Overdrive Assembly
Description:
ASSEMBLY
1. Install pressure plate springs into transmission case pockets as shown in Figure. The location, number and type of springs may vary from one transmission to another. Use Figure only as a guide when installing springs.
2. Position pressure plate on top of the springs. Ensure springs are seated into pockets of pressure plate.
3. Position plate tool No. J-21420-2 or equivalent onto top of pressure plate with bolt of tool No. J-23327 through center of the plate. Position tool No. J-23327 onto rear of case and install retaining nut Tighten nut on tool until pressure plate is drawn approximately 1/8 inch below overdrive clutch plate step.
4. Install (3) pressure plate attaching bolts. Remove tools J-21420-2 and J-23327 from case.
5. Install output shaft assembly into case. Ensure 0-rings are properly positioned on pump housing.
6. Install pump attaching bolts. Torque bolts to 10-12 ft. lbs.
7. Check alignment of output shaft to tail housing bushing as follows:
a. Install slip yoke or propeller shaft onto output shaft
b. Rotate several times and check for tightness during rotation. If tightness is evident, misalignment is indicated. Proceed to step C.
c. Loosen pump bolts, reinstall slip yoke onto output shaft, then retorque pump bolts to specifications.
d. Remove slip yoke.
8. Install thrust bearing onto output sun gear.
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9. Install tanged direct clutch washer with tabs facing pressure plate. The finger on the thrust washer with the dried hole should be positioned at the bottom of the case as shown in image. Ensure that tabs on back of washer are properly seated in pressure plate pockets before proceeding to next step.
10. Install direct clutch thrust bearing.
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11. Install direct clutch thrust washer. The thrust washer will have a tooth missing from its outer edge. The side of the thrust washer with the circular grind pattern must face the thrust bearing. The side with the grind pattern can be identified by notch ground into the tooth.
12. Install (1) composition clutch disc and then a selective clutch plate. Selective clutch plates are available in five sizes, from 0.O8O-0.12O inch, and are used to maintain a correct clutch pack clearance of 0.050-0.070 inch. Failure to maintain this clearance, will result in damage to clutch plates and/or discs.
13. Alternate the remaining clutch discs and plates until all plates and discs are installed. On 1986-88 units, the direct clutch pack contains 6 clutch plates and 6 discs, rather than the 5 plates and discs found on 1984-85 units.
14. Install lower portion of the carrier assembly onto the direct clutch set Shift the carrier until all clutch plates are engaged.
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15. Install steel overdrive stop clutch plate, then alternate with a disc and a plate until all plates and discs are installed. On 1986-88 units, the overdrive clutch pack contains 5 clutch plates and 5 discs, rather than the 4 plates and discs found on 1984-85 units.
16. Install finger pressure plate. Ensure that one of the tabs on outside edge of plate are at 12 o'clock position when installed.
17. Install carrier thrust plate with tabs facing sprag clutch.
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18. Install (2) pinion gears with index mark on gears facing inward or toward each other. Install the other (2) pinion gears with index mark 90° off from the first (2) gears.
19. Install output sun thrust washer onto rear of input sun gear. Retain washer in position with petroleum jelly.
20. Install input sun gear. If the input sun gear spreads the pinion gears while installing, the pinion gears are not indexed properly.
21. Install selective thrust washer with oil grooves on washer facing input sun gear.
22. Install thrust bearing onto input sun gear.
23. Install carrier thrust washer onto cover. Retain washer in position with petroleum jelly.
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24. Install (4) pinion gear thrust washers onto carrier cover. Retain washers in position with petroleum jelly.
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25. Install carrier cover. If cover does not align properly with pinion gears, gears are not properly indexed as shown in image.
26. Install new attaching nuts. Torque nuts to 6-8 ft lbs.
27. Measure overdrive unit endplay as follows:
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a. Position bar J-34673 or equivalent across face of overdrive unit as shown in image. Using depth micrometer J-34672 or equivalent, measure distance from inner bearing race to top of bar and record reading. On 1986-88 units, add 0.003 inch to reading obtained.
b. Measure thickness of bar (J-34673) with a 0 to 1 micrometer and subtract this reading from reading obtained from previous step. Note reading obtained.
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c. Place bar J-34673 or equivalent across rear of adapter plate as shown image. Use depth micrometer J-34672 or equivalent and measure distance from top of the bar to adapter plate mounting surface. Note reading obtained.
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d. Measure distance from top of the bar to bearing seat in adapter plate as shown image.
e. Subtract reading obtained in step 27d from reading obtained in step 27c and note difference.
f. Subtract reading obtained in step 27e from reading obtained in step 27b.
g. The difference should be 0.000 ± 0.003 inch. if not, remove carrier cover and install a correct size input sun selective thrust washer. Selective thrust washers are available in 8 sizes, from 0.123-0.158 inch, in increments of 0.005 inch.
28. Lubricate seals with Dexron II automatic transmission fluid, then install accumulator and piston assembly.
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29. Install large snap ring onto the front of the overdrive unit as shown in image.
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30. Using tool No. J-34523 or equivalent, install new seal onto adapter plate.
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31. Install seal protector J-34621 or equivalent onto input sun gear, then install adapter plate. Apply RTV sealant around heads of adapter plate bolts, then install bolts and torque to 18-20 ft lbs. Remove seal protector.
32. On 1986-88 models, proceed as follows:
a. Install speedometer gear and sensor.
b. Coat output shaft seal lip with Dexron II automatic transmission fluid, then using tool J-21426 or equivalent, install new outputs shaft seal.
c. Position new gaskets on each side of separator plate, install spring and check ball into valve body, then position separator plate onto valve body. Install valve body onto case, then torque attaching bolts to 6-8 ft lbs.
d. Install oil filter on pickup tube.
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33. On all models, remove first 1/8 inch pipe plug from left side of the overdrive unit Install air line fitting J-34742 or equivalent into plug hole and tighten.
34. Measure clutch pack clearance as follows:
a. Loosen pressure plate attaching bolts evenly until spring pressure is released.
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b. Position dial indicator J-8001 or equivalent onto rear of overdrive unit as shown in image.
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c. On 1986-88 models, seat valve body check ball with suitable drift. On all models, apply a minimum of 100 psi to the air line fitting (J-34742) and note dial indicator reading. Indicator reading obtained should be 0.050-0.070 inch. If not, replace direct clutch selective plates. Plates are available in 5 sizes, in 0.010 inch increments from 0.080-0.120 inch. If indicator reading obtained is within specified limits, remove clutch pack retaining bolts.
35. Coat the (3) 1/8 inch pipe plugs with a suitable anti-seize compound and install plugs. Torque plugs to 7-9 ft lbs.
36. Remove air line adapter. Coat plug with a suitable anti-seize compound and install plug. Torque plug to 9-12 ft lbs. Steps 37 through 40 apply to 1984-85 models only.
37. Install speedometer gear and sensor.
38. Using tool J-21426 or equivalent, install new output shaft seal.
39. Install valve body as follows:
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a. Install check ball into overdrive case.
b. Position new gaskets, one on each side of separator plate.
c. Install separator plate onto valve body.
d. Install valve body onto overdrive unit case. Torque valve body to case bolts to 6-8 ft lbs.
e. Install T.V. cable, retaining clip and bolt.
f. Install T.V. lever. Connect T.V. cable onto lever.
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g. Install tool No. J-34671 -1 or equivalent into T.V. cable bore located on side of case. Place hook onto T.V. cable, setting the cable onto high step of gauge (J-34671-1). Position cam stop onto valve body as close to the lever as possible and install retaining bolt Set hook on T.V. cable onto lower step of the gauge (J-34671-1). Place tool No. J-34671 -2 or equivalent, between piston and solenoid bracket. Adjust screw bolt on T.V. lever until bolt contacts cam stop.
40. Install pickup tube and oil filter onto valve body.
41. On all models, apply a bead of suitable RTV sealant onto oil pan flange, then install oil pan with sealant wet.
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42. Install magnet into oil pan as shown in image.
43. Install oil pan bolts. Torque bolts to 6-8 ft lbs.
44. Install overdrive unit onto transmission reverse housing. Guide idler shaft onto adapter plate and into idler gears. Align splines on main shaft with splines on input sun gear. Slide units together and install overdrive unit case to transmission reverse housing attaching bolts. Torque bolts to 34-36 ft lbs.