Disassembly and Assembly
Tag all springs as they are removed for reassembly identification.
Do not clamp any portion of valve body or transfer plate in a vise. Any slight distortion of the aluminum body or transfer plate will result in sticking valves, excessive leakage or both. When removing or installing valves or plugs, slide them in or out carefully. Do not use force.
Remove "E" clip and park control rod from manual lever.
Filter, Transfer Plate, and Pressure Regulators
(1) Place valve body assembly on repair stand, Tool C-3749, (Fig.1). Remove three screws from the fluid filter and lift off filter.
(2) Remove top and bottom screws from spring retainer and adjustment screw bracket.
(3) Hold spring retainer firmly against spring force while removing last retaining screw from side of valve body.
(4) Remove spring retainer, with line and throttle pressure adjusting screws (do not disturb setting) and the line pressure and switch valve regulator springs.
(5) Slide switch valve and line pressure valve out of their bores.
(6) Remove three screws from lock-up module (or stiffener plate) and carefully remove tube and lock-up module (or stiffener plate). Disassemble lock-up module, tagging springs.
(7) Remove transfer plate retaining screws and lift off transfer plate and separator plate assembly.
(8) Remove three screws from separator plate and separate parts for cleaning (Fig. 5).
(9) Remove rear clutch ball check, reverse servo ball check, and line pressure regulator valve screen from separator plate for cleaning (Fig. 5).
(10) Remove the seven balls from valve body as shown in figure 6.
LOCK-UP MODULE (Fig. 4)
(1) Remove end cover.
(2) Remove lock-up spring and valve.
(3) Remove fail-safe valve and spring.
Tag these springs as they are removed, for reassembly identification.
Shuttle Valve and Governor Plugs (fig. 7)
(1) Turn valve body over and remove shuttle valve cover plate.
(2) Remove governor plug end plate (Fig. 7) and slide out the shuttle valve throttle plug and spring, the 1-2 shift valve governor plug and the 2-3 shift valve governor plug.
(3) Remove shuttle valve "E" clip and slide shuttle valve out of its bore. Also, remove the secondary spring and guides which were retained by "E" clip.
Manual Lever and Throttle Lever
(1) Remove "E" clip and washer from throttle lever shaft (Fig. 3). Remove any burrs from shaft, then while holding manual lever detent ball and spring in their bore with Tool C-3765 or similar tool, slide manual lever off the throttle shaft. Remove the detent ball and spring.
(2) Slide manual valve out of its bore.
(3) Slide out the kickdown detent, kickdown valve, throttle valve spring, and the throttle valve.
Shift Valves and Regulator Valve Pressure Sensing Plugs
(1) Remove the line pressure regulator valve end plate (Fig. 8) and slide out the regulator valve sleeve, line pressure plug, throttle pressure plug, and spring.
(2) Remove the end plate and downshift housing assembly.
(3) Remove throttle plug from housing.
(4) Slide retainer from housing and remove limit valve and spring.
(5) Remove the three springs and shift valves from the valve body.
Cleaning and Inspection
Allow all parts to soak a few minutes in a suitable clean solvent. Wash thoroughly and blow dry with compressed air. Make sure all passages are clean and free from obstructions.
Inspect manual and throttle valve operating levers and shafts for being bent, worn or loose. If a lever is loose on its shaft, the lever and shaft assembly should be replaced. Do not attempt to straighten bent. levers.
Inspect all mating surfaces for burrs, nicks and scratches. Minor blemishes may be removed with crocus cloth, using only a very light pressure. Using a straightedge, inspect all mating surfaces for warpage or distortion. Slight distortion may be corrected, using a surface plate.
Make sure all metering holes in steel plate and valve body are open. Using a pen light, inspect bores in valve body for scores, scratches, pits and irregularities.
Make sure orifice referred to in (Fig. 6) is open by inserting a 1/32 inch diameter drill through it into the 1-2 shift control valve bore.
Inspect all valve springs for distortion and collapsed coils. Inspect all valves and plugs for burrs, nicks, and scores. Small nicks and scores may be removed with crocus cloth, providing extreme care is taken not to round off sharp edges. The sharpness of these edges is vitally important because it prevents foreign matter from lodging between valve and valvebody, thus reducing possibility of sticking. Inspect all valves and plugs for freedom of operation in valve body bores.
When bores, valves, and plugs are clean and dry, the valves and plugs should fall freely in the bores. The valve body bores do not change dimensionally with use. Therefore, a valve body that was functioning properly when vehicle was new, will operate correctly if it is properly and thoroughly cleaned. There is no need to replace valve body unless it is damaged in handling.
VALVE BODY REASSEMBLY
(Tighten all valve body screws to 35 inch-pounds) (4 Newton-meters).
Shift Valves and Regulator Valve Pressure Sensing Plugs (Fig. 8)
(1) Slide shift valves and springs into proper valve body bores.
(2) Subassemble the 3-2 downshift and limit valve assembly housing as follows:
(a) Insert limit valve and spring into housing.
(b) Slide spring retainer into groove in housing.
(c) Insert throttle plug in housing bore. Position assembly against the shift valve springs.
NOTE: Omit step (2) when no 3-2 downshift and limit valve assembly is used.
(3) Install end plate and tighten screws.
(4) Install throttle pressure spring and plug, line pressure plug and sleeve, then fasten end plate to valve body.
Shuttle Valve and Governor Plugs (Fig. 7)
(1) Place 1-2 and 2-3 shift valve governor plugs in their respective bores.
(2) Install shuttle valve and hold it in bore with index finger while installing the secondary spring with guides and retaining "E" clip.
(3) Install primary shuttle valve spring and throttle plug.
(4) Install governor plug end plate and tighten the five retaining screws.
(5) Install shuttle valve cover plate and tighten the six retaining screws.
Manual Lever and Throttle Lever (fig. 3)
(1) Install throttle valve, throttle valve spring, kickdown valve, and kickdown detent.
(2) Slide manual valve into its bore
.
(3) Install throttle lever and shaft on valve body. Insert detent spring and ball in its bore in valve body. Depress ball and spring with Tool C-3765 (Fig. 9) or similar tool and slide manual lever over throttle shaft so that it engages manual valve and detent ball. Install seal, retaining washer, and "E" clip on throttle shaft.
filter, Transfer Plate, and Pressure Regulators
(1) Install the seven balls in valve body as shown in Figure 6.
(2) Install rear clutch ball check and low-reverse servo ball check (see Fig. 5) in transfer plate and regulator valve screen in separator plate (Fig. 5).
(3) Install three screws in separator plate.
(4) Place transfer plate assembly on valve body. Be careful to align filter screen as the 17 shorter screws are installed finger tight (three longer screws are for oil filter).
(5) Starting at the center and working outward, tighten screws to 35 in. lbs. (4 N.m).
(6) Slide switch valve and line pressure valves and springs into their bores (Fig. 3).
(7) Install pressure adjusting screw and bracket assembly on the springs and fasten with one screw for now. Use screw which goes into side of valve body. This screw is to be tightened first, after starting the top and bottom screws.
(8) Install oil filter and tighten screws to 35 in. lbs. (4 N.m).
(9) Install lock-up valve and spring, then install fail safe spring and valve into the lock-up module (Fig. 4). Install lock-up module to transfer and separator plate assembly with three screws. (Install stiffener plate on non lock-up valve body).
(10) After valve body has been serviced and completely assembled, measure throttle and line pressure adjustments (see "Maintenance and Adjustments"). However, if pressures were satisfactory prior to disassembly, use original settings.
(11) Install parking lock rod and "E"clip retainer to manual lever.
VALVE BODY AND ACCUMULATOR PISTON INSTALLATION
(1) Make sure combination Back-up Lamp/Neutral Start Switch is not installed in transmission case.
(2) Place valve body manual lever in low position to move parking rod to rear position.
(3) Use a screwdriver to push park sprag into engagement with parking gear, turning output shaft to verify engagement. This will allow "knob" on end of parking rod to move past the sprag as valve body is installed.
(4) Install accumulator piston in the transmission case.
(5) Position accumulator spring between piston and valve body.
(6) Place valve body in position, working park rod through opening and past sprag. Install retaining bolts finger tight.
(7) With neutral starting switch installed, place manual lever in the neutral position. Shift valve body if necessary, to center neutral finger over the neutral switch plunger. Snug bolts down evenly, then tighten to 100 in. lbs. (11 N.m).
(8) Install gearshift lever and tighten clamp bolt. Check lever shaft for binding in the case by moving lever through all detent positions. If binding exists, loosen valve body bolts and realign.
9) Make sure throttle shaft seal is in place, then in� stall flat washer and throttle lever and tighten the clamp bolt. Connect throttle and gearshift linkage and adjust as required.
(10) Install oil pan, with a new gasket. Add transmission fluid to bring it up to proper level.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum transmission case and body can be repaired by the use of Heli-Coils, or equivalent. Essentially, this repair consists of drilling out the worn or damaged threads, tapping the hole with a special Heli-Coil, or equivalent, Tap, and installing a Heli-Coil, or equivalent insert into the tapped 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.