SECTION 7C5 - HYDRA-MATIC 4L60-E AUTOMATIC

TRANSMISSION: UNIT REPAIR

CAUTION:

This vehicle will be equipped with a Supplemental Restraint System (SRS). An SRS

will consist of either seat belt pre-tensioners and a driver's side air bag, or seat belt

pre-tensioners and a driver's and front passenger's side air bags. Refer to

CAUTIONS, Section 12M, before performing any service operation on or around any

SRS components, the steering mechanism or wiring. Failure to follow the CAUTIONS

could result in SRS deplo yment, resulting in possible p ersonal injury or unnecessary

SRS system repairs.

CAUTION:

This vehicle may be equipped with LPG (Liquefied Petroleum Gas. In the interests of

safety, the LPG fuel system should be isolated by turning ‘OFF’ the manual service

valve and then draining the LPG serv ice lines, before any service w ork is carried out

on the vehicle. Refer to the LPG leaflet included with the Owner's Handbook for

details or LPG Section 2 for more specific servicing information.

1. TRANSMISSION DISASSEMBLE

1.1 GENERAL SERVICE INFORMATION

The use of air powered tools to disassemble or reassemble this transmission is not recommended. Apart from the

fact that thread stripping is more likely when incorrect torque values are applied to fasteners, component parts can

be distorted to the point where malfunctions will occur.

Teflon Sealing Rings

If any sealing rings are found to be damaged, cut or do not rotate freely in their groove, check that the ring groove

has no trapped debris, is not burred or damaged in such a way that early failure of a replacement ring will occur.

Thrust Washer Surfaces

On inspection, thrust washer and thrust bearing surfaces may appear to be polished at points of contact. This is a

normal condition and should not be considered as damage, requiring replacement.

Techline

1.2 TRANSMISSION PREPARATION

1. Thoroughly clean exterior of transmission.

2. Install transmission holding fixture, E1363 (or

J8763-02) as shown. Note that the 2-4 Servo

should be facing away from the workbench.

NOTE:

If removal of the wiring harness is anticipated as

being necessary, the wiring harness connector

should be pushed into the case before fitting the

transmission holding fixture. This removal

operation can be achieved by pushing down

squarely on the wiring harness connec tor, us ing a 1

5/16" socket (¾" drive) to compress the connector

retaining lugs.

3. Rotate the transmission so that the converter

housing faces upward and drain the fluid from

the case extension.

Ensure that the container has the capacity to

hold at least 8 litres. Figure 7C5-1

4. Remove torque converter by sliding clear of

input shaft. Drain fluid into a suitable

container.

Figure 7C5-2

1.3 2-4 SERVO ASSEMBLY

REMOVE

1. Depress 2-4 servo cover (1) with a hammer

handle and hold.

2. Remove cover retainer ring.

Figure 7C5-3

3. To remove cover (28), either cut the O-ring

seal (not shown) and remove with thin nosed

pliers first, or stretch the O-ring by pulling it

through one of the two openings, while

removing the cover.

NOTE:

The four th apply piston (25) m ay com e out with the

cover (28) . If so, and the piston acc identally falls to

the floor, check that the teflon ring grooves have

not been damaged to the point where ring binding

and/or damage could occur.

4. Remove fourth apply piston (25) from second

apply piston assembly.

5. Remove second apply piston (17).

6. Remove servo return spring (12).

Figure 7C5-4

DISASSEMBLE

1. Remove servo pin retainer clip (24) from

second apply piston pin assembly.

2. Remove washer (23) and apply pin spring

(22).

3. Remove second apply piston pin (13).

Legend - 2nd Apply Piston Assembly

12 Spring, servo re turn

13 Pin, 2nd apply piston

14 Ring, retainer (2nd apply piston)

15 Retainer, servo cushion spring

16 Spring, servo cushion (outer)

105 Spring, servo cushion (inner) -

V6 engine only

17 Piston, 2nd apply

18 Ring, oil seal (2nd apply piston -

outer)

19 Ring, oil seal (2nd apply piston -

inner)

20 Housing, servo piston (inner)

21 Seal, O-ring

22 Spring, servo apply pin

23 Washer, servo apply pin

24 C-clip retainer, servo apply pin

Figure 7C5-5

4. Fit a suitable G-clamp (1) and socket (2), to

the second apply piston assembly as shown.

5. Use this arrangement to compress piston

assembly.

6. Remove second apply piston retainer ring

(14).

7. Remove G-clamp and socket.

8. Remove cushion spring (16) and tapered

cushion spring (105) (V6 only) and retainer

(15).

Figure 7C5-6

SERVO PIN LENGTH

NOTE:

At this point, it is advisable to measure the servo

pin, installed length as described in the next four

steps. Should the pin prove to be too short or too

long, look closely at the 2-4 band and reverse input

drum for wear and/or damage, once the

transmission has been disassembled.

1. Install the pin, tapered end first.

2. Install Tool No. J33037 as s hown, and refit the

servo cover retaining ring, to hold the tool.

3. Apply 11 Nm torque. If white line appears in

gauge slot (1), pin length is correct.

4. Remove Tool No. J33037.

Figure 7C5-7

5. Measure the pin length ‘A’ and record.

6. If pin length is incorrect and requires

replacement, use selection chart to determine

correct pin length.

2 - 4 SERVO PIN SELECTION

PIN LENGTH (mm) IDENTIFICATION

65.82 - 66.12 2 RINGS

67.23 - 67.53 3 RINGS

68.64 - 68.94 WIDE BAND

Figure 7C5-8

1.4 SPEED SENSOR AND CASE EXTENSION

1. Remove the speed sensor retaining bolt (35)

from the extension housing, then remove the

sensor (36) and O-ring (37).

NOTE:

No special tool is required for this operation.

Figure 7C5-9

2. If required, remove the case extension seal,

using a suitable seal removing tool, such as

E308 or similar.

3. Remove six case extension bolts (32).

4. W ithdraw case extension (31) and O-ring seal

(30).

Figure 7C5-10

5. To support and stop the output shaft from

falling from the transm ission at a later point in

the disassembly process, fabricate a support

brack et (1) fr om a s trip of suitable sheet m etal

(as shown). Install bracket using two case

extension bolts.

Figure 7C5-11

1.5 OIL PAN AND FILTER ASSEMBLY

1. Clean all dirt from around the oil pan, screws

and transmission case.

2. Remove all oil pan screws (76), the oil pan

(75), gasket (73) and magnet (not shown),

from the transmission case.

Figure 7C5-12

3. Lift the oil filter and twist to remove f r om the oil

pump body.

Open filter by prying the metal crimping away

from the top of the filter and pull apart. Ins pect

the filter material for particles that might

indicate the reason f or the tr ansmis sion failur e

(Not necessarily the cause!). Examples of the

type of material are;

- Clutch friction material.

- Bronze slivers, indicating bush wear.

- Steel particles.

Figure 7C5-13

4. Using suitable circlip pliers or a two-legged

puller and slide hammer, such as Litchfield

E6668 or other commercial equivalent,

remove the filter seal, taking care not to

damage the oil pump bore during the process.

NOTE:

If scratched, fluid leakage could occur from this

point, once the vehicle has been put back into

service.

Figure 7C5-14

1.6 CONTROL VALVE BODY AND WIRING HARNESS

NOTE:

If removal of the wiring harness is necessary, the

wiring harness connector should have been pus hed

into the case before fitting the transm ission holding

fixture.

After removing the holding fixture from the

transmission case, use a 1 5/16" socket (¾" drive)

and push down squarely on the wiring harness

connector, to compress the connector retaining

lugs.

1. Disconnect wiring harness connectors from all

electrical components, except the Torque

Converter Clutch (TCC) Solenoid:

1. Pressure Switch Assembly (PSA).

2. 1-2 Shift Valve Solenoid

3. 2-3 Shift Valve Solenoid

4. Pressure Control Solenoid (PCS)

5. TCC Pulse Width Modulated (TCC PWM)

Solenoid

6. 3-2 Control Solenoid

Figure 7C5-15

2. Remove the TCC Pulse Width Modulated

(PWM) solenoid retainer clip (1), then the

solenoid (2).

Figure 7C5-16

3. Remove wiring harness retaining bolts from

the control valve body.

4. Remove two bolts holding the TCC solenoid

assembly.

Figure 7C5-17

5. Lift the TCC solenoid assembly from oil pump.

6. Carefully drape the wiring harness over the

side of the transmiss ion cas e, af ter wrapping a

piece of lint free cloth around the wiring

harness to pr event chafing of the insulation on

the transmission oil pan rail.

NOTE:

If rem oval of the wiring harness /TCC Solenoid f rom

the transmission case is required, it will not be

possible until the control valve body has been

removed.

Figure 7C5-18

7. Remove the Transmission Range Fluid

Pressure Switch Assembly (PSA) retaining

bolts, then remove the PSA from the valve

body.

Figure 7C5-19

8. Remove the bolt securing the manual detent

spring.

9. Progressively loosen, then remove remaining

control valve bolts (62) and the fluid level

indicator stop bracket (93).

Figure 7C5-20

10. Rem ove control valve body assem bly by lifting

from the rear, s upporting the valve body in one

hand, while holding the manual valve link with

the other. As the valve body is being lifted,

rotate it slightly to release the manual valve

link from the manual valve.

11. Remove manual valve link from the inner

detent lever.

Figure 7C5-21

NOTE:

Take care not to lose the seven check balls that

are located under the control valve body. Shown

are the ball locations on the spacer plate after the

control valve body has been removed.

Figure 7C5-22

12. W hile holding the cover (57) down against 1-2

accumulator spring force (54/104),

progress ively loosen, then rem ove the three 1-

2 accumulator cover bolts ('58'x 1 and '59' x

2). Remove the cover (57), 1-2 accumulator

piston (56), two springs (54/105) and the pin

(not shown).

13. Remove the 1-2 accumulator piston (56) from

the cover, by applying low air pressure to the

oil drilling in the cover.

CAUTION:

To avoid the possibility of personal injury

and/or damage to the 1-2 accumulator piston,

do not use air pressure in excess of 70 kPa for

this operation.

14. Remove and discard the seal from the 1-2

accumulator piston.

15. Tag the outer 1-2 accumulator spring/s

(54/104) for correct reassembly. Figure 7C5-23

16. Remove the three spacer plate retaining bolts

(77) and plate (53).

Figure 7C5-24

17. Remove the spacer plate (48) and two spacer

plate gaskets (47/52) from the transmission

case.

Figure 7C5-25

18. Remove the 3-4 accumulator spring and tag

for correct reassembly.

19. Using flat blade snap ring pliers, remove the 3-

4 accumulator piston (44) from the

transm ission case, by rotating the piston while

pulling it from the case.

20. Remove and discard the seal from the 3-4

accumulator piston.

Figure 7C5-26

20. Remove the check ball from the transmission

case, as shown.

NOTE:

For control valve body disassembly procedure,

refer to 2.16 CONTROL VALVE BODY in this

Section.

Figure 7C5-27

1.7 CONVERTER HOUSING

1. Rotate the transmission assembly until the

converter housing is facing upward as shown,

then lock the assembly in that position.

2. Using Torx Plus bit, Tool No. J41510 or

commercial equivalent, progressively loosen,

then remove the converter housing bolts (94).

NOTE:

Do not use a standard, # 50 Torx bit, as the bolt

design is such that only the Torx Plus bit is capable

of applying sufficient loosening torque without bolt

damage.

3. Remove the converter housing (102) from the

transmission case (103).

Figure 7C5-28

1.8 TRANSMISSION E ND P LAY CHECK

To assist in the diagnostic process, transmission

end play should be checked prior to removing

internal components. If the measured end play is

outside specifications, then a careful inspection for

worn or misassembled parts can then be made

during the disassembly process.

1. Leave the transmission with the input shaft in

a vertical position.

2. Remove an oil pump bolt and install Tool No.

J25025-B and locknut.

3. Install dial indicator (1) on Tool No. J25025-B

and set to zero in contact with end of input

shaft.

4. Pull up on input shaft by hand to m easure end

play.

TRANSMISSION END PLAY 0.13 - 0.92 mm

5. Remove Tool No. J25025-B and dial indicator. Figure 7C5-29

1.9 OIL PUMP ASSEMBLY

1. Remove input shaft O-ring (618) from the

turbine shaft (V8 input shaft is shown).

2. Prise the front helix seal retainer from the oil

pump housing.

3. Using a suitable seal removing tool, such as

E308 or similar, extract the seal and discard.

Figure 7C5-30

4. Remove remaining oil pump bolts and seals.

5. Slide Tool No. J39119 over the stator shaft

until it locks under the splines. Install Tool No.

J37789-A over J39119 and tighten the clamp

bolt. Unseat oil pump assem bly by turning the

forcing screw against the input shaft. Remove

the oil pump assembly from the transmission

case.

6. Remove special tools from the oil pump.

Figure 7C5-31

7. Remove oil pump to case seal (5) and gasket

(6).

8. Rem ove rever s e input clutc h to oil pump thrus t

washer (601).

Figure 7C5-32

1.10 REVERSE INPUT CLUTCH, INPUT CLUTCH, 2-4 BAND AND INPUT GEAR SET

For a complete parts identification listing, refer to

Figure 7C5-37 and legend.

1. Remove reverse input clutch (605) and input

clutch assembly by grasping input shaft (621)

and withdrawing the assembly from

transmission case .

NOTE:

Take care, as this assembly is heavy.

Figure 7C5-33

2. Remove 2-4 band anchor pin from the

transmission case .

Figure 7C5-34

3. Remove 2-4 band assembly (602).

Figure 7C5-35

4. Remove input sun gear (658).

Figure 7C5-36

5. Remove input carrier to output shaft retaining

ring (661) using suitable snap ring pliers.

NOTE 1.

Do not over expand ring.

NOTE 2.

Using the snap ring pliers that ar e available as T ool

No. J34627, will not only make the task of circlip

removal easier but there will be less chance of the

snap ring being over expanded.

NOTE 3.

The output shaft will tend to fall out of the

transmission when the retaining ring is removed,

unless the fabricated bracket was fitted to the

output shaft (Refer to 1.4 SPEED SENSOR AND

CASE EXTENSION).

Figure 7C5-38

6. Remove input carrier assembly (662).

7. Remove thrust bearing (663).

8. Remove fabricated bracket and withdraw

output shaft ('687' in Figure 7C5-37).

Figure 7C5-39

Figure 7C5-37 - Internal Parts

REF

No. PART NAME REF

No. PART NAME

600.

601.

602.

603.

605.

606.

607.

608.

609.

610.

611.

612A.

612B.

613.

614.

615.

616.

617.

618.

619.

620.

621.

622.

623.

625.

626.

627.

628.

630.

632.

633.

634.

635.

636.

637.

638.

639.

641.

642.

643.

644.

645a.

645b.

646.

648.

649a.

649b.

Bush, case

Spring assembly, 3-4 clutch boost - 5 places

Washer, thrust

Band assembly

Bush, reverse input clutch (front)

Housing & drum assembly, reverse input clutch

Bush, reverse input clutch (rear)

Piston assembly, reverse input clutch

Seals, reverse input clutch, inner and outer

Spring assembly, reverse input clutch

Ring, reverse input clutch, spring retainer

Plate, reverse input clutch, Belleville

Plate, reverse input clutch, turbulator, steel

Plate, reverse input clutch, composition

Plate, reverse input clutch, selective

Ring, reverse input clutch, retaining

Bearing assembly, stator shaft

Washer, thrust selective

Retainer and check ball assembly,

Seal, O-ring, turbine shaft

Ring, oil seal (solid)

Retainer and check ball assembly

Housing and shaft assembly, input

Seal, O-ring, input to forward clutch housing

Piston, 3rd and 4th clutch

Ring, 3rd and 4th clutch (apply)

Spring assembly, 3rd and 4th clutch

Retainer and ball assy, forward clutch housing

Housing, forward clutch

Piston, forward clutch

Piston, overrun clutch

Ball, overrun clutch

Spring assembly, overrun clutch

Snap ring, overrun clutch spring retainer

Seal, input housing to output shaft

Bearing assembly, input sun gear

Snap ring, overrun clutch hub retaining

Hub, overrun clutch

Retainer and race assembly, sprag

Forward sprag assembly

Retainer rings, sprag assembly

Race, forward clutch (outer)

Plate assembly, overrun clutch (steel)

Plate assembly, overrun clutch (composition)

Plate, forward clutch (apply)

Plate, forward clutch (waved)

Plate assembly, forward clutch (steel)

Plate assembly, forward clutch (composition)

650.

651.

653.

654a.

654b.

655.

656.

657.

658.

659.

661.

662.

663.

664.

665.

666.

667.

668.

669.

670.

671.

672.

673.

674.

675.

676.

677.

678.

679.

680.

681.

682A.

682B.

682C.

682D.

683.

684.

685.

686.

687.

692.

693.

694.

695.

696.

698.

699.

Plate, forward clutch backing (selective)

Ring, forward clutch backing plate retainer

Plate, 3rd and 4th clutch apply (stepped)

Plate assy, 3rd and 4th clutch (composition)

Plate assy, 3rd and 4th clutch (steel)

Plate, 3rd and 4th clutch backing (selective)

Ring, 3rd and 4th clutch backing plate retainer

Plug, orifice cup

Gear, input sun

Bush, input sun gear (rear)

Retainer, output shaft to input carrier

Carrier assembly, input

Bearing assembly, thrust

Gear, input internal

Bush, reaction carrier shaft (front)

Shaft, reaction carrier

Bush, reaction carrier shaft (rear)

Retainer ring, reaction shaft/internal gear

Washer, thrust

Shell, reaction sun

Retainer ring, reaction sun gear

Bush, reaction sun

Gear, reaction sun

Washer, thrust

Race, low and reverse roller clutch

Retainer ring, low and reverse support to case

Retainer ring, low and reverse roller assembly

Clutch assembly, low and reverse roller

Support assembly, low and reverse clutch

Spring, low and reverse clutch support retainer

Carrier assembly, reaction

Plate, low and reverse clutch (waved)

Plate, low and reverse clutch (selective)

Plate, low and reverse clutch (composition)

Plate, low and reverse clutch, turbulator (steel)

Bearing assembly, thrust

Gear, internal reaction

Support, internal reaction gear

Retainer ring, reaction gear/support

Shaft, output

Bearing, reaction gear support to case

Retainer ring, low and reverse clutch

Spring assembly, low and reverse clutch

Piston, low and reverse clutch

Seal, low and reverse clutch (outer/centre/inner)

Orifice cup

Rotor, internal transmission speed sensor

1.11 REACTION GEAR SET

1. Remove input internal gear (664) and reaction

carrier shaft (666).

Figure 7C5-40

2. Remove reaction shaft/shell thrust washer

(669) and reaction sun shell (670).

Figure 7C5-41

3. Remove reaction sun gear (673).

4. Remove race/reaction shell thrust washer

(674).

5. Remove low and reverse roller clutch race

(675), by holding the inner surf ace and turning

the race in the 'free' direction.

Figure 7C5-42

6. Remove low and reverse support to case

retaining ring (676).

Figure 7C5-43

7. Reinsert mainshaft and push up to dislodge

the low and reverse clutch support assembly.

8. Remove the low and reverse clutch support

from the transmission case.

Figure 7C5-44

9. Remove low and reverse clutch support

retainer spring (680).

Figure 7C5-45

10. Remove the reaction carrier (681).

Figure 7C5-46

11. Remove low and reverse clutch plate

assembly;

682C Composition plates.

682D Steel plates.

682B Selective spacer plate.

682A Wave plate.

Figure 7C5-47

12. Remove reaction carrier support thrust bearing

(683), reaction internal gear (684) and support

assembly (685).

13. Remove r eaction gear s upport to cas e bearing

assembly (692).

Figure 7C5-48

1.12 LOW AND REVERSE CLUTCH ASSEMBLY

1. Remove bolt (87) securing the parking pawl

bracket (86). This will allow the spring (80) to

retract the parking pawl (81), providing

clearance to remove the low and reverse

clutch.

NOTE:

If the parking pawl needs to be removed completely

because of interference, follow the next three

steps.

Otherwise, continue the disassembly from step 5.

2. Remove pawl shaft plug with a suitable easy

out extractor (not shown).

3. Use a magnet to remove pawl pivot shaft.

4. Remove parking pawl bracket, pawl and

spring.

Figure 7C5-49

5. Install Tool No. J23327 as shown and

compress spring assembly (694).

6. Remove low and reverse clutch retaining ring

(693), using snap ring pliers J34627 or

equivalent.

7. Remove J23327 and low and reverse clutch

spring assembly (694).

Figure 7C5-50

8. Apply air pressure to low and reverse apply

passage in transmiss ion cas e as s hown (A), to

assist in the removal of the low and reverse

clutch piston. Remove piston (695).

CAUTION:

To reduce the possibility of injury, do not use

air pressure in excess of 70 kPa for this

operation.

Figure 7C5-51

1.13 INNE R MANUAL SHAFT, LINKAGE AND SEAL

1. Remove the two sc rews ( 1 and 3) s ec uring the

neutral start and bac k-up lam p switch ( 2), then

remove the switch (2) from the transmission

case.

Figure 7C5-52

2. Remove the nut (90) s ecuring the inner detent

lever (88) to the manual shaft (84).

3. Remove the inner detent lever (88) and

parking pawl actuator rod (85).

4. Remove the retaining clip (83) from the

manual shaft (84).

5. Withdraw the manual shaft (84) from the

transmission case .

Figure 7C5-53

6. Pry out the manual shaft seal (82) from the

transmission case with a suitable screwdriver.

Figure 7C5-54

2. COMPONENT DISASSEMBLE, INSPECTION, REASSEMBLE

2.1 TRANSMISSION CASE

INSPECT

1. Wash case thoroughly with solvent, dry with

air and blow out all oil passages.

NOTE:

Do not use cloth to dry.

2. Inspect case for cracks or porosity.

3. Check case to valve body face for damage,

distortion and inter-connected oil passages.

NOTE:

Face flatness can be checked by inspecting the

case, spacer plate gasket for complete witness

marks. If the marks are incomplete, an uneven

case surface, or cross channel leaks are indicated.

4. Check vent assembly for damage.

5. Using compressed air, check all oil passages.

For case channel identification, refer to

7C3-5 HYDRAULIC PATHS IN

TRANSMISSION COMPONENTS for

identification of these fluid passages. Figure 7C5-55

6. Check oil pump fluid passages by blowing

LOW pressure compressed air into the

numbered passages, as shown.

Legend - Case, Oil Pump Fluid Passages

3 Line pressure

7 To External Cooler

8 From External Cooler

11 Torque Signal

16 Reverse Input Clutch

18 Forward Clutch Feed

26 Torque Converter Clutch Signal

29 3-4 Clutch

37 Overrun Clutch

A Line Pressure Plug

Figure 7C5-56

7. Inspect 2-4 servo bore (1) for damage or

porosity. Ensure all slots and passages are

clear. Check for sharp edges. Check orifice

cup plug in the servo bore (11) for debris or

damage.

Legend - 2-4 Servo Bore and Components

A 2-4 Servo Bore

B Servo Exhaust Hole

C 2nd and 4th Band Apply Passage

D 3rd Accumulator Pressure Tap

Passage

11 Orifice Cup Plug

40 3rd Accumulator Retainer and Ball

Assembly

Figure 7C5-57

8. Inspect 3-4 accumulator bore (A) and orifice

cup plug (38) for damage or porosity. Ensure

all slots and passages are clear. Check for

sharp edges. Check for pin damage.

Figure 7C5-58

9. Inspect vehicle speed sender unit bore for

damage or porosity.

10. Inspect all bolt holes and oil cooler pipe

connections for thread damage. Repair with

thread inserts or equivalent, as necessary.

11. If rem oved, tighten oil cooler pipe connections

to the correct torque specification.

OIL COOLER PIPE CONNECTIONS 35 - 41

TORQUE SPECIFICATION Nm

12. Inspect case interior for:

a. Damaged ring grooves or casting flash.

b. Clutch plate lugs worn or damaged.

c. Worn or damaged bushes.

2.2 THIRD ACCUMULATOR RETAINER AND BALL ASSEMBLY

INSPECT

1. Inspect third accumulator ball and retainer

(refer Figures 7C5-57 and 7C5-59) for:

a. Ball missing, damaged or sticking.

b. Retainer loose or not seated correctly.

c. Feed slots restricted.

2. Check third acc umulator ball as sembly (40) f or

leaking as follows:

a. Reinstall the assembled 2-4 servo

components, including cover and

retaining ring, into 2-4 servo bore (D).

b. Pour suitable solvent into third

accumulator bore (A).

c. Watch for leakage into case interior (C).

NOTE:

Because fluid will flow from the orifice in the case

servo plug (11 in Figure 7C5-57), careful

observation of the source of the fluid leakage will

be required.

d. Remove 2-4 servo components.

Figure 7C5-59

REPLACE

If leakage is observed to come from the third

accumulator ball assembly, replace as follows:

1. Remove old assembly with a suitable screw

extractor (6.3 mm or #4).

Figure 7C5-60

2. Select a suitable length of 9.5 mm rod and

scribe a mark, 42 mm from a squared end, to

indicate the correct depth of installation.

Figure 7C5-61

3. Using the 9.5 mm rod, install a new 3r

accumulator retainer and ball check assembly

(40), aligning the oil feed slots with the servo

bore (see Figure 7C5-57 for reference).

4. Install the third accumulator ball and retainer

assem bly (40) until the scribe mark (A) on the

rod, is level with the case face.

Figure 7C5-62

2.3 CASE BUSHING

REPLACE

1. Using bush remover Tool J34196-10 and

driver handle Tool J8092, press the rear

bushing from the transmission case.

Figure 7C5-63

2. Install a new bush, using the sam e tools as for

removal.

Figure 7C5-64

2.4 2-4 SERVO ASSEMBLY

INSPECT

1. Inspect components for wear or damage.

Check springs for broken coils and/or

distortion.

2. Inspect bore in transmission case for any

sharpness that may damage servo seals.

2.5 LOW AND REVERSE CLUTCH ASSEMBLY

INSPECT

1. Inspect piston (695) for porosity or damage.

2. Inspect spring assembly (694) for damage.

3. Inspect retaining ring (693) for distortion.

4. Remove piston seals (696) and discard.

Lubricate new seals with transmission fluid

and install on piston.

Figure 7C5-65

5. Inspect low and reverse clutch plates

(682C/D). Check composition plates for wear,

heat damage or delamination and check steel

plates for heat damage or surface finish

damage.

Figure 7C5-66

SPACER PLATE SELECTION

Select the correct spacer plate (682-B) as

described in the following steps.

1. Stack the low and reverse clutch plates on a

flat surface in the following order:

a. 1 waved plate (682-A).

b. 5 fibre (682-C) and 4 steel (682-D) plates,

starting with a fibre (composition) plate

and alternating with a steel plate, etc.

c. Low and reverse clutch s upport (679) (not

shown).

2. Apply a light (approx. 2 kg), evenly distributed

load to the low and reverse support assembly.

IMPORTANT:

Excessive pressure will start to flatten the wave

plate, resulting in an incorrect measurement.

Figure 7C5-67

3. Using a vernier caliper, measure height of

clutch pack from work surface to top of low

and reverse clutch support, noting the

dimension (D) as shown, with load applied.

4. Use the following Selection Chart to select

the correct spacer plate, relative to the

measured height.

LOW AND REV E RSE CLUTCH SPACER

PLATE SELECTION

IF PACK HEIGHT IS USE THIS SELECTIVE PLATE

FROM TO IDENTITY PLATE THICKNESS

(mm) (mm) (mm)

27.545 28.065 NONE 1.684 1.829

28.066 28.586 0 1.168 1.314

27.026 27.544 1 2.198 2.344

OVERALL CLUTCH P ACK HEI GHT 29.22 - 29.90 mm

(Includi ng S pacer Plat e)

NOTE 1:

The s elective plate shown as 'NONE' in the above

chart, refer s to a fifth, steel reac tion plate, which is

to be used as the spacer plate.

NOTE 2:

Should a measurement fall in an overlap in the

Selection Chart, either the selective plate that is

thinner or thicker, can be fitted.

NOTE 3:

Regardless of the combinations used, the critical

specification that must be achieved, is the overall

clutch pack height (including the spacer plate),

which is to be between 29.22 mm and 29.90 mm.

5. Install correct spacer plate between wave

plate and first fibre clutch plate with

identification side facing upwards.

Figure 7C5-68

2.6 LOW AND REVERSE CLUTCH SUPPORT ASSEMBLY

1. Disassemble low and reverse support

assembly as follows:

a. Remove inner race (675).

b. Remove one retaining ring (677).

c. Remove roller clutch assembly (678).

2. Inspect inner race for damage.

3. Inspect roller clutch assembly for damaged

rollers or broken springs.

4. Inspect support assembly for loose cams,

cracks or damage.

NOTE:

The low and reverse support assembly is

reassembled during transmission reassembly.

Figure 7C5-69

2.7 REACTION INTERNAL GEAR AND CARRIER ASSEMBLY

INSPECT

1. Inspect reaction gear support case bearing

surface and thrust bearing assembly (692) for

damage.

Figure 7C5-70

2. Inspect reaction internal gear (684) and

support (685) for incorrec t assembly, stripped

splines, cracks, teeth or lug damage.

Figure 7C5-71

3. Inspect reaction carrier bearing surface and

thrust bearing assembly (683) for damage.

Figure 7C5-72

4. Inspect reaction carrier assembly (681) for

pinion gear wear, proper pinion staking and

free turning of pinions.

5. Check for excessive pinion washer wear by

meas ur ing pinion end play. End play should be

0.20 to 0.60 mm. The reaction carrier

assembly is serviced as a complete assembly

and should be replaced if worn or defective.

Figure 7C5-73

5. Check carrier assembly captive thrust bearing

as follows:

a. Place a suitable bush (or socket) on

bearing race ( do not contac t pinion gear s )

and turn bush with palm of your hand.

b. Any imperfections will be felt through

bush.

Figure 7C5-74

2.8 REACTION SUN GEAR AND SHELL

INSPECT

1. Inspect reaction sun gear (673) for dam age to

bush, damage to spline or teeth, loose or

weak retaining ring. Do not remove ring ex cept

for replacement.

Figure 7C5-75

2. Inspect reac tion sun shell (670) for damage or

wear to tangs.

3. Inspect thrust washers (669, 674 - not shown)

for wear or damage.

Figure 7C5-76

SUN GEAR BUSH - REPLACE

1. Should the sun gear bushing (672) require

replacement, use bush remover Tool J34196-

1 and driver handle J8092 to press the bush

from the gear.

Figure 7C5-77

2. Install a replacement bush (672) using the

same tools but press the bush in from the

other side of the sun gear, as shown.

3. If removed, install a new retaining ring ( 671) to

the sun gear (see Figure 7C5-75).

Figure 7C5-78

2.9 INPUT INTERNAL GEAR AND OUTPUT SHAFT

INSPECT

1. Remove retaining ring (668) from input internal

gear (664).

2. Remove reac tion carrier shaf t (666) f rom input

internal gear and inspect shaft for:

a. Damaged or worn bushes.

b. Cracks.

c. Damaged spline or gear teeth.

d. Undercutting around shaft from

interference with sun gear.

3. Inspect input internal gear (664) f or cr ack ed or

damaged splines or gear teeth.

4. Inspect carrier to reaction shaft thrust bearing

for wear or damage (663).

5. If all parts are serviceable, reassemble the

reaction carrier shaft (666) into the input

internal gear (664) and inst all the retaining r ing

(668). Figure 7C5-79

6. Inspect transmission output shaft (687) for:

a. Blocked or restricted lube passages.

b. Damage to splines or ring groove.

c. Burrs or damage to bearing journals.

d. Burrs or damage to case extension seal

surface. Polish with crocus cloth if

necessary.

e. Tooth damage to transmission output

shaft sensor rotor.

Figure 7C5-80

REACTION CARRIER SHAFT BUSHES - REPLACE

1. Using universal bushing remover J29369-2

and slide hammer J23907 or equivalent,

remove front bushing (665) from the reaction

carrier gear shaft (666).

Figure 7C5-81

2. Remove the rear bushing (667) from the

reaction car rier gear shaf t (666) by using bush

puller Tool J25019-14 and slide hammer

J7004-1 or equivalent.

Figure 7C5-82

3. Install front bushing (665), using bush installer

Tool J34196-3 and driver handle J8092.

Figure 7C5-83

4. Install rear bushing (667), using the same

tools as for the front bushing.

Figure 7C5-84

2.10 TRANSMISSION OUTPUT SPEED SENSOR RING

REPLACE

NOTE:

Normally this operation is not necessary and should

only be carried out, if inspection of the Speed

Sensor Ring shows that tooth damage has

occurred. Once removed, the ring must be

replaced and not re-used.

1. Using Tool Nos. J8433 and J21427-01,

remove the ring (699) from the output shaft

(687).

Figure 7C5-85

2. Place a new rotor over the trans miss ion output

shaft.

3. Insert Tool No. J36352-4 into the groove on

the transmission output shaft.

4. Place Tool No. J36352- 6 over the output shaft

and press sensor ring onto the output shaft

until the tube contacts the C-washer, in the

window.

Figure 7C5-86

2.11 INPUT CARRIER AND S UN GEAR

INSPECT

1. Inspect sun gear (658) for damage to bush,

cracks and damage to spline or gear teeth.

2. Inspect carrier assembly (662) for pinion gear

wear, proper pinion stak ing and free turning of

pinions.

3. Check for excessive pinion washer wear by

meas ur ing pinion end play. End play should be

0.20 to 0.60 mm. The input ca rr ier as s embly is

serviced as a complete assembly and should

be replaced if components are worn or

defective.

Figure 7C5-87

4. Check carrier assembly captive thrust bearing

as follows:

a. Place a suitable bush (or socket) on

bearing race ( do not contac t pinion gear s )

and turn bush with palm of your hand.

b. Any imperfections will be felt through

bush.

Figure 7C5-88

INPUT SUN GEAR BUSHES - REPLACE

1. Using bush rem oving tool J34196-5 and driver

handle J8092, press both sun gear bushes

(657/ 659) from the gear.

Figure 7C5-89

2. Press the front sun gear bush (657) in to the

gear, using Tool J34196-4 and driver handle

J8092.

3. Press the rear sun gear bush (659) in to the

gear, using Tool J34196-6 and driver handle

J8092.

Figure 7C5-90

2.12 INPUT CLUTCH HOUSING ASSEMBLY

DISASSEMBLE

1. Remove reverse input clutch housing and

drum assembly (605) from input housing and

shaft assembly (621).

2. Remove thrust bearing (615) and selective

thrust washer (616).

Figure 7C5-91

3. Place input clutch hous ing and dr um ass embly

(621) on work bench with input shaft

protruding through hole in workbench.

Figure 7C5-92

NOTE:

For identification of parts, refer to Figure 7C5-94.

4. Remove 3-4 clutch plate retaining ring (656)

and backing plate (655).

5. Remove 3-4 clutch plates (654).

6. Remove five, 3-4 clutch boost spring

assemblies (600).

7. Remove stepped, 3-4 clutch apply plate (653).

8. Remo ve forward c lutch back ing plate retaining

ring (651) and backing plate (650).

9. Remove forward clutch sprag assembly ‘A’

(parts 637 - 644).

10. Remove input sun gear bearing assembly

(637).

11. Remove input housing to output shaft lip seal

(636).

12. Remove forward clutch plates (649 A/B).

13. Remove forward clutch wave plate (648).

14. Remove forward clutch apply plate (646).

15. Remove overrun clutch plates (645 A/B).

16. Place input housing and shaft assembly in a

suitable press.

17. Install part of Tool Nos . J23327-1 and J 25018-

A underneath, as shown.

18. Compress overrun clutch spring assembly

(634) in press and remove overrun clutch

retaining ring (635).

19. Return input housing and shaft assembly to

workbench.

20. Remove overrun clutch spring assembly (634).

21. Remove forward clutch piston assembly (630,

together with the overrun clutch piston (632.

22. Separate the two pistons and remove all seals.

NOTE:

Separate assembly by impacting the input housing

assembly on a wooden block.

23. Remove forward clutch housing (628).

24. Remove 3-4 clutch spring assembly (626).

25. Remove 3-4 clutch apply ring (625) and piston

(623) with seals.

26. Discard all seals.

Figure 7C5-93

REF

No. PART NAME REF

No. PART NAME

600.

615.

616.

620.

621.

622.

623.

625.

626.

627.

628.

630.

632.

633.

634.

635.

636.

645a.

645b.

‘A’

Spring assembly, 3-4 clutch boost - 5 places

Bearing assembly, stator shaft

Washer, thrust selective

Retainer and check ball assembly

Housing and shaft assembly, input

Seal, O-ring, input to forward clutch housing

Piston, 3rd and 4th clutch

Ring, 3rd and 4th clutch (apply)

Spring assembly, 3rd and 4th clutch

Retainer and ball assy, forward clutch housing

Housing, forward clutch

Piston, forward clutch

Piston, overrun clutch

Ball, overrun clutch

Spring assembly, overrun clutch

Snap ring, overrun clutch spring retainer

Seal, input housing to output shaft

Plate assembly, overrun clutch (steel)

Plate assembly, overrun clutch (composition)

Forward clutch sprag assembly, consisting of;

637

638

639

641

642

643

644

646

648

649a

649b

650

651

653

654a

654b

655

656

698

Bearing assembly, input sun gear

Snap ring, overrun clutch hub retaining

Hub, overrun clutch

Retainer and race assembly, sprag

Forward sprag assembly

Retainer rings, sprag assembly

Race, forward clutch (outer)

Plate, forward clutch (apply)

Plate, forward clutch (waved)

Plate assembly, forward clutch (steel)

Plate assembly, forward clutch (composition)

Plate, forward clutch backing (selective)

Ring, forward clutch backing plate retainer

Plate, 3rd and 4th clutch apply (stepped)

Plate assy, 3rd and 4th clutch (composition)

Plate assy, 3rd and 4th clutch (steel)

Plate, 3rd and 4th clutch backing (selective)

Ring, 3rd and 4th clutch backing plate retainer

Plug, orifice cup

Figure 7C5-94 Input Clutch Housing - Exploded View

INSPECT

1. Inspect input housing and shaft assembly for

porosity, wear or damage.

2. Blow through all input shaft passages with

compressed air. The three turbine shaft

sealing balls must not be loose or leaking (the

open hole (A) is a lube oil passage to the

output shaft).

3. Check orifice cup plug (698) is not missing.

4. Check for cracks at all lube holes.

5. Check that the four turbine shaft sealing rings

rotate freely in their grooves and that they are

undamaged and free from burrs.

6. Inspect check ball and retainer (620). Check

that the ball moves freely and that the retainer

is not loose in the housing. Leak test the

check ball, with solvent.

Figure 7C5-95

7. If required, replace the turbine shaft check ball

assembly (617), as follows;

a. Straighten the retainer tangs and remove

the ball.

b. Use a suitable easy out extractor (A) to

remove retainer from the turbine shaft

(B).

c. Install new check ball and retainer

assembly (617), using 9.5 mm (3/8”) rod

(C), until the retainer is 3.0 mm below the

end of the input shaft.

d. Check that the check ball moves freely.

Figure 7C5-96

8. Replace input shaft housing check ball

assembly, if necessary, as follows:

a. Tap out retainer and ball assembly (620),

using 5.7 mm (1/4 inch) rod.

Figure 7C5-97

b. Install new assembly with 5.7 mm rod

until shoulder is seated in housing from

input shaft side, as shown.

Figure 7C5-98

8. Inspect 3-4 clutch piston (623) for porosity or

damage.

9. Inspect 3-4 clutch apply ring (625) for bent

tangs.

10. Inspect 3-4 clutch spring assembly (626) for

distortion or damage.

11. Inspect each of the five 3-4 clutch spring

assemblies (600) for damage or distortion.

12. Inspect the 3-4 clutch plates for damaged

tangs, delamination and/or excessive wear.

NOTE:

The green/black appearance of the 3-4 clutch

plates is normal. Therefore, do not assume that

these plates are burned because of colour.

13. Inspect forward clutch housing (628) for:

a. Correct check ball (627) operation.

b. Damage, distortion or cracks.

c. Burrs in seal areas.

Figure 7C5-99

14. Inspect forward clutch piston (630) for:

a. Porosity or damage.

b. Ring groove damage.

c. Apply leg damage.

NOTE:

As the inner and outer piston seals are bonded to

the forward clutch piston, if any seal damage is

found, then the piston assembly must be replaced.

Figure 7C5-100

15. Inspect overrun clutch piston (632) for:

a. Porosity or damage.

b. Ring groove damage.

c. Seal damage.

d. Check ball operation (overrun) (633).

NOTE:

As the inner and outer piston s eals ar e now bonded

to the overrun clutch piston, if any seal damage is

found, then the piston assembly must be replaced.

16. Inspect overrun spring assembly (634) for

damage or distortion.

17. Inspect overrun clutch plates (645), forward

clutch plates (649) and 3- 4 clutch plates ( 654).

Check composition plates for damaged tangs,

delamination or excessive wear. Check steel

plates for damaged tangs, wear or heat

damage. Figure 7C5-101

18. Inspect input sun gear bearing as sem bly (637)

and input housing to output shaft seal (636) for

wear, damage or distortion.

Figure 7C5-102

19. Disassemble forward sprag clutch assembly

as follows:

a. Remove overrun clutch hub retaining

snap ring (638) and clutch hub (639).

b. Remove forward clutch outer race (644).

c. Remove sprag retainer and race

assembly (641).

Figure 7C5-103

d. Remove sprag assembly retainer rings

(643).

e. Remove the forward sprag assembly

from the forward clutch outer race (644).

Figure 7C5-104

20. Inspect forward clutch sprag assembly (642)

for:

a. Wear or damage.

b. Weak or broken springs.

c. Damaged or missing retaining caps.

Figure 7C5-105

21. Inspect overrun clutch hub (639) for:

a. Spline damage.

b. Plugged lubrication holes.

c. Damaged tangs.

d. Cracks.

22. Inspect sprag retainer and race assembly

(641) for:

a. Spline damage.

b. Ring groove damage.

c. Surface finish damage.

d. Loose retainer.

23. Inspect forward clutch outer race (644) for:

a. Spline damage.

b. Surface finish damage.

c. Plugged lubrication holes.

24. Inspect forward (650) and 3-4 clutch backing

plates (655) for:

a. Flatness.

b. Surface finish damage.

c. Burrs and nicks.

25. Inspect forward clutch apply plate (646) and

spacer plate for:

a. Flatness.

b. Surface finish damage.

c. Burrs and nicks.

26. Inspect 3-4 clutch apply plate (653) for flatness

and surface finish damage.

27. Inspect 3-4 clutch r ing retaining plate (652) for

bent tangs and flatness.

Figure 7C5-106

REASSEMBLE

FORWARD CLUTCH SPRAG ASSEMBLY

1. Reinstall forward sprag assembly (642) into

forward clutch outer race (644). Notches in

sprag cage point in the direction shown.

Figure 7C5-107

2. Reinstall one sprag retaining ring (643) onto

sprag retainer and race hub assembly (641)

with retaining ring recess facing outward.

Figure 7C5-108

3. Locate sprag r etaining ring (643) and r ace hub

assembly (641) into the sprag outer race

assembly as follows:

a. Hold outer race (644) in right hand

supporting sprag assembly (642) with

fingers at recessed side of outer race.

b. Insert retaining ring and race hub

assembly from opposite side of outer

race by pushing in and turning anti-

clockwise.

4. Reinstall remaining sprag assembly outer

retaining ring (643), with the recess facing

inward toward the sprag (642).

Figure 7C5-109

5. Reinstall overrun clutch hub (639).

6. Reinstall overrun clutch hub retaining snap

ring (638) into groove in sprag retainer and

race assembly (641).

7. Test assembly for correct operation as follows;

a. Hold the forward clutch outer race (644)

in the left hand and grasp the overrun

clutch hub (639) with the r ight. Attempt to

rotate the hub in both directions.

b. Provided the overrun clutch hub rotates

when turned clockwise and locks up

when attempting to turn it counter-

clockwise, then the sprag has been

assembled correctly. If however, the

assembly operates backwards, the sprag

is assembled incorrectly. Dismantle and

re-assemble correctly.

Figure 7C5-110

8. Place input housing and shaft assembly (621)

on workbench with input shaft protruding

through hole in workbench.

Figure 7C5-111

3-4 CLUTCH ASSEMBLY

9. Lubricate a new O-ring (622) with petroleum

jelly and install on input housing.

Figure 7C5-112

10. Coat new 3-4 clutch piston inner and outer lip

seals with petroleum jelly.

11. Reinstall 3-4 clutch piston in input housing as

shown, taking care not to damage seals.

Figure 7C5-113

12. Locate 3-4 clutch spring assembly (626) onto

the five legged 3-4 clutch apply ring (625).

13. Coat forward clutch piston inner and outer

bonded seals with petroleum jelly and install

the forward clutch piston (630) into forward

clutch housing (628) taking care not to

damage the outer seal.

14. Reinstall forward clutch assembly onto 3-4

clutch spring ass em bly, locating forward clutch

piston smaller apply legs between 3-4 clutch

apply ring legs, as shown.

15. Use the forward clutch backing plate retaining

ring (651) to hold these parts in place during

installation.

Figure 7C5-114

16. Fit Tool J29883 on input housing as shown

and coat with petroleum jelly.

17. Reinstall 3-4 clutch apply ring/forward clutch

assembly into input housing as follows:

a. Hold assembly by apply ring legs and

carefully lower into the input housing and

shaft assembly.

b. Do not let forward clutch piston separate

from forward clutch housing.

c. Seat assembly by pushing down firmly

onto the forward clutch piston. It may be

necessary to slightly 'rock' assembly to

overcome cocking. Ensure the forward

clutch housing is seated over the O-ring

(622).

18. Remove Tool No. J29883 and the temporarily

installed retaining ring (651).

Figure 7C5-115

OVERRUN CLUTCH ASSEMBLY

19. Fit Tool J29882 on input housing, as shown

and coat with petroleum jelly.

20. Lubricate overrun clutch pis ton inner and outer

bonded seals with petroleum jelly and install

piston (632) with hub facing upwards, as

shown.

NOTE:

If all components are correctly seated, overrun

clutch piston hub locates approximately 3 mm

below snap ring groove in input housing hub.

21. Remove tool J29882.

Figure 7C5-116

22. Reinstall overrun clutc h spring assem bly (634)

onto overrun clutch piston.

Figure 7C5-117

23. Install part of J23327 and J25018-A as shown.

24. Place input housing and shaft assembly in a

suitable press.

25. Compr ess over run clutc h spring ass em bly and

install clutch retaining ring (635). Do not over-

compress springs. Remove specia l tools.

Figure 7C5-118

26. Install new output shaft seal (636) into input

housing, noting seal lip orientation.

Figure 7C5-119

27. Pre-lubricate overrun clutch plates (645B) in

automatic transmission fluid and reinstall into

input housing; steel (645A) first, then

composition (645B), steel and the second

composition plate. Align the steel plates with

the wide notch, as shown.

NOTE:

This clutch pack is the smallest set in the

transmission.

Figure 7C5-120

28. Reinstall input sun gear thrust bearing

assembly (637) onto input clutch hub with

inside race facing input housing hub, as

shown. Retain thrust bearing in place with

petroleum jelly.

Figure 7C5-121

29. Align the two composition over run clutch plate,

inner tangs.

30. Reinstall forward clutch sprag assembly into

input clutch housing, locating overrun clutch

hub (639) into overrun clutch plates.

Figure 7C5-122

FORWARD CLUTCH ASSEMBLY

31. Reinstall forward clutch apply plate (646) into

input clutch housing (621), indexing as shown.

32. Reinstall waved steel forward clutch plate

(648) into input clutch housing, again indexing

as before.

33. Reinstall rem aining forward clutch plates (649)

into input housing; starting with a steel plate

(649A), then composition (649B, etc.

34. Reinstall for ward c lutch s elec tive bac king plate

(650) and then reinstall retaining ring (651).

Figure 7C5-123

35. Measure end clearanc e between backing plate

(650) and retaining ring (651) with two feeler

gauges. Clearance should be 0.75 to 1.60

mm. If clearanc e is incorrect, s elect a s uitable

selective backing plate (650) from chart below

and install instead of the original backing plate.

FORWARD CLUTCH SELECTIVE PLATE

PLATE THICKNESS (mm) IDENTIFICATION

6.97 - 7.07 A

6.38 - 6.48 B

5.79 - 5.89 C

5.20 - 5.30 D

4.61 - 4.71 E

Figure 7C5-124

3-4 CLUTCH

36. Reinstall 3-4 clutch apply plate (653), with the

protruding lugs facing inward, as shown.

37. Reinstall 3-4 clutch plates (654), starting with a

composition (654A), then steel (654B), etc.

Figure 7C5-125

NOTE:

Install the steel plates with the wider lug openings

in the wide gap of the input housing (621), to allow

space for the five spring boost assemblies.

38. Reinstall five spring boost assemblies (600),

exposed spring ends uppermost and equally

spaced in the locations shown.

Figure 7C5-126

39. Reinstall 3-4 clutch backing plate (655),

chamfered side up and wide tangs over the

spring boost assemblies (600). Reinstall

retaining ring (656).

Figure 7C5-127

40. Measure clearance between backing plate

(655) and adjacent composition plate with a

feeler gauge. Clearance should be 0.90 -

2.10 mm. If clearance is incorrect, select a

suitable selective backing plate from the chart

below and install in the place of the original

backing plate.

3-4 CLUTCH SELECTIVE PLATE

PLATE THICKNESS (mm) IDENTIFICATION

5.88 - 5.68 A

4.99 - 4.76 B

4.10 - 3.90 C

Figure 7C5-128

INPUT CLUTCH HOUSING AIR CHECKS

1. Check overrun clutch by using a rubber tipped

air nozzle (4) to apply air pressure to the

overrun clutch passage (1) while blocking

forward clutch apply hole (2). Overrun clutch

should apply. Lube passage (3) is shown to

assist with correct orifice identification.

NOTE:

Unless the forward clutch apply hole is blocked

during this test, air will leak past the forward clutch

piston lip seals and exit via the forward clutch feed

hole in the input shaft.

2. Check the forward clutch by applying air

pressure to the forward clutch apply hole.

Forward clutch should apply.

Figure 7C5-129

3. Check 3-4 clutch by applying air pressure (3)

to the 3-4 clutch ball and retainer assembly

(1), while blocking the 3-4 feed hole (2) in the

turbine shaft. The 3-4 clutch should apply.

Figure 7C5-130

REINSTALL TURBINE SHAFT SEALING RINGS

1. Fit Tool No. J36418-1 over input shaft.

2. Install four new input shaft oil seal rings (619).

3. Remove J36418-1 and install J36418-2A over

seals to re-size them. Leave J36418-2A in

place until transmission is reassembled.

Figure 7C5-131

2.13 REVERSE INPUT CLUTCH ASSEMBLY

DISASSEMBLE

1. Remove backing plate retaining ring (614)

from housing and drum assembly.

2. Remove backing plate (613) and clutch plates

(612A/B) including Belleville plate (611).

Figure 7C5-132

3. Install Tools J23327 with J25018-A

underneath and com pres s rever se input c lutch

sprin g assembly.

Figure 7C5-133

4. Remove spring assembly retaining ring.

5. Remove J23327 and J25018-A and remove

sprin g assembly.

6. Remove piston and discard piston seals.

Figure 7C5-134

INSPECT

1. Inspect selective backing plate (613) for

damage, burrs or distortion.

2. Inspect clutch plates. Check composition

plates (612B) for tang damage, delamination

or wear. Check steel plates (612A) for tang

damage, wear or heat damage.

3. Check the waved plate (611) for heat dam age

or tang wear.

4. Inspect spring assembly for distortion or

damage.

Figure 7C5-135

5. Inspect the reverse input clutch piston (607)

for:

a. Damage or porosity.

b. Ring groove damage.

6. Remove both piston seals (608) and discard.

Figure 7C5-136

7. Inspect housing and drum assembly (605) for:

a. Damaged or worn bushes.

b. Surface damage to hub or outer housing.

c. Leaking weld.

Figure 7C5-137

d. Outer housing 'dishing' at point ‘A’.

Should the bushes require replacement, refer to the

following procedure.

Figure 7C5-138

REVERSE INPUT CLUTCH HOUSING BUSHES - REPLACE

1. Using bush remover J25019-16 and slide

hammer J7004-1, remove the front bushing

from the reverse input clutch housing.

Figure 7C5-139

2. Use bush remover J 25019-4 and dr iver handle

J8092 to press the rear bush from the reverse

input clutch housing.

Figure 7C5-140

3. Press a new front bush (603) into the reverse

input clutch housing, using installer J25019-9

and driver handle J8092.

Figure 7C5-141

4. Support the reverse input clutch housing on

suitable pieces of wood and install a new rear

bush (606), using installer J 34196-3 and driver

handle J8092

Figure 7C5-142

REASSEMBLE

1. Lubricate new piston seals with transmission

fluid and install s eals on piston with lips facing

in the direction shown.

Figure 7C5-143

2. Position a strip of thin plastic material

(approximately 0.01 mm thick) (1) around one

half of the hub and coat with petroleum jelly.

3. Coat piston seals with petroleum j elly and, with

seal lips facing down, reinstall piston (607) by

tilting down on the side opposite the plastic

strip.

4. Gently work the piston down against the

plastic strip and into the hub. Remove the

plastic strip.

5. Reinstall spring assembly with larger opening

facing piston.

6. Install Tools J25018A and J23327 to

com press spring ass embly and reinstall s pring

assembly retaining ring. Remove tools.

Figure 7C5-144

6. Reinstall Belleville clutch plate (611), concave

side down.

7. Reinstall remaining clutch plates, starting with

a steel plate (612A), then composition (612B),

etc.

8. Reinstall selective backing plate (613),

chamfered side up and reinstall retaining ring

(614).

Figure 7C5-145

9. Apply an evenly distributed, medium load

(approx. 10 kg) to the backing plate (613) as

shown in the inset.

NOTE:

Excessive pressure will distort the Belleville plate.

10. Use a feeler gauge to measure the gap

between the backing plate (613) and retaining

ring (614). The gap should be between 1.02

and 1.95 mm.

11. If gap is not to specification, select another

backing plate from the table below to replace

the original. Thes e specif ications apply to both

the V6 and V8 applications.

REVERSE INPUT CLUTCH BACKING

PLATE SELECTION

PLATE THICKNESS (mm) IDENTIFICATION

7.249 - 7.409 2

6.519 - 6.678 3

5.787 - 5.947 4 Figure 7C5-146

REVERSE INPUT CLUTCH AIR CHECK

NOTE:

Even though air pressure will be lost through the

bleed hole in the piston during this process, it is

recommended that the reverse input clutch be

completely assembled, prior to conducting this test.

If air tested with only the piston and return spring

assembly secured with a retaining ring, the piston

may 'over-stroke' and dis lodge the snap ring and/or

cause the piston seals to become dislodged from

the piston and damaged. In either case, there is a

safety risk that is to be avoided.

1. Mount the reverse input drum assembly (605)

and thrust washer (601), onto the inverted

pump assembly (4), as shown.

2. Apply air pressure in bursts to the oil pump

housing passage (# 4) and observe the

movement of the clutch piston and the clutch

pack.

If the clutch does not apply, there is a

possibility that the air pressure is too low.

Therefore, increase the pressure before

condemning the clutch piston assembly.

Figure 7C5-147

2.14 2-4 BAND

INSPECT

1. Inspect 2-4 band assembly for damage,

delamination or excessive wear.

2.15 OIL PUMP

DISASSEMBLE

1. Position the oil pump assembly so that the

stator shaft (214) protrudes through a hole in

the workbench.

2. Remove the thrust washer (601), from the

reverse input drum support and the O-ring

seal (5) from the pump body.

Figure 7C5-148

3. Remove five bolts (233) securing the pump

cover to the pump body.

4. Separate the pump c over as s embly (215) from

pump body (200).

Figure 7C5-149

OIL PUMP BODY

1. Compress pump slide springs (206 and 207)

with a suitable lever or long nose pliers and

remove spri ngs.

CAUTION:

Springs are under a high load. Place a covering

over springs (as shown) before removal to

prevent possible injury.

Figure 7C5-150

2. Remove following components from pump

cavity in body (200):

a. Pump guide ring (210).

b. Thirteen pump vanes (213). Note wear

mark patterns for reassembly.

c. Pump rotor (212).

d. Rotor guide (211).

e. Pump vane guide ring (210).

Figure 7C5-151

f. Slide (203).

g. Slide seal (209).

h. Seal support (208).

i. Pivot slide pin (205) and spring (204).

j. Slide seal ring (201) and back up seal

(202).

Figure 7C5-152

3. Use a screwdriver to prise out the front helix

seal retainer ( 244) and oil seal as sem bly (243)

from the pump body.

Figure 7C5-153

OIL PUMP COVER

1. Compress converter clutch apply stop valve

(223) with a screwdriver and use circlip pliers

to remove the circlip (222). Slowly release

spring force and remove the stop valve (223),

the converter clutch apply valve (224) and the

two converter clutch valve springs (225 and

226). Lay components out in order for

inspection.

Figure 7C5-154

9. Repeat this process for the pressure regulator

valve assembly (216 to 221).

Figure 7C5-155

10. Prise pressure release pin (227) from pump

cover then remove spring (229) and ball (228).

CAUTION:

Spring is under very high load. Cover assembly

with cloth when removing pin.

11. Using long nose pliers , pull cover s creen ( 232)

and O-ring seal (231) from the pump cover.

Figure 7C5-156

12. Carefully cut the two stator shaft seals (230)

and discard.

13. W ash all c omponents with solvent and air dry.

Do not dry with a cloth.

Figure 7C5-157

INSPECT

1. Inspect pump cover (215) and body (200) for:

a. Worn or damaged bushes.

b. Porosity.

c. Scored or irregular mating faces.

d. Foreign material.

e. Cross channel leaks.

f. Ring groove damage.

2. Inspect valve trains for chips, burrs, distortion,

blocked passages and free movement of

components in bores. Remove burrs with

lapping compound.

3. Inspect pressure relief components for

damage or distortion.

Figure 7C5-158

4. Inspect pump rotor and slide for cracks.

5. If inspection indicates that the pump rotor

(212) or slide (203) require replacement,

measure components over undamaged

surfaces and ensure that the rotor and slide

selected, are from the same size groups.

Lightly hone both sides of r eplac ement rotor or

slide to remove any nicks or burrs.

OIL PUMP ROTOR AND OIL PUMP SLIDE

SELECTION CHART

THICKNESS (mm) IDENTIFICATION

17.948 - 17.961 1

17.961 - 17.974 2

17.974 - 17987 3

17.987 - 18.00 4

18.000 - 18.013 5

Figure 7C5-159

OIL PUMP BUSHINGS - REPLACE

OIL PUMP COVER

1. Remove the pum p, cavity body bushing (242),

using a bench press and Tool J41778-1.

Figure 7C5-160

2. To install a new bushing, first place the stop

plate, Tool J 41778-2 under the oil pum p cavity

body (200), as shown.

Figure 7C5-161

3. Position both components under a bench

press.

4. Install a new bush (242) into the oil pump

cavity body, using Tool J41778-1.

NOTE:

Having stop plate J41778-2 under the pump cavity

body, eff e ctively limits how far the new bus h c an be

installed.

Figure 7C5-162

PUMP COVER

1. Using bush remover J21465-15 and slide

hammer J7004-1, remove the stator shaft,

front bushing.

Figure 7C5-163

2. Using bush remover J25019-14 and slide

hamm er J 7004-1, rem ove the stator s haft rear

bushing, from the pump cover.

Figure 7C5-164

3. Install a new front stator shaft bush (234),

using installer J21465-2 and driver handle

J8092.

Figure 7C5-165

4. Install a new stator shaft rear bush (241),

using installer J21465-2 and driver handle

J25019-6.

Figure 7C5-166

REASSEMBLE

1. Install new oil seal (243), using seal installer,

Tool J25016.

Figure 7C5-167

2. Install front helix retainer (244).

Figure 7C5-168

3. Install new slide seal bac k-up O-r ing (202) and

support ring (201) into groove on rear side of

slide, retaining both with petroleum jelly.

4. Reinstall pump slide into body, aligning notch

with pivot pin hole.

5. Reinstall slide s eal support ( 208) together with

slide seal (209) into notch in pump slide.

6. Install pivot pin spring (204) and pin (205).

Figure 7C5-169

7. Carefully compress slide springs (206/207)

with long nose pliers, then use a piece of

hacksaw blade against the slide flange to

assist (or a wide bladed screwdriver as shown)

and reinstall springs in pump body.

CAUTION:

Spring tension is very high when both are

compressed. Protect eyes from possible

damage.

Figure 7C5-170

8. Reinstall one of the vane guide rings ( 210) into

pump body (200).

9. Locate rotor guide (211) onto rotor and retain

with petroleum jelly.

10. Reinstall rotor, with rotor guide facing pump

body.

11. Reinstall pump vanes (213), assembling with

the wear marks in the same position as

originally found on disassembly.

12. Reinstall remaining vane guide ring (210).

Figure 7C5-171

Place pump body assembly to one side and

reassemble pump cover as follows:

13. Reinstall inner (225) and outer (226) converter

clutch apply valve springs onto the stem of the

converter clutch apply valve (224) and, as an

assembly, reinstall into valve bore of the

cover.

14. Reinstall valve stop (223) and while

compressing the springs, install the retaining

circlip (222) in converter clutch valve bore,

ensuring that the circlip is correctly seated in

groove.

Figure 7C5-172

15. Reinstall pressure regulator valve (216) and

springs ( 217/218) into pr es sur e r egulator valve

bore of oil pump cover.

16. Insert the rever se boost valve (219) in rever se

boost valve sleeve (220), and reinstall

assembly into pressure regulator valve bore,

orientated as shown.

17. While compressing the valve train against the

pressure regulator spring forces, install the

retaining circlip (221), ensuring the circlip is

correctly seated in groove.

Figure 7C5-173

18. Reinstall pressure relief ball (228), spring

(229) and pin (227) in pump cover.

19. Reinstall cover filter screen (232) with new

seal (231).

Figure 7C5-174

20. Expand new solid stator shaft oil seals (230)

over Tool No. J 39855-1 and install, using T ool

No. J38735-3.

21. Once both seals are installed, compress to

size by fitting sizing tool, J39855-2, using

petroleum jelly to assist, as required. Leave

sizing tool installed until the pump ass embly is

reinstalled into the transmission.

Figure 7C5-175

22. Place the stator shaft through a hole in the

workbench.

23. Install pump cover assembly (215) on pump

body assem bly (200) and reinstall f ive cover to

body bolts (233), finger tight.

24. To align pump cover to body, fit alignment

band tool J21368 as shown, and secure finger

tight.

25. Tighten cover to pump body bolts to specified

torque. Remove pump assembly alignment

band tool.

PUMP COVER TO PUMP BODY 20 - 27

TORQUE SPECIFICATION Nm

Figure 7C5-176

OIL PUMP AIR CHECKS

NOTE 1.

It is advisable to wear safety glasses when

performing any of the following air check

procedures.

NOTE 2.

To check for a restriction (rather than a blocked

passage), perform tests with a piston type oil can

filled with transmission fluid, rather than use

compressed air.

Air check oil pump as indicated in Figures 7C5-

177 and 7C5-178 to ensure that all passages are

open and all cup plugs are correctly installed.

Figure 7C5-177

BLOW AIR IN: CHECK FOR AIR OUT:

#18 Forward Clutch Feed The second hole down inside the stator shaft bore.

#11 Torque Signal Block hole #47 with a finger. Inject short blasts of

compressed air into hole #11. The Boost valve will click with

each blast of air.

#29 3 - 4 Clutch The first hole down inside the stator shaft bore.

#16 Reverse Input Clutch The reverse input feed hole between the two oil seals on

the outside of the pump hub. The air seats the reverse

check ball, shown as #237 (A).

#3 (B) Line Pressure (To Valve Body) Line Pressure hole #3 (A) and through the filter screen

(232).

CAUTION: Take care that the air pressure does not blow

the filter screen out, as personal injury could result.

#47 Void This drilling terminates in a cavity in the pump body.

#3 (A) Line Pressure (To Pressure Tap Point) Line pressure hole #3 (B) and through the filter screen

(232).

CAUTION: Take care that the air pressure does not blow

the filter screen out, as personal injury could result.

#45 Vent The vent cavity.

#8 From Oil Cooler From the lube cavity in the top of the stator support shaft.

#43 Torque Converter Clutch Release Insert an Allen key through the hole in the converter clutch

valve and push on the valve against spring force. Air will

then come out of the lower hole inside the stator support.

#7 To Oil Cooler Through the filter screen.

CAUTION: Take care that the air pressure does not blow

the filter screen out, as personal injury could result.

#26 Torque Converter Clutch Signal Through the hole normally filled by the converter clutch

solenoid.

#37 Overrun Clutch The third hole down inside the stator support shaft. Air

pressure will also seat the Check Valve, shown as #237 (B).

#46 Seal Drain Back Between the stator shaft and the oil pump body seal.

2.16 CONTROL VALVE BODY

DISASSEMBLE

NOTE 1:

Some valve trains are under pressure from spring force. Cover the bores while removing roll pins and retainer clips.

NOTE 2:

Valves, springs and bushings must be laid out in the exact order of removal, to ensure correct orientation when

reassembling.

NOTE 3:

While the following sequence of disassembly is suggested, it is not mandatory. Refer to exploded view for

identification of the various components and their locations for this control valve body.

1. Remove the pressure control solenoid retaining bolt (364), the retainer (378) and the solenoid (377).

2. W hile supporting the bore plug (376), remove the retaining clip (395), the bore plug, actuator feed limit valve

spring (375) and valve (374).

3. Rem ove the 2-3 shift solenoid retaining c lip (379), the solenoid (367B); then r emove the valve train c onsisting

of the 2-3 shuttle valve (369) and 2-3 shift valve (368).

4. Remove the 1-2 shift solenoid retaining clip (379), then the solenoid (367A), 1-2 shift valve (366) and spring

(365).

5. Remove the 1-2 accum ulator roll pin (360), bore plug (373) and then the 1-2 accumulator sleeve (372), valve

(371) and spring (370).

6. Remove the three forward accumulator cover retaining bolts (364), then the cover (363).

7. Remove the f orward accum ulator spring (356), pist on (354) and pin (355). Disc ard the sealing ring (353) after

removing it from the piston.

8. Remove the low overrun valve spring (362) and valve (361).

9. While supporting the bore plug (359) with a suitable probe, remove the r oll pin (360) , the bore plug, the forward

abuse valve spring (358) and valve (357).

REF

No. PART NAME REF

No. PART NAME

350

353.

354

355

356

357

358

359

360

361

362

363

364

365

Valve Assembly, Control Body

Seal, Forward Accumulator

Piston, Forward Accumulator

Pin, Forward Accumulator

Spring, Forward Accumulator

Valve, Forward Abuse

Spring, Forward Abuse Valve

Plug, Bore

Pin, Coiled Spring

Valve, Low Overrun

Spring, Low Overrun Valve

Cover, Forward Accumulator

Bolt, Forward Accumulator Cover

Spring, 1 - 2 Shift Valve

366

367A

367B

368

369

370

371

372

374

375

376

377

378

Valve, 1 - 2 Shift

1 - 2 Shift Solenoid (A)

2 - 3 Shift Solenoid (B)

Valve, 2 - 3 Shift

Valve, 2 - 3 Shuttle

Spring, 1 - 2 Accumulator Valve

Valve, 1 - 2 Accumulator

Sleeve, 1 - 2 Accumulator

Valve, Actuator Feed Limit

Spring, Actuator Feed Limit Valve

Plug, Bore

Pressure Control Solenoid

Retainer, Pressure Control Solenoid

Figure 7C5-178 Control Valve Body ‘A’ - Exploded View

10. Turn the control valve body around and remove the manual valve (340).

11. While supporting the 3-2 control solenoid (394), remove the retaining clip (379) and the solenoid.

12. Remove the 3-2 control valve (391) and spring (392).

13. Hold 3-2 downshift bore plug (381) in, then remove the retaining clip (395). Follow this with the 3-2 downshift

valve spring (390) and valve (389).

14. W hile supporting the reverse abuse bore plug (359) with a suitable probe, rem ove the roll pin (360) and plug.

Then remove the reverse abuse valve spring (388) and valve (387).

15. Support the 3-4 shift valve bore plug (381), while removing the clip (395). Then remove the 3-4 shift valve

spring (386) and valve (385).

16. Support the 3-4 relay valve bore plug (381), while removing the clip (395). Then remove the 3-4 relay valve

(384), 4-3 sequence valve (383) and spring (382).

17. Support the bore plug (381) while removing the retaining clip (395), then remove the regulator apply valve

(380), spring (397) and isolator valve (398), behind it.

18. Clean all valves, springs, bushings and control valve body in clean solvent, then dry with compressed air.

NOTE:

The Torque Converter Clutch PWM Solenoid (396) is removed prior to the TCC Solenoid, during the process of

removing the control valve body from the transmission.

REF

No. PART NAME REF

No. PART NAME

340

379

380

381

382

383

384

385

386

387

Valve, Manual

Retainer, Solenoid

Valve, Regulator Apply

Plug, Bore

Spring, 4 - 3 Sequence Valve

Valve, 4 - 3 Sequence

Valve, 3 - 4 Relay

Valve, 3 - 4 Shift

Spring, 3 - 4 Shift Valve

Valve, Reverse Abuse

388

389

390

391

392

394

395

387

398

Spring, Reverse Abuse Valve

Valve, 3 - 2 Downshift

Spring, 3 - 2 Downshift Valve

Valve, 3 -2 Control

Spring, 3 -2 Control Valve

3 - 2 Control Solenoid

Retainer, Bore Plug

Spring, Regulator Supply

Valve, Isolator

Figure 7C5-179 Control Valve Body ‘B’ - Exploded View

INSPECT

NOTE 1:

The use of a honing stone, fine sandpaper or

crocus cloth is not recommended for servicing

stuck valves. All valve lands have sharply

ma chined cor ners that are nec ess ary for "cleaning"

the bore. If these corners are rounded, foreign

material could wedge between the valve and its

bore, causing valve sticking.

NOTE 2:

If it is found to be necessary to clean a valve,

"micro fine" lapping compound with a 900 grit or

finer may be used.

NOTE 3:

Too m uc h "lapping" of a valve will c reate exc ess ive

clearances, increasing the chance of valve

malfunction.

1. Inspect all valves and bushings for scoring,

scratches or nicks.

2. Inspect all springs for damaged or distorted

coils.

3. Inspect valve body casting for porosity,

crack s, damaged m achined surfaces, blocked

or partially blocked passages and scored or

damaged valve train bores.

SPACER PLATE EVALUATION

During inspection of the spacer plate, it is

acceptable for some check ball peening to be

evident but the following is recommended when

establishing the serviceability of this component.

Procedure 1:

The spacer plate (48) must be inspected thoroughly

for r aised m aterial on the opposite side of all c heck

ball (61) locations. If the material on the opposite

side is raised (A), the peening is considered to be

too severe and the spacer plate must be replaced.

Figure 7C5-180

Procedure 2:

To verify that a check ball location has peened

evenly and the ball is seating correctly, seat the

check ball (61) on the spacer plate. Us e a torch (A)

to shine a beam of light on the opposite side and

check for light between the spacer plate and the

check ball.

No light should be visible, as indic ated at ‘X’. If it is ,

as indicated by ‘Y’, the spacer plate must be

replaced. Perform this check for all check ball

locations on the spacer plate.

Figure 7C5-181

REASSEMBLE

1. Reassemble all components in the reverse

order to disassembly. Use Figures 7C5-

178/179 as a ref erence. Note orientation of all

valves, sleeves and solenoids.

IMPORTANT:

When reinstalling each of the bore plug retainer

clips (395), ensure that they are installed from the

transmission case side of the valve body (i.e. the

ma chined side). If this is not done, then r einstalling

the wiring harness will not be possible without

damage. Also, correct installation of the fluid filter

will not be possible, preventing fitment of the oil

pan.

NOTE:

The TCC PWM Solenoid (396) is not to be installed

until the TCC Solenoid has been installed and

the retaining bolts torqued to specification.

This operation occurs during the installation of

the control valve body to the transmission

case.

2. Tighten all retaining bolts to the corr ect torque

specification.

PRESSURE CONTROL SOLENOID

BRACKET TO VALVE BODY 8 - 14 Nm

TORQUE SPECIFICATION

FORWARD ACCUMULATOR COVER

TO VALVE BODY BOLT 8 - 14 Nm

TORQUE SPECIFICATION

3. To prevent dust contamination, store

assembled control valve body in a clean

plastic bag, until transmission is reassembled

3. TRANSMISSION REASSEMBLE

3.1 MANUAL SHAFT AND PARKING LINKAGE

If previously removed, reinstall manual shaft and

parking linkage components, as detailed in the

following steps:

1. Using a suitable sized socket, install a new

manual shaft seal (82) into the transmission

case. Lubricate the seal lips with a small

amount of clean, automatic transmission fluid.

Figure 7C5-182

2. Install the parking pawl actuator (85) to the

inner detent lever (88).

3. Remove any burrs from the manual shaft (84)

and, after lubricating with transmission fluid,

carefully install into the transmission case,

locating the inner detent lever (88), over the

flats on the manual shaft (84).

4. Install the inner manual shaft nut (80) and

tighten to the correct torque specification.

MANUAL SHAFT TO INNER

DETENT LEVER NUT 27 - 34 Nm

TORQUE SPECIFICATION

5. Install the manual shaft retainer clip (83) over

the manual shaft (84).

Figure 7C5-183

3.2 LOW AND REVERSE CLUTCH PISTON

1. Lubricate new low and reverse clutch piston,

square section seals (696), with transmission

fluid (or petroleum jelly) and install on piston

(695).

Figure 7C5-184

2. Reinstall piston (695) in transmission case,

aligning piston with notch in bottom of c as e, as

indicated. Use Tool J23327 (shown next), to

ensure the piston is installed square to its

bore.

Figure 7C5-185

3. Locate spring assembly on piston as shown,

with flat side uppermost.

4. Install Tool J23327 and compress spring

assembly below groove in case.

NOTE:

Make sure the lower plate of Tool J23327 indexes

correctly in the recess in the end of the

transmission case .

5. Reinstall retaining ring and remove J23327.

Figure 7C5-186

6. If previous ly removed, loc ate par king pawl (81)

and return spring (80) in case.

7. Reinstall parking pawl pivot shaft (79). Check

for free movement of components.

8. Coat retaining plug (78) with Loctite 242

sealant or equivalent, to Holden's Spec if ic ation

HN1256 and install with hammer and punch.

9. Reinstall park pawl brack et (86) and bolts (87)

and tighten to the specified torque.

PARK PAWL BRACKET BOLT 27 - 34

TORQUE SPECIFICATION Nm

Figure 7C5-187

3.3 REACTION PLANE TARY GEAR SET

1. Reinstall gear support to case bearing (692)

onto transmission case hub (685) as shown;

i.e. with outside bearing race towards case

hub. Retain with petroleum jelly.

2. Reinstall reaction internal gear (684) and

support (685) assem bly into bearing (692) and

transmission case hub.

3. Reinstall reaction carrier to support thrust

bearing (683) on support (685) with outer

bearing race facing support.

Figure 7C5-188

4. Reinstall reaction carrier assembly (681) onto

thrust bearing.

Figure 7C5-189

3.4 LOW AND REVERSE CLUTCH PLATES AND SUPPORT ASSEMBLY

1. Soak composition plates in new transmission

fluid.

2. Reinstall low and reverse clutch assembly by

starting with the waved plate (682A), then

selective plate (682B), (as correctly selected

during component inspection procedures).

3. Then install a c omposition c lutch plate (682C),

then a turbulator steel (682D), etc.

Figure 7C5-190

4. Index the waved, selective and steel plates, as

shown.

Figure 7C5-191

5. Apply petroleum jelly to the flat portion of the

spring and insert the spring into the curved

area in the transmission case as shown.

Figure 7C5-192

6. Reinstall low and reverse roller clutch

assembly (678) into cam and support

assembly (679).

7. Reinstall both retaining rings (677) that were

removed during roller clutch disassembly.

8. Reinstall inner low and reverse clutch race

(675) by pushing and turning in the direction

shown.

NOTE:

Test for correct operation as shown. The race

should ‘free-wheel’ in the direction indicated by the

arrow.

Figure 7C5-193

9. Pull the low and reverse roller clutch inner

race (675) up fr om its norm ally seated position

(as shown), to enable a grip on the support

assembly (679) to be made. Slightly tilt the

support assembly while aligning the wide

notch on the support with a matching wide lug

on the case.

10. Push the assembly into the case until it is

squarely seated and then, while turning the

roller clutch inner race in a clockwise direction

(free), push it down until the internal splines

line up with those on the reaction carrier.

Figure 7C5-194

11. Reinstall support retaining ring (676) by

aligning one end against the low and reverse

clutch suppor t retainer spring (680), then work

the remainder into the groove with the aid of a

screwdriver. Make sure the snap ring is fully

seated in the groove.

12. To c heck the operation of the low and reverse

piston, apply low pressure air to 'A', as shown

in Figure 7C5-51. As air is supplied, the low

and reverse piston should be seen to move

when viewed in the parking pawl area of the

case. Air leaks should also be listened for,

during this check.

Figure 7C5-195

3.5 REACTION GEAR, INPUT GEAR AND OUTPUT SHAFT

1. If removed, install a new reaction sun gear

retaining ring (671) onto reaction sun gear.

2. Reinstall reaction sun gear (673), helical gear

side down, into reaction carr ier in tr ansm iss ion

case meshing teeth with pinion gears.

3. Reinstall thrust washer (674) into the

transmission case, ensuring that the lugs on

the thrust washer face downward and locate in

the inner race of the low and reverse roller

clutch (675).

Figure 7C5-196

4. Reinstall bronze thrust washer (669) onto

reaction sun shell and secure with petroleum

jelly. Tangs on washer locate in four holes in

reaction sun shell.

5. Reinstall reaction sun shell (670) onto thrust

washer (674), locating shell over reaction sun

gear.

Figure 7C5-197

6. Reinstall thrust bearing (663) onto reaction

carrier shaft assembly with outer race against

reaction carrier shaft, as shown. Turn and

press until the splines on the reaction carrier

shaft (666) are aligned with the splines on the

reaction car rier as sem bly (681, in Figure 7C5-

189).

Figure 7C5-198

7. Reinstall input carrier assembly (662), rotating

back and forth, to index with the teeth of the

input internal gear.

Figure 7C5-199

8. While supporting the input carrier assembly

(662), reinstall output shaft into the input

carrier and attach the support bracket (1) that

was used during disassembly.

Figure 7C5-200

9. Reinstall retaining ring (661) into output shaft

ring groove. If ring was previously over-

expanded, use a new ring. Do not over-

expand ring during installation.

NOTE:

Using snap ring pliers, Tool No. J34627, will assist

in preventing retaining ring over-expans ion, as they

have been specifically designed for this particular

task.

Figure 7C5-201

10. Reinstall input sun gear (658) into the input

carrier, meshing helical sun gear teeth with

carrier pinion gear teeth.

Figure 7C5-202

3.6 REVERSE INPUT CLUTCH, INPUT CLUTCH AND INPUT GEAR SET

1. Remove Tool J36418-2A (Refer

Figure 7C5-131) from input shaft and reinstall

selective thrust washer (616) on input housing

and shaft assembly.

NOTE 1:

This selective washer controls the end play of the

transmission, measured in 1.8 Transmission End

Play Check.

NOTE 2:

If end play was not to specif ication, replace original

selective washer with a new one, selec ted fr om the

table below.

TRANSMISSION END PLAY WASHER SELECTION

WASHER THICKNESS (mm) IDENTIFICATION

1.87 - 1.97 67

2.04 - 2.14 68

2.21 - 2.31 69

2.38 - 2.48 70

2.55 - 2.65 71

2.72 - 2.82 7

2.89 - 2.99 73

3.06 - 3.16 74

2. Reinstall bearing assembly (615) on selective

thrust washer with inside race (black)

uppermost, as shown.

Figure 7C5-203

3. Reinstall reverse input clutch assembly (605)

onto input housing and shaft assembly (621),

aligning reverse input clutch plate tangs with

input housing hub. Ensure all c lutch plates are

engaged.

Figure 7C5-204

4. Reinstall reverse input (605) and input clutch

(621) assemblies into transmission case.

Locate 3-4 clutch plate tangs over input

internal gear. Ensure all clutch plates are fully

engaged. When correctly installed, reverse

input clutch housing (605) is loc ated j ust below

case oil pump, machined land in the

transmission case.

Figure 7C5-205

NOTE:

There should be approximately 3.8 mm clearance

(A) between reverse input clutch ( 605) and reac tion

sun gear shell (670), as shown. This is normal.

Figure 7C5-206

3.7 2-4 BAND ASSEMBLY

1. Inspect 2-4 band assembly for damage or

wear, noting that the band material is now

grey/black in colour. Only replace the band if

the material is scored, flaking or heavily worn.

2. Rotate transm ission through 90° as shown, s o

that the case channels are uppermost.

3. Using both hands, squeeze the 2-4 band into a

circle and work the band into place around the

reverse input drum housing (605). With the

transmission in the position shown, the weight

of the reverse input and input clutch assem bly

will be such that adequate clearance will be

provided for reinstallation of the band.

Figure 7C5-207

4. After reinstalling 2-4 band assembly (602) into

transmission, align the anchor pin end of the

band, with the hole in case.

5. Reinstall 2-4 band anchor pin into

transmission case, as indicated. Ensure pin

engages 2-4 band assembly.

Figure 7C5-208

3.8 OIL PUMP

1. Install T ool J25025-1 alignm ent pins , into c ase

as shown. (Part of Tool J25025-B).

Figure 7C5-209

2. Reinstall thrust washer (601) on oil pump (4)

as shown. Retain with petroleum jelly.

Figure 7C5-210

3. Fit new oil pump gasket (6) to transmission

case, align bolt holes and locate over the

alignment pins ( arrows). Retain with petroleum

jelly.

4. Remove oil pump hub sealing ring sizing tool

J39855-2 (see Figure 7C5-175).

5. Lubricate new oil pum p s quare s ec tion s eal (5 )

with petroleum jelly and install in the pump

body groove. W hen correctly installed and not

twisted, the seal colour strip should be visible

around the pump body (4).

Figure 7C5-211

6. Prime oil pump with new transmission fluid

and reinstall assembly into case, over

alignment pins.

7. Reinstall bolts, complete with new sealing

washers, then remove alignment pins,

J25025-1.

8. Progressively tighten bolts in an alternating

pattern to draw the pump body fully into the

transmission case. Tighten bolts to specified

torque.

OIL PUMP TO CASE BOLT 20 - 27

TORQUE SPECIFICATION Nm

Figure 7C5-212

8. After removing the output shaft support

bracket, turn input shaft by hand. If unable to

do so, transmission is incorrectly assembled

(possible thrust washer dislodgment).

Dismantle and rectify problem.

9. Measure transmission end play as described

in 1.8 T ransmission En d Play Check. If end

play is not to specification, replace selective

thrust washer ( 616) between the input hous ing

(621) and the stator shaft bearing assembly

(615). Refer to Step 1 of 3.6 Reverse Input

Clutch, Input Clutch and Input Gear Set

NOTE:

If end play is to specification, the output shaft can

be turned in both forward and reverse directions.

The effort required to turn the output shaft in the

reverse direction however, will be greater than in

the forward direction.

10. Install new O-ring seal (618) into groove at

end of input shaf t ( ‘A’ is the V8, ‘B’, the V6 and

V6 supercharged engines).

Figure 7C5-213

3.9 CONVERTE R HOUS ING

1. Install the converter housing to the

transmission case .

2. Apply Loctite 242, 243 or equivalent (to

Holden’s Specific ation HN1256) to the threads

of the bolt located at the 7 o’clock position

(when looking into the converter housing).

3. Install all converter housing bolts and tighten

to the specified torque, using Torx Plus bit,

Tool No. J41510 or commercial equivalent.

CONVERTER HOUSING BOLT 72 - 78

TORQUE SPECIFICATION Nm

NOTE:

Do not use a standard, # 50 Torx bit, as the bolt

design is such that only the Torx Plus bit is capable

of applying the correct torque without bolt damage. Figure 7C5-214

3.10 CONTROL V ALVE BODY AND ASSOCIATED COMPONENTS

1. Reinstall check ball into case. Secure with a

smear of petroleum jelly.

2. If previously removed, install a new O-ring

onto the wiring harness through connector,

smear with petroleum jelly and install into the

case. Ensure that each of the four lugs on the

connector body has 'clicked' into place, on the

outside of the case.

Figure 7C5-215

3. Reinstall 3-4 accumulator pin into case.

NOTE:

The 3-4 and 1-2 accumulator piston pins are

different diameters. Ensure that the 3-4

accumulator pin is not a loose fit in the case. The

correct pin should be a snug fit.

4. Coat new 3-4 accumulator piston seal with

petroleum jelly and install on piston. Rotate

piston seal in the piston groove to ensure that

no binding occurs.

5. Reinstall 3-4 accumulator piston over pin with

three lugs facing out of bore.

6. Reinstall 3-4 accumulator piston spring.

Figure 7C5-216

7. if a new spacer plate is to be fitted, it will be

necessary to install two filter screens (49 and

50) to the spacer plate before fitment. Location

of these two screens is as shown.

Figure 7C5-217

8. Install two suitable guide pins (part of T ool No.

J25025-B), into cas e at the locations indicated

by an asterisk (V). These locations are

impor tant, as the matching holes in the spacer

plate have a closer clearance tolerance than

the other holes.

The view shown, also confirms the location of

the check ball #1 (91) , the orifice plug #10 ( 38)

and the 3rd accumulator, check ball assembly

#7 (40).

IMPORTANT:

Ensure that the guide pins are f ully installed s o that

no thread is visible. Otherwise, the spacer plate

gasket could become caught in a thread during

installation, resulting in incorrect alignment.

Figure 7C5-218

9. Sm ear petroleum j elly over a new spacer plate

to case gas k et ( 47) and install on tr ans miss ion

case, over the guide pins. Gasket is identified

with a 'C' (Case).

10. Reinstall spacer plate (48) over the guide pins.

11. Smear petroleum jelly over a new valve body

to spacer plate gasket (52) and install on

transmission case, over the guide pins.

Gasket is identified with a 'V' (Valve body).

IMPORTANT:

Incorrect placement of the spacer plate gaskets

may cause transmission shift problems.

Figure 7C5-219

12. Install three spacer plate support plate (53)

retaining bolts (77), tightening to specified

torque.

SPACER PLATE SUPPORT PLATE 8 - 14

BOLT TORQUE SPECIFICATION Nm

Figure 7C5-220

13. Coat new 1-2 accumulator piston seal (55)

with petroleum jelly and install on piston (54).

Rotate piston seal in the piston groove to

ensure that no binding occurs.

Figure 7C5-221

14. Reinstall piston pin and the previously tagged,

two 1-2 accumulator springs (54) into the

accumulator cover.

15. Reinstall piston into cover and pin assembly.

The three lugs on the piston point into the

cover.

Figure 7C5-222

16. Reinstall 1-2 accumulator assembly onto

transmission, while holding piston in place.

Tighten bolts to specified torque.

1 -2 ACCUMULATOR COVER BOLT 8 - 14

TORQUE SPECIFICATION Nm

Figure 7C5-223

17. Remove spacer plate guide pins from case.

18. Reinstall seven check balls onto the control

valve body spacer plate in the locations as

shown and secure with a small amount of

petroleum jelly.

Figure 7C5-224

19. Insert the m anual valve link (89) into the inner

detent lever (88).

20. Turn the valve body over and, while supporting

the manual valve link in one hand and the

valve body in the other, rotate the valve body

slightly and connect the link with the manual

valve. Move the manual valve forward, to

retain the link connection and carefully lower

the valve body into position.

Figure 7C5-225

21. Reinstall bolts to the transmission range

pressure switch assembly (PSA), but do not

tighten.

Figure 7C5-226

22. Install the dipstick stop bracket (93) and

retaining bolt (62). Do not tighten at this time.

Figure 7C5-227

23. Loosely install harness bracket bolts.

24. Loosely install the remainder of the control

valve body bolts.

Figure 7C5-228

25. Reinstall the manual detent spring assembly

retaining bolt.

Figure 7C5-229

26. Coat a new TCC solenoid O-ring with

petroleum jelly and install on solenoid, then

reinstall TCC solenoid assembly into the oil

pump body

27. Tighten all bolts to the specified torque

specification, in the order shown.

CONTROL VALVE BODY and PSA 8 - 14

TORQUE SPECIFICATION Nm

MANUAL DETENT SPRING 20 - 27

BOLT TORQUE SPECIFICATION Nm

TCC SOLENOID BOLT 8 - 14

TORQUE SPECIFICATION Nm

IMPORTANT:

The control valve body bolts must be tightened in

an outward spiral from the centre, as shown.

Failure to follow this pattern may distort the valve

body, causing valves to jam in their bores.

NOTE:

There are 7 different bolt sizes used. The letters

shown, relate to the following bolt sizes.

Control Valve Body Fastener Specifications

A — M6 x 1.00 x 65.0

B — M6 x 1.00 x 54.4

C — M6 x 1.00 x 47.5

D — M6 x 1.00 x 18.0

E — M6 x 1.00 x 35.0

F — M8 x 1.25 x 20.0

G — M6 x 1.00 x 12.0

Figure 7C5-230

28. Coat a new TCC PWM solenoid O-ring with

petroleum jelly, install on the solenoid (2).

Then reinstall the solenoid into the control

valve body, securing with retaining clip (1).

Figure 7C5-231

29. Reinstall electrical wiring harness connectors

to the respective components as shown, and

indicated below.

Electrical Connector Identification

1. Pressure Switch Assembly (PSA).

2. 1-2 Shift Valve Solenoid

3. 2-3 Shift Valve Solenoid

4. Pressure Control Solenoid (PCS)

5. TCC Pulse Width Modulated (TCC PWM)

Solenoid

6. 3-2 Control Solenoid

Figure 7C5-232

3.11 OIL FILTER AND OIL PAN

1. Lubricate new oil filter seal with petroleum jelly

and install into the oil pump bore, using a

suitable size socket or piece of tubing.

Figure 7C5-233

2. Install a new oil filter into the oil filter seal.

Figure 7C5-234

3. Check that the magnet is in the designated

position in the oil pan.

4. Install a new oil pan gasket.

5. Reinstall oil pan and tighten bolts to specified

torque.

OIL PAN BOLT 9.5 - 13.8

TORQUE SPECIFICATION Nm

Figure 7C5-235

3.12 CASE EXTENSION HOUSING AND SPEED SENSOR

INSPECT

1. Inspect the for nicks or burrs to machined

surfaces, removing as required with a fine cut

file.

2. Check the propeller s haft sliding yoke bus h f or

wear.

Figure 7C5-236

CASE EXTENSION HOUSING BUSH - REPLACE

1. If not previously carried out, remove the case

extension oil seal, using a removing tool such

as Tool E308 or commercial equivalent.

Figure 7C5-237

2. Using bush remover, Tool J23062-14 and

driver handle J8092, press the bush (33) f rom

the extension housing.

Figure 7C5-238

3. Install a new bush (33) into the extension

housing (31), using installer J34196-4 and

driver handle J8092.

Figure 7C5-239

REINSTALL

1. Install a new seal (30) to the case extension

(31), then install to the rear of the tr ans miss ion

case.

2. Reinstall the six attaching bolts (32) and

tighten to the correct torque specification.

CASE EXTENSION HOUSING BOLT 42 - 48

TORQUE SPECIFICATION Nm

Figure 7C5-240

3. Inspect the speed sensor for damage and, if

serviceable, lubricate new O-ring (37) with

petroleum jelly and install on speed sensor

(36).

4. Reinstall the sensor to the case extension,

install the retaining bolt and tighten to the

correct torque specification.

SPEED SENSOR RETAINING BOLT 10.5 - 13.5

TORQUE SPECIFICATION Nm

Figure 7C5-241

5. Install new extension housing seal (34), using

Tool J21426.

Figure 7C5-242

3.13 2-4 SERVO ASSEMBLY

SERVO PIN LENGTH - CHECK

1. Install the pin, tapered end first, into the

transmission case .

2. Install Tool J33037 as shown, then install the

servo cover retaining ring to secure the tool.

3. Apply 11 Nm of torque to the tool arm. If the

white line appears in the gauge eyelet (1), then

the pin length is correct.

4. Remove Tool J330307 and the 2nd apply

piston pin, from the transmission case.

5. Should the white line not appear in the gauge

eyelet, then a replacement pin must be

selected from the following:

2 - 4 SERVO PIN SELECTION

PIN LENGTH (mm) IDENTIFICATION

65.82 - 66.12 2 RINGS

67.23 - 67.53 3 RINGS

68.64 - 68.94 WIDE BAND

Figure 7C5-243

REINSTALL

1. Reinstall cus hion springs (16 and 105) into the

well of the second apply piston (17) , as shown

next.

NOTE:

The V8 application has only one cushion spring.

2. Reinstall cus hion spring retainer (15) on top of

spring (16).

3. Fit a G-clam p (1) and suitable sized socket ( 2)

to the second apply piston assembly as

shown.

4. Use this arrangement to compress piston

assembly sufficient to allow the retaining ring

(14), to be reinstalled.

5. Remove tools to release spring tension. Figure 7C5-244

6. Reinstall the apply pin ring retainer (24) and

test that the 2-4 servo pin does not bind.

7. Reinstall servo apply pin spring (22) and

washer (23), securing with C-clip (24).

8. After applying petroleum jelly to the inner and

outer 2nd apply piston sealing rings (18 and

19), install to piston (17).

9. Apply petroleum jelly to a new servo piston,

inner housing O-ring seal (21) and install on

inner housing (20), ensuring that the seal is

correctly seated in the groove.

10. Reinstall the inner housing (20) over the 2nd

apply piston's inner sealing ring (19).

Figure 7C5-245

11. Lubricate a new 4th apply piston oil seal ring

(26) (not shown) with petroleum jelly and

reinstall on the 4th apply piston (25).

12. Reinstall 4th apply piston assembly (25) into

the servo cover (28), with the piston boss

facing the cover, as shown.

13. Lubricate a new servo cover O-ring (27) (not

shown), with petroleum jelly and fit to the

groove in the servo cover (28).

14. Reinstall servo return spring (12), servo apply

pin and 2nd apply piston assembly into servo

bore in the transmission case.

15. Reinstall the 4th apply piston and outer cover

over the servo pin and press in until the

retaining ring groove in the case is visible.

16. Reinstall retaining ring (29).

Figure 7C5-246

3.14 NEUTRAL START & BACK-UP LAMP SWITCH ASSEMBLY

1. Reinstall the neutral start and back-up lamp

switch (2) but do not fully tighten the attaching

screws (1 and 3).

NOTE:

Final adjustment of the neutral start and back-up

lamp switch is carried out after the transmission is

reinstalled into the vehicle and the shift linkage

installed.

2. Reinstall the selector lever and the retaining

nut. Tighten to the correct torque specification.

SELECTOR LEVER RETAINING 15 - 35

NUT TORQUE SPECIFICATION Nm

NOTE:

The lever must be held securely while the nut is

tightened.

Figure 7C5-247

3.15 TORQUE CONV E RTER

INSPECT

The torque converter is serviced as an assembly

and should be replaced if any of the following

conditions exist:

a. Metal particles found when flushing

cooler or converter pipes - converter

flushing is not recommended. Refer to

Section 7C4 ON-VEHICLE SERVICING

for more detailed information regarding

cooler flushing procedures.

b. Oil pump damaged.

c. Leaking converter welds.

d. Converter pilot broken, damaged or poor

fit in crankshaft.

e. Converter hub scored or damaged.

f. Internal damage to stator.

g. Transmission fluid contaminated with

coolant.

h. Excess end play.

The Torque Converter Should NOT be Replaced

If: a. The transmission fluid has an odour,

discolouration or no evidence of metallic

or clutch plate material has been found.

If any of these conditions apply:

– Drain as much fluid as possible from the

torque converter.

– Replace the oil filter and pan gasket.

– Fill transmission with the correct fluid, to

the recommended level. See

Section 7C4 ON-VEHICLE SERVICING

for more specific information.

b. Any converter bolt hole threads are

damaged or stripped.

If either of these instances are found to

exist, install thread inserts.

TORQUE CONVERTER END PLAY - CHECK

The only satisfactory method of accurately

determ ining torque c onverter end play, is to use the

optional Tool No. J35138, in conjunction with an

accurate dial indicator and a magnetic stand, set up

as shown.

After zeroing the dial indicator, move the handle up

and down and take the end play reading from the

dial indicator needle fluctuation.

TORQUE CONVERTER END PLAY

Engine - Converter Diameter End Play (mm)

V6 - 245 mm 0 - 0.5

V8 - 298 mm 0 - 0.6

Figure 7C5-248

REINSTALL

1. Reinstall torque converter to tur bine shaf t, with

the transmission in a horizontal position, as

shown.

2. Install a restraining plate across the

transmission converter housing to prevent the

converter from accidentally being dislodged.,

prior to transmission installation.

Figure 7C5-249

3.16 TRANSMISSION FIXTURE REMOVAL

1. Remove the transmission and holding fixture

(J8763-02) from the bench bracket.

2. Loosen the clamp screws and remove the

bracket from the transmission.

3. Plug all openings suc h as the oil cooler fittings

and output shaft to prevent the ingress of

foreign material, prior to installation in the

vehicle.

Figure 7C5-250

4. TRANSM I SSION REFERENCE DIAGRAMS

TRANSMISSION CASE AND EXTERNAL PARTS

Figure 7C5-251 - Transmission Case and External Parts

REF

No. PART NAME REF

No. PART NAME

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

Torque Converter Assembly

Bolt, Oil Pump to Case

O-ring, Oil Pump to Case Bolt

Pump Assembly, Oil

Seal, Oil (Oil Pump to Case)

Gasket, Oil Pump Cover to Case

Bush, Case

Vent Assembly, Transmission

Connector, Oil Cooler Pipe

Plug, Case Servo

Spring, Servo Retu rn

Pin, 2nd Apply Piston

Ring, Retainer (2nd Apply Piston)

Retainer, Servo Cushion Spring (Outer)

Spring, Servo Cushion (Outer)

Piston, 2nd Apply

Ring, Oil Seal (2nd Apply Piston - Outer)

Ring, Oil Seal (2nd Apply Piston - Inner)

Housing, Servo Piston (Inner)

Seal O-ring

Spring, Servo Apply Pin

Washer, Servo Apply Pin

Ring, Retainer (Apply Pin)

Piston 4th Apply

Ring, Oil Seal (4th Apply Piston - Outer)

Seal, O-ring (2-4 Servo Cover)

Cover, 2-4 Servo

Ring, Servo Cover Retain ing

Seal, Case Extension to Case

Extension, Case

Bolt, Case Extension to Case

Bush, Case Extensi on

Seal Assembly, Case Extension Oil

Bolt, Speed Sensor Retaining

Sensor, Vehicle Speed

Seal, O-ring (Vehicle Speed Sensor)

Plug, Transmission Case (Accumulator

Bleed)

Plug, Line Pressure

Retainer and Ball Assembly, 3rd Accumulator

Pin, Band Anchor

Retainer and Ball Assembly, (Double Orifice)

Pin, Accumulator Piston

44.

45.

46.

47.

48.

49.

50.

52.

53.

54.

55.

56.

57.

58.

59.

60.

61.

62.

63.

64.

65.

66.

67.

68.

69.

70.

71.

72.

73.

74.

75.

76.

77.

91.

93.

94.

97.

98.

102.

103.

104.

105.

Piston, 3-4 Accumulator

Ring, Oil Seal (3-4 Accumulator Piston)

Spring, 3-4 Accumulator

Gasket, Spacer Plate to Case

Plate, Valve Body Spacer

Screen, Shift Solenoids

Screen, Pressure Control Solenoid

Gasket, Spacer Plate to Valve Body

Plate, Spacer Plate Support

Spring, 1-2 Accumulator (Outer)

Ring, Oil Seal (1-2 Accumulator)

Piston, 1-2 Accumulator

Cover and Pin Assembly, 1-2 Accumulator

Bolt, Accumulator Cover

Valve Assembly, Control Body

Checkball

Bolt, Valve Body

Spring Assembly, Manual Detent

Bolt, Manual Detent Spring

O-ring Seal, Wiring Harness Pass-through

Connector,

Solenoid Assembly Harness, Wiring

Seal, O-ring, (Solenoid)

Bolt, Hex Washer Head (Solenoid)

Switch A ssembly, Transmission Pressure

Bolt, Pressure Switch Assembly

Seal, Filter

Filter Assembly, Transmission Oil

Gasket, Transmission Oil Pan

Magnet, Chip Collector

Pan, Transmission Oil

Screw, Transmission Oil Pan

Bolt, Spacer Plate Support

Number 10 Checkball

Bracket, Dipstick Stop

Bolt, Converter Housing to Case

Plug, Converter Housing Access Hole

Plate, Converter Bolt Inspection

Housing, Torque Converter

Case, Transmission Main

Spring, 1-2 Accumulator (Inner)

Spring, Servo Cushion (Inner)

CONTROL VALVE BODY ASSEMBLY

Figure 7C5-252 - Control Valve Body Assembly

REF

No. PART NAME REF

No. PART NAME

340.

350.

353.

354.

355.

356.

357.

358.

359.

360.

361.

362.

363.

364.

365.

366.

367A.

367B.

368.

369.

370.

371.

372.

Valve, Manual

Valve Assembly, Control Body

Seal, Forward Accumulator

Piston, Forward Accumulator

Pin, Forward Accumulator

Spring, Forward Accumulator

Valve, Forward Abuse

Spring, Forward Abuse Valve

Plug, Bore

Pin, Coiled Spring

Valve, Low Overrun

Spring, Low Overrun Valve

Cover, Forward Accumulator

Bolt, Forward Accumulator Cover

Spring, 1 - 2 Shift Valve

Valve, 1 - 2 Shift

1 - 2 Shift Solenoid (A)

2 - 3 Shift Solenoid (B)

Valve, 2 - 3 Shift

Valve, 2 - 3 Shuttle

Spring, 1 - 2 Accumulator Valve

Valve, 1 - 2 Accumulator

Sleeve, 1 - 2 Accumulator

374.

375.

376.

377.

378.

379.

380.

381.

382.

383.

384.

385.

386.

387.

388.

389.

390.

391.

392.

394.

395.

387.

398.

Valve, Actuator Feed Limit

Spring, Actuator Feed Limit Valve

Plug, Bore

Pressure Control Solenoid

Retainer, Pressure Control Solenoid

Retainer, Solenoid

Valve, Regulator Apply

Plug, Bore

Spring, 4 - 3 Sequence Valve

Valve, 4 - 3 Sequence

Valve, 3 - 4 Relay

Valve, 3 - 4 Shift

Spring, 3 - 4 Shift Valve

Valve, Reverse Abuse

Spring, Reverse Abuse Valve

Valve, 3 - 2 Downshift

Spring, 3 - 2 Downshift Valve

Valve, 3 -2 Control

Spring, 3 -2 Control Valve

3 - 2 Control Solenoid

Retainer, Bore Plug

Spring, Regulator Supply

Valve, Isolator

CONTROL VALVE IDENTIFICATION

Figure 7C5-253 - Control Valve Identification

Ref. No. PART NAME

A Located in the Oil Pump

216.

219.

224.

Valve, Pressure Regulator

Valve, Reverse Boost

Valve, Converter Clutch

B Located in the Control Valve Body

340.

357.

361.

366.

368.

369.

371.

374.

380.

383.

384.

385.

387.

389.

391.

398.

Valve, Manual

Valve, Forward Abuse

Valve, Low Overrun

Valve, 1 - 2 Shift

Valve, 2 - 3 Shift

Valve, 2 - 3 Shuttle

Valve, 1 - 2 Accumulator

Valve, Actuator Feed Limit

Valve, Regulator Apply

Valve, 4 - 3 Sequence

Valve, 3 - 4 Relay

Valve, 3 - 4 Shift

Valve, Reverse Abuse

Valve, 3 -2 Downshift

Valve, 3 -2 Control

Valve, Isolator

CONTROL VALVE SPRING IDENTIFICATION

Figure 7C5-254 - Control Valve Spring Identification

Ref. No. PART NAME

A Located in the Oil Pump

217.

218.

225.

226.

Spring, Pressure Regulator Valve

Spring, Pressure Regulator Isolator

Spring, Converter Clutch Valve (Inner)

Spring, Converter Clutch Valve (Outer)

B Located in the Control Valve Body

358.

362.

365.

370.

375.

382.

386.

388.

390.

392.

387.

Spring, Forward Abuse Valve

Spring, Low Overrun Valve

Spring, 1 - 2 Shift Valve

Spring, 1 - 2 Accumulator Valve

Spring, Actuator Feed Limit Valve

Spring, 4 - 3 Sequence Valve

Spring, 3 - 4 Shift Valve

Spring, Reverse Abuse Valve

Spring, 3 - 2 Downshift Valve

Spring, 3 -2 Control Valve

Spring, Regulator Supply

SEAL LOCATIONS AND ORIENTATION

Figure 7C5-255 Seal Locations and Orientation

Ref.

No. PART NAME Ref.

No. PART NAME

18.

19.

21.

26.

27.

30.

34.

37.

230.

O-ring, Pump to Case Bolt

Seal, Oil (Pump to Case)

Ring, Oil Seal (2nd Apply Piston - Outer)

Ring, Oil Seal (2nd Apply Piston - Inner)

Seal, O-ring.

Ring, Oil Seal (4th Apply Piston - Outer)

Seal, O-ring (2-4 Servo Cover)

Seal, Case Extension to Case

Seal, Case Extension

Seal, O-ring (Vehicle Speed Sensor)

Ring, Oil Seal (Stator Shaft)

243.

608.

618.

619.

622.

624.

630.

632.

636.

696.

Seal Assembly, Oil

Seals, Reverse Input Clutch

Seal, O-ring (Turbine Shaft)

Ring, Oil Seal (Solid)

Seal, O-ring (Input to Forward Housing)

Seals, 3rd and 4th Clutch (Service

Replacement)

Piston, Forward Clutch

Piston, Overrun Clutch

Seal, Input Housing to Output Shaft

Seals, (Low and Reverse Clutch Piston)

BUSH/BEARING LOCATIONS AND ORIENTATION

Figure 7C5-256 Bush/Bearing Locations and Orientation

Ref.

No. PART NAME Ref.

No. PART NAME

33.

234.

241.

242.

601.

603.

606.

615.

616.

637.

657.

659.

Bushing, Case

Bushing, Case Extension

Bushing, Stator Shaft (Front)

Bushing, Stator Shaft (Rear)

Bushing, Oil pump Body

Washer, Thrust (Pump to Drum)

Bushing, Reverse Input Clutch (Front)

Bushing, Reverse Input Clutch (Rear)

Bearing Assembly, Stator Shaft Selective

Washer

Washer, Thrust (Selective)

Bearing Assembly, Input Sun Gear

Bushing, Input Sun Gear (Front)

Bushing, Input Sun Gear (Rear)

663.

665.

667.

669.

672.

674.

683.

692.

Bearing Assembly, Thrust (Input carrier to

Reaction Shaft

Bushing, Reaction Carrier Shaft (Front)

Bushing, Reaction Carrier Shaft (Rear)

Washer, Thrust (Reaction Shaft/Shell)

Bushing, Reaction Gear

Washer, Thrust (Race/Reaction Shell)

Bearing Assembly, (Reaction

Carrier/Support)

Bearing, Reaction Gear Support to Case

5. SPECIFICATIONS

GENERAL

Type Hydra-matic 4L60-E.

Code V6 Engine - HFD.

V6 Supercharged Engine - HND.

V8 Engine - HBD.

Special Features Electronically controlled shift pattern,

feel and torque converter clutch operation.

Overdrive 4th speed range.

Selector Location Floor mounted console.

GEAR RATIOS:

Park (P) 

Reverse (R) 2.294:1

Neutral (N) 

Overdrive (OD - 4) 0.696:1

Drive (D - 3) 1.000:1

Second (2) 1.625:1

First (1) 3.059:1

SHIFT SPEEDS Refer to Section 7C3 DIAGNOSIS.

OIL PRESSURE Refer to Section 7C3 DIAGNOSIS.

TORQUE CONVERTER:

Number of Elements 3 plus torque converter clutch.

Maximum torque ratio at stall V6 Engine - 1.63:1 (k=122).

V6 Supercharged Engine - 1.63:1 (k=133).

V8 Engine - 2.15:1 (k=115).

Nominal Diameter V6 Engine - 245 mm.

V6 Supercharged Engine - 258 mm.

V8 Engine - 298 mm.

LUBRICANT:

Type recommended Dexron® III (To Holden's Specification HN2126)

Capacity Nominal only. Check when transmission

is at operating temperature.

Refill V6 Engine - 4.8 litres.

V8 Engine - 5.0 litres.

Total (Dry) V6 Engine - 7.9 litres.

V8 Engine - 10.6 litres.

Fluid Cooling Engine coolant to fluid in both radiator tanks and

externally, air to fluid cooler (where fitted).

CLUTCHES AND BAND

2 - 4 BAND:

Type Composition lined, steel band.

Operation Servo.

Adjustment Selective Apply Pin.

65.82 - 66.12 mm 2 Rings.

67.23 - 67.53 mm 3 Rings.

68.64 - 68.94 mm Wide Band.

REVERSE INPUT CLUTCH:

Type Multiple wet disc.

Clutch plate, number and thickness:

Steel 4 1.892 - 2.045 mm.

Composition 4 1.730 - 1.880 mm.

Belleville 1 2.210 - 2.311 mm.

Backing plate 1 Selective.

Backing plate, identification

and thickness: '2' 7.249 - 7.409 mm.

'3' 6.519 - 6.678 mm.

'4' 5.787 - 5.947 mm.

Backing plate travel 1.02 - 1.94 mm

FORWARD CLUTCH:

Type Multiple wet disc

Clutch plate, number

and thickness:

Flat steel plates 5 2.29 mm

Composition plates 5 1.78 mm

Apply plate 1 4.30 mm

Waved steel plate 1 1.79 mm

Backing plate 1 Selective

Backing plate, identification

and thickness: 'A' 6.97 - 7.07 mm

'B' 6.38 - 6.48 mm

'C' 5.79 - 5.89 mm

'D' 5.20 - 5.30 mm

'E' 4.61 - 4.71 mm

Backing plate travel 0.75 - 1.60 mm

OVERRUN CLUTCH:

Type Multiple wet disc

Clutch plates, number and thickness:

Flat steel 2 2.248 - 2.400 mm

Composition 2 2.03 mm

3 - 4 CLUTCH:

Type Multiple wet disc

Clutch plates, number and thickness:

Flat steel 5 2.71 mm

Composition 6 2.03 mm

Flat steel apply plate 1 5.60 mm

Flat steel (same spline

configuration as flat steel) 1 1.78 mm

Backing plate 1 Selective

Backing plate, identification

and thickness: 'A' 5.88 - 5.68 mm

'B' 4.99 - 4.76 mm

'C' 4.10 - 3.90 mm

Backing plate travel 0.90 - 2.10 mm

LOW AND REVERSE CLUTCH:

Type Multiple wet disc

Clutch plates, number and thickness:

Flat steel 5 1.75 mm

Composition 5 2.25 mm

Flat steel - waved 1 2.42 mm

Selective flat steel plate 1 Selective

Selective plate, identification

and thickness: NONE 1.684 - 1.829 mm

'0' 1.168 - 1.314 mm

'1' 2.198 - 2.344 mm

Overall clutch pack height

(Including spacer plate) 29.22 - 29.90 mm

Clutch plate support thickness 6.655 - 6.909 mm

CLEARANCES:

Transmission end play 0.13 - 0.92 mm

Pinion gears end play (all) 0.20 - 0.60 mm

Torque converter end play V6 engine: 0 - 0.5 mm

V8 Engine: 0 - 0.6 mm

6. TORQUE WRENCH SPECIFI CATIONS

NOTE:

For a listing of torque wrench specifications relating to the removal and reinstallation procedures associated with the

automatic transmission, refer to Section 7C4 HYDRA-MATIC 4L60-E AUTOMATIC TRANSMISSION: ON-

VEHICLE SERVICING.

Manual shaft to inner detent lever nut 27 - 34

Manual shaft selector lever nut 15 - 35

Neutral start and back-up lamp switch bolts 15 - 35

Oil cooler pipe connections 35 - 41

Oil pump cover to pump body bolt 20 - 27

Pressure control solenoid bracket to valve body bolt 8 - 14

Forward accumulator cover to valve body bolt 8 - 14

Park pawl bracket bolt 27 - 34

Oil pump to case bolt 20 - 27

Spacer plate support plate bolt 8 - 14

1 - 2 accumulator cover bolt 8 - 14

Control valve body bolt 8 - 14

Manual detent spring retaining bolt 20 - 27

Torque converter clutch solenoid bolt 8 - 14

Oil pan bolt 9.5 - 13.8

Converter housing to case bolt 72 - 78

Case extension housing bolt 42 - 48

Speed sensor retaining bolt 10.5 - 13.5

7. SPECIAL TOOLS

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

J8763-02 HOLDING FIXTURE PREVIOUSLY RELEASED AS

E1363 FOR TRIMATIC AND

THM 400 TRANSMISSIONS.

ALSO REQUIRED IS THE

BENCH FIXTURE, J3289-20.

J33037 2 - 4 BAND APPLY PIN TOOL PREVIOUSLY RELEASED.

J25025-B DIAL INDICATOR STAND AND GUIDE PIN

SET PREVIOUSLY RELEASED

FOR THM 125 TRANSAXLE.

J39119 OIL PUMP REMOVER ADAPTOR PREVIOUSLY RELEASED.

J37789-A OIL PUMP REMOVER PREVIOUSLY RELEASED

FOR 4L60.

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

J23327 CLUTCH SPRING COMPRESSOR PREVIOUSLY RELEASED

FOR THM 400.

J8433 PULLER PREVIOUSLY RELEASED

FOR THM 400.

J21427-01 PULLER ADAPTOR PREVIOUSLY RELEASED

FOR THM 400.

J36352 SPEED SENSOR INSTALLER &

GAUGING TOOL PREVIOUSLY RELEASED.

COMPRISES SLEEVE, J36352-

6 AND 'C' STOP, J36352-4.

J25018-A CLUTCH SPRING COMPRESSOR

ADAPTOR PREVIOUSLY RELEASED

FOR TRIMATIC AND THM 400.

J29882 INNER OVERRUN CLUTCH SEAL

PROTECTOR PREVIOUSLY RELEASED.

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

J29883 INNER FORWARD CLUTCH SEAL

PROTECTOR PREVIOUSLY RELEASED.

J34627 SNAP RING PLIERS PREVIOUSLY RELEASED AS

AN OPTIONAL TOOL.

SPECIFIC PURPOSE IS TO

ASSIST IN THE

REMOVAL/REPLACEMENT

OF THE OUTPUT SHAFT

SNAP RING.

J35138 TORQUE CONVERTER END PLAY PREVIOUSLY RELEASED AS

AN OPTIONAL TOOL.

TO BE USED IN

CONJUNCTION WITH

COMMERCIALLY AVAILABLE

MAGNETIC STAND AND DIAL

INDICATOR.

J36418-B TURBINE SHAFT SEAL INSTALLER &

RESIZER PREVIOUSLY RELEASED.

J39855-1 STATOR SHAFT SEAL EXPANDER PREVIOUSLY RELEASED.

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

J39855-2 STATOR SHAFT SEAL RESIZER PREVIOUSLY RELEASED.

J38735-3 STATOR SHAFT SEALING RING

INSTALLER PREVIOUSLY RELEASED.

J21368 OIL PUMP ALIGNMENT BAND PREVIOUSLY RELEASED

FOR 4L60.

J21426 REAR SEAL INSTALLER PREVIOUSLY RELEASED

FOR TRIMATIC, AS 7AT-6.

J25016 OIL PUMP SEAL INSTALLER PREVIOUSLY RELEASED.

J23062-14 BUSH REMOVER NEW RELEASE. USED IN

CONJUNCTION WITH DRIVER

HANDLE J8092

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

J23907 SLIDE HAMMER PREVIOUSLY RELEASED

J24036 BUSH REMOVER NEW RELEASE.

J25019-9 BUSH INSTALLER NEW RELEASE. USED IN

CONJUNCTION WITH DRIVER

HANDLE J8092

J25019-12 BUSH INSTALLER NEW RELEASE. USED IN

CONJUNCTION WITH DRIVER

HANDLE J8092

J25019-14 BUSH REMOVER NEW RELEASE

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

J25019-16 BUSH REMOVER NEW RELEASE

J29369-1 UNIVERSAL BUSH REMOVER PREVIOUSLY RELEASED

J29369-2 UNIVERSAL BUSH REMOVER PREVIOUSLY RELEASED

J34196-B BUSH REMOVER/INSTALLER SET NEW RELEASE

J41510 #50 TORX PLUS BIT NEW RELEASE

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

J41778-1 OIL PUMP BUSH INSTALLER PREVIOUSLY RELEASED

FOR VS

J41778-2 SUPPORT PLATE PREVIOUSLY RELEASED

FOR VS

J6125-1B SLIDE HAMMER PREVIOUSLY RELEASED

J8092 DRIVER HANDLE PREVIOUSLY RELEASED.