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

TRANSMISSION: UNIT REPAIR

CAUTION:

This vehicle will be equipped w ith 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, of the VT Series I Service Information 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 deployment, resulting in possible personal injury or

unnecessary SRS system repairs.

1. TRANSMISSION DISASSEMBLE

1.1 GENERAL SERVICE INFORMATION

The use of air powered tools to disassem ble or reassem ble this transmission is not recom mended. Apart from the

fact that thr ead stripping is m ore likely when incorr ect torque values are applied to f asteners, com ponent parts can

be distorted to the point where malfunctions will occur.

Teflon Sealing Rings

If any sealing rings are found to be dam aged, 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 m ay 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 tr ans miss ion holding f ixtur e. This r emoval

operation can be achieved by pushing down

squarely on the wiring harnes s c onnec tor, us ing a 1

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

connector retaining lugs.

Figure 7C5-1

3. Remove torque converter by sliding clear of

input shaft. Drain stored converter fluid into a

suitable container.

CAUTION: T ake care when removin g the torq ue

converter as it is a heavy assembly and

personal injury may result if lifted incorrectly.

4. 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 7C5-2

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 fourth apply piston (25) may come out

with the cover (28). If so, and the piston

accidentally 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 and servo pin

assembly (13).

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 return

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 -c lamp (1) and soc ket (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) and retainer (15), refer

Fig. 7C5-5.

Figure 7C5-6

SERVO PIN LENGTH

NOTE: At this s tage, it is advisable to m easure 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 shown, and refit the

servo cover retaining ring, to hold the tool.

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

gauge hole (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 LE NGTH (mm) IDENTIFI CATION

65.82 - 66.12 1 Groove

67.23 - 67.53 2 Grooves

68.64 - 68.94 No Groove

Figure 7C5-8

1.4 SPEED SENSOR AND CASE EXTENSION

1. Remove the speed sensor retaining screw (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. Withdraw case extension (31) and O-ring seal

(30).

Figure 7C5-10

5. To support and stop the output shaft from

falling from the transmission at a later point in

the disassembly process, fabricate a support

bracket (1) from a strip of suitable sheet metal

(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 (72) and twist to remove from

the oil pump body.

4. Particles trapped by the filter may help in

diagnosis. Cut away the top of the plastic filter

housing and remove. Inspect the filter material

for particles that might indicate the reason for

the transmission failure (Not necessarily the

cause!). Examples of the type of material are;

- Clutch friction material.

- Bronze slivers, indicating bush wear.

- Steel particles.

Figure 7C5-13

5. Using suitable circlip pliers as shown, or a

commercially available, two-legged puller and

slide hammer, remove the filter seal, taking

care not to damage the oil pump bore during

the process.

NOTE: If scratched, f luid leakage could occ ur 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 pushed into the case before fitting the

transmission 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. Transmission Fluid Pressure Manual Valve

Position Switch Assembly (TFP).

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.

NOTE: The s ec urity tang on the PCS (4), is located

at the rear of the connector.

Figure 7C5-15

2. Remove the TCC Pulse Width Modulated

(PWM) solenoid retainer clip (395), then the

solenoid (396).

Figure 7C5-16

3. Remove two bolts (68) holding the TCC

solenoid assembly.

Figure 7C5-17

4. Lift the TCC solenoid assembly from oil pump.

5. Carefully drape the wiring harness over the

side of the transmission case, after wrapping a

piece of lint free cloth around the wiring

harness to prevent chafing of the insulation on

the transmission oil pan rail.

NOTE: If removal of the wiring harness/TCC

Solenoid from the transmission case is required, it

will not be possible until the control valve body has

been removed.

Figure 7C5-18

6. Remove the Transmission Fluid Pressure

Manual Valve Position Switch Assembly (TFP)

retaining bolts, then remove the TFP (69) and

shield (106) from the valve body.

Figure 7C5-19

7. Remove the bolt (64) securing the manual

detent spring (63), then remove the detent

sprin g assembly.

Figure 7C5-20

8. Progressively loosen, then remove all

remaining control valve bolts (62).

9. In the process, remove the fluid level indicator

stop bracket (93).

Figure 7C5-21

10. Remove control valve body assembly by lifting

from the rear, supporting the valve body in one

hand, while holding the manual valve link (89)

with the other.

NOTE: Take care when lifting the control valve

body, not to disturb the seven checkballs located

on the spacer plate.

11. As the valve body is being lifted, rotate it

slightly to release the manual valve link (89)

from the manual valve (340). After removing

the control valve body, disconnect the manual

valve link (89) from the inner detent lever (88).

Figure 7C5-22

12. Remove the seven checkballs from the spacer

plate (2, 3, 4, 5, 6, 8 and 12).

NOTE: Shown are the ball locations on the spacer

plate after the control valve body and other

components have been removed.

Figure 7C5-23

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

accumulator spring force (54/104),

progressively loosen, then remove the three 1-

2 acc um ulator c over bolts ( '58'x 1 and '59' x 2) .

Remove the cover and pin (57), 1-2

accumulator piston (56), two springs (54/105).

14. 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 pres sure in exc ess of 70 k Pa for this

operation.

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

accumulator piston.

16. Tag the outer 1-2 accumulator spring (54) for

correct reassembly.

Figure 7C5-24

17. Remove the three spacer plate retaining bolts

(77) and retaining plate (53).

Figure 7C5-25

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

plate gaskets (47/52) from the transmission

case.

Figure 7C5-26

19. Remove the 3-4 accumulator spring (46) and

tag for correct reassembly.

NOTE: T here is no 3-4 ac cumulator s pring fitted to

the automatic transmission fitted to the GEN III V8

engine (code HPD).

20. Using f lat blade snap ring pliers, rem ove the 3-

4 accumulator piston (44) from the

transmission case (103), by rotating the piston

while pulling it from the case, then remove the

position guide pin (43) from the case.

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

accumulator piston.

Figure 7C5-27

22. Remove the check ball #1 from the

transmission case, as shown.

NOTE: For control valve body disassembly

procedure, refer to 2.16 CONTROL VALVE BODY

in this Section.

Figure 7C5-28

1.7 CONVERTER HOUS ING

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 standar d, # 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).

NOTE: The converter housing (102) shown is

‘typical’ and is not intended to be specific to any

particular engine application.

Figure 7C5-29

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 trans miss ion with the input shaft in a

vertical position.

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

J25025-B and secure with the locknut.

3. Install dial indicator (1) using a commercially

available clamp 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 measure end

play.

TRANSMISSION END PLAY

SPECI F ICATIO N 0.13 - 0.92 mm

5. Remove Tool No. J25025-B and dial indicator.

Figure 7C5-30

1.9 OIL PUMP ASSEMBLY

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

turbine shaft.

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 7C5-31

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 assembly 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 7C5-32

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

(6).

8. Rem ove reverse input clutch to oil pum p thrust

washer (601).

NOTE: Thrust washer (601) is selectable to obtain

the correct transmission end play, measured in

1.8 TRANSMISSION END PLAY CHECK in this

Section.

Figure 7C5-33

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

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 7C5-34

2. Remove 2-4 band anchor pin from the

transmission case .

Figure 7C5-35

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

Figure 7C5-36

4. 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 are

available as Tool 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. T he output shaf t will tend to f all 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 A ND CASE EXTENSION).

Figure 7C5-37

5. Remove input carrier assembly (662).

6. Remove thrust bearing (663).

Figure 7C5-38

1.11 REACTION GEAR SET

1. Remove input internal gear (664) and reaction

carrier shaft (666).

Figure 7C5-39

2. Remove reaction shaft/shell thrust washer

(669) and reaction sun shell (670).

Figure 7C5-40

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 surface and turning

the race in the 'free' direction.

Figure 7C5-41

6. Remove low and reverse support to case

retaining ring (676).

7. Remove fabricated bracket and withdraw

output shaft (see Fig. 7C5-11).

NOTE: Depending on the distance the transmission

has travelled, there may be some resistance to

removal of the mainshaft from the input carrier. If

so, tap the inboard end of the output shaft with a

plastic faced hammer to dislodge.

Figure 7C5-42

8. Reinser t m ainshaf t and push up to dislodge the

low and reverse clutch support assembly.

9. Remove the low and reverse clutch support

from the transmission case.

Figure 7C5-43

10. Remove low and reverse clutch support

retainer spring (680).

Figure 7C5-44

11. Remove the reaction carrier (681).

Figure 7C5-45

12. Remove low and reverse clutch plate

assembly;

682C Composition plates.

682D Steel plates.

682B Selective spacer plate.

682A Wave plate.

Figure 7C5-46

13. Remove reaction carrier support thrust bearing

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

assembly (685).

14. Remove reaction gear support to case bearing

assembly (692).

NOTE: The orientation of the two thrust bearings

for correct reassembly.

Figure 7C5-47

1.12 LOW AND REVERSE CLUTCH ASSEMBLY

1. Remove bolts (87- two places) 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 7C5-48

5. Install the forcing bolt of Tool No. J23327-1

through plate J42628, then install into the rear

of the transmission case.

6. Install press c age of Tool No. J23327-1 into the

transmission case, over the forcing bolt and

secure with the provided wing nut.

Figure 7C5-49

7. Tighten the wing nut of Tool J23327-1 to

compress the low and reverse clutch springs

(694) and clear access to the retaining snap

ring (693).

8. Remove low and reverse clutch retaining snap

ring (693), using snap ring pliers J34627 or

equivalent.

9. Remove J23327-1 and low and reverse clutch

spring assembly (694).

Figure 7C5-50

10. Apply low pressure air to either the Low feed

passage (1) or the Reverse feed passage (2),

as shown, 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 INNER MANUAL SHAFT, LINKAGE AND SEAL

1. Rem ove the two screws (1 and 3) securing the

neutral start and back-up lamp switch (2), then

remove the switch (2) from the transmission

case.

Figure 7C5-52

2. Remove the nut (90) securing the inner detent

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

3. Remove the inner detent lever ( 88) and par king

pawl actuator rod (85).

4. Rem ove the retaining c lip (83) f rom the m anual

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.

NOTE: An alternative method of seal removal is to

use the released special tools. Refer to

7C4 AUTOMATIC TRANSMISSION – ON-

VEHICLE SERVICING in the VX Series, for details.

Figure 7C5-54

2. COMPONENT DISASSEMBLE, INSPECTION, REASSEMBLE

2.1 CASE

INSPECT

1. W ash 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: F ac e f latness c an be chec ked by inspecting

the case, spacer plate gask et for complete witness

marks. If the marks are incomplete, an uneven

case surface, or cross channel leaks are indicated.

4. Check transmission vent tube, located at the

top of the transmission case (refer ‘9’ in Fig.

7C5-56), for damage and/or blockage.

5. Using compressed air, check all oil passages.

For case channel identification, refer to

7C3 DIAGNOSIS of the VT Series I Service

Information 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

29 3-4 Clutch

37 Overrun Clutch

45 Vent

48 Torque Converter Clutch Regulated Apply

A Line Pressure Plug

Figure 7C5-56

7. Inspect 2-4 servo bore (A) 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.

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.

Figure 7C5-58

11. If removed, tighten oil c ooler pipe connections to

the correct torque specification.

OIL COOLER PI PE CONNECTIONS

TORQUE SPECIFICATION ............................. 35 - 41 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 ‘40’ in Figs. 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 accumulator ball assembly (40) for

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 ac cum ulator

bore (A).

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

NOTE: Bec aus e f luid will flow f rom the or if ic e in the

case servo plug (‘11’ in Fig. 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 3rd

accumulator retainer and ball check assembly

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

bore (refer ‘40’ in Fig. 7C5-57).

4. Install the 3rd accumulator ball and retainer

assembly (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 re m over T ool J34196-10 and dr iver

handle Tool J8092, press the rear bushing from

the transmission case.

Figure 7C5-63

2. Install a new bush, using the same tools as f or

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 transm ission f luid and

install on piston.

Figure 7C5-65

5. Inspect low and reverse clutc h plates ( 682C/D).

Check composition plates (682C) for wear,

heat damage or delamination and check steel

plates ( 682D) f or heat damage or s ur f ac e f inish

damage.

Figure 7C5-66

SPACER PLATE SELECTION

Select the correct spacer plate 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 (682A).

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

starting with a fibre ( compos ition) plate and

alternating with a steel plate, etc.

c. Low and reverse clutch support (679).

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 commercially available dial indicator

(1) and magnetic stand (2), measure height of

clutch pac k f rom work s ur f ace to top of low and

reverse clutch support, noting the dimension,

with the light load applied.

4. Use the following Selection Chart to select the

correct spacer plate, relative to the measured

height.

LOW AND REVERSE CL UTCH S P ACER 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 CLUT CH PACK HE IGHT 29.22 - 29.90 mm

(Including Spacer Plate)

NOTE 1: The selective plate shown as 'NONE' in

the above chart, refers to a fifth, steel reaction

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 s elec tive plate that

is thinner or thicker, can be fitted.

NOTE 3: Regardless of the com binations us ed, 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.

Figure 7C5-68

5. Install correct spacer plate between wave plate

and first composition clutch plate with

identification side facing upwards.

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 both the reaction to support thrust

bearing assembly (683) and the reaction gear

to support case bearing assembly (692) for

damage.

Figure 7C5-70

2. Inspect reaction internal gear (684) and support

(685) for correct assembly, stripped splines,

cracks, teeth or lug damage.

Figure 7C5-71

3. Inspect reaction carrier assembly (681) for

pinion gear wear, proper pinion staking and

free turning of pinions.

4. Check for excessive pinion washer wear by

measuring pinion end play. End play should be

0.20 to 0.60 mm. The reac tion car r ier assembly

is ser viced as a c om plete assembly and should

be replaced if worn or defective.

Figure 7C5-72

5. Check carrier assembly captive thrust bearing

(lower arrow) as follows:

a. Place a suitable bush (or socket) on

bearing race (do not contact pinion gears)

and turn bush with palm of your hand.

b. Any imperfections will be felt through the

bush.

Figure 7C5-73

2.8 REACTION SUN GEAR AND SHELL

INSPECT

1. Inspect reaction sun gear (673) for damage to

bush, dam age to spline or teeth, loose or weak

retaining ring. Do not remove snap ring (671)

except for replacement.

Figure 7C5-74

2. Inspect reaction sun shell (670) for damage or

wear to tangs.

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

for wear or damage.

Figure 7C5-75

SUN GEAR BUSH - REPLACE

1. Should the sun gear bushing (672) require

replacem ent, use bush remover Tool J34196-1

and driver handle J8092 to pr ess the bus h f r om

the gear.

Figure 7C5-76

2. Install a replacement bush (672) using the

sam e tools but pres s the bus h in f rom the other

side of the sun gear, as shown.

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

the sun gear (see Fig. 7C5-74).

Figure 7C5-77

2.9 INPUT INTERNAL GEAR AND OUTPUT SHAFT

INSPECT

1. Rem ove retaining ring (668) from input internal

gear (664).

2. Remove reaction carrier shaft (666) from 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) for cracked or

damaged splines or gear teeth.

4. Inspect carrier to reaction shaft thrust bearing

(not shown) for wear or damage.

5. If all parts are serviceable, reassemble the

reaction carrier shaft (666) into the input

internal gear (664) and install the retaining ring

(668).

Figure 7C5-78

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 dam age to transmiss ion output shaft

sensor rotor (699).

Figure 7C5-79

REACTION CARRIER SHAFT BUSHES - REPLACE

1. Using univer sal bushing r em over J29369- 2 and

slide hammer J23907 or equivalent, remove

front bushing (665) from the reaction carrier

gear shaft (666).

Figure 7C5-80

2. Remove the rear bushing (667) from the

reaction carrier gear shaft (666) by using bush

puller Tool J25019-14 and slide hammer

J7004-1 or equivalent.

Figure 7C5-81

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

Tool J34196-3 and driver handle J8092.

Figure 7C5-82

4. Install r ear bushing ( 667), using the sam e tools

as for the front bushing.

Figure 7C5-83

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 (699) shows that tooth damage

has occurred. Once removed, the ring must be

replaced and not re-used.

1. Using T ool Nos. J 8433 and J 21427-01, r emove

the speed sensor ring (699) from the output

shaft (687).

Figure 7C5-84

2. Place a new speed sensor ring (699) over the

transmission output shaft (687).

3. Insert C-washer, Tool No. J36352-4 into the

groove on the transmission output shaft (687).

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 (J36352-

4), in the window.

Figure 7C5-85

2.11 INPUT CARRIER AND SUN GEAR

INSPECT

1. Inspect carrier assembly (662) for pinion gear

wear, proper pinion staking and free turning of

pinions.

2. Check for excessive pinion washer wear by

measuring pinion end play. End play should be

0.20 to 0.60 mm.

NOTE: T he input carrier assem bly is serviced as a

complete assembly and must be replaced if

components are worn or defective.

Figure 7C5-86

3. Check carrier assembly captive thrust bearing

as follows:

a. Place a suitable bush (or socket) on

bearing race (do not contact pinion gears)

and turn bush with palm of your hand.

b. Any imperfections will be felt through bush.

Figure 7C5-87

INPUT SUN GEAR BUSHES - REPLACE

1. Using bush removing tool J34196-5 and driver

handle J8092, press both sun gear bushes

(657/ 659) from the gear.

Figure 7C5-88

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 7C5-89

2.12 INPUT CLUTCH HOUSING ASSEMBLY

DISASSEMBLE

1. Remove r ever se input c lutc h housing and dr um

assembly (605) from input housing and shaft

assembly (621).

2. Remove thrust bearing (615) and selective

thrust washer (616).

Figure 7C5-90

3. Place input clutch housing and drum assembly

(621) on work bench with input shaft protruding

through hole in workbench.

NOTE: F or identification of par ts, refer to Fig. 7C5-

93.

Figure 7C5-91

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

and backing plate (655).

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

6. Remove five, 3-4 clutch boost spring

assemblies (600).

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

Figure 7C5-92

Figure 7C5-93 Input Clutch Housing - Exploded View

Legend – Input Clutch Housing Components

REF

No. PART NAME REF

No. PART NAME

600.

615.

616.

617.

618.

619.

620.

621.

622.

623.

625.

626.

627.

628.

630.

632.

633.

634.

635.

636.

637.

638.

Spring Assembly, 3-4 Clutch Boost - 5 places

Bearing Assembly, Stator Shaft – Selective

Washer

Washer, Thrust Selective

Retainer & Ball Assy., Check Valve

Seal, O-Ring, Turbine Shaft

Ring, Oil Seal (Solid)

Retainer & Checkball Assy.

Seal, O-Ring Input to Forward Clutch Housing

Piston, 3rd and 4th Clutch

Ring, 3rd & 4th Clutch (Apply)

Spring Assy., 3rd and 4th Clutch

Retainer & Ball Assy, Forward Clutch Housing

Housing, Forward Clutch

Piston, Forward Clutch

Piston, Overrun Clutch

Ball, Overrun Clutch

Spring Assy., 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

639.

640.

642.

643.

644.

645a.

645b.

646.

648.

649a.

649b.

650.

651.

653.

654a.

654b.

655.

656.

657.

659.

688.

698.

Hub, Overrun Clutch

Forward Sprag Clutch Inner Race & Input Clutch

Assy Forward Sprag Assy.

Retainer Ring, Sprag Assy.

Race, Forward Clutch (Outer)

Plate Assy., Overrun Clutch (Steel)

Plate Assy., Overrun Clutch (Composition)

Plate, Forward Clutch (Apply)

Plate, Forward Clutch (Waved)

Plate, Forward Clutch (Steel)

Plate Assy., Forward Clutch (Composition)

Plate, Forward Clutch Backing (Selective)

Ring, Forward Clutch Backing Plate Retainer

Plate, 3rd & 4th Clutch Apply (Stepped)

Plate Assy., 3rd & 4th Clutch (Composition)

Plate Assy., 3rd & 4th Clutch (Steel)

Plate, 3rd & 4th Clutch Backing (Selective)

Ring, 3rd & 4th Clutch Backing Plate Retainer

Bush, Input Sun Gear, Front

Bush, Input Sun Gear, Rear

Plug, Cup

Plug, Orifice Cup

8. Remove forward clutch backing plate retaining

ring (651) and backing plate (650).

9. Lif t the forward clutch s prag and input sun gear

assembly ‘A’ from the input shaft and housing

assembly (621).

Figure 7C5-94

10. Remove forward clutch plates (649A and

649B).

11. Remove forward clutch wave plate (648).

12. Remove forward clutch apply plate (646).

13. Remove input sun gear bearing assembly

(637).

14. Remove input housing to output shaft lip seal

(636).

15. Remove overrun clutch plates (645A and

645B).

Figure 7C5-95

16. Place input housing and shaft assembly (621)

in a suitable press.

17. Install part of Tool Nos. J23327-1 and J25018-

A underneath, as shown.

18. Compress overrun clutch spring assembly (not

visible) in press and remove overrun clutch

retaining ring (not visible), using suitable snap

ring pliers (1).

19. Return input housing and shaft assembly to

workbench.

Figure 7C5-96

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 removed seals.

Figure 7C5-97

INSPECT

1. Inspect input housing and shaft assembly for

porosity, wear or damage.

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

3. Check for cracks at all lube holes.

4. Check that the four turbine shaft sealing rings

(619) rotate f r eely in their grooves and that they

are undamaged and free from burrs.

5. 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 c heck

ball, with solvent.

Figure 7C5-98

6. Blow through all input shaft passages with

com press ed air. T he three tur bine shaft sealing

balls must not be loose or leaking

Figure 7C5-99

7. If required, replace the turbine shaft retainer

and 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.

NOTE: The end of the turbine shaft (B) may vary,

depending on the engine application.

Figure 7C5-100

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 (A).

Figure 7C5-101

b. Install new assembly with 5.7 mm rod (A)

until shoulder is seated in housing from

input shaft side, as shown.

Figure 7C5-102

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

damage.

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

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

distortion or damage.

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

assemblies (600) for damage or distortion.

13. 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.

14. Inspect forward clutch housing (628) for:

a. Correct check ball (627) operation.

b. Damage, distortion or cracks.

c. Burrs in seal areas.

Figure 7C5-103

15. 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 7C5-104

16. 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 pis ton seals ar e now

bonded to the overrun clutch piston, if any seal

damage is found, then the piston assembly must be

replaced.

17. Inspect overrun spring assembly (634) for

damage or distortion.

18. 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 7C5-105

19. Inspect input sun gear bearing assembly (637)

and input housing to output s haft seal (636) f or

wear, damage or distortion.

Figure 7C5-106

20. Inspect forward clutch waved plate (648), the

apply plate (646), the steel plates (649A), the

composition plates (649B) and the selective

backing plate (650) for:

a. Flatness.

b. Delamination of the composition plates

(649B).

c. Heat damage and/or excessive wear.

d. Burrs, nicks and other surface finish

damage.

Figure 7C5-107

21. Inspect 3-4 clutch apply plate (653), the

composition plates (654A), the steel plates

(654B) and the selective backing plate (655),

for:

a. Flatness.

b. Delamination of the composition plates

(654A).

c. Heat damage and/or excessive wear.

d. Burrs, nicks and other surface finish

damage.

Figure 7C5-108

FORWARD CLUTCH SPRAG ASSEMBLY

DISASSEMBLE

1. 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 forward sprag clutch inner race

and sun gear assembly (640) from the

forward clutch sprag assembly (644).

Figure 7C5-109

d. Remove sprag assembly retainer rings

(643).

e. Remove the forward sprag assembly from

the forward clutch outer race (644).

Figure 7C5-110

Inspect

1. Inspect forward clutch sprag assembly (642)

for:

a. Wear or damage.

b. Weak or broken springs.

c. Damaged or missing retaining caps.

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

a. Spline damage.

b. Surface finish damage.

c. Plugged lubrication holes.

Figure 7C5-111

3. Inspect overrun clutch hub (639) for:

a. Spline damage.

b. Plugged lubrication holes.

c. Damaged tangs.

d. Cracks.

4. Inspect forward sprag clutch inner race and

input sun gear assembly (640) for:

a. Spline damage.

b. Ring groove damage.

c. Surface finish damage.

d. Loose retainer.

Figure 7C5-112

REASSEMBLE

Forward Clutch Sprag A ssembly

1. Reinstall forward sprag assembly (642) into

forward clutch outer race (644). Notches in

sprag cage point in the direction shown.

Figure 7C5-113

2. Reinstall a sprag retaining ring (643) to each

side of the forward clutch outer race (644) with

the retaining ring recesses facing outward.

Figure 7C5-114

3. Reinstall the forward sprag clutch inner race

and input sun gear assembly (640) into the

sprag retaining ring (643) and the outer race

(644), as follows:

a. Hold outer race (644) in right hand,

supporting the forward sprag assembly

(642) with fingers at the recessed side of

outer race (644).

b. Insert retaining ring and the forward sprag

clutch inner race and input sun gear

assembly (640) from the opposite side of

outer race (644) by pushing in and turning

anti-clockwise (curved arrow).

4. Turn the assembly over and reinstall the

remaining sprag assembly outer retaining ring

(643), with the recess facing inward toward the

sprag (642).

Figure 7C5-115

5. Reinstall overrun clutch hub (639) onto the

forward sprag clutch inner race and input sun

gear assembly (640).

6. Reinstall overrun clutc h hub retaining snap ring

(638) into groove in the forward sprag clutch

inner race and input sun gear assembly (640).

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 right. Attempt to rotate

the hub in both directions.

b. Provided the overrun clutch hub (639)

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 back wards, the s pr ag is

assembled incorrectly. Dismantle and re-

assemble correctly.

Figure 7C5-116

8. Place input housing and shaft assembly (621)

on workbench with input shaft protruding

through hole in workbench.

Figure 7C5-117

3-4 Clutch Assembly

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

jelly and install on input housing.

Figure 7C5-118

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

seals with petroleum jelly.

3. Reinstall 3-4 clutch piston (623) in input

housing as shown, taking care not to damage

seals.

Figure 7C5-119

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

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

5. Coat forward clutch piston inner and outer

bonded seals with petroleum jelly and install

the forward clutch piston (630) into forward

clutch hous ing ( 628) tak ing car e not to dam age

the outer seal.

6. Reinstall forward clutch assembly onto 3-4

clutch spring assembly, locating forward clutch

piston smaller apply legs between 3-4 clutch

apply ring legs, as shown.

7. Use the forward clutch backing plate retaining

ring (651) to hold these parts in place during

installation.

Figure 7C5-120

8. Fit T ool J29883 on input housing as shown and

coat with petroleum jelly.

9. 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).

10. Remove Tool No. J29883 and the temporarily

installed retaining ring (651).

Figure 7C5-121

Overrun Clutch Assembly

11. Fit Tool J29882 on input housing, as shown

and coat with petroleum jelly.

12. Lubricate overrun clutch piston (632) inner and

outer bonded seals with petroleum jelly and

install pis ton (632) with hub fac ing upwards, as

shown. To ease ins tallation of the outer bonded

seal, coat a straightened paper clip or similar

with petroleum jelly and work around the piston

circumference.

NOTE: If all components are correctly seated, the

overrun clutch piston hub (632) locates

approximately three mm below snap ring groove in

input housing hub.

13. Remove tool J29882.

Figure 7C5-122

14. Reinstall overrun clutch spring assembly (634)

onto overrun clutch piston.

Figure 7C5-123

15. Install J23327-1 and J25018-A as shown.

16. Place input housing and shaft assembly (621)

in a suitable press.

17. Compress overrun clutch spring assembly and

install a new clutch retaining ring (not visible),

using suitable s nap ring pliers (1). Do not over-

compress springs or over-expand the retaining

ring. Remove special tools.

Figure 7C5-124

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

housing, noting seal lip orientation.

Figure 7C5-125

19. 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 7C5-126

20. Reinstall input sun gear thrust bearing

assembly (637) onto input clutch hub with

inside race f ac ing input housing hub, as s hown.

Retain thrust bearing in place with petroleum

jelly.

Figure 7C5-127

21. Using a fine bladed screwdriver or similar, line

up the inner tangs of the two composition

overrun clutch plates.

22. Reinstall forward clutch sprag assembly into

input clutch housing, locating overrun clutch

hub (639) into overrun clutch plates.

Figure 7C5-128

Forward Clutch Assembly

23. Reinstall forward clutch apply plate (646) into

input clutch housing (621), indexing as shown.

24. Reins tall waved steel f orward c lutch plate (648)

into input clutch housing, again indexing as

before.

25. Reinstall remaining forward clutch plates (649)

into input housing; starting with a steel plate

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

26. Reinstall forward clutch selective backing plate

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

Figure 7C5-129

27. Measure end clearance between backing plate

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

gauges.

BACKING PLATE CLEARANCE

V6 and V6 Supercharged Engines

with 258 mm Torque Converter 0.866 – 1.876 mm

GEN III V8 Engine with

300 mm Torque Converter 0.866 – 1.876 mm

If clearance is incorrect, select a suitable

selective backing plate (650) from chart below

and install instead of the original backing plate.

FORWARD CLUTCH SEL ECTIVE P LATE

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

NOTE: Identification letters are stamped on the

backing plate.

Figure 7C5-130

3-4 Clutch

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

protruding lugs facing inward, as shown.

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

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

NOTE: The first steel plate (654B) has the same

spline configuration as the 3-4 clutch apply plate

(653).

Figure 7C5-131

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.

30. Reinstall five spring boost assemblies (600),

exposed spring ends uppermost and equally

spaced in the locations shown.

Figure 7C5-132

31. Reinstall 3-4 clutch selective backing plate

(655), chamfered side up (if applicable) and

wide tangs over the spring boost assemblies

(600). Reinstall retaining ring (656).

Figure 7C5-133

32. 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

NOTE: Identification letters are stamped on the

backing plate.

Figure 7C5-134

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 7C5-135

3. Check 3-4 c lutch by applying air pres sure (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 7C5-136

REINSTALL TURBINE SHAFT SEALING RINGS

1. Install Tool No. J36418-1B over input shaft.

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

lubricated with petroleum jelly over tool J36418-

1B and install as follows:

a. Use the knurled screw (1) in the end of

Tool J36418-1B, to adjust the inner end of

the Tool so the innermost seal groove in

the input shaft is exposed.

b. Slide the first input shaft seal ring down

until it slips off the end of the Tool and is

installed in the input shaft groove.

c. Turn the knurled crew (1) in a clockwise

direction until the second groove in the

input shaft is exposed, then repeat step ‘b’.

d. Continue to install remaining sealing rings,

using the above steps ‘a’ and ‘b’ until all

sealing rings have been installed.

3. Rem ove J36418-1B and ins tall J36418-2A over

all of the seals to re-size them. Leave J36418-

2A in place until the transmission is

reassembled.

Figure 7C5-137

2.13 REVERSE INPUT CLUTCH ASSEMBLY

DISASSEMBLE

1. Rem ove backing plate retaining r ing (614) from

housing and drum assembly (605).

2. Remove backing plate (613) and clutch plates

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

Figure 7C5-138

3. Install Tools J23327-1 with J25018-A

underneath and compress reverse input clutch

sprin g assembly.

4. Remove spring assembly retaining ring (610).

Figure 7C5-139

5. Remove J23327 and J25018-A and remove

spring assembly (609).

6. Remove piston (607) and discard piston seals.

Figure 7C5-140

INSPECT

1. Inspect selective backing plate (613) for

damage, burrs or distortion.

2. Inspect clutch plates:

a. Check composition plates (612B) for tang

damage, delamination or wear.

b. Check steel plates (612A) for tang

damage, wear or heat damage.

3. Check the waved plate (611) for heat damage

or tang wear.

4. Inspect spring assembly for distortion or

damage.

Figure 7C5-141

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 7C5-142

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 7C5-143

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

Should the bushes require replacement, refer to the

following procedure.

Figure 7C5-144

REVERSE INPUT CLUTCH HOUSING BUSHES - REPLACE

1. Using bush remover J25019-16 and slide

hammer J7004-1, remove the front bushing

(603) from the reverse input clutch housing.

Figure 7C5-145

2. T urn the reverse input clutch housing over and

use bush remover J25019-4 and driver handle

J8092 to remove the rear bush (606) from the

reverse input clutch housing.

Figure 7C5-146

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

input clutch housing (605), using installer

J25019-9 and driver handle J8092.

Figure 7C5-147

4. Support the reverse input clutch housing on

suitable pieces of wood and install a new rear

bush (606), using installer J34196-3 and driver

handle J8092

Figure 7C5-148

REASSEMBLE

1. Lubricate new piston seals (608) with

transmission fluid and install seals on piston

(607) with lips facing in the directions shown.

Figure 7C5-149

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 jelly 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.

Figure 7C5-150

6. Install Tools J25018-A and J23327-1,

compress the spring assembly and reinstall

spring assembly retaining ring (610). Remove

tools.

Figure 7C5-151

7. Reinstall Belleville clutch plate (611), concave

side down, as shown.

8. Reinstall rem aining c lutch plates , starting with a

steel turbulator plate (612A), then composition

(612B), etc.

9. Reinstall selective backing plate (613),

chamfered side up and reinstall retaining ring

(614).

Figure 7C5-152

10. Apply an evenly distributed, medium load

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

shown in the inset.

NOTE: Exce ssive pressur e will distort the Belleville

plate.

11. Use a feeler gauge to measure the gap

between the selective backing plate (613) and

retaining ring (614). Clearance should be

between 1.02 and 1.95 mm.

12. If gap is not to specification, select another

backing plate from the table below to replace

the original.

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

NOTE: Identification numbers are stamped on the

backing plate.

Figure 7C5-153

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-s trok e' and dislodge the snap r ing 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 7C5-154

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 (4) so that the

stator shaft protrudes through a hole in the

workbench.

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

reverse input dr um support and the O -ring seal

(5) from the pump body.

Figure 7C5-155

3. Remove five bolts (233) securing the pump

cover to the pump body.

4. Separate the pump cover assembly (215) from

pump body (200).

Figure 7C5-156

Oil Pump Body

1. Compress pump slide springs (206 and 207)

with a suitable lever or long nose pliers and

remove springs.

CAUTION: Springs are under a high load. Place

a rag over the springs (as shown) before

removal to prevent possible injury.

Figure 7C5-157

2. Remove following components from pump

cavity in body (200):

a. Upper pump vane guide ring (210).

b. Thirteen pump vanes (213). Note wear

mark patterns for reassembly.

c. Pump rotor (212).

d. Rotor guide (211).

e. Lower pump vane guide ring (210).

Figure 7C5-158

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 7C5-159

3. Use a screwdriver to prise out the front helix

seal retainer (244) and oil seal assembly (243)

from the pump body.

Figure 7C5-160

Oil Pump Cover

1. Compress converter clutch apply stop valve

(223) with a screwdriver and use circlip pliers to

remove the circlip (222).

2. 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 7C5-161

3. Using a screwdriver, push the reverse boost

valve sleeve (220) in against spring force and

remove circlip (221) with suitable circlip pliers.

4. Slowly release spring force and remove the

reverse boost valve sleeve (220), the reverse

boost valve (219), the pressure regulator

isolator spring (218), the pressure regulator

spring (217) and the pressure regulator valve

(216). Lay all components out in order for

inspection.

Figure 7C5-162

5. 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.

6. Using long nose pliers, pull cover screen (232)

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

Figure 7C5-163

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

and discard.

8. Wash all components with solvent and air dry.

Do not dry with a cloth.

Figure 7C5-164

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. Inspec t press ure relief com ponents for damage

or distortion.

Figure 7C5-165

4. Inspect pump rotor and slide for cracks.

5. If inspection indic ates that the pum p 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 replacement 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 – 17.987 3

17.987 - 18.000 4

18.000 - 18.013 5

NOTE: While there are no identification numbers

stamped on the oil pump rotor and slide, the size

grading is used in manufacture to achieve a ‘best

match’ rotor and slide to the oil pump body.

Therefore, should inspection show excessive wear

and/or dam age to these components, the com plete

oil pump body assembly must be replaced.

Figure 7C5-166

OIL PUMP BUSHINGS – REPLACE

Oil Pump Cover

1. Remove the pump, cavity body bushing (242),

using a bench press and Tool J41778-1.

Figure 7C5-167

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

plate, Tool J41778-2 under the oil pump cavity

body (200), as shown.

Figure 7C5-168

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, effectively limits how far the new bush

can be installed.

Figure 7C5-169

Pump Cover

1. Using bush remover J21465-15 and slide

hammer J7004- 1, remove the s tator s haf t, f r ont

bushing.

Figure 7C5-170

2. Using bush remover J25019-14 and slide

hammer J7004-1, remove the stator shaft rear

bushing, from the pump cover.

Figure 7C5-171

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

installer J21465-2 and driver handle J8092.

Figure 7C5-172

4. Install a new stator s haft rear bush (241) , using

installer J25019-6 and driver handle J8092.

Figure 7C5-173

REASSEMBLE

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

Tool J25016.

Figure 7C5-174

2. Install front helix retainer (244).

Figure 7C5-175

3. Install new slide seal back-up O-ring (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 seal support (208) together with

slide seal (209) into notch in pump slide.

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

Figure 7C5-176

7. Carefully com pres s slide s pr ings ( 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 7C5-177

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 7C5-178

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 7C5-179

15. Reinstall pressure regulator valve (216),

pressure regulator isolator spring (218) and

pressure regulator spring (217) into the

pressure regulator valve bore of oil pump

cover.

16. Reinstall the reverse boost valve (219) into the

reverse boost valve sleeve (220), then reinstall

the assembly into the pressure regulator valve

bore, aligned 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 7C5-180

18. Reinstall pres sure relief ball (228) , spring (229)

and pin (227) in pump cover.

19. Reins tall c over filter sc reen (232) with new seal

(231).

Figure 7C5-181

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

over Tool No. J39855-1 and install, using Tool

No. J38735-3.

21. Once both s eals ar e ins talled, c ompres s to size

by fitting s izing tool, J 39855-2, using petroleum

jelly to assist, as required. Leave sizing tool

installed until the pump assembly is reinstalled

into the transmission.

Figure 7C5-182

22. Place the stator shaft through a hole in the

workbench.

23. Install pump cover assembly (215) on pump

body assembly (200) and reinstall five 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

TORQUE SPECIFICATION ............................. 20 - 27 Nm

Figure 7C5-183

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 transm ission f luid, rather than use

compressed air.

Air check oil pump as indicated in Fig. 7C5-184 and

the following table to ensure that all passages are

open and all cup plugs are correctly installed.

Figure 7C5-184

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.

#48 Torque Converter Clutch Regulated Apply 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 V ALVE 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 bus hings m ust be laid out in the exact or der of rem oval, to ensure c orrect or ientation

when reassembling.

NOTE 3: While the following sequenc e of dis assem bly is suggested, it is not m andatory. 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 (364A), the retainer (378) and the solenoid (377).

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

spring (375) and valve (374).

3. Remove the 2-3 s hif t s olenoid retaining c lip ( 395), the s olenoid ( 367B); then remove the valve train consisting of

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

4. Remove the 1-2 shift solenoid retaining clip (395), then the solenoid (367A), 1-2 shift valve (366) and spring

(365).

5. Remove the 1-2 accumulator roll pin (360), the 1-2 accumulator sleeve (372), valve (371) and spring (370).

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

7. Remove the forward accum ulator spring (356), piston (354) and pin (355). Discard 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 pr obe, rem ove the roll pin ( 360), the bore plug, the f orward

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

Techline

REF No. PART NAME REF No. PART NAME

350

353

354

355

356

357

358

359

360

361

362

363

364A

364B

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, Pressure Control Solenoid Retainer

Bolt, Forward Accumulator Cover

Spring, 1 - 2 Shift Valve

366

367A

367B

368

369

370

371

372

374

375

376

377

378

395

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

Retainer, Bore Plug and Solenoid

Figure 7C5-185 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 (395) 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, remove 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

380

381

382

383

384

385

386

387

Valve, Manual

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 and Solenoid

Spring, Regulator Supply

Valve, Isolator

Figure 7C5-186 Control Valve Body ‘B’ - Exploded View

INSPECT

NOTE 1: T he use of a honing stone, f ine sandpaper or croc us cloth is not recom m ended f or s ervicing stuck valves.

All valve lands have sharply machined corners that are necessary 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 much "lapping" of a valve will create excessive 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, cracks, damaged machined surfaces, blocked or partially blocked

passages and scored or damaged valve train bores.

SPACER PLATE EVALUA TION

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 7C5-187

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 spac er plate. Use a tor ch (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 s hould be vis ible, as indicated 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 7C5-188

REASSEMBLE

1. Reassemble all components in the reverse

order to disassembly. Use Fig’s 7C5-185/186

as a reference. Note orientation of all valves,

sleeves and solenoids.

Important: W hen 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 machined side). If this is not done, then

reinstalling the wiring harness will not be possible

without damage. Also, c orr ec t ins tallation of the fluid

filter will not be possible, preventing fitment of the oil

pan.

NOTE: The TCC PW M Solenoid (396) is not to be

installed until the TCC Solenoid has been installed

and the retaining bolts torqued to specif ication. This

operation occurs during the installation of the

control valve body to the transmission case.

2. Tighten all retaining bolts to the correct torque

specification.

PRESS URE CONT ROL SOLENOID

BRACKET TO VALVE BODY

TORQUE SPECIFICATION ............................. 8 - 14 Nm

FORWA RD A CCUMULA T OR COVER

TO VALVE BODY BOLT

TORQUE SPECIFICATION ............................. 8 - 14 Nm

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 7C5-189

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 (90) and

tighten to the correct torque specification.

MANUAL SHAFT TO INNER

DETENT LEVER NUT

TORQUE SPECIFICATION ............................. 27 - 34 Nm

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

the manual shaft (84).

Figure 7C5-190

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 7C5-191

2. Reinstall piston (695) in transmission case,

aligning piston with notch in bottom of cas e, as

indicated. Use Tool J23327-1 (refer Fig. 7C5-

193), to ensure the pis ton is installed square to

its bore.

Figure 7C5-192

3. Locate spring assembly on piston as shown,

with flat side uppermost.

4. Install Tool J23327 and J42628, then com pres s

spring assembly below groove in case.

NOTE: Make sure the lower plate, Tool J42628

indexes correctly in the recess in the end of the

transmission case .

5. Reinstall retaining ring and remove special

tools.

Figure 7C5-193

6. To check the operation of the low and reverse

piston, apply low pressure air to either the Low

feed passage (1) or the Reverse feed passage

(2), as shown. As air is supplied, the low and

reverse piston should be seen to move when

viewed in the parking pawl area of the cas e. Air

leaks should also be listened for, during this

check.

NOTE: The low and reverse clutch spring assembly

and retainer ring are not shown, to more clearly

show the air passage arrangements.

Figure 7C5-194

7. If previously removed, locate parking pawl (81)

and return spring (80) in case.

8. Reinstall parking pawl pivot shaft (79) - not

shown. Check for free movement of

components.

9. Coat retaining plug (78) - not shown, with

Loctite 242 sealant or equivalent and install

plug with hammer and punch.

10. Reinstall park pawl bracket (86) and bolts (87)

and tighten to the specified torque.

PARK PAWL BRACKET BOLT

TORQUE SPECIFICATION ............................. 27 - 34 Nm

Figure 7C5-195

3.3 REACTION PLANETARY 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) assembly 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 7C5-196

4. Reinstall reaction carrier assembly (681) onto

thrust bearing.

Figure 7C5-197

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), indexing

in the transmission case (8) as shown.

3. Reinstall the selective plate (682B), (as

correctly selected during com ponent inspection

procedures), also indexing the same as for the

waved plate.

Figure 7C5-198

4. Reinstall a composition clutch plate (682C),

then a turbulator steel plate (682D),

composition, steel, etc. Also index the

turbulator steel plates the s ame as for the wave

and selective plates.

Figure 7C5-199

5. Apply petroleum jelly to the flat portion of the

spring (680) and insert the spring into the

curved area in the transmission case as

shown.

Figure 7C5-200

6. Reinstall low and reverse roller clutch ass embly

(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 7C5-201

9. Pull the low and reverse ro ller clutch inner r ace

(675) up from its normally 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 7C5-202

11. Reinstall support retaining ring (676) by

aligning one end against the low and reverse

clutch support 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.

Figure 7C5-203

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

(673).

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

side down, into reaction carrier in transmission

case meshing teeth with pinion gears.

Figure 7C5-204

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 7C5-205

4. Reinstall bronze thrust washer (669) onto

reaction sun shell (670) 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 7C5-206

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 carrier assembly (681, in Figure 7C5-

197).

Figure 7C5-207

7. Reinstall input carrier assembly (662), rotating

back and forth, to index with the teeth of the

input internal gear.

Figure 7C5-208

8. While supporting the input carrier assembly

(662), reins tall output shaf t into the input carr ier

and attach the support bracket (1) that was

used during disassembly.

Figure 7C5-209

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-expansion,

as they have been designed for this specific task.

Figure 7C5-210

3.6 REVERSE INPUT CLUTCH, INPUT CLUTCH AND INPUT GEAR SET

1. Remove Tool J36418-2A (refer Fig. 7C5-137)

from input shaft and reinstall selective thrust

washer (616) on input housing and shaft

assembly.

NOTE: This selective washer (616) controls the

end play of the transmission, measured in

1.8 TRANSMISSION END PLAY CHECK, in this

Section. If the measured end play was not to

specification, replace original selective washer with

a new one, selected from the table below. The

identification number is stamped on the washer.

TRANSMISSION END PLAY W ASHER 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 72

2.89 - 2.99 73

3.06 - 3.16 74

2. Reinstall bearing assembly (615) on selective

thrust washer with inside race (black) facing the

selective washer (616).

Figure 7C5-211

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 clutch plates are

engaged.

Figure 7C5-212

4. Reinstall reverse input (605) and input clutch

(621) assemblies into transmission case.

Locate 3- 4 clutc h plate tangs over input inter nal

gear. Ensure all c lutc h plates ar e fully engaged.

When correctly installed, reverse input clutch

housing (605) is located just below case oil

pump, machined land in the transmission case.

Figure 7C5-213

NOTE: There should be approximately 3.8 mm

clearance (A) between reverse input clutch (605)

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

normal.

Figure 7C5-214

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 transmission through 90° as shown, so

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 assembly

will be such that adequate clearance will be

provided for reinstallation of the band.

Figure 7C5-215

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 tr ansmiss ion

case, as indicated. Ensure pin engages 2-4

band assembly.

Figure 7C5-216

3.8 OIL PUMP

1. Install Tool J25025-1 alignment pins, into case

as shown (part of Tool J25025-B).

Figure 7C5-217

2. Rem ove st ator shaf t oil seal sizing tool J39855-

2 (refer Fig. 7C5-182).

3. Reinstall thrust washer ( 601) on oil pum p (4) as

shown. Retain with petroleum jelly.

4. Lubricate new oil pump square section seal (5)

with petroleum jelly and install in the pump

body groove. When correctly installed and not

twisted, the seal colour strip should be visible

around the pump body (4).

Figure 7C5-218

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

case, align bolt holes and locate over the

alignment pins (arrows). Retain with petroleum

jelly.

Figure 7C5-219

6. Prim e oil pum p with new transm ission fluid and

reinstall assembly into case, over alignment

pins.

7. Reinstall bolts (2), complete with NEW sealing

washers (3), 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

TORQUE SPECIFICATION ............................. 26 - 32 Nm

Figure 7C5-220

9. Af ter rem oving the output shaf t suppor t brack et,

turn input shaft by hand. If unable to do so,

transmission is incorrectly assembled (possible

thrust washer dislodgment). Dismantle and

rectify problem.

10. Measure transmission end play as described in

1.8 TRANSMISSION END PLAY CHECK, in

this Section. If end play is not to specification,

replace selective thrust washer (616) between

the input housing (621) and the stator shaft

bearing assembly (615). Refer to Step 1 of

3.6 REVERSE INPUT CLUTCH, INPUT

CLUTCH AND INPUT GEAR SET, in this

Section.

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.

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

of turbine shaft.

Figure 7C5-221

3.9 CONVERTER HOUS ING

1. Install the converter housing to the

transmission case .

2. Install all converter hous ing bolts and tighten to

the specified torque, using Torx Plus bit, Tool

No. J41510 or commercial equivalent.

CONVERTER HOUSING BOLT

TORQUE SPECIFICATION ............................. 65 - 75 Nm

NOTE: Do not use a standar d, # 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 7C5-222

3.10 CONTROL V ALVE BODY AND ASSOCIATE D COMP ONENTS

1. Reinstall check ball into case. Secure with a

smear of petroleum jelly.

2. If previously remo ved, 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 7C5-223

3. Coat new 3-4 accum ulator piston s eal (45) with

petroleum jelly and install on piston (44). Rotate

piston seal in the piston groove to ensure that

no binding occurs and that it is correctly

seated.

Figure 7C5-224

4. Reinstall 3-4 accumulator pin (43) into case

(103).

5. Reinstall 3-4 accumulator piston (44) over pin

(43) with three lugs facing out of bore.

6. Reinstall 3-4 accumulator piston spring (46).

NOTE: There is no 3-4 accumulator spring (46)

fitted to the 4L60-E automatic transmission used

with the GEN III V8 engine (code HPD).

Figure 7C5-225

7. if a new spacer plate is to be fitted (or if

inspection of the screens shows them to be

fouled with debris) , it will be neces sary to install

two filter screens (49 and 50) to the spacer

plate before fitment. Location of these two

screens is as shown.

Figure 7C5-226

8. Install two suitable guide pins (part of Tool No.

J25025-B), into case at the locations indicated

by an asterisk (!). These locations are

important, 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 chec k ball #1 (91), the orif ice plug #10 (38)

and the 3rd accumulator, check ball assembly

#7 (40).

Important: Ensure that the guide pins are fully

installed s o that no thread is visible. Ot herwise, the

spacer plate gasket could become caught in a

thread during installation, resulting in incorrect

alignment.

Figure 7C5-227

9. Smear petroleum jelly over a new spacer plate

to case gasket (47) and install on transmission

case, over the guide pins. Gasket is identified

with a 'C' (Case).

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

11. Smear petroleum je lly over a new valve body to

spacer plate gasket (52) and install on

transm ission cas e, over the guide pins. Gask et

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

Important: Incorrec t placement of the spacer plate

gaskets may cause transmission shift problems.

Figure 7C5-228

12. Install three spacer plate support plate (53)

retaining bolts (77), tightening to specified

torque.

SPACER PLATE SUPPORT PLATE

TORQUE SPECIFICATION ............................. 8 - 14 Nm

Figure 7C5-229

13. Coat new 1-2 accum ulator pis ton seal (55) with

petroleum jelly and install on piston (56). Rotate

piston seal in the piston groove to ensure that

no binding occurs.

Figure 7C5-230

14. Reinstall the previously tagged, two 1-2

accumulator springs (54 and 104) into the

accumulator cover.

15. Reinstall piston into cover and pin assembly.

The three lugs on the piston point into the

cover.

Figure 7C5-231

16. Reinstall 1-2 accumulator assembly onto

transmission, while holding piston in place.

Reinstall and tighten bolts (58/59) to the c orr ec t

torque specification.

1-2 ACCUMULATOR COVE R B O LT

TORQUE SPECIFICATION ............................. 8 - 14 Nm

Figure 7C5-232

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 7C5-233

19. Insert the manual valve link (89) into the inner

detent lever (88).

20. Turn the valve body over and, while supporting

the m anual valve link (89) in one hand and the

valve body in the other, rotate the valve body

slightly and connect the link with the manual

valve (340). Move the manual valve (340)

forward, to retain the link connection and

carefully lower the valve body into position.

Figure 7C5-234

21. Reinstall the dipstick stop bracket (93) and

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

Figure 7C5-235

22. Install a new shield (106) to the transmission

fluid pressure (TFP) manual valve position

switch, reinstall bolts (‘70’ two places and ‘62’

three places) but do not fully tighten at this

stage.

23. Loosely install the remainder of the control

valve body bolts.

Figure 7C5-236

24. Coat a new TCC solenoid O-ring with

petroleum jelly, install on the TCC solenoid,

then the assembly into the oil pump body.

25. Reinstall the two TCC solenoid retaining bolts

(68) but do not fully tighten at this time.

NOTE: Do not install the wiring harness locating

clips to the control valve body at this time, as they

would hinder access to the control valve body

retaining bolts.

Figure 7C5-237

26. Reinstall the manual detent spring assembly

(63) retaining bolt (64).

Figure 7C5-238

27. Tighten all bolts to the specified torque

specification, in the order shown.

CONTROL VALVE BODY and

TFP MANUAL VALVE POSITION

SW ITCH ASSEMBLY BOLT

TORQUE SPECIFICATION ............................. 8 – 14 Nm

MANUAL DETENT SP RING

TORQUE SPECIFICATION ............................. 20 – 27 Nm

TCC SOLENOID BOLT

TORQUE SPECIFICATION ............................. 8 – 14 Nm

Important: The control valve body bolts must be

tightened in an outward spiral from the centre, as

shown. Failure to follow this pattern m ay dis tort 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 7C5-239

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

petroleum jelly, install on the solenoid (396).

Then reinstall the solenoid into the control valve

body, securing with retaining clip (395).

Figure 7C5-240

29. Reinstall electrical wiring harness connectors to

the respective components as shown, and

indicated below.

Electrical Connector Identification

1. Transmission Fluid Pressure (TFP) Manual

Valve Position Switch.

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.

30. Check the security of each connection by

gentling pulling on the connector.

31. Install the wiring harness carrier over the

control valve body bolt lugs, ensuring that the

tag (arrow) is located under the TFP Manual

Valve Position Switch.

NOTE: If the harness carrier is not located

correctly, the oil filter will not be installed fully and

will foul the oil pan.

Figure 7C5-241

3.11 OIL FILTER AND OIL PAN

1. Lubricate new oil filter seal (71) with petroleum

jelly and install into the oil pump bore, using a

suitable size socket or piece of tubing (A).

Figure 7C5-242

2. Install a new oil filter (72) into the oil filter seal.

Figure 7C5-243

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

TORQUE SPECIFICATION ............................. 10 – 14 Nm

Figure 7C5-244

3.12 CASE EXTENSION HOUSING AND SPEED SENSOR

INSPECT

1. Inspect all machined surfaces for nicks or

burrs, removing as required with a fine cut file.

2. Check the propeller shaft sliding yoke bush for

wear.

Figure 7C5-245

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 7C5-246

2. Using bush remover, Tool J23062-14 and

driver handle J8092, press the bush (33) from

the extension housing.

Figure 7C5-247

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

housing (31), using installer J34196-4 and

driver handle J8092.

Figure 7C5-248

REINSTALL

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

(31), then install to the rear of the transm ission

case.

2. Reinstall the six attac hing bolts (32) and tighten

to the correct torque specification.

CASE EXTENSION HOUSING BOLT

TORQUE SPECIFICATION ............................. 42 – 48 Nm

Figure 7C5-249

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.

SPEE D SENSOR RE T AINING BO LT

TORQUE SPECIFICATION ............................. 11 – 14 Nm

Figure 7B-250

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

Tool J21426.

Figure 7C5-251

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

hole (1), then a replacement pin must be

selected from the following:

2 - 4 SERVO PIN SELECTION

PIN LE NGTH (mm) IDENTIFI CATION

65.82 - 66.121 Groove

67.23 - 67.53 2 Grooves

68.64 - 68.94 No Groove

Figure 7C5-252

REINSTALL

1. Install new seals to the 2-4 servo pistons

components as follows:

a. The square section 4th apply piston outer

seal (26) to the 4th apply piston (25).

b. The 2-4 servo cover round section O-ring

seal (27) to the 2-4 servo cover (28).

c. The 2nd apply piston outer (18) and inner

(19) square section seals to the 2nd apply

piston (17).

d. The round section O-ring seal (21) to the

servo piston inner housing (20).

Figure 7C5-253

2. Reinstall cushion springs (16 and 105) into the

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

next.

NOTE: An automatic transmission fitted to the GEN

III V8 engine (code HPD) only has the outer

cushion spring (16).

3. Reinstall cushion spring retainer (15) on top of

spring (16).

4. Use a G-clamp (1) and suitable sized socket

(2), to c ompress the spring/s under the second

apply piston assembly.

5. Reinstall retaining ring (14), checking that the

ring is fully installed into the piston groove.

6. Remove tools to release spring tension.

Figure 7C5-254

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

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

8. Reinstall servo apply pin spring (22) and

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

9. After applying petroleum jelly to the inner and

outer 2nd apply piston sealing rings (18 and

19), install to piston (17).

10. 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.

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

apply piston's inner sealing ring (19).

Figure 7C5-255

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

the servo cover (28), with the piston boss

facing the cover.

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

pin and 2nd apply piston assembly into servo

bore in the transmission case.

14. Reinstall the 4th apply piston and outer cover

over the servo pin.

15. Using a hammer handle, press the outer cover

(28) in until the retaining ring groove in the case

is visible.

16. Reinstall retaining ring (29).

Figure 7C5-256

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

NUT TORQUE SPECIFICATION..................... 15 - 35 Nm

NOTE: The lever must be held securely while the

nut is tightened.

Figure 7C5-257

3.15 TORQUE CONV ERTER

INSPECT

The torque converter is serviced as an assembly and should be replaced if any of the following conditions exist:

a. Metal particles f ound when f lushing c ooler or c onver ter pipes - c onver ter flushing is not r ec ommended. Refer to

7C4 ON-VEHICLE SERVICING, the VT Series I Service Information 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. T he tr ansm iss ion fluid has an odour , disc olouration or no evidence of m etallic or c lutch plate m aterial 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, the VT Series I Service Information the 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.

END PLAY - CHECK

The only satisfactory method of accurately

determ ining torque c onver ter end play, is to use the

optional Tool No. J35138, in conjunction with an

accurate dial indicator and a magnetic stand.

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

Torque Converter Diameter End Play

V6 & V6 Supercharged - 258 mm 0.1 – 0.5 mm

GEN III V8 – 300 mm 0.1 – 0.5 m m

Figure 7C5-258

REINSTALL

1. Reinstall torque converter to turbine shaft, with

the transmission in a horizontal position.

2. Reinstall a restraining plate across the

transmission converter housing to prevent the

converter from accidentally being dislodged,

prior to transmission installation.

Figure 7C5-259

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 such as the oil cooler fittings

and output shaft to prevent the ingress of

foreign material, prior to installation in the

vehicle.

Figure 7C5-260

4. TRANSM I SSION REFERENCE DIAGRAMS

Figure 7C5-261 - 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.

44.

45.

46.

47.

48.

49.

50.

52.

53.

54.

55.

56.

57.

58.

59.

60.

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 Return

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 Retaining

Seal, Case Extension to Case

Extension, Case

Bolt, Case Extension to Case

Bush, Case Extension

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

Piston, 3-4 Accumulator

Ring, Oil Seal (3-4 Accumulator Piston)

Spring, 3-4 Accumulator (V6 Engine Only)

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

61.

62.

63.

64.

65.

66.

67.

68.

69.

70.

71.

72.

73.

74.

75.

76.

77.

78.

79.

80.

81.

82.

83.

84.

85.

86.

87.

88.

89.

90.

91.

93.

94.

97.

98.

102.

103.

104.

105.

106.

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 Assembly, Transmission Fluid Pressure

Manual Valve Position

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

Plug, Steel Cup (not shown)

Shaft, Parking Brake Pawl (not shown)

Spring, Parking Brake Pawl

Pawl, Parking Brake

Seal, Manual Shaft

Retainer, Manual Shaft

Shaft, Manual

Actuator Assembly, Parking Lock

Bracket, Parking Lock

Bolt, Parking Lock Bracket

Lever, Inside Detent

Link, Manual Valve

Nut, Hex Head

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) (V6 Engine

Only)

Shield, Transmission Fluid Pressure Switch

Assembly, Manual Valve Position

Figure 7C5-262 - Control Valve Body Assembly

REF No. PART NAME

340.

350.

353.

354.

355.

356.

357.

358.

359.

360.

361.

362.

363.

364A.

364B.

365.

366.

367A.

367B.

368.

369.

370.

371.

372.

374.

375.

376.

377.

378.

380.

381.

382.

383.

384.

385.

386.

387.

388.

389.

390.

391.

392.

394.

395.

396.

397.

398.

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, Pressure Control Solenoid Retainer

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

Valve, Actuator Feed Limit

Spring, Actuator Feed Limit Valve

Plug, Bore

Pressure Control Solenoid

Retainer, Pressure Control 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 and Solenoid

TCC PW M Solenoid Valve

Spring, Regulator Supply

Valve, Isolator

igure 7C5-263 - 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

Figure 7C5-264 - 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

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)

Figure 7C5-265 Seal Locations and Orientation

Ref. No. PART NAME Ref. No. PART NAME

33.

234.

241.

242.

601.

603.

606.

615.

616.

637.

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

657.

659.

663.

665.

667.

669.

672.

674.

683.

692.

Bushing, Input Sun Gear (Front)

Bushing, Input Sun Gear (Rear)

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

Figure 7C5-266 Bush/Bearing Locations and Orientation

5. SPECIFICATIONS

GENERAL

Type........................................................................ Hydra-matic 4L60-E.

Code ....................................................................... V6 Engine – HFD.

V6 Supercharged Engine – HND.

GEN III V8 Engine – HPD.

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 7C3 DIAGNOSIS of the VT Series I and of the

VT Series II Service Information.

OIL PRESSURE ........................................................ Refer to 7C3 DIAGNOSIS of the VT Series I and of the

VT Series II Service Information.

TORQUE CONVERTER:

Number of Elements.......................................... 3 plus torque converter clutch.

Maximum torque ratio at stall............................. V6 and V6 Supercharged Engines – 1.63:1 (k=133).

GEN III V8 Engine – 1.9:1 (k=101)

Nominal Diameter.............................................. V6 and V6 Supercharged Engines – 258 mm.

GEN III V8 Engine – 300 mm.

End Play............................................................. 0.1 – 0.5 mm (All Engines)

LUBRICANT:

Type recommended........................................... Dexron® III

Capacity............................................................. Nominal only. Check when transmission is at operating

temperature.

Refill................................................................. V6 and V6 Supercharged Engines – 4.8 litres.

GEN III V8 Engine – 5.0 litres

Total (Dry)........................................................ V6 and V6 Supercharged Engines – 7.9 litres.

GEN III V8 Engine – 10.6 litres.

Fluid Cooling...................................................... Engine coolant to fluid in one or 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 1 Groove.

67.23 - 67.53 mm 2 Grooves.

68.64 - 68.94 mm No Groove.

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:

V6 and V6 Supercharged Engines ........................ 0.866 – 1.876 mm

GEN III V8 Engine ................................................. 0.866 – 1.876 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 ................................................. 2.10 – 0.90 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:

Measured Dimension: 28.065 – 27.545 mm.......... NONE 1.684 - 1.829 mm

28.586 – 28.066 mm.......... '0' 1.168 - 1.314 mm

27.544 – 27.026 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............................................ 0 - 0.5 mm

6. TORQUE WRENCH SPECIFICATIONS

NOTE: For a lis ting of tor que wrench spec ific ations relating to the re m oval and reinstallation pr ocedures assoc iated

with the automatic trans miss ion, ref er to Section 7C4 HYDRA-MATIC 4L60-E AUTOMATIC TRANSMISSION: ON-

VEHICLE SERVICING of the VX Series Service Information. Nm

1 - 2 accumulator cover bolt............................................................ 8 - 14

Control valve body bolt.................................................................... 8 - 14

Converter housing to case bolt ....................................................... 65 - 75

Extension housing to transmission case bolt.................................. 42 - 48

Forward accumulator cover to valve body bolt................................ 8 - 14

Manual detent spring retaining bolt................................................. 20 - 27

Manual shaft selector lever nut....................................................... 15 - 35

Manual shaft to inner detent lever nut............................................. 27 - 34

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

Oil cooler pipe connections............................................................. 35 - 41

Oil pan bolt...................................................................................... 10 - 14

Oil pump cover to pump body bolt .................................................. 20 - 27

Oil pump to case bolt ...................................................................... 26 - 32

Pressure control solenoid bracket to valve body bolt...................... 8 - 14

Park pawl bracket bolt..................................................................... 27 - 34

Spacer plate support plate bolt ....................................................... 8 - 14

Speed sensor retaining bolt ............................................................ 11 - 14

Torque converter clutch solenoid bolt............................................. 8 - 14

7. SPECIAL TOOLS

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

J7004-1 SLIDE HAMMER

Used for a number of bush

removal operations.

J8092 DRIVER HANDLE

Used for a number of bush

installation operations.

J8433 PULLER

Used with J21427-01 to remove

the output speed sensor ring

from the mainshaft.

J8763-02

HOLDING FIXTURE

Also required is the bench

fixture, J3289-20.

J21368 OIL PUMP ALIGNMENT BAND Used to align the two oil pump

sections before tightening the

securing bolts.

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

J21426 REAR SEAL INSTALLER

Used to install the extension

housing oil seal.

J21427-01 PULLER ADAPTOR

Used with J8433 to remove the

output speed sensor ring from

the mainshaft.

J21465-2 INSTALLER

Used with driver J8092 to install

the front stator shaft bush

J21465-15 REMOVER

Used in conjunction with slide

hammer J7004-1 to remove the

stator shaft front bushing.

J23062-14 BUSH REMOVER

Used in conjunction with driver

handle J8092

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

J23327-1 CLUTCH SPRING COMPRESSOR

Needed to compress the clutch,

before dismantling.

Plate J42628 is also required.

J23907 SLIDE HAMMER

Used with J29369-2 to remove

the reaction carrier shaft

bushes.

J25016 OIL PUMP SEAL INSTALLER

Used to install the oil pump oil

seal/

J25018-A CLUTCH SPRING COMPRESSOR

ADAPTOR

Used with compressor J23327

to compress the reverse input

clutch during disassembly.

J25019-9 BUSH INSTALLER

Used in conjunction with driver

handle J8092

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

J25019-12 BUSH INSTALLER

Used in conjunction with driver

handle J8092

J25019-14 BUSH REMOVER

Used with slide hammer J7004-

J25019-16 BUSH REMOVER

Used with slide hammer J7004-

J25025-B DIAL INDICATOR STAND AND GUIDE PIN

SET Used for various tasks, stated in

the text.

J29369-2 UNIVERSAL BUSH REMOVER

Used with slide hammer

J23907.

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

J29882 INNER OVERRUN CLUTCH SEAL

PROTECTOR

Used to protect the inner,

overrun clutch piston seal from

damage during installation.

J29883 INNER FORWARD CLUTCH SEAL

PROTECTOR

Used to protect the inner,

forward clutch piston seal from

damage during installation.

J33037 2 - 4 BAND APPLY PIN TOOL

Used to check the selective

apply pin length.

J34196-B BUSH REMOVER/INSTALLER SET

Used for various applications,

described in the text.

J34627 SNAP RING PLIERS

Specific purpose is to assist in

the removal/replacement of the

output shaft snap ring.

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

J35138 TORQUE CONVERTER END PLAY

To be used in conjunction with

commercially available

magnetic stand and dial

indicator.

J36352 SPEED SENSOR INSTALLER &

GAUGING TOOL

Needed to correctly install the

output speed sensor ring to the

mainshaft.

Comprises sleeve, J36352-6

and C-washer J36352-4.

J36418-B TURBINE SHAFT SEAL INSTALLER &

RESIZER

Used to install and re-size the

turbine shaft seal.

Comprises J36418-1B installer

(revised to suit 300 mm torque

converter turbine shaft

dimensions) and J36418-2A

resizer.

NOTE: J36418-1B will service

back to all 4L60-E

transmissions.

J37789-A OIL PUMP REMOVER

Used with J39119 to remove

the oil pump assembly.

J38735-3 STATOR SHAFT SEALING RING

INSTALLER

Used with J39855-1 to install

the stator shaft seal.

TOOL No. REF. IN TEXT TOOL DESCRIPTION COMMENTS

J39119 OIL PUMP REMOVER ADAPTOR

Used with J37789-A to remove

the oil pump assembly.

J39855-1 STATOR SHAFT SEAL EXPANDER

Used to expand the stator shaft

seal prior to installation.

J39855-2 STATOR SHAFT SEAL RESIZER

Used to re-size the stator shaft

seal after installation.

J41510 #50 TORX PLUS BIT

Used to loosen and tighten the

torque converter housing to

transmission case bolts.

J41778-1 OIL PUMP BUSH INSTALLER

Used with a bench press.

TOOL NO. REF. IN TEXT TOOL DESCRIPTION COMMENTS

J41778-2 SUPPORT PLATE

Used to support the oil pump

during bush installation.

J42628 PLATE

New release.

Used with clutch spring

compressor, J23327-1.

AU MANUAL SHAFT OIL SEAL REMOVER

New release.

Used to remove the manual

shaft oil seal without first

removing the manual shaft.

NOTE: Can be used on all

4L60-E transmissions.

AU MANUAL SHAFT OIL SEAL INSTALLER

New release.

Used to install the manual shaft

oil seal.

NOTE: Can be used on all

4L60-E transmissions.