove Back-up Lamp and Neutral Start Switch.
(3) Remove the ten hex-head valve body to trans� mission bolts. Remove "E" clip securing parking lock rod to the valve body manual lever.
(4) While lifting valve body upward out of transmission case, disconnect parking lock rod from the lever.
Accumulator Piston and Spring
(1) Lift spring off accumulator piston and withdraw piston from the case.
Extension Housing
Before removing extension housing, pull parking lock rod forward out of the case. Rotate output shaft, if necessary, to align parking gear and sprag to permit knob on end of control rod to pass the sprag.
(1) Remove speedometer pinion and adapter assembly.
(2) Remove extension housing to transmission bolts.
(3) Remove two screws, plate, and gasket from bottom of extension housing mounting pad. Spread large snap ring from output shaft bearing. With snap ring spread as far as possible, carefully tap extension housing off the output shaft and bearing.
(4) Using heavy duty snap ring pliers, remove output shaft bearing rear snap ring. Remove bearing from shaft, then remove front snap ring (A-727). The A-904 family has no front snap ring.
Governor and Support
(1) Carefully pry snap ring from weight end of governor valve shaft. Slide valve and shaft assembly out of the governor body.
(2) Remove snap ring from behind governor body, then slide governor body and support assembly off the output shaft.
Oil Pump and Reaction Shaft Support
(1) Tighten front band adjusting screw until band is tight on front clutch retainer. This prevents clutch retainer from coming out with pump which might cause unnecessary damage to the clutches.
(2) Remove oil pump housing retaining bolts.
(3) Attach Tool C-3752 to pump housing flange, (Fig. 7), in threaded holes in the flange.
(4) Bump outward evenly with the two "knocker weights" to withdraw pump and reaction shaft support assembly from the case.
Front Band and Front Clutch
(1) Loosen front band adjuster, remove band strut (and A-727 anchor) and slide band out of the case.
(2) Slide front clutch assembly out of the case.
Input Shaft and Rear Clutch
(1) Grasp input shaft, and slide input shaft and rear clutch assembly out of the case. Be careful not to lose thrust washer located between rear end of input shaft and forward end of the output shaft.
Planetary Gear Assemblies, Sun Gear, and Driving Shell
(1) While supporting output shaft and driving shell, carefully slide assembly forward and out through the case. Be very careful not to damage ground surfaces on output shaft during removal.
Rear Band and Low-Reverse Drum
(1) Remove low-reverse drum, then loosen rear band adjuster, remove band strut and link, then remove band from the case. (Double Wrap Band): Loosen band adjusting screw then remove band and low-reverse drum.
Overrunning Clutch
(1) Note position of overrunning clutch rollers and springs before disassembly to assist in reassembly.
(2) Carefully slide out clutch hub and remove rollers and springs.
Kickdown Servo (front)
(1) Compress kickdown servo spring by using engine valve spring compressor, Tool C-3422-A, remove snap ring (Fig. 8).
(2) Remove rod guide, spring and piston assembly from the case. Be careful not to damage piston rod or guide during removal.
(3) Withdraw piston from the transmission case.
Low-Reverse Servo (Rear)
(1) Compress low and reverse servo piston spring by using engine valve spring compressor, Tool C-3422-A, then remove the snap ring.
(2) Remove spring retainer, spring, and servo piston and plug assembly from the case.
RECONDITION SUBASSEMBLIES
The following procedures cover disassembly, inspection, repair, and assembly of each subassembly as removed from the transmission. Heli-Coil inserts are recommended for repairing damaged, stripped or worn threads in aluminum parts.
Pre-sized service bushings are available for replacement for most all bushings in the TorqueFlite transmission. The two bushings in sun gear are not serviced because of the low cost of sun gear assembly. If bushings are found worn or scored, they should be replaced as outlined in the following reconditioning procedures.
The bushing replacement tools listed by "SP" numbers are part of Tool Kit C-3887-B.
The use of crocus cloth is permissible where necessary, providing it is used carefully. When used on valves, use extreme care to avoid rounding off the sharp edges. The sharp edge is vitally important to this type of valve. Sharp edges prevent dirt and foreign matter from getting between the valve and body, thus reducing possibility of sticking. When it becomes necessary to recondition transmission, and vehicle has accumulated considerable mileage, install new seal rings on parts requiring their usage. Coat each part with "DEXRON II" type Automatic Transmission Fluid during assembly.
OIL PUMP AND REACTION SHAFT SUPPORT-A-904
Due to the lock-up torque converter, it is important that the oil pump be within the clearance limits as specified. Also note that the oil pump bushing should be replaced in any overhaul.
Disassembly
Figure 9 shows the oil pump and reaction shaft support disassembled.
(1) Remove bolts from rear side of reaction shaft support and lift support off the pump.
(2) Remove rubber seal ring from pump body flange.
(3) Drive out oil seal with a blunt punch.
Inspection
Inspect interlocking seal rings (Fig. 9) on reaction shaft support for wear or broken locks, make sure they turn freely in the grooves. Seal rings have to be removed to allow clearance for #1 thrust washer removal or installation. Inspect front clutch piston retainer to reaction shaft support thrust washer for wear. Washer thickness should be .061 to .063 inch, replace if necessary. Inspect machined surfaces on pump body and reaction shaft support for nicks and burrs. Inspect pump body and reaction shaft support bushings for wear or scores. Inspect pump rotors for scoring or pitting. With rotors cleaned and installed in pump body, place a straightedge across face of rotors and pump body. Use a feeler gauge to measure clearance between straightedge and face of rotors. Clearance limits are from .001 to .0025 inch. Also, measure rotor tip clearance between inner and outer rotor teeth. Clearance limits are from .0045 to .0095 inch. Clearance between outer rotor and its bore in oil pump body should be .0035 to .0075 inch.
Pump Bushing Replacement-A-904
(1) Place pump housing (seal face down) on a smooth firm surface.
(2) Place removing head, Tool SP-3551 in bushing and install handle, Tool SP-3549 or C-4171 in the removing head (Fig. 10).
(3) Drive bushing straight down and out of pump housing bore. Be careful not to cock tool in the bore.
(4) Position new bushing on installing head Tool SP-5117.
(5) With pump housing on a smooth clean surface, start bushing and installing head in the bushing bore. install handle in the installing head (Fig. 10).
(6) Drive bushing into housing until tool bottoms in the pump cavity. Be careful not to cock tool during installation.
(7) Stake bushing in place by using a blunt punch or similar tool (Fig. 11). A gentle tap at each stake slot location will suffice.
(8) Using a narrow-bladed knife or similar tool, remove high points or burrs around staked area (Fig. 11). Do not use a file or similar tool that will remove more metal than is necessary.
Reaction Shaft Bushing Replacement-A-904
For identification purposes, the lock-up reaction shaft support has 3 steel balls in the support at outside diameter of reaction shaft and the non lock-up has 2 steel balls. In case of a reaction shaft bushing failure, always inspect the support for wear from the input shaft seal ring lands. If worn or grooved, replace support assembly.
(1) Assemble remover Tool SP-5324, cup Tool SP-3633, and hex nut Tool SP-1l91 (Fig. 12). Do not clamp any part of reaction shaft or support in a vise.
(2) With cup held firmly against reaction shaft, thread remover into bushing as far as possible by hand.
(3) Using a wrench, screw remover into bushing 3 to 4 additional turns to firmly engage threads in the
(4) Turn hex nut down against cup to pull bushing from reaction shaft. Thoroughly clean reaction shaft to remove chips made by remover threads.
(5) Lightly grip bushing in a vise or with pliers and back tool out of the bushing. Be careful not to damage threads on bushing remover.
(6) Slide a new bushing on installing head Tool SP-5325, and start them in the bore of reaction shaft Fig. 12).
(7) Support reaction shaft upright on a clean smooth surface and install handle Tool SP-3549 or C-4171 in installing head. Drive bushing into the shaft until tool bottoms.
(8) Thoroughly clean reaction shaft support assembly before installation.
Assembly
(1) Place reaction shaft support in assembling Tool C-3759, with hub of support and tool resting on a smooth flat surface bench (Fig. 13). Screw two pilot studs, Tool C-3283-A into threaded holes of reaction shaft support flange.
(2) Assembly and place rotors in center of the support.
(3) Lower pump body over the pilot studs, insert Tool C-3756 through pump body and engage pump inner rotor. Rotate the rotors with tool to center rotors in pump body, then with pump body firm against reaction shaft support, tighten clamping tool securely.
(4) Invert pump and reaction shaft support assembly with clamping tool intact. Install support to pump body bolts and tighten to 160 in. lbs. (18 N.m). Remove clamping tool, pilot studs and rotor alignment tool.
(5) Place a new oil seal in opening of pump housing (lip of seal facing inward). Using Tool C-4193, drive seal into housing until tool bottoms.
OIL PUMP AND REACTION SHAFT SUPPORT-A-727
Due to the lock-up torque converter, it is important that the oil pump be within the clearance limits as specified. Also note that the oil pump bushing should be replaced in any overhaul.
Disassembly
For identification purposes, the lock-up reaction shaft support has 3 steel balls in the support at the outside diameter of reaction shaft and the non lock-up has 2 steel balls. Figure 14 shows the oil pump and reaction shaft support disassembled.
(1) Remove bolts from rear side of reaction shaft support, and lift support off the pump.
(2) Remove rubber seal ring from pump body flange.
(3) Drive out oil seal with a blunt punch.
Inspection
Inspect interlocking seal rings (Fig. 14) on reaction shaft support for wear or broken locks, make sure they turn freely in the grooves. Inspect machined surfaces on pump body and reaction shaft support for nicks and burrs. Inspect pump body and reaction shaft support bushings for wear or scores. Inspect pump rotors for scoring or pitting. With rotors cleaned and installed in pump body, place a straightedge across face of rotors and pump body. Use a feeler gauge to measure clearance between straightedge and face of rotors. Clearance limits are from .001 to .0025 inch. Also, measure rotor tip clearance between inner and outer teeth. Clearance limits are from .005 to .010 inch. Clearance between outer rotor and its bore in oil pump body should be .004 to .008 inch.
Pump Bushing Replacement-A-727
(1) Place pump housing on a clean smooth surface with rotor cavity down.
(2) Place removing head Tool SP-3550 in the bushing, and install handle Tool SP-3549 or C-4I71 in the removing head (Fig. 15).
(3) Drive bushing straight down and out of the bore. Be careful not to cock tool in the bore.
(4) Position a new bushing on installing head Tool SP-5118.
(5) With pump housing on a smooth clean surface (hub end down), start bushing and installing head in the bushing bore. Install handle in installing head.
(6) Drive bushing into housing until tool bottoms in the pump cavity. Be careful not to cock tool during installation.
(7) Stake the bushing in place by using a blunt punch or similar tool (Fig. 16). A gentle tap at each stake slot location will suffice.
(8) Using a narrow-bladed knife or similar tool, remove high points or burrs around staked area. Do not use a file or similar tool that will remove more metal than is necessary.
(9) Thoroughly clean pump housing before installation.
Reaction Shaft Bushing Replacement-A-727
(1) Assemble remover Tool SP-530I, cup Tool SP-3633, and hex nut Tool SP-119I (Fig. 17). Do not clamp any part of reaction shaft or support in a vise.
(2) With cup held firmly against reaction shaft, thread remover into bushing as far as possible by hand.
(3) Use a wrench to screw remover into bushing 3 to 4 additional turns to firmly engage threads in the bushing.
(4) Turn hex nut down against the cup to pull bushing from reaction shaft. Thoroughly clean reaction shaft to remove chips made by remover threads.
(5) Lightly grip bushing in a vise or with pliers and back tool out of the bushing. Be careful not to damage threads on bushing remover.
(6) Slide a new bushing (chamfered end first) on installing head Tool SP-5302, and start them in the bore of reaction shaft (Fig. 17).
(7) Support reaction shaft upright on a clean smooth surface and install handle Tool SP-3549 or C-4I71 in installing head. Drive bushing into shaft until tool bottoms.
(8) Thoroughly clean the reaction shaft support assembly before installation.
Assembly
(1) Assemble pump rotors and "O" ring in the pump housing (Fig. 14).
(2) Install reaction shaft support. Install retaining bolts and tighten to 160 in. lbs. (18 N.m).
(3) Place a new oil seal in opening of pump housing (lip of seal facing inward) using Tool C-3860, drive seal into housing until tool bottoms.