Assembly

ASSEMBLY

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 housings resulting in valve sticking, cross leakage and unsatisfactory operation. Tighten valve body screws to recommended tightening specifications only.

LOWER HOUSING





Lower Housing Shift Valves and Springs






1. Lubricate valves, springs, and the housing valve and plug bores with clean transmission fluid.
2. Install 3-4 timing valve spring and valve (13) in lower housing.
3. Install 3-4 quick fill valve (18) in lower housing.
4. Install 3-4 quick fill valve spring (18) and plug (12) in housing.
5. Install timing valve end plate (11). Tighten end plate screws to 4 Nm (35 in. lbs.) torque.

3-4 ACCUMULATOR





1. Lubricate accumulator piston, seals and housing piston bore with clean transmission fluid.
2. Install new seal rings (3) on accumulator piston.
3. Install piston (1) and spring (4) in housing.
4. Install end plate on housing (5).

TRANSFER PLATE





1. Install rear clutch steel check ball (1) and rear servo plastic check ball (2) into the transfer plate (3).




2. Install filter screen (2) in upper housing separator plate (1).




3. Align and position upper housing separator plate (3) on transfer plate (2).
4. Install brace plate (1). Tighten brace attaching screws to 4 Nm (35 in. lbs.) torque.
5. Install remaining separator plate attaching screws. Tighten screws to 4 Nm (35 in. lbs.) torque.

UPPER AND LOWER HOUSING





1. Position upper housing so internal passages and check ball seats are facing upward. Then install check balls in housing (1, 2). Seven check balls are used. The single large check ball (2) is approximately 8.7 mm (11/32 in.) diameter. The remaining 6 check balls are approximately 6.3 mm (1/4 in.) in diameter.




2. Position assembled transfer plate and upper housing separator plate (2) on upper housing. Be sure filter screen (1) is seated in proper housing recess.




3. Install the Number 10 check ball (1) into the transfer plate. The check ball is approximately 4.8 mm (3/16 in.) in diameter.




4. Position lower housing separator plate (3) on transfer plate (2).




5. Install lower housing (2) on assembled transfer plate (4) and upper housing (3).
6. Install and start all valve body screws by hand except for the screws to hold the boost valve tube brace. Save those screws for later installation. Then tighten screws evenly to 4 Nm (35 in. lbs.) torque. Start at center and work out to sides when tightening screws (1).

UPPER HOUSING VALVE AND PLUG


Refer to the following graphic, to perform the following steps.





1. Lubricate valves, plugs, springs with clean transmission fluid.
2. Install the boost valve plug (4), boost valve (3), spring (1), and retainer (2) into the housing.
3. Install the boost valve cover (14). Tighten cover plate screws to 4 Nm (35 in. lbs.) torque.
4. Install shuttle valve as follows:
a. Insert plastic guides (5) in shuttle valve secondary spring (7) and install spring on end of shuttle valve (9).
b. Install shuttle valve (9) into housing.
c. Hold shuttle valve in place.
d. Compress secondary spring (7) and install E-clip (6) in groove at end of shuttle valve.
e. Verify that spring and E-clip are properly seated before proceeding.
5. Install shuttle valve cover plate (8). Tighten cover plate screws to 4 Nm (35 in. lbs.) torque.




6. Install 1-2 (9) and 2-3 (12) valve governor plugs in valve body.
7. Install shuttle valve primary spring (13) and throttle plug (11).
8. Align and install governor plug cover (11). Tighten cover screws to 4 Nm (35 in. lbs.) torque.
9. Install the switch valve (3).
10. Install the throttle valve and spring (7), kickdown (5), and kickdown detent (6).
11. Install the manual valve (8).
12. Assemble regulator valve (2) and spring (4). Insert assembly in upper housing.




Upper Housing Shift Valve and Pressure Plug Locations






13. Install 1-2 (2) and 2-3 (3) shift valves and springs.
14. Install 1-2 shift control valve and spring (9).
15. Install retainer (8), limit valve and spring (7), and 2-3 throttle plug (4) into the limit valve housing (5).
16. Install the throttle pressure spring and plug (12) and plug sleeve (11).
17. Install pressure plug cover (10) and cover plate (6). Tighten screws to 4 Nm (35 in. lbs.).
18. Install limit valve housing (5) and cover plate (6). Tighten screws to 4 Nm (35 in. lbs.).

BOOST VALVE TUBE AND BRACE





1. Position valve body assembly so lower housing (2) is facing upward.
2. Lubricate tube ends and housing ports with transmission fluid or petroleum jelly.
3. Start tube in lower housing port first. Then swing tube downward and work opposite end of tube into upper housing port.
4. Insert and seat each end of tube in housings.




5. Slide tube brace (2) under tube and into alignment with valve body screw holes.
6. Install and finger tighten three screws that secure tube brace to valve body housings.




7. Bend tube brace tabs up and against tube to hold it in position.
8. Tighten all valve body housing screws to 4 Nm (35 in. lbs.) torque after tube and brace are installed. Tighten screws in diagonal pattern starting at center and working outward.

3-4 ACCUMULATOR





1. Position converter clutch valve (4) and 3-4 shift valve (3) springs in housing.
2. Loosely attach accumulator housing (2) with right-side screw (1). Install only one screw at this time as accumulator must be free to pivot upward for ease of installation.
3. Install 3-4 shift valve and spring (3).




4. Position plug (2) on end of converter clutch valve spring. Then compress and hold springs and plug in place with fingers of one hand.
5. Swing accumulator housing upward over valve springs and plug.
6. Hold accumulator housing firmly in place and install remaining two attaching screws. Be sure springs and clutch valve plug are properly seated. Tighten screws to 4 Nm (35 in. lbs.).

VALVE BODY FINAL





1. Insert manual lever detent spring in upper housing.
2. Position detent ball on end of spring. Then hold detent ball and spring in detent housing with Retainer Tool 6583 (1).




3. Install throttle lever (1) in upper housing. Then install manual lever (2) over throttle lever and start manual lever into housing.
4. Align manual lever with detent ball and manual valve (3). Hold throttle lever upward. Then press down on manual lever until fully seated. Remove detent ball retainer tool after lever is seated.
5. Then install manual lever seal, washer and E-clip.
6. Verify that throttle lever is aligned with end of kickdown valve (4) stem and that manual lever arm is engaged in manual valve.




7. Lubricate solenoid case connector (1) O-rings and shaft of manual lever with light coat of petroleum jelly.
8. Attach solenoid case connector to 3-4 accumulator with shoulder-type screw. Connector has small locating tang that fits in dimple at top of accumulator housing (2). Seat tang in dimple before tightening connector screw.
9. Install solenoid assembly and gasket. Tighten solenoid attaching screws to 8 Nm (72 in. lbs.) torque.




10. Verify that solenoid wire harness is properly routed. Solenoid harness must be clear of manual lever and park rod and not be pinched between accumulator housing and cover.
11. Position line pressure adjusting screw in adjusting screw bracket.
12. Install switch valve spring on tang at end of adjusting screw bracket.
13. Position adjusting screw bracket on valve body. Align valve springs and press bracket into place. Install short, upper bracket screws first and long bottom screw last. Verify that valve springs and bracket are properly aligned. Then tighten all three bracket screws to 4 Nm (35 in. lbs.) torque.
14. Perform Line Pressure and Throttle Pressure adjustments.

GOVERNOR BODY, SENSOR AND SOLENOID

1. Turn valve body assembly over so accumulator side of transfer plate is facing down.
2. Install new O-rings on governor pressure solenoid and sensor.
3. Lubricate solenoid and sensor O-rings with clean transmission fluid.
4. Install governor pressure sensor in governor body.
5. Install governor pressure solenoid in governor body. Push solenoid in until it snaps into place in body.
6. Position governor body gasket on transfer plate.
7. Install retainer plate on governor body and around solenoid. Be sure solenoid connector is positioned in retainer cutout.
8. Align screw holes in governor body and transfer plate. Then install and tighten governor body screws to 4 Nm (35 in. lbs.) torque.
9. Connect harness wires to governor pressure solenoid and governor pressure sensor.
10. Install fluid filter and pan.
11. Lower vehicle.
12. Fill transmission with recommended fluid and road test vehicle to verify repair.