Valve Body: Service and Repair

VALVE BODY

REMOVAL
1. Raise vehicle.
2. Remove oil pan and drain fluid.
3. Loosen clamp bolts and remove throttle and manual valve levers from manual lever shaft.
4. Remove [1][2]park/neutral position switch.
5. Remove filter from valve body





6. Depress retaining clip and pull solenoid wire from case connector (Fig. 207).
7. Remove valve body attaching screws.





8. Lower valve body enough to remove accumulator piston and piston spring (Fig. 208).
9. Pull valve body forward to disengage park rod.
10. Push manual lever shaft and solenoid case connector out of transmission case.





11. Lower valve body rotate it away from case, pull park lock rod out of sprag, and remove valve body (Fig. 209).

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. 210) 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. 211).
3. Remove switch valve and spring, pressure regulator valve and spring, kickdown valve and spring, and throttle valve from valve body (Fig. 211).





4. Secure detent ball and spring in housing with Retainer Tool 6583 (Fig. 212).





5. Remove manual shaft E-clip, washer, and seal (Fig. 213).
6. Pull manual shaft and park rod assembly upward out of valve body and off throttle lever (Fig. 213).





7. Remove manual valve from valve body (Fig. 214)
8. Remove Retainer Tool 6583. Then remove and retain detent ball and spring (Fig. 213).
9. Remove throttle lever (Fig. 213).





10. Remove park rod E-clip and separate rod from manual lever (Fig. 215).





11. Remove converter clutch solenoid from separator plate (Fig. 216). 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. 217).





13. Remove screws attaching end cover plate to torque converter module (Fig. 218).
14. Remove converter clutch valve, fail safe valve, and springs (Fig. 218)





15. Turn valve body over so transfer plate is facing upward (Fig. 219). 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. 219).
17. Remove transfer plate and separator plate from valve body (Fig. 219). 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.





19. Remove screws attaching separator plate to transfer plate (Fig. 220).





20. Note position of filter, rear clutch servo and rear servo check balls for assembly reference (Fig. 220) and (Fig. 221).





21. Remove shuttle valve end plate (Fig. 222).





22. Remove shuttle valve E-clip and remove secondary spring and spring guides from end of valve (Fig. 223).





23. Remove governor plug end plate (Fig. 224).
24. Remove 1-2 and 2-3 shift valve governor plugs from valve body (Fig. 224).
25. Remove shuttle valve throttle plug, primary spring and shuttle valve from valve body (Fig. 224).
26. Remove screws attaching kickdown limit valve body to valve body (Fig. 224).
27. Remove 1-2 shift control valve and spring from valve body (Fig. 224).
28. Remove 2-3 shift valve and spring from valve body (Fig. 224).
29. Remove 1-2 shift valve and spring from valve body (Fig. 224).
30. Remove throttle pressure plug from kickdown limit valve body (Fig. 224).
31. Remove retainer from end of kickdown limit valve body (Fig. 224).
32. Remove kickdown limit valve and spring from kickdown limit valve body (Fig. 224).
33. Remove regulator valve end plate from valve body (Fig. 224).
34. Remove regulator valve line pressure plug, pressure plug sleeve, regulator valve throttle pressure plug and spring (Fig. 224).

CLEANING





Serviceable valve body components (Fig. 225) are:
- park lock rod and E-clip
- switch valve and spring pressure adjusting screw bracket
- throttle valve lever manual lever
- manual lever shaft seal, washer, E-clip and detent ball
- fluid filter
- converter clutch solenoid

The remaining valve body components are serviced only as part of a complete valve body assembly.
Clean the valve body components in a parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Dry the parts with compressed air. Make sure all passages are clean and free from obstructions.

NOTE: Do not use rags or shop towels to wipe off valve body components. Lint from these materials will adhere to the valve body components. Lint will interfere with valve operation and may clog filters and fluid passages.

Minor distortion of a valve body mating surface may be corrected by smoothing the surface with crocus cloth. The cloth should be in sheet form and be positioned on a surface plate, sheet of plate glass, or equally flat surface. However, if distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced.

CAUTION: Many of the valve body valves and plugs are made of coated aluminum. Aluminum components can be identified by the dark color of the special coating applied to the surface (or by testing with a magnet). DO NOT polish or sand aluminum valves or plugs with any type of material, or under any circumstances. This practice might damage the special coating and cause the valves and plugs to stick and bind.

Aluminum valves and plugs should not be sanded or polished under any circumstances. However, minor burrs or scratches on steel valves and plugs can be removed with crocus cloth but do not round off the valve or plug edges. Squareness of these edges is vitally important. These edges prevent foreign matter from lodging between the valves, plugs and bore.

INSPECTION
Inspect the throttle and manual valve levers and shafts. Do not attempt to straighten a bent shaft or correct a loose lever. Replace these components if worn, bent, loose or damaged in any way.
Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure.





Inspect the valves and plugs for scratches, burrs, nicks, or scores. Also inspect the coating on the aluminum valves and plugs (Fig. 226). If the coating is damaged or worn through, the valve (or valve body) should be replaced.
Inspect all the valve and plug bores in the valve body Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils.
Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling.

ASSEMBLY
Clean and inspect all valve body components for damage or wear.

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 Mopar ATF Plus 4, Type 9602, transmission fluid.
2. Install regulator valve line pressure plug, pressure plug sleeve, regulator valve throttle pressure plug, and spring into valve body (Fig. 224). Verify valve components slide freely.
3. Install regulator valve end plate on valve body (Fig. 224).
4. Install kickdown limit valve and spring in kickdown limit valve body (Fig. 224). 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. 224).
7. Install throttle pressure plug in kickdown limit valve body (Fig. 224).
8. Install 1-2 shift valve and spring into valve body (Fig. 224).
9. Install 2-3 shift valve and spring into valve body (Fig. 224).
10. Install 1-2 shift control valve and spring into valve body (Fig. 224).
11. Verify valve components slide freely.
12. Place kickdown limit valve body and end plate in position on valve body and compress springs (Fig. 224).
13. Install screws to attach kickdown limit valve body to valve body (Fig. 224).
14. Install shuttle valve throttle plug, primary spring and shuttle valve into valve body (Fig. 224). Verify valve components slide freely.
15. Install 1-2 and 2-3 shift valve governor plugs into valve body (Fig. 224). 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. 224).
18. Assemble shuttle valve spring and guides (Fig. 224). Place spring and guides in position on shuttle valve stem.





19. Compress spring and install E-clip in groove on shuttle valve stem (Fig. 227).





20. Place shuttle valve end plate in position on valve body (Fig. 228).
21. Install screws to attach shuttle valve end plate to valve body (Fig. 228).





22. Install rear clutch servo and rear servo check balls in proper cavities in transfer plate (Fig. 229).





23. Insert filter into opening in separator plate (Fig. 230).
24. Place separator plate in position on transfer plate and install screws to attach separator plate to transfer plate (Fig. 230).





25. Place one 11/32 inch check ball and six 1/4 inch check balls in the proper cavities in the valve body (Fig. 231).





26. Place transfer plate in position on valve body (Fig. 232).
27. Install screws to attach transfer plate to valve body (Fig. 232).
28. Turn valve body over to expose the separator plate.





29. Insert converter clutch valve and spring into converter clutch valve module (Fig. 233). Verify valve components slide freely.
30. Insert spring and fail-safe valve into converter clutch valve module (Fig. 233). Verify valve components slide freely.
31. Place cover plate in position on converter clutch valve module (Fig. 233).
32. Install screws to attach cover to converter clutch valve module (Fig. 233).
33. Insert connecting tube into converter clutch valve module (Fig. 233).





34. Insert connecting tube into valve body opening (Fig. 234).
35. Place converter clutch valve module in position on separator plate. Install screws to attach converter clutch module to valve body (Fig. 234).





36. If necessary, install a new O-ring on converter clutch solenoid (Fig. 235).
37. Insert converter clutch solenoid into transfer plate (Fig. 235).
38. Install screw to attach solenoid to transfer plate (Fig. 235).





39. If necessary, insert park rod end into manual lever and install E-clip (Fig. 236).





40. Insert detent spring and ball into opening in valve body and install Retainer Tool 6583 (Fig. 237).





41. Install manual valve into valve body (Fig. 238).





42. Insert throttle lever through transfer plate side of valve body and upward (Fig. 239).





43. Insert throttle lever into groove in manual valve (Fig. 240).
44. Install seal, washer, and E-clip to retain manual shaft to valve body (Fig. 239).





45. Install switch valve and spring, pressure regulator valve and spring, kickdown valve and spring, and throttle valve into valve body (Fig. 241).
46. Place adjusting screw bracket and line pressure adjusting screw in position on valve body and compress springs (Fig. 211).
47. Install screws to attach adjuster bracket to valve body.

INSTALLATION
1. Verify that [1][2]park/neutral position switch is NOT installed. Valve body cannot be installed with switch in place. Remove switch if necessary.
2. Install new seals on accumulator piston if necessary, and install piston in case. Use small amount of petroleum jelly to hold piston in place.
3. Place valve body manual lever in low (1 position) to ease inserting park rod into sprag.
4. Use screwdriver to push park sprag into engagement with park gear. This makes clearance for knob on lock rod to move past sprag when valve body is installed. Rotate output shaft to verify sprag engagement.
5. Position accumulator spring between accumulator piston and valve body
6. Position valve body on transmission and work knob on park lock rod past sprag. Be sure accumulator piston and spring remain in position.
7. Hold valve body in position and install valve body screws finger tight.
8. Install [1][2]park/neutral position switch.
9. Tighten valve body screws alternately and evenly to 11 Nm (100 in. lbs.) torque.
10. Install new fluid filter on valve body Install and tighten filter screws to 4 Nm (35 in. lbs.) torque.
11. Connect solenoid wire to case connector.
12. Install manual and throttle levers on throttle lever shaft. Tighten lever clamp screws and check for free operation. Shaft and levers must operate freely without any bind.
13. Install oil pan and new gasket. Tighten pan bolts to 11 Nm (150 in. lbs.) torque. Install gasket dry; do not use sealer.
14. Connect [1][2]park/neutral position switch and converter clutch solenoid wires.
15. Install speedometer pinion gear, adapter and speed sensor.
16. Lower vehicle.
17. Fill transmission with Mopar ATF Plus 4, Type 9602, fluid.
18. Adjust gearshift and throttle cable if necessary.