Jeep Cherokee (XJ): Governor and park gear. Valve body. Transmission

Governor and park gear

DISASSEMBLY

(1) Remove governor body from transmission.

(2) Clean and inspect governor filter (Fig. 89).

(3) Remove snap ring and washer that secure governor weight assembly in body (Fig. 90).

(4) Remove governor weight assembly from governor body bore.

(5) Slide intermediate and inner weight from outer weight.

(6) Position intermediate weight on suitable size socket (Fig. 91).

(7) Push inner weight downward with nut driver.

Then remove inner weight snap ring with Miller Plier Tool 6823 (Fig. 91).

(8) Remove inner weight and spring from intermediate weight.

Fig. 88 Park Lock

1 - EXTENSION HOUSING
2 - SPRAG
3 - 888
4 - SHAFT
5 - E-CLIP
6 - SPRING
7 - CONTROL ROD
8 - SNAP RING
9 - PLUG AND PIN
10 - SPRING

Fig. 89 Governor Filter

1 - GOVERNOR FILTER
2 - PARK GEAR

ASSEMBLY

CAUTION: Exercise care when installing the rings.

They are easily broken if overspread or twisted during installation.

If it was necessary to remove the park gear, inspect the seal rings and bore in rear support

Fig. 90 Snap Ring, Washer, and Outer Weight

1 - SNAP-RING
2 - E-CLIP
3 - PARK GEAR
4 - GOVERNOR VALVE
5 - SHAFT
6 - GOVERNOR
7 - OUTER WEIGHT
8 - INTERMEDIATE WEIGHT
9 - WASHER

Fig. 91 Inner Weight Snap Ring

1 - NUT DRIVER
2 - SUITABLE SIZE SOCKET
3 - INTERMEDIATE WEIGHT
4 - INNER WEIGHT SNAP RING
5 - SPECIAL TOOL 6823

Fig. 92 Intermediate and Inner Governor Weights

1 - INTERMEDIATE WEIGHT
2 - INNER WEIGHT
3 - SNAP-RING

Install new seal rings on park gear hub only if original rings are damaged, or worn. Install ring with interlock ends first and ring with plain ends last.

Slip each ring on hub and seat them in grooves. Verify that rear ring ends are securely interlocked before proceeding. If the bore in rear support is damaged, replace the rear support.

(1) Lubricate governor components with Mopart ATF Plus 3, Type 7176 transmission fluid before assembly.

(2) Clean and inspect governor weights and bores for scoring or wear. Replace the governor body and weights if damaged. Refer to Cleaning and Inspection section of this group for proper procedure.

(3) Insert spring into intermediate weight.

(4) Insert inner weight into intermediate weight and install snap-ring (Fig. 92). Verify snap-ring is fully seated in groove in intermediate weight (Fig.

91).

(5) Assemble governor weights into governor body (Fig. 90).

(6) Install washer and snap ring to hold weights in governor body.

(7) Install governor body in transmission

Valve body

DISASSEMBLY

Position the valve body on a clean work surface to avoid contamination.

CAUTION: Do not clamp any part of the valve body assembly (Fig. 93) in a vise. This practice will distort the valve body and transfer plate resulting in valve bind. Slide valves and plugs out carefully. Do not use force at any time. The valves and valve body will be damaged if force is used. Also tag or mark the valve body springs for reference as they are removed. Do not allow them to become intermixed.

(1) Remove screws attaching adjusting screw bracket to valve body and transfer plate. Hold bracket firmly against spring force while removing last screw.

(2) Remove adjusting screw bracket, line pressure adjusting screw (Fig. 94).

(3) Remove switch valve and spring, pressure regulator valve and spring, kickdown valve and spring, and throttle valve from valve body (Fig. 94).

(4) Secure detent ball and spring in housing with Retainer Tool 6583 (Fig. 95).

(5) Remove manual shaft E-clip, washer, and seal (Fig. 96).

(6) Pull manual shaft and park rod assembly upward out of valve body and off throttle lever (Fig.

96).

(7) Remove manual valve from valve body (Fig. 97) (8) Remove Retainer Tool 6583. Then remove and retain detent ball and spring (Fig. 96).

(9) Remove throttle lever (Fig. 96).

Fig. 93 Valve Body Assembly

1 - VALVE BODY
2 - CONVERTER CLUTCH MODULE
3 - SOLENOID
4 - PARK ROD
5 - CONVERTER CLUTCH SOLENOID CONNECTOR
6 - MANUAL VALVE
7 - MANUAL LEVER

(10) Remove park rod E-clip and separate rod from manual lever (Fig. 98).

Fig. 94 Adjusting Screw Bracket, Springs, Valve Removal

1 - ADJUSTER BRACKET
2 - LINE PRESSURE ADJUSTER
3 - PRESSURE REGULATOR VALVE
4 - SWITCH VALVE
5 - VALVE BODY
6 - TRANSFER PLATE
7 - THROTTLE VALVE
8 - SLEEVE
9 - KICKDOWN VALVE
10 - THROTTLE PRESSURE ADJUSTER

Fig. 95 Securing Detent Ball And Spring With Retainer Tool

1 - SPECIAL TOOL 6583
2 - DETENT BALL AND SPRING HOUSING

(11) Remove converter clutch solenoid from separator plate (Fig. 99). A T25 torx bit is required to remove solenoid attaching screw.

(12) Remove screws attaching converter clutch module to valve body and remove module and connecting tube (Fig. 100).

(13) Remove screws attaching end cover plate to torque converter module (Fig. 101).

(14) Remove converter clutch valve, fail safe valve, and springs (Fig. 101)

Fig. 96 Manual And Throttle Levers

1 - PARK ROD
2 - E-RING
3 - WASHER
4 - MANUAL LEVER
5 - MANUAL VALVE
6 - SPRING
7 - DETENT BALL
8 - VALVE BODY

Fig. 97 Manual Valve

1 - MANUAL VALVE
2 - VALVE BODY

(15) Turn valve body over so transfer plate is facing upward (Fig. 102). With valve body in this position, valve body check balls will remain in place and not fall out when transfer plate is removed.

(16) Remove screws attaching transfer plate to valve body (Fig. 102).

(17) Remove transfer plate and separator plate from valve body (Fig. 102). Note position of filter and clutch solenoid for reference. Remove valve body check balls.

(18) Position transfer plate on bench so separator plate, and filter are facing up. This will avoid having rear clutch and rear servo check balls fall out when plates are separated.

Fig. 98 Park Rod

1 - MANUAL LEVER
2 - E-CLIP
3 - PARK ROD

Fig. 99 Converter Clutch Solenoid

1 - VALVE BODY
2 - TORQUE CONVERTER CLUTCH SOLENOID

Fig. 100 Clutch Module And Connecting Tube

1 - MODULE AND CONNECTING TUBE

1 - COVER PLATE
2 - CONVERTER CLUTCH VALVE
3 - TORQUE CONVERTER CLUTCH MODULE
4 - MODULE CONNECTING TUBE
5 - FAIL-SAFE VALVE

Fig. 101 Converter Clutch and Fail Safe Valves

1 - TRANSFER PLATE
2 - VALVE BODY
3 - SEPARATOR PLATE

(19) Remove screws attaching separator plate to transfer plate (Fig. 103).

(20) Note position of filter, rear clutch servo and rear servo check balls for assembly reference (Fig.

103) and (Fig. 104).

(21) Remove shuttle valve end plate (Fig. 105).

(22) Remove shuttle valve E-clip and remove secondary spring and spring guides from end of valve (Fig. 106).

Fig. 103 Transfer And Separator Plates

1 - SEPARATOR PLATE
2 - FILTER
3 - TRANSFER PLATE

Fig. 104 Rear Servo and Rear Clutch Check Balls

1 - REAR SERVO CHECK BALL
2 - TRANSFER PLATE
3 - REAR CLUTCH CHECK BALL

(23) Remove governor plug end plate (Fig. 107).

(24) Remove 1-2 and 2-3 shift valve governor plugs from valve body (Fig. 107).

(25) Remove shuttle valve throttle plug, primary spring and shuttle valve from valve body (Fig. 107).

(26) Remove screws attaching kickdown limit valve body to valve body (Fig. 107).

(27) Remove 1-2 shift control valve and spring from valve body (Fig. 107).

(28) Remove 2-3 shift valve and spring from valve body (Fig. 107).

(29) Remove 1-2 shift valve and spring from valve body (Fig. 107).

(30) Remove throttle pressure plug from kickdown limit valve body (Fig. 107).

Fig. 105 Shuttle Valve End Plate

1 - VALVE BODY
2 - SHUTTLE VALVE END PLATE

Fig. 106 Shuttle Valve E-Clip And Secondary Spring

1 - E-CLIP
2 - SECONDARY SPRING AND GUIDES
3 - SHUTTLE VALVE

(31) Remove retainer from end of kickdown limit valve body (Fig. 107).

(32) Remove kickdown limit valve and spring from kickdown limit valve body (Fig. 107).

(33) Remove regulator valve end plate from valve body (Fig. 107).

(34) Remove regulator valve line pressure plug, pressure plug sleeve, regulator valve throttle pressure plug and spring (Fig. 107).

ASSEMBLY Clean and inspect all valve body components for damage or wear. Refer to the Cleaning and Inspection section of this group for proper procedure.

Fig. 107 Control Valves, Shift Valves, And Governor Plugs

1 - GOVERNOR PLUG END PLATE
2 - SHUTTLE VALVE
3 - 1-2 GOVERNOR PLUG
4 - VALVE BODY
5 - REGULATOR VALVE THROTTLE PRESSURE PLUG
6 - SLEEVE
7 - LINE PRESSURE PLUG
8 - RETAINER
9 - 1-2 SHIFT VALVE
10 - 1-2 SHIFT CONTROL VALVE
11 - KICKDOWN LIMIT VALVE
12 - END PLATE
13 - THROTTLE PRESSURE PLUG
14 - KICKDOWN LIMIT VALVE BODY
15 - E-RING
16 - 2-3 SHIFT VALVE
17 - GUIDES
18 - 2-3 GOVERNOR PLUG
19 - PRIMARY SPRING
20 - SHUTTLE VALVE THROTTLE PLUG

CAUTION: Do not force valves or plugs into place during reassembly. If the valve body bores, valves, and plugs are free of distortion or burrs, the valve body components should all slide into place easily.

In addition, do not overtighten the transfer plate and valve body screws during reassembly. Overtightening can distort the valve body resulting in valve sticking, cross leakage and unsatisfactory operation. Tighten valve body screws to recommended torque only.

(1) Lubricate valve body bores, valves and plugs with Mopart ATF Plus 3, Type 7176, transmission fluid.

(2) Install regulator valve line pressure plug, pressure plug sleeve, regulator valve throttle pressure plug, and spring into valve body (Fig. 107). Verify valve components slide freely.

(3) Install regulator valve end plate on valve body (Fig. 107).

(4) Install kickdown limit valve and spring in kickdown limit valve body (Fig. 107). Verify valve components slide freely.

(5) Compress spring into kickdown limit valve body.

(6) Install retainer in grooves at end of kickdown limit valve body (Fig. 107).

(7) Install throttle pressure plug in kickdown limit valve body (Fig. 107).

(8) Install 1-2 shift valve and spring into valve body (Fig. 107).

(9) Install 2-3 shift valve and spring into valve body (Fig. 107).

(10) Install 1-2 shift control valve and spring into valve body (Fig. 107).

(11) Verify valve components slide freely.

(12) Place kickdown limit valve body and end plate in position on valve body and compress springs (Fig.

107).

(13) Install screws to attach kickdown limit valve body to valve body (Fig. 107).

(14) Install shuttle valve throttle plug, primary spring and shuttle valve into valve body (Fig. 107).

Verify valve components slide freely.

(15) Install 1-2 and 2-3 shift valve governor plugs into valve body (Fig. 107). Verify valve components slide freely.

(16) Place governor plug end plate in position on valve body and compress spring.

(17) Install screws to attach governor plug end plate to valve body (Fig. 107).

(18) Assemble shuttle valve spring and guides (Fig. 107). Place spring and guides in position on shuttle valve stem.

(19) Compress spring and install E-clip in groove on shuttle valve stem (Fig. 108).

(20) Place shuttle valve end plate in position on valve body (Fig. 109).

(21) Install screws to attach shuttle valve end plate to valve body (Fig. 109).

Fig. 108 Shuttle Valve E-Clip And Secondary Spring

1 - E-CLIP
2 - SECONDARY SPRING AND GUIDES
3 - SHUTTLE VALVE

(22) Install rear clutch servo and rear servo check balls in proper cavities in transfer plate (Fig. 110).

(23) Insert filter into opening in separator plate (Fig. 111).

(24) Place separator plate in position on transfer plate and install screws to attach separator plate to transfer plate (Fig. 111).

(25) Place one 11/32 in. check ball and six 1/4 in.

check balls in the proper cavities in the valve body (Fig. 112).

Fig. 109 Shuttle Valve End Plate

1 - VALVE BODY
2 - SHUTTLE VALVE END PLATE

Fig. 110 Rear Servo and Rear Clutch Check Balls

1 - REAR SERVO CHECK BALL
2 - TRANSFER PLATE
3 - REAR CLUTCH CHECK BALL

(26) Place transfer plate in position on valve body (Fig. 113).

(27) Install screws to attach transfer plate to valve body (Fig. 113).

(28) Turn valve body over to expose the separator plate.

(29) Insert converter clutch valve and spring into converter clutch valve module (Fig. 114). Verify valve components slide freely.

(30) Insert spring and fail-safe valve into converter clutch valve module (Fig. 114). Verify valve components slide freely.

(31) Place cover plate in position on converter clutch valve module (Fig. 114).

(32) Install screws to attach cover to converter clutch valve module (Fig. 114).

Fig. 111 Transfer And Separator Plates

1 - SEPARATOR PLATE
2 - FILTER
3 - TRANSFER PLATE

Fig. 112 Correct Position Of Valve Body Check Balls

1 - 1/488 CHECK BALLS (6)
2 - 11/3288 CHECK BALL (1)

(33) Insert connecting tube into converter clutch valve module (Fig. 114).

(34) Insert connecting tube into valve body opening (Fig. 115).

(35) Place converter clutch valve module in position on separator plate. Install screws to attach converter clutch module to valve body (Fig. 115).

(36) If necessary, install a new O-ring on converter clutch solenoid (Fig. 116).

Fig. 114 Converter Clutch Valve Module

1 - COVER PLATE
2 - CONVERTER CLUTCH VALVE
3 - TORQUE CONVERTER CLUTCH MODULE
4 - MODULE CONNECTING TUBE
5 - FAIL-SAFE VALVE

Fig. 115 Clutch Module And Connecting Tube

1 - MODULE AND CONNECTING TUBE'

(37) Insert converter clutch solenoid into transfer plate (Fig. 116).

(38) Install screw to attach solenoid to transfer plate (Fig. 116).

(39) If necessary, insert park rod end into manual lever and install E-clip (Fig. 117).

(40) Insert detent spring and ball into opening in valve body and install Retainer Tool 6583 (Fig. 118).

(41) Install manual valve into valve body (Fig.

119).

(42) Insert throttle lever through transfer plate side of valve body and upward (Fig. 120).

(43) Insert throttle lever into groove in manual valve (Fig. 121).

(44) Install seal, washer, and E-clip to retain manual shaft to valve body (Fig. 120).

(45) Install switch valve and spring, pressure regulator valve and spring, kickdown valve and spring, and throttle valve into valve body (Fig. 122).

Fig. 116 Converter Clutch Solenoid

1 - VALVE BODY
2 - TORQUE CONVERTER CLUTCH SOLENOID

(46) Place adjusting screw bracket and line pressure adjusting screw in position on valve body and compress springs (Fig. 94).

(47) Install screws to attach adjuster bracket to valve body.

Transmission

DISASSEMBLY

(1) Remove transmission from vehicle.

Fig. 113 Valve Body Transfer Plate Screws

1 - TRANSFER PLATE
2 - VALVE BODY
3 - SEPARATOR PLATE

Fig. 117 Park Rod

1 - MANUAL LEVER
2 - E-CLIP
3 - PARK ROD

Fig. 118 Securing Detent Ball And Spring With Retainer Tool

1 - SPECIAL TOOL 6583
2 - DETENT BALL AND SPRING HOUSING

(2) Install a suitable tail shaft housing plug to avoid contaminating internal components with cleaning solvents.

(3) Clean exterior of transmission with suitable solvent or pressure washer.

(4) Remove torque converter from transmission.

(5) Remove throttle and shift levers from valve body manual shaft and throttle lever shaft.

(6) Mount transmission in repair stand C-3750-B or similar type stand (Fig. 123).

(7) Remove extension housing.

(8) Remove fluid pan.

(9) Remove park/neutral position switch and seal (Fig. 124).

(10) Remove valve body.

(11) Remove accumulator spring and piston (Fig.

125).

(12) Loosen front band adjusting screw lock nut (Fig. 126) 4-5 turns. Then tighten band adjusting screw until band is tight around front clutch. This prevents front/rear clutches from coming out with pump and possibly damaging clutch or pump components.

Fig. 119 Manual Valve

1 - MANUAL VALVE
2 - VALVE BODY

Fig. 120 Manual And Throttle Levers

1 - PARK ROD
2 - E-RING
3 - WASHER
4 - MANUAL LEVER
5 - MANUAL VALVE
6 - SPRING
7 - DETENT BALL
8 - VALVE BODY

(13) Remove oil pump bolts.

(14) Thread bolts of Slide Hammer Tools C-3752 into threaded holes in pump body flange (Fig. 127).

(15) Bump slide hammer weights outward to remove pump and reaction shaft support assembly from case (Fig. 127).

Fig. 121 Manual Valve And Throttle Lever Alignment

1 - THROTTLE LEVER
2 - MANUAL LEVER VALVE ARM
3 - MANUAL VALVE
4 - KICKDOWN VALVE

Fig. 122 Adjusting Screw Bracket, Springs, and Valves

1 - ADJUSTER BRACKET
2 - LINE PRESSURE ADJUSTER
3 - PRESSURE REGULATOR VALVE
4 - SWITCH VALVE
5 - VALVE BODY
6 - TRANSFER PLATE
7 - THROTTLE VALVE
8 - SLEEVE
9 - KICKDOWN VALVE
10 - THROTTLE PRESSURE ADJUSTER

(16) Loosen front band adjusting screw until band is completely loose (Fig. 126).

(17) Squeeze front band together and remove band strut (Fig. 128).

Fig. 123 Repair Stand

1 - TRANSMISSION
2 - STAND

Fig. 124 Park/Neutral Position Switch

1 - NEUTRAL SWITCH
2 - SOLENOID CONNECTOR

Fig. 125 Accumulator Piston And Spring

1 - ACCUMULATOR PISTON
2 - PISTON SPRING

Fig. 126 Front Band Adjusting Screw Lock Nut

1 - LOCK-NUT
2 - FRONT BAND ADJUSTER

Fig. 127 Oil Pump/Reaction Shaft Support

1 - OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY
2 - SLIDE HAMMER TOOLS C-3752

Fig. 128 Front Band Strut

1 - BAND LEVER
2 - BAND STRUT
3 - FRONT BAND

(18) Remove front and rear clutch units as an assembly. Grasp input shaft, hold clutch units together and remove them from case (Fig. 129).

(19) Lift front clutch off rear clutch (Fig. 130). Set clutch units aside for overhaul.

(20) Remove output shaft thrust washer from output shaft (or from rear clutch hub) (Fig. 131).

(21) Remove output shaft thrust plate and washer from output shaft hub (Fig. 131).

(22) Remove front band from case (Fig. 132).

(23) Remove extension housing from transmission case.

Fig. 129 Front/Rear Clutch Assemblies

1 - FRONT BAND
2 - FRONT CLUTCH AND DRUM
3 - TRANSMISSION HOUSING
4 - REAR CLUTCH

(24) Remove governor body and park gear from output shaft.

(25) Remove output shaft and planetary geartrain as assembly (Fig. 133). Support geartrain with both hands during removal. Do not allow machined surfaces on output shaft to become nicked or scratched.

Fig. 130 Separating Front Clutch From Rear Clutch

1 - FRONT CLUTCH
2 - REAR CLUTCH

Fig. 131 Output Shaft Thrust Plate and Washer

1 - OUTPUT SHAFT
2 - THRUST PLATE
3 - THRUST WASHER

Fig. 132 Front Band

1 - FRONT BAND
2 - TRANSMISSION HOUSING

Fig. 133 Planetary Geartrain

1 - SLOTS
2 - LOW-REVERSE DRUM
3 - PLANETARY GEARTRAIN
4 - TRANSMISSION HOUSING
5 - LUGS

(26) Loosen rear band adjusting screw 4-5 turns (Fig. 134).

(27) Remove snap ring that secures low-reverse drum to rear support hub, however do not remove drum (Fig. 135).

(28) Remove bolts attaching rear support to transmission case and pull support from low-reverse drum (Fig. 136).

(29) Remove bolts attaching overrunning clutch cam and low-reverse drum to transmission case (Fig.

137).

Fig. 134 Rear Band Adjuster Location

1 - PLANETARY GEARTRAIN
2 - REAR BAND
3 - LEVER
4 - SERVO
5 - ADJUSTER

Fig. 135 Low-Reverse Drum Snap Ring

1 - REAR BAND
2 - REAR SUPPORT HUB
3 - LOW-REVERSE DRUM SNAP RING
4 - LOW-REVERSE DRUM

Fig. 136 Rear Support

1 - OIL PAN FACE
2 - TRANSMISSION HOUSING
3 - REAR SUPPORT

Fig. 137 Overrunning Clutch Cam Bolt Locations

1 - OVERRUNNING CLUTCH CAM BOLTS

(30) Using snap-ring plier, pull rear band anchor pin (located on the servo side of the rear support) from transmission case.

(31) Remove rear band and link from transmission (Fig. 138).

(32) Separate link from rear band (Fig. 139).

(33) If necessary remove front and rear band servo levers. All transmission components can be serviced without removing the levers.

(a) Using a 1/4 inch drive extension remove front band reaction pin access plug (Fig. 140).

Fig. 138 Rear Band and Link

1 - LINK
2 - REAR BAND

Fig. 139 Rear Band and Link

1 - NOTCHED SIDE OF LINK GOES TOWARD BAND

(b) Remove front band reaction pin with pencil magnet. Pin is accessible from converter housing side of case (Fig. 141).

(c) Remove front band lever (Fig. 142).

(d) Using snap-ring plier, pull rear band lever pivot from transmission case (Fig. 143).

(e) Separate rear band servo lever from transmission.

Fig. 140 Front Band Reaction Pin Access Plug

1 - 1/488 DRIVE EXTENSION
2 - FRONT BAND REACTION PIN ACCESS PLUG

Fig. 141 Front Band Reaction Pin

1 - PENCIL MAGNET
2 - FRONT BAND REACTION PIN

Fig. 142 Front Band Lever

1 - FRONT BAND LEVER

Fig. 143 Rear Band Servo Lever Pin

1 - PARALLEL JAW SNAP RING PLIERS
2 - REAR BAND LEVER PIVOT PIN

(34) Compress front servo rod guide about 1/8 in.

with large C-clamp and Tool C-4470, or Spring Compressor Tool C-3422-B (Fig. 144).

(35) Remove front servo rod guide snap ring (Fig.

144). Exercise caution when removing snap ring. Servo bore can be scratched or nicked if care is not exercised.

(36) Remove compressor tools and remove front servo rod guide, spring and servo piston.

(37) Compress rear servo spring retainer about 1/16 in. with C-clamp and Tool C-4470 or SP-5560 (Fig. 145). Valve Spring Compressor C-3422-B can also be used to compress spring retainer.

(38) Remove rear servo spring retainer snap ring.

Then remove compressor tools and remove rear servo spring and piston.

Fig. 144 Compressing Front Servo

1 - SPRING COMPRESSOR TOOL C-3422-B
2 - ROD GUIDE SNAP RING

ASSEMBLY

(1) Install rear servo piston, spring and spring retainer. Compress rear servo spring and retainer with Compressor Tool C-3422-B (Fig. 145) or a large C-clamp.

(2) Install front servo piston, spring, and rod guide. Compress front servo rod guide with Valve Spring Compressor C-3422-B and install servo snap ring (Fig. 144).

(3) Assemble link bar to band. Notched side of link toward band (Fig. 143).

(4) Insert rear band through pan opening in transmission case.

(5) Insert hook on band onto adjuster lever.

(6) Align holes in link bar with hole in transmission case outboard of rear support opening (Fig. 142).

(7) Insert anchor pin into case through link bar.

Fig. 145 Compressing Rear Servo Spring

1 - LARGE C-CLAMP
2 - TOOL C-4470 OR SP5560
3 - SERVO SPRING RETAINER

(8) Examine bolt holes in overrunning clutch cam.

Note that one hole is not threaded (Fig. 146). This hole must align with blank area in clutch cam bolt circle.

NOTE: The bolt holes in cam are slightly countersunk on one side. This side of cam faces rearward (toward rear support).

(9) Lubricate overrunning clutch rollers, springs and cam with Mopart ATF Plus 3, type 7176, transmission fluid.

(10) Position overrunning clutch on a clean, flat work surface with countersunk holes downward.

(11) Place rear of low-reverse drum over overrunning clutch and align clutch rollers to hub of drum.

(12) While slightly pivoting low-reverse drum, push hub of drum into overrunning clutch. Verify that countersunk holes are facing outward. Cam should be able to rotate in the drum clockwise only.

(13) Insert a suitable awl through the rear support mounting hole closest to the pan sealing face. The awl should be next to the wide space area at the back of transmission case.

(14) Insert low-reverse drum and overrunning clutch into front of transmission case and into rear band.

(15) Insert awl tip into the threaded hole next to the non-threaded hole in the overrunning clutch cam.

Verify that non-threaded hole is aligned with wide space area on transmission case.

(16) Push low-reverse drum rearward to close gap between cam and case.

(17) Install overrunning clutch cam bolts. Clutch cam bolts are shorter than rear support bolts.

Tighten cam bolts to 17 N·m (150 in. lbs. or 13 ft.

lbs.) torque.

Fig. 146 Clutch Cam Alignment

1 - TRANSMISSION CASE
2 - OVERRUNNING CLUTCH
3 - NON-THREADER HOLE
4 - WIDE SPACE AREA

(18) Hold low-reverse drum in position so rear support will not push it out of overrunning clutch.

(19) Insert rear support into opening at rear of transmission case (Fig. 147).

(20) Align support with the embossed arrow in the direction of the pan face.

Fig. 147 Rear Support

1 - OIL PAN FACE
2 - TRANSMISSION HOUSING
3 - REAR SUPPORT

(21) Install and tighten rear support bolts to 17 N·m (150 in. lbs.) torque.

(22) Install snap ring to retain low-reverse drum to hub of rear support (Fig. 148).

Fig. 148 Low-Reverse Drum Snap Ring

1 - REAR BAND
2 - REAR SUPPORT HUB
3 - LOW-REVERSE DRUM SNAP RING
4 - LOW-REVERSE DRUM

(23) Lubricate output shaft, rear support bore and low-reverse drum hub with transmission fluid.

(24) Install assembled output shaft and planetary geartrain in case (Fig. 149).

(25) Align drive lugs on rear planetary gear with slots in low-reverse drum (Fig. 149). Then seat planetary assembly in drum.

(26) Install governor on output shaft.

Fig. 149 Output Shaft And Planetary Geartrain

1 - SLOTS
2 - LOW-REVERSE DRUM
3 - PLANETARY GEARTRAIN
4 - TRANSMISSION HOUSING
5 - LUGS

(27) Turn and secure transmission so that front opening is upward.

(28) Assemble front and rear clutches together.

(a) Check input shaft seal rings (Fig. 150). Verify that diagonal-cut ends of Teflony seal ring are properly joined and ends of metal ring are correctly hooked together. Also be sure rings are installed in sequence shown.

(b) Align teeth on clutch discs in line.

(c) Insert input shaft on rear clutch into center of front clutch (Fig. 151).

(d) Engage teeth on rear clutch hub into teeth on clutch (Fig. 153). Rotate front clutch retainer bac

Fig. 150 Input Shaft Seal Ring Location

1 - INPUT SHAFT
2 - TEFLON SEAL RING
3 - METAL SEAL RING
4 - REAR CLUTCH RETAINER

Fig. 151 Front and Rear Clutches

1 - REAR CLUTCH
2 - INPUT SHAFT
3 - FRONT CLUTCH

(29) Install output shaft thrust plate on shaft hub in planetary geartrain driving shell (Fig. 152). Use petroleum jelly to hold thrust plate in place.

(30) Check rear clutch thrust washer. Use additional petroleum jelly to hold washer in place if necessary.

(31) Coat output shaft thrust washer with petroleum jelly. Install washer in rear clutch hub (Fig.

154). Use enough petroleum jelly to hold washer in place. Be sure grooved side of washer faces rearward (toward output shaft) as shown. Also note that washer only fits one way in clutch hub.

Fig. 152 Output Shaft Thrust Plate

1 - OUTPUT SHAFT HUB
2 - OUTPUT SHAFT THRUST PLATE

Fig. 153 Assembling Front And Rear Clutch Units

1 - TURN FRONT CLUTCH BACK & FORTH UNTIL SEATED
2 - REAR CLUTCH ASSEMBLY

(32) Align drive teeth on rear clutch discs with small screwdriver (Fig. 155). This will make installation into front of planetary geartrain easier

Fig. 154 Output Shaft Thrust Washer

1 - REAR CLUTCH HUB
2 - OUTPUT SHAFT THRUST WASHER
3 - OUTPUT SHAFT

Fig. 155 Aligning Rear Clutch Disc Lugs

1 - REAR CLUTCH DISCS
2 - USE SMALL SCREWDRIVER TO ALIGN CLUTCH DISC TEETH

(33) Insert front band into opening at front of transmission case (Fig. 156).

(34) Install front and rear clutch units as assembly (Fig. 157). Align rear clutch with front annulus gear and install assembly in driving shell. Be sure output shaft thrust washer and thrust plate are not displaced during installation.

(35) Carefully work assembled clutches back and forth to engage and seat rear clutch discs on front annulus gear. Verify that front clutch drive lugs are fully engaged in slots of driving shell after installation.

Fig. 156 Front Band

1 - FRONT BAND
2 - TRANSMISSION HOUSING

Fig. 157 Installing Front/Rear Clutch

1 - FRONT BAND
2 - FRONT CLUTCH AND DRUM
3 - TRANSMISSION HOUSING
4 - REAR CLUTCH

(36) Engage front band on adjusting screw and hold band in place.

(37) Install strut between band lever and front band (Fig. 158).

(38) Tighten front band adjusting screw until band just grips clutch retainer. Verify that front/rear clutches are still seated before continuing.

(39) Verify that reaction shaft support hub seal rings are hooked together (Fig. 159).

(40) Coat front clutch thrust washer with petroleum jelly to hold it in place. Then install washer over reaction shaft hub and seat it on pump (Fig.

160).

CAUTION: The thrust washer bore (I. D.), is chamfered on one side. Make sure the chamfered side is installed so it faces the pump.

Fig. 158 Front Band Linkage Installation

1 - BAND LEVER
2 - BAND STRUT
3 - FRONT BAND

Fig. 159 Reaction Shaft Support Seal Rings

1 - REACTION SHAFT SUPPORT HUB
2 - FRONT CLUTCH THRUST WASHER
3 - SEAL RINGS

Fig. 160 Front Clutch Thrust Washer Installation

1 - THRUST WASHER
2 - CHAMFERED SIDE OF WASHER BORE GOES TOWARD PUMP

(41) Thread two Pilot Stud Tools C-3288-B into bolt holes in oil pump flange (Fig. 161).

(42) Align and install oil pump gasket (Fig. 161).

(43) Lubricate oil pump seals with Mopart Door- Ease, or Ru-Glyde, Door Eze, or ATF Plus 3.

(44) Install oil pump (Fig. 162). Align and position pump on pilot studs. Slide pump down studs and work it into front clutch hub and case by hand. Then install two or three pump bolts to hold pump in place.

(45) Remove pilot stud tools and install remaining oil pump bolts. Tighten bolts alternately in diagonal pattern to 20 N·m (15 ft. lbs.).

Fig. 161 Installing Pilot Studs And Oil Pump Gasket

1 - OIL PUMP GASKET
2 - PILOT STUD TOOLS C-3288-B

Fig. 162 Installing Oil Pump And Reaction Shaft Support

1 - OIL PUMP
2 - PILOT STUD TOOL
3 - PILOT STUD TOOL

(46) Measure input shaft end play (Fig. 163).

NOTE: If end play is incorrect, transmission is incorrectly assembled, or output shaft thrust washer and/or thrust plate are worn and need to be changed.

(a) Attach Adapter 8266-7 to Handle 8266-8.

(b) Attach dial indicator C-3339 to Handle 8266-8.

(c) Install the assembled tool onto the input shaft of the transmission and tighten the retaining screw on Adapter 8266-7 to secure it to the input shaft.

(d) Position the dial indicator plunger against a flat spot on the oil pump and zero the dial indicator.

(e) Move input shaft in and out and record reading.

End play should be 0.56 - 2.31 mm (0.022 - 0.091 in.).

(47) Position transmission on work surface with pan face upward.

(48) Install valve body.

(49) Adjust front and rear bands.

(50) Install fluid filter and pan.

(51) Install rear extension housing.

(52) Install torque converter.

Fig. 163 Checking Input Shaft End Play

1 - TOOL 8266-8
2 - TOOL 8266-7
3 - TOOL C-3339