FORD AOD

INDEX
INTRODUCTION................................................................... ............................................................................... 3

SHIFT DIAGNOSIS.............................................................. ................................................................................ 4

LINKAGE-GENERAL........................................................ ................................................................................... 6

UNIT REMOVAL..................................................................... .............................................................................. 14

UNIT INSTALLATION.............................. .................................... ....................................................................... 21

TEAR-DOWN.............................................................. ............................................................................................ 26

ASSEMBLY ...................................................................... ........................................................................................ 36

COMPONENT REBUILD .............................................................. ........................................................................ 52

PUMP ...................................................................... .................................................................................................. 78

VALVE BODY ...................................................................... ................................................................................... 84

BEARING LOCATIONS................................................................ . ....................................................................... 91

SPECIFICATIONS.................................................................. ................................................................................ 94

PRESSURE SPECIFICATIONS............................................................................................................................. 96

AUTOMATIC TRANSMISSION SERVICE GROUP

18639 S.W. 107TH AVENUE
MIAMI, FLORIDA 33157
(305) 670-4161
Copyright © ATSG 2006

2
,~ATSlil Updated
October, 2006

INTRODUCTION
FORD AOD
The Ford AOD transmission was the first domestic produced Automatic Overdrive Transmission. This book
contains the general description of the transmission, adjustment procedures, diagnosis, removal and installation
in the vehicle and dis-assembly and assembly of the unit.

The information and part numbers contained in this booklet have been carefully compiled from industry sources
known for their reliability, but ATSG does not guarantee their accuracy.

No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or
by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise,
without written permission of Automatic Transmission Service Group. This includes all text illustrations,
tables and charts.

WE WISH TO THANK
FORD MOTOR COMPANY
FOR THE INFORMATION AND
ILLUSTRATIONS THAT MADE
THIS BOOKLET POSSIBLE

DALE ENGLAND JIM DIAL

FIELD SERVICE CONSULTANT TECHNICAL CONSULTANT
WAYNE COLONNA ED KRUSE
TECHNICAL SUPERVISOR TECHNICAL CONSULTANT
PETER LUBAN GREGORY LIPNICK
TECHNICAL CONSULTANT TECHNICAL CONSULTANT
JON GLATSTEIN DAVID CHALKER
TECHNICAL CONSULTANT TECHNICAL CONSULTANT
JERRY GOTT MIKE SOUZA
TECHNICAL CONSULTANT TECHNICAL CONSULTANT
GERALD CAMPBELL ROLAND ALVAREZ
TECHNICAL CONSULTANT TECHNICAL CONSULTANT

AUTOMATIC TRANSMISSION SERVICE GROUP

18639 S.W. 107TH AVENUE
MIAMI, FLORIDA 33157
(305) 670-4161
1
(~AT56) Technical Service Information
The Automatic Overdrive Transmission provides (55 mph), the transmission will downshift to first gear
fully automatic operation in either the © (OVER- when the acclerator is pushed to the floor. At most
DRIVE) or D (3-OVERDRIVE LOCKOUT) positions. vehicle speeds in{O}(OVERDRIVE), the tranmission
will downshift from fourth gear to third gear when the
NOTE: A 2 (SECOND) selector position replaces accelerator is pushed for moderate to heavy
the 1 (LOW) selector position in ve:1icles equipped acceleration.
with the low gear lockout position. AUTOMATIC OVERDRIVE TRANSMISSION MODEL TAG

{Ol(OVERDRIVE)-This is the normal driving posi-

tion for an automatic overdrive transmission . In this SERVICE 1.0. LEVEL
position the transmission starts in first gear and as
TRANSMISSION MODEL BUILD DATE CODE.
the vehicle accelerates, automatically upshifts to
MONTH DAY
second, third and fourth ge.ir. The transmission will
automatically downshift as vehicle speed decreases.

NOTE: The transmission will not shift into or re-

main in overdrive gear when the accelerator is
pushed to the floor.

The Automatic Overdrive Transmission differs

@;~~:l?5 SERIAL NO.
from conventional 3-speed automatic transmissions
in that the planetary gear set operates in 4th gear. ASSY. PART NO.
Some audible perception of planetary action can PREFIX & SUFFIX
exist as with any other mechanical device and
should be accepted as being commercially quiet
unless some abnormal noise is present. ATTACHED TO UPPER
RIGHT HAND EXTENSION
D (OVERDRIVE LOCKOUT)-ln this position the HOUSING TO CASE BOLT.
transmission operates as in©(OVERDRIVE) except
there will be no shift into the overdrive gear. This
position may be used when driving up or down DIAGNOSIS AND TESTING
mountainous roads to provide better performance
and greater engine braking than the overdrive posi-
tion . The transmission may be shifted from©to D Refer to Section 17-01, for the complete Diagnosis
or D to© at any vehicle speed. and Testing procedures. The procedures in this.Sec-
tion apply only to transmission shift complaints that
1 (LOW)-This position can be used when max- are attributed to a misadjusted or malfunctioning
imum engine braking is desired. To help brake the Throttle Valve Control System.
vehicle on hilly roads where D (OVERDRIVE
LOCKOUT) does not provide enough braking, shift
the selector lever to 1 (LOW). At vehicle speeds
above approximately 40 km/h (25 mpr.), the
transmission will shift to second gear, and remain
in second gear. When vehicle speed drops below 40
km/h (25 mph), the transmission will downshift to first Throttle -✓alve (TV) Control Systems
gear, and remain in first gear. Upshifts from 1 (LOW)
can be made by manually shifting to © (OVER- The AOD Transmission employs two Throttle Valve
DRIVE} .or D (OVERDRIVE LOCKOUT). When 1 (TV) Control Systems.
(LOW) is used for starting up, the transmission starts
in fir~! gear and stays if first gear. A TV Control Rod Linkage System-used with all
3.8L and 5.8L engines.
FORCED DOWNSHIFTS-At vehicle speeds from
89-40 km/h (55-25 mph) in(O)(OVERDRIVE) ORD A TV Cable Control System-used with all 5.0L and
(OVERDRIVE LOCKOUT), the transmission will 5.0L HO engines.
downshift to second gear when the accelerator is
pushed to the floor. At vehicle speeds below 40 km/h TV Control hardware, adjustments, and diagnosis is
different for each system . Before diagnosis or ad-
justment, verify which system is on the vehicle and
follow the appropriate diagnosis and adjustment.

3
 Shift Trouble Diagnosis Remedy: Correct interference area.
TV Rod Linkage System Cause: Excess friction due to binding of grom-
3.8L and 5.8L Engines. mets prevents return of TV control linkage.

A. Symptoms: Excessively early and/or soft up- Remedy: Check for bent or twisted rod or levers
shifts with or without slip-bump feel. Slip-bump causing misalignment of grommets. Service or
feel on light throttle shift into and out ofQ.)) (3-4 replace defective components . Replace grom-
and/or 4-3 shifts) . No forced downshift mets if damaged . Reset TV control linkage us-
(kickdown) function at appropriate speeds. ing procedure in this Section.

Cause: TV control linkage is set too short. Cause: TV control rod disconnected. (Transmis-
sion is at maximum TV pressure).
Remedy: Adjust linkage using procedure in
Linkage Adjustment at Carburetor. Since Remedy: Reconnect TV control rod. Replace
linkage is short, initial gap should exist between grommet(s) if rod disconnect was due to
throttle lever and linkage lever adjusting screw damaged grommet(s).
or a gap should develop after backing out screw
no more than one turn. If this is not the case, Cause: Clamping bolt on trunnion at lower end
short linkage diagnosis is incorrect. of TV control rod is loose.

If the adjusting screw has insufficient travel to Remedy: Reset TV control linkage using pro-
be turned in at least one turn after closing the cedure in this Section .
gap between the screw and throttle lever, it will
be necessary to adjust as described in Linkage C_ause: Linkage lever return spring broken or
Adjustment at Transmission. disconnected. (Transmission is at maximum TV
pressure).
If the adjusting screw was initially backed out
all the way and the linkage lever is in contact Remedy: Reconnect or replace spring.
with the throttle lever, turn in screw at least two
turns but no more than four turns. If problem D. Symptoms: Harsh coasting downshifts harsh
1s not corrected, readjust linkage as described 3-4 upshifts when backing off throttl~. and
in Linkage Adjustment at Transmission. possible harsh idle engagement.

B. Symptoms: Shift clunk when throttle is backed Cause: TV lever spring at carburetor not return-
off after full or heavy throttle acceleration. Harsh ing TV lever completely, or TV linkage grom-
coasting downshifts out of @ (automatic 4-3 mets binding.
shifts in D-Overdrive range).
Remedy; Replace TV lever spring at car-
Cause: TV Control Linkage is set too long. buretor. Check for binding grommets. Clean
and lubricate with dry lubricant. Replace, ii
Remedy: Follow linkage adjustment procedure necessary.
using Linkage Adjustment at Carburetor.

Since linkage is long, it should be necessary to

backout linkage lever adjustment screw at least
five turns before a gap develops between screw TV Control Cable System
and throttle lever. If this is not the case, long
linkage diagnosis is incorrect. 5.0L and 5.0L HO Engines

If the adjusting screw has insufficient travel to A. Symptoms: Excessively early and/or soft up-
develop a gap between screw and throttle lever shifts with or without slip-bump feel. Slip-bump
as ~escribed above, return screw to original feel on light throttle shift into and out of 4th gear
pos1t1on and then backout screw at least two (3-4 and/or 4-3 shifts). No forced downshift (kick-
turns but no more than four turns. If screw has down) function at appropriate speeds.
insufficient travel to be backed out a minimum
of two turns or if the problem is not corrected, Cause: TV control cable set too long.
readjust linkage as described in Linkage Adjust-
ment at Transmission . Remedy: Reset cable per procedure for the TV
control cable system.
C. Symptoms: Extremely delayed and harsh up-
shifts, especially at light to moderate accelera- CAUTION: Do not drive vehicle if cable is
tion and harsh idle engagement. broken or disconnected at throrne body
lever.
Cause: Interference prevents return of TV con-
trol rod .

4
(~ATSG) Technical Service Information

Damage to friction elements in transmission Cause: Transmission lever stays at WOT or part
may result due to excessive slipping since TV throttle although cable is correctly set.
pressure will remain near zero . If it is necessary
to drive vehicle before servicing or resetting Remedy: Check for binding conditions as
cable, disconnect cable at the transmission detailed in Step B. Service or replace as
lever. TV pressure will now be near maximum, necessary. Set cable per procedure for the TV
allowing light throttle operation . However, shift control cable system .
will be delayed and harsh.

Remedy: Replace/reconnect cable and reset

per procedure for the TV control cable system.

B. Symptoms: Shift clunk when throttle is back- TV Linkage Diagnostic Check

ed off after full or heavy throttle acceleration.
Harsh coasting downshifts out of 4th gear With selector lever in N, carburetor de-cammed,
(automatic 4-3 shifts in D range) . there should be no gap at TV linkage. If gap exists,
check for binding grommets and TV return spring
Cause: TV control cable is set too short. not returning TV lever at carburetor . Check linkage
adjustment at carburetor, if necessary.
Remedy: Reset cable per procedure for the TV
control cable system .

Cause: TV control cable is not locked , locking

key is in up position . ADJUSTMENTS
Remedy: Set cable per procedure for the TV
control cable system .
Throttle Valve (TV) Control Linkage System
Cause: Transmission lever does not return to
idle (lever to rear as far as possible) although 3.SL and 5.SL Engines
cable is correctly set.
Service Adjustment Procedure
Remedy: Check for binding due to misaligned
or damaged cable brackets or damaged cable The Throttle Valve (TV) Control Linkage System
or return spring (in rubber boot). Check for bind- consists of the linkage lever on the carburetor, the
ing at cable connections at throttle body or transmission control rod assembly, and the external
transmission . Pry off cable from the TV lever TV control lever on the transmission.
ball stud and check for free movement of the
cable. Lubricate the ball stud with a small
amount of Multi-Purpose Long-Life Lubricant,
C1AZ-19590-B (ESA-M1C75-B) lubricant or
equivalent and reattach the cable. Check for TYPICAL TV ROD CONTROL SYSTEM
frozen moisture in cable due to damaged boot.
Service or replace as necessary. Set cable per
procedure for the TV control cable system.

Cause: Cable assembly not correctly attached

to bracket at either throttle body or
transmission .

ijemedy: Determine reason for cable becom-

ing detached . Replace if necessary. Set cable
per procedure for the TV control cable system.

C. Symptoms: Extremely delayed and harsh up-

shift, especially at light to moderate accelera-
tion and harsh idle engagement.

Cause: Cable disconnected at transmission

(transmission TV pressure is at maximum).

Remedy: Determine cause for cable becoming

disconnected . Service or replace as necessary.
Set cable per procedure for the TV control cable
system .

5
(~ATSCiJ Technical Service Information

The linkage lever follows the motion of the car- Without DC Motor Idle Speed Control (ISC)
buretor throttle lever and has an adjustment screw
for limited linkage adjustment capability. The TV con- 5.SL Engine
trol rod transmits motion between the linkage lever
on the carburetor and the TV control lever on the 1. Check/adjust the engine curb idle speed to
transmission and is adjusted to proper length dur- specification. Refer to the Engine/Emissions
ing 1nit1al assembly . The external TV control lever Diagnosis· manual for procedures to adjust
actuates the internal TV control mechanism which throttle solenoid applications. Make sure the
regulates the TV control pressure . The external TV curb idle speed is set to specification with and
control lever motion is controlled by stops internal without the throttle solenoid posit(oner (anti-
to the transmission at idle and wide open throttle dieseling solenoid energized, if so equipped).
(WOT)
The TV control linkage is set to its proper length 2. Shut engine off. Remove air cleaner .
during initial assembly using the sliding trunnion
block at the transmission end of the TV control rod 3. De-cam the fast idle cam on the carburetor so
assembly. Under normal circumstances, it should that the throttle lever is against the idle stop or
not be necessary to alter this adjustment. Any re- throttle solenoid positioner stop.
quired adjustment of the TV control linkage can nor-
mally be accomplished using the adjustment screw
on the linkage lever at the carburetor. Major linkage
adjustment (sliding trunnion on rod) may only be re-
quired after maintenance involving the removal
and/or replacement of the carburetor, TV control rod
assembly, or the transmission. Minor linkage adjust-
ment (adjustment screw on linkage lever) may be re-
quired after installing a new main control assembly,
or after idle speed adjustments greater than 50 rpm, With DC Motor Idle Speed Control (ISC)
and to correct complaints of poor transmission shift
quality as outlined in following parts. 3.SL Engine

Minimum Idle Stop NOTE: When engine is shut off, the ISC plunger
automatically extends and moves the throttle lever
When the linkage is correctly adjusted, the TV to fast idle in preparation for the next time the engine
control lever on the transmission will be at its internal is started. The TV linkage cannot be correctly ad-
idle stop position (lever up as far as it will travel) justed in this position. The ISC plunger will retract
when the carburetor throttle lever is at its minimum only if the procedure is followed in the exact
idle stop. There will be a light contact force between sequence.
the throttle lever and end of the linkage lever adjust-
ment screw. Due to flexibilty in the linkage system,
the linkage lever adjustment screw would have to
be backed out approximately three turns before a
gap between the screw and throttle lever could be
detected.

At wide open throttle (WOD, the TV Control Lever

on the transmission may or may not be at its wide
open stop. The wide open throttle position must not
be used as the reference point in adjusting linkage.

Linkage Adjustment-General Instructions

Before any engine TV linkage adjustment can be

done, the throttle lever at the carburetor (or fuel
charging assembly on EFI vehicles) must be posi-
tioned at its minimum idle stop.

6
(~AT56) Technical Service Information

1. Locate the Self Test Connector and Self Test 3. Turn the ignition key to the RUN position. Do
Input Connector in the engine compartment. not start engine. The ISC plunger will retract.
Typically in the area of the RH (passenger side) Wait until the plunger is fully retracted, about
fender apron . These two connectors are located 10 seconds.
next to each other.

4. Shut off key and remove jumper wire and air

cleaner.

2. Connect a jumper wire between the STI Con- Linkage Adjustment at Carburetor
nector and the Signal Return Ground on the
Self Test Connector. The TV control linkage may be adjusted at the car-
buretor using the following procedure :

1. Set carburetor at minimum idle stop as describ-

ed in Linkage Adjustment General Instructions .
Place shift lever in NEUTRAL and set parking
brake.

IMPORT ANT: The transmission selector

lever must be in NEUTRAL.

2. Backout (CCW) linkage lever ad1usting screw

all the way (screw end is flush with lever face) .

3. Turn in (CW) adjusting screw until a thin shim

of .127mm (0 .005 inch) maximum. or piece of
writing paper fits snug between end of screw
and throttle lever. To eliminate effect of fric-
tion, push linkage lever forward (tending to
close gap) and release before checking
clearance between end of screw and throttle
lever.

Do not apply any load on levers with tools

or hands while checking gap.

7
(~ATSCij Technical Service Information

4. Turn in (CW) adjusting screw an additional three 1. Set carburetor at its minimum idle stop as
turns. (Three turns are preferred. One turn described in Linkage Adjustment General
minimum is permissible if screw travel is Instructions. Place shift lever in NEUTRAL and
limited). set parking brake. Engine off.
5. If it is not possible to turn in adjusting screw at NOTE: Transmission selector must be in
least one additional turn or if there was insuffi- NEUTRAL.
cient screw adjusting capacity to obtain an initial
gap in Step 2, refer to Linkage Adjustment at 2. Set the linkage lever adjustment screw at
Transmission. approximately mid-range.
Idle Speed Adjustment 3. If a new TV control rod assembly is being in-
stalled, connect the rod to the linkage lever at
Whenever it is required to adjust idle speed by the carburetor.
more then 50 rpm, the adjustment screw on the
linkage lever at the carburetor should also be read- CAUTION: The following steps involve work-
justed as shown: ing in proximity to the exhaust system. Allow
the exhaust system to cool before
Linkage Adjustment proceeding.
Idle Speed Change at Carburetor
4. Raise the vehicle on the hoist. Refer to the Pre-
50 rpm or more Check TV Lever Delivery manual, Section 50-04.
decrease adjustment at car-
buretor 5. Loosen the bolt on the sliding trunnion block on
Less than 50 rpm No change Required the TV control rod assembly. Remove any cor-
rosion from the control rod and free-up the trun-
50 rpm or more Check TV nion block so that it slides freely on the control
increase lever adjustment at rod.
carburetor
6. Push up on the lower end of the control rod to
After making any idle speed adjustments, always ensure that the linkage lever at carburetor is
verify that the linkage lever and throttle lever are in firmly against the throttle lever. Release force
contact with the throttle lever at its idle stop (or throt- on rod. Rod must stay up.
tle solenoid positioner) and the shift lever is in N
(NEUTRAL). If this is not the case refer to 7. Push the TV control lever on the transmission
paragraphs A and C in Shift Trouble Diagnosis. up against its internal stop with a firm force,
approximately 22 N (5 lb), and tighten the bolt
On vehicles equipped with DC motor idle speed on the trunnion block. Do not relax force on
control, idle speed adjustment is automatic and TV lever until bolt is tightened.
linkage adjustment will normally not be required. In
some cases, a new low mileage engine may cause 8. Lower the vehicle and verify that the throttle
the transmission to exhibit moderate symptoms of lever is still against the minimum idle stop or
a long TV rod (refer to Shift Trouble Diagnosis). throttle solenoid positioner stop. If not, repeat
These symptoms will correct themselves as the Steps 2 through 8.
engine is broken in and the ISC adjusts the idle
speed.

Linkage Adjustment Using TV Control

Pressure
NOTE: This procedure requires the use of TV
Pressure Gauge with Hose (0-60 psi) T86L-70002-A
Linkage Adjustment at Transmission or equivalent. The results of the adjustment pro-
cedure depends on the accuracy of the pressure
The linkage lever adjustment screw has limited gauge.
ad1ustment capability . If it is not possible to adjust
the TV linkage using this screw, the length of the A pressure gauge should be checked periodically
TV control rod assembly must be readjusted using (approximately once a year) or when the following
the following procedure . This procedure must also occurs:
be followed whenever a new TV control rod 1. The needle will not return to O kPa (0 psi) under
assembly is installed . no pressure.
This procedure requires placing the vehicle on a
hoist to give access to the linkage components at 2. The needle goes past O kPa (0 psi) (negative
the transmission TV control lever. side) under no pressure.

3. Bumping or dropping a pressure gauge.

8
[~ATSG) Technical Service Information

The following procedure may be used to check 3. Obtain Rod TV Control Pressure Gauge Block
and/or adjust the throttle valve (TV) control linkage D84P-70332-A, or fabricate a block 10mm +
using the TV control pressure. 0.17mm (0.397 ± 0.007 inch) thick. The follow-
ing drill bit shanks may also be used in order
1. Check/adjust the engine curb idle speed to of preference: Letter X (.397 inch), 10mm (.3937
specification required. Refer to the inch) or 25/64 (.3906 inch).
Engine/Emissions Diagnosis· manual for
appropriate procedure. Make sure the curb idle ADAPTER
speed is set to specification with and without FITTING
DB0L-77001-A
the throttle solenoid positioner (anti-diesel
solenoid) energized, if so equipped.
2. Attach TV Pressure Gauge (0-60 psi) with Hose
T86L-70002-A or equivalent, to the TV port on
the transmission.

NOTE: If the service tool is not available, in order

to avoid the exhaust system, obtain the following
locally available material and assemble as shown:

• One 1/8-inch NPT Female Hansen Fitting .

SERVICE TOOL USAGE SHOP MADE GAUGE BLOCK
OR DRILL SHANK
• One 1/8-inch NPT Male Hansen Fitting . ROD TV CONTROL 10mm ± 17mm
PRESSURE SERVICE (.397 ± .007 INCH)
• One 1/4-inch NPT 90 degree elbow connector. TOOL D84P-70332·A
H-1
• One high-pressure hose fitting.

The pressure gauge should have 200mm (8 feet) of

flexible hose to make the gauge accessible while
operating the engine.

TV LINKAGE
LEVER
CAUTION:
MAKE SURE GAUGE
CARBURETOR BLOCK OR DRILL
THROTTLE CONTACTS SCREW
LEVER POINT AND DOES
VIEW B NOT TOUCH HERE.

NOTE: USE ROD TV CONTROL

PRESSURE GAUGE TOOL
DUP-70332-A IF
AVAILABLE. IF NOT
AVAILABLE. USE ONE OF
THE FOLLOWING DRILL
SIZES (LETTER X. 10mm.
118 INCH NATIONAL PIPE THREAD OR 25164).
MALE HANSEN FITTING

HIGH PRESSURE
HOSE FITTING 1/4 INCH NATIONAL PIPE THREAD LETTER X
90 DEGREES ELBOW CONNECTOR 10mm OR
25/64 DRILL VIEW C

4. Operate the engine until normal operating

temperature is reached and the throttle lever is
off fast idle or the idle speed control plunger (if
equipped) is at its normal idle position. The
transmission fluid temperature should be ap-
proximately 38°-72°C (1 oo 0 -1 so°F). Do not
make pressure check if transmission fluid is
cold or too hot to touch.

9
(~ATSG) Technical Service Information

5. Set parking brake, place shift selector in N sion function, use the adjusting screw to set the
(NEUTRAL), remove air cleaner, shut off air pressure as close as possible to 241 kPa (35
conditioner. If equipped with a vacuum psi). Turning the screw in will raise the pressure
operated throttle modulator, disconnect and 10.3 kPa (1 .5 psi) per turn . Backing out the
plug the vacuum line to this unit. If equipped screw will lower the pressure. If equipped with
with a throttle solenoid positioner or an idle idle speed control, some "hunting may occur
speed control , do not disconnect either of these and an average pressure reading will have to
components. be determined. If the adjusting screw does not
have enough adjustment range to bri'lg TV
NOTE: The following pressure check must be pressure within specification, first adjust rod at
made with the engine idling at normal curb idle the transmission .
in NEUTRAL. parking brake set , with no ac-
cessory load on engine . Do not make pressure 7. Remove gauge block, allowing TV lever to
check in PARK. return to idle. With engine still idling in
NEUTRAL, TV pressure must be less than 34
6. With engine idling in NEUTRAL insert gauge kPa (5 psi). If not, back out adjusting screw un-
block (or drill shank) between the carburetor til TV pressure is less than 34 kPa (5 psi).
throttle lever and adjust screw on the transmis- Reinstall gauge block and check that TV
sion linkage lever. The TV pressure should be pressure is still 241 ± 34 kPa (35 ± 5 psi).
241 ± 34 kPa (35 ± 5 psi) . For best transmis-

Throttle Valve (TV) Control Cable System

5.0l and 5.0l HO Engines

The throttle valve (TV) control cable system consists

of a cable attaching stud on the throttle body throttle
lever. the TV control cable assembly, the external THROTTLE BODY
TV control lever on the tranmission , and the cable
mounting brackets at the throttle body and
transmission .

CRIMPED
SLUG

10
(~ATSG) Technical Service Information

CONTINENTAL. THUNDERBIRD/COUGAR

THROTTLE BODY

VIEW A
TV CABLE ASSY ENGINE END

TV CABLE

MARK VII, MUSTANG/CAPRI

TRA NS . LE VER

On Continental and Thunderbird/Cougar vehicles ,

there I~ also a bellcrank assembly mounted on the
transmission bell housing in the area of the TV lever
and bracketry holding the cable in the upper bell
housing area.

11
(~ATSG] Techni cal Service Inform ation

As the throttle is moved from idle to wide open A pressure gauge should be checked periodically
throttle (WOT). the TV control cable pulls the (approximately once a year) or when the following
transmission TV control lever from idle to WOT. occurs:
Return of the cable and transmission lever toward
idle is accomplishe d by the return spring on the 1. The needle will not return to O kPa (0 psi) under
tram1ssion end of the cable assembly. This spring no pressure.
and the end of the cable assembly is protected by
a flexible rubber boot. The transmission external TV 2. The needle goes past O kPa (0 psi) (negative
control lever actuates the internal TV control side) under no pressure.
mechanism which regulates the TV control pressure.
The travel of this lever is controlled by stops inter- 3. Bumping or dropping a pressure gauge.
nal to the transmission.

The TV control cable is set and locked to its proper

length during initial assembly by pushing down on
the locking lever at the throttle body end of the cable Adjustment and/or Check
assembly. When the lever is unlocked, the cable is
released for adjustment. The take-up spring at this
end of the cable automaticall y tensions the cable 1. Attach TV Pressure Gauge with Hose (0-60 psi)
when released. With the slack taken up and the lock- T86L-70002-A or equivalent, to the TV port on
ing lever pushed, the take-up spring plays no part the transmission .
in the operation of the system.
NOTE: If service tool is not available, in order
to avoid the exhaust system . obtain the follow-
Under normal circumstanc es , it should not be ing locally available material and assemble as
necessary to alter or readjust the initial setting of the shown:
TV control cable . Situations requiring readjustmen t
of the TV control cable include maintenance involv-
ing the removal and/or replacement of the throttle • One 1/8-inch NPT Female Hansen Fitting.
body, transmission, TV cable assembly or installing
a new main control assembly. Readjustmen t of the • One 1/8-NPT Male Hansen Fitting.
TV control cable would also be necessary to correct
complaints of poor transmission shift quality that • One 1/4-inch NPT 90 degree elbow connector.
would have been caused by a misadjustme nt of the
TV control cable. • One high-pressure hose fitting .

When the TV control cable is properly set, the The pressure gauge should have 200mm (8 feet) of
transmission TV control lever will be at its internal flexible hose to make the gauge accessible while
idle stop (lever to rear as far as it will travel) when operating the engine.
the throttle lever is at its idle stop.

Idle Speed Affect on TV Control Cable

The 5.0L and 5.0L HO (302 CID) SEFI (Sequential

Electronic Fuel Injection) engine uses an Air Bypass
(ISC) that does not affect throttle position. Therefore,
idle _automatic setting does not affect TV cable
adjustment. 118 INCH NATIONAL PIPE THREAD
MALE HANSEN FITTING

1/4 INCH NATIONAL PIPE THREAD

90 DEGREES ELBOW CONNECTOR

Linkage Adjustmen t Using Throttle Valve TV

Control Pressure (TV Cable System)

NOTE: This procedure requires the use of TV

Pressure Gauge with Hose (0-60 psi) T86L-70002-A
or equivalent. The results of the adjustment pro-
cedure depends on the accuracy of the pressure
gauge.

12
(~ATSG) Technical Service Information

2. On Lincoln Town Car or Ford Crown Vic- 6. Using a screwdriver or pointed tool, pry up white
toria/Mercury Grand Marquis only, remove the toggle lever on cable adjuster located
air cleaner cover and inlet tube from the throttle immediately behind the throttle body cable
body inlet for easier access to throttle lever. mounting bracket.

3. Insert tapered end of the tool between the

crimped slug on the end of cable and plastic
cable fitting that attaches to the throttle lever.
Push in Cable TV Gauge Tool T86L-70332-A,
or equivalent forcing the crimped slug away
from the plastic fitting . Make sure gauge block
is pushed in as far as it will go.

WARNING: THIS PROCEDURE REQUIRES

WORKING IN CLOSE PROXIMITY TO THE
EGR SPACER ASSEMBLY WHICH MAY BE
HOT.

The adjuster preload spring should cause the

adjusting slider to move away from the throttle
body and TV pressure should increase.

NOTE: Toggle lever must be completely up to

allow slider to move freely.

7. Push on the slider from behind bracket until TV

pressure is 241 kPa (35 psi). While still holding
slider, push down on toggle lever as far as it
will go, locking slider in position .

4. Operate engine until normal operating

temperature is reached. The transmission fluid
temperature should be approximately 38-72°C
(100-150°F). Do not make pressure check if
transm ission fluid is cold or too hot to touch.

5. Set parking brake and place shift selector in

NEUTRAL. With gauge tool in place and engine
idling in NEUTRAL, the TV pressure should be
241 ± 34 kPa (35 ± 5 psi). For best transmis-
sion function , set the TV pressure as close as
possible to 241 kPa (35 psi) using the following
procedure.
NOTE: Do not check or set TV pressure in
PARK.

13
(~ATSG) Technical Service Information

NOTE : Toggle lever must be completely down 4. Remove the converter-to-flywheel attaching
(lying flat in cable adjuster assembly) to lock nuts. Place a wrench on the crankshaft pulley
properly. attaching bolt to turn the converter to gain ac-
cess to the nuts.
8. Remove gauge tool . allowing cable to return to
its normal idle position. With engine still idling 5. Place a drain pan under the converter to catch
in NEUTRAL. TV pressure must be at or near the fluid. With the wrench on the crankshaft
O (less than 241 kPa (5 psi). If not, reinstall pulley attaching bolt, turn the converter to gain
gauge block. taking care to avoid the hot EGR access to the converter drain plug and remove
spacer . Repeat Steps 6 and 7 but set TV the plug. After the fluid has been drained,
pressure to a pressure less than 241 kPa (35 reinstall the plug.
psi) but not less than 207 kPa (30 psi). Remove
gauge block and recheck TV pressure to deter- 6. Disconnect the driveshaft from the rear axle and
mine if it is at or near 0. slide shaft rearward from the transmission. To
maintain driveshaft balance, mark the rear
driveshaft yoke and axle companion flange so
the driveshaft can be installed in its original
position. Refer to Section 15-60 or 15-66. Install
a seal installation tool in the extension housing
REMOVAL AND INSTALLATION to prevent fluid leakage.

7. Disconnect the cable from the terminal on the

NOTE : If the transmission is being removed for starter motor. Remove the three attaching bolts
a major overhaul, it is important to completely clean and remove the starter motor. Disconnect the
all transmission components, including converter, neutral start switch wires at the plug connector.
cooler, cooler lines, main control valve body, gover-
nor, all clutches, and all check balls after any 8. Remove the rear mount-to-crossmember at-
transmission servicing that generates contamination. taching bolts and the two crossmember-to-
These contaminants are a major cause for recurr- frame attaching bolts.
ing transmission troubles and must be removed from
the system before the transmission is put back into 9. Remove the two engine rear support-to-
service . extension housing attaching bolts.

The cleaning of debris from the direct clutch check 10. Disconnect TV linkage rod or cable from
ball is often omitted. This omission can lead to a transmission TV lever ball stud. On Continen-
repeat servicing of the transmission. tal and Thunderbird/Cougar vehicles, discon-
nect cable from bellcrank lever stud and remove
Cleaning and flushing procedures for transmission self-tapping bolt from bell housing bracketry.
components , including the direct clutch check ball,
can be found in Section 17-01. Cleaning and
Inspection.

Transmission

Removal
1. Raise the vehicle on a hoist or stands. Refer to
Pre-Delivery manual Section 50-04.

2. Place the drain pan under the transmission fluid

pan . Starting at the rear of the pan and work-
ing toward the front, loosen the attaching bolts
and allow the fluid to drain. Finally remove all
cf the pan attaching bolts except two at the
front, to allow the fluid to further drain. With fluid
drained, install two bolts on the rear side of the 11 . Carefully disconnect manual rod from transmis-
pan to temporarily hold it in place. sion manual lever at transmission using Shift
Linkage Grommet Removal Tool T84P-7341-A
3. Remove the converter drain plug access cover or equivalent. For tool usage instructions, refer
from the lower end of the converter housing. to Section 17-02.

14
(~ATSG) Technical Service Information

12. Remove the two bolts securing the bellcrank 6. Move the converter and transmission assembly
bracket to the converter housing. forward into position, using care not to damage
the flywheel and the converter pilot. The con-
13. Raise the transmission with a transmission jack verter face must rest squarely against the
to provide clearance to remove the flywheel. This indicates that the converter pilot
crossmember. Remove the rear mount from the is not binding in the engine crankshaft.
crossmember and remove the crossmember
from the side supports. NOTE: Before installing the torque converter to
the flywheel attaching nut, a check should be
NOTE : Disconnect and remove any intefering made to ensure that the converter is properly
exhaust system hardware. seated . The converter should move freely with
respect to the flywheel. Grasp the stud. Move-
14. Lower the transmission to gain access to the ment back and forth should result in a metallic
oil cooler lines. clank noise if the converter is properly seated .
If the converter will not move, the transmission
15 . Disconnect cooler oil line from the fittings on the must be removed and the converter reposition-
transmission using Cooler Line Disconnect Tool ed so that the impeller hub is properly engaged
T82L-9500-AH or equivalent. in the pump gear.

16. Disconnect the speedometer cable from the ex- 7. Install and tighten the transmission housing-to-
tension housing . engine attaching bolts to 55-68 N·m (40-50 lb-h).

17. Remove the bolt that secures the transmission 8. Remove the safety chain from around the
fluid filler lube to the cylinder block . Lift the filler transmission .
tube and the dipstick from the transmission .
9. Install a new O-ring on the lower end of the
18. Secure the transmission to the jack with the transmission filler tube . Insert the tube in the
chain . transmission case and secure the tube to the
engine with the attaching bolt.
19. Remove the converter housing-to-cylinder block
attaching bolts. 10. Connect the speedometer cable to the exten-
sion housing .
20. Carefully move the transmission and converter
assembly away from the engine and, at the 11. Connect the oil cooler lines to the right side of
same time, lower the jack to clear the under- transmission case. Tighten lines to 24-31 N·m
side of the vehicle. (18-23 lb-h).

21. Remove the converter and mount the transmis- 12. Position the crossmember on the side supports.
sion in a holding fixture. Position the rear mount on the crossmember
and install the attaching bolt and nut .

13. Secure the engine rear support to the extension

Installation housing and tighten the bolts to specification.
Refer to Group 21 for specifications.
1. Tighten converter drain plug to 11-38 N·m (8-28
lb-ft). 14. If removed, install any exhaust system
hardware.
2. Position the converter on the transmission,
making sure the converter drive flats are fully 15. Lower the transmission and remove the jack.
engaged in the pump gear by rotating the
converter. 16. Secure the crossmember to the side supports
with the attaching bolts and tighten them to
IMPORTANT: Lubricate pilot with chassis specifications.
grease.
17. Position the bellcrank to the converter housing
3. With the converter properly installed , place the and install the two attaching bolts. Tighten to
transmission on the jack. Secure the transmis- specification .
sion to the jack with a chain.
18. Connect the TV linkage rod to the transmission
4. Rotate the converter until the studs and drain TV lever. Connect the manual linkage rod to the
plug are in alignment with the holes in the manual lever at the transmission.
flywheel.

5. Align the orange balancing marks on converter

stud and flywheel bolt hole if balancing marks
are present.

15
(~ATSG) Technical Service Information

19. Connect TV linkage rod or cable to transmis- 27. Adjust the manual shift linkage as required.
sion TV lever ball stud. On Continental and Refer to Section 17-02.
Thunderbird/Cougar vehicles, attach cable to
bell housing bracketry by installing self-tapping 28. Adjust TV linkage as outlined in this Section.
bolt. Also, connect cable to bell crank lever stud.

Main Control Valve Body

Removal

1. Raise the vehicle on a hoist so the transmission

fluid pan is accessible. Refer to Pre-Delivery
manual, Section 50-04.

NOTE: Some vehicles may require the removal

of interfering exhaust system components.

2. Starting at the rear and working toward the

front, loosen the oil pan attaching bolts and
drain the fluid from the transmission . It may be
necessary to use a 3/8-inch or 1/4-inch drive rat-
chet and a 10mm universal socket to remove
the oil pan bolts. If the same fluid is to be used
again, filter the fluid through a 100 mesh
screen. Reuse the fluid only if the fluid is in good
condition.

3. Remove the transmission oil pan attaching

bolts, pan and gasket. Discard gasket.
20. Connect manual linkage rod to manual lever at 4. Remove three filter-to-valve body attaching
transmission using the Shift Linkage Grommet bolts and remove the filter, grommet and
Installation Tool T84P-7341-8 or equivalent. For gasket. Discard gasket. If the fluid is con-
tool usage instructions, refer to Section 17-02. taminated, discard the filter (do not clean the
filter).
21 . Secure the converter-to-flywheel attaching nuts
and tighten them to 27-46 N·m (20-34 lb-ft). 5. Remove the detent spring attaching bolt and
spring.
22. Install the converter housing access cover and
secure it with the attaching bolts. Tighten to 6. Remove the 24 valve body-to-case attaching
16-22 N·m (12-16 lb-ft). bolts. Remove the valve body. Discard valve
body-to-case gasket.
23. Secure the starter motor in place with the
attaching bolts. Connect the cable to the ter-
minal on the starter. Connect the neutral start
switch harness at the transmission.

24. Connect the driveshaft to the rear axle. Install

the driveshaft so the index marks, made dur- Installation
ing removal, are correctly aligned.
1. Clean and inspect the valve body. Refer to Sec-
NOTE: Lubricate the yoke splines with Multi- tion 17-01.
Purpose Long Life Lubricant C1AZ-19590-8 or
equivalent. Refer to Sections 15-60 and 15-66. 2. Using Valve Body Guide Pins T80L-77100-A or
equivalent, position the valve body to the case,
25. Lower the vehicle . making sure that the inner manual lever and
inner TV levers are engaged.
26. Lower vehicle and fill the transmission to the
correct level with the specified fluid. Start the 3. Install and tighten the 24 valve body-to-case at-
engine and shift the transmission to all ranges, taching bolts to 9-11 N·m (80-100 lb-in).
then recheck the fluid level. Refer to Section
17-01 for Transmission Fluid Level Check 4. Install and tighten the detent spring and at-
procedure. taching bolts to 9-11 N·m (80-100 lb-in).

16
(~RTSG) Technical Service Information

5. Remove the guide pins and install and tighten 6. Remove the 24 valve body-to-case attaching
the remaining two attaching bolts. bolts. Remove the valve body. Discard valve
body-to-case gasket.
6. Load TV lever torsion spring against the
separator plate. 7. Depress overdrive servo piston cover with a
hammer handle and remove the retaining snap
7. Using three filter attaching bolts, install the filter ring.
and gasket to the valve body and tighten at-
taching bolts to 9-11 N ·m (80-100 lb-in). 8. Using Servo Piston Remover T80L-77030-B or
equivalent, apply air pressure to the servo
8. Clean the transmission oil pan and gasket sur- piston release passage in order to ren1ove the
faces thoroughly . overdrive servo piston cover and spring.
Remove the piston from the cover.
9. Using a new oil pan gasket, secure the pan to
the transmission case. It may be necessary to 9. Remove the rubber seals from the piston and
use a 3/8 inch or 1/4 inch drive ratchet with a the cover.
10mm socket to install the oil pan bolts. Tighten
the attaching bolts to 16-22 N·m (12-16 lb-ft).

10. Lower the vehicle and fill the transmission to the Installation
correct level with the specified fluid. Start the
engine and shift the transmission to all ranges, 1. Clean and inspect the servo piston and cover
then recheck the fluid level. Refer to Section for nicks and/or burrs. Clean and inspect the
17-01 for the Transmission Fluid Level Check. servo piston pocket in the case for nicks and
procedure. burrs also.
11. Adjust the linkage rod or cable system as 2. Install new servo piston and cover seals on the
outlined under the linkage adjustment. piston and cover, respectively.

3. Lubricate the piston seals with either clean

transmission fluid or a petroleu,n jelly.
Overdrive Servo Assembly
4. Install the servo piston into the cover, lubricate
Removal the cover seals and the overdrive servo pocket
in the case.
1. Raise the vehicle on a hoist so the transmission
oil pan is accessible. Refer to Pre-Delivery 5. Assemble the return spring to the servo piston.
manual, Section 50-04.
6. Install the overdrive piston cover and spring into
NOTE: Some vehicles may require the removal the overdrive servo pocket in the case. Make
of interfering exhaust system components. sure the servo rod contacts the overdrive band
apply pocket. Failure to do so will result in a no
2. Starting at the rear and working toward the 3-4 shill condition .
front, loosen the oil pan attaching bolts and
drain the fluid from the transmission. It may be 7. Using the handle of a hammer, depress the
necessary to use a 3/8 inch or 1/4 inch drive overdrive servo sufficiently to gain clear access
ratchet with a 10mm universal socket to remove to the retaining snap ring groove in the case.
oil pan bolts. If the same fluid is to be used Install the snap ring.
again, filter the fluid through a 100 mesh
screen. Reuse the fluid only if the fluid is in good 8. Inspect the outer edge of the overdrive servo
ceindition . pocket for possible nicks and burrs which might
have been raised during the removal or installa-
3. Remove the transmission fluid pan attaching tion of the retaining snap ring.
bolts, pan and gasket. Discard gasket.
9. Remove nicks and burrs with a fine honing
4. Remove three filter-to-valve body attaching stone and clean the effected areas thoroughly.
bolts and remove the filter, grommet and Failure to do so may cause improper seating
gasket. Discard gasket. If the fluid is con- of the valve body separator plate to the
taminated. discard the filter. (Do not clean the hydraulic passages in the case, and subse-
filter.) quent cross leakage.

5. Remove the detent spring and attaching bolt.

17
(~ATSCi) Technical Service Information

10. Clean and inspect the valve body. Refer to necessary to use a 3/8-inch or 1/4-inch drive rat-
Section 17-01 . chet with a 10mm universal socket to remove
the oil pan bolts. If the same fluid is to be used
11 . Position a new separator plate gasket to the again, filter the fluid through a 100 mesh
separator plate. screen . Reuse the fluid only if the fluid is in good
condition .
12. Using Valve Body Guide Pins T80L-77100-A or
equivalent. position the valve body to the case. 3. Remove the transmission oil pan attaching
making sure that the inner manual lever and bolts, pan and gasket. Discard gasket.
inner TV lever are engaged.
4. Remove three filter-to-valve body· aitaching
13. Install and tighten the 24 attaching bolts to 9-11 bolts and remove the filter. grommet and
N·m (80-100 lb-in). gasket. Discard gasket. If the fluid is con-
taminated, discard the filter (do not clean).
14. Install the detent spring and attaching bolt.
5. Remove the detent spring and attaching bolt.
15. Remove the Valve Body Guide Pins
TB0L-77100-A or equivalent and install and 6. Remove the 24 valve body-to-case attaching
tighten the remaining two valve body-to-case bolts. Remove the valve body. Discard valve
bolts. body-to-case gasket.

16. Position the TV lever torsion spring against the 7. Depress the reverse servo piston cover with a
separator plate . hammer handle as shown. Remove the retain-
ing snap ring and piston cover.
17. Using three filter attaching bolts install the filter
and gasket to the valve body and tighten at- NOTE: Care must be taken to prevent reverse
taching bolts to 9-11 N·m (80-100 lb-in). servo piston from springing free from case when
cover is removed.
18. Clean the transmission oil pan and gasket sur-
faces thoroughly. 8. To remove the reverse servo piston and spring,
apply air pressure to the servo piston release
19. Using a new 011 pan gasket, secure the pan to passage using Servo Piston Remover
the transmission case. Tighten the attaching T80L-77030-B or equivalent. Cover the servo
bolts to 16-22 N·m (12-16 lb-ft). piston pocket to prevent the piston from falling
out from the case when air is applied and
20 . Install any exhaust sy~tem hardware that might becoming damaged.
have been removed.

21 . Lower the vehicle and fill the transmission to the

correct level with the specified fluid. Start the
engine and shift the transmission to all ranges,
then recheck the fluid level. Refer to Section
17-01 for the Transmission Fluid Level Check Installation
procedure .
1. Clean and inspect the servo pocket in the case.
22 . Adjust TV linkage rod or cable system as
outlined under linkage adjustment. 2. Clean the reverse servo piston, cover and return
spring. Inspect the piston and cover sealing
edges for cuts , burrs or irregular wear pattern.
Replace if necessary.

3. Assemble the return spring to the servo piston .

.Low-Reverse Servo Assembly
4. Install the reverse servo piston and spring, and
Removal the servo cover into the case reverse servo
pocket.
1. Raise the vehicle on a hoist so the transmission
fluid pan is accessible. NOTE: Make sure that the servo piston is
reinstalled with the same rod length as the one
NOTE: Some vehicles may require removal of which was removed .
interfering exhaust system components.
5. Using the handle of a hammer, depress the
2. Starting at the rear and · working toward the reverse servo piston and cover sufficiently to
front, loosen the oil pan attaching bolts and gain clear access to the retaining snap ring
drain the fluid from the transmission . It may be groove in the case. Install the snap ring.

18
(~ATSG] Technical Service Information

6. Inspect the outer edge of reverse servo pocket 3-4 Accumulator Piston
for nicks or burrs which might have been raised
during the removal or installation of the retain- Removal
ing snap ring.
1. Raise the vehicle on a hoist so the transmission
7. Remove nicks or burrs with a "fine" honing oil pan is accessible.
stone and clean the effected surfaces
thoroughly. Failure to do so may cause im- NOTE: Some vehicles may require the removal
proper seating of the valve body separator plate of interfering exhaust system components.
to the hydraulic passages in the case and
subsequent cross leakage. 2. Starting at the rear and working toward the
front, loosen the oil pan attaching bolts and
8. Clean and inspect the valve body. Refer to drain the fluid from the transmission . It may be
Section 17-01. necessary to use a 3/8-inch or 1/4-inch drive rat-
chet and a 10mm universal socket to remove
9. Position a new valve body gasket to the the oil pan bolts . If the same fluid is to be used
separator plate . again, filter the fluid through a 100 mesh
screen . Reuse the fluid only if the fluid is in good
10. Install Valve Body Guide Pins T80L-77100-A or condition.
equivalent to the case. Position a new separator
plate gasket to the valve body and case, mak- 3. Remove the transmission oil pan attaching
ing sure that the inner manual lever and inner bolts, pan and gasket. Discard gasket.
TV lever are engaged .
4. Remove the filter-to-valve body attaching bolts
11 . Install and tighten 24 attaching bolts to 9-11 N·m and remove the filter, grommet and gasket.
(80-100 lb-in) . Discard gasket. If the fluid was contaminated ,
discard the filter.
12. Install and tighten the detent spring and at-
taching bolt to 9-11 N·m (80-100 lb-in). 5. Remove the detent spring and attaching bolts.

13. Position the TV lever torsion spring against the 6. Remove the 24 valve body-to-case attaching
separator plate. bolts. Remove the valve body. Discard valve
body-to-case gasket.
14 . Remove the Valve Body Guide Pins
T80L-77100-A or equivalent and install and 7. To remove the 3-4 accumulator piston, depress
tighten the remaining two valve body attaching the cover and remove the retaining snap ring.
bolts.
8. Slowly release the tension on the 3-4
15. Using three filter attaching bolts install the filter accumulator cover, allowing the removal of the
and gasket to the valve body and tighten the piston cover, return spring and piston. (Some
attaching bolts to 9-11 N·m (80-100 lb-in). models may not use a spring).

16. Clean the transmission oil pan and gasket sur- 9. If necessary, apply air pressure to the hydraulic
faces thoroughly. apply passage using Servo Piston Remover
T80L-77030-B or equivalent.
17. Using a new oil pan gasket, secure the pan to
the transmission case. Tighten the attaching 1O. Remo·,e the seals from the 3-4 accumulator
bolts to 16-22 N·m (12-16 lb-ft) . It may be cover and piston . Inspect seals tor possible
necessary to use a 3/8-inch or 1/4-inch drive rat- nicks, cuts or irregular wear patterns. If damag-
chet with a 10mm universal socket to install the ed, discard the seals .
oil pan bolts.

18. Install any exhaust system components that

might have been removed.
Installation
19. Lower the vehicle and fill the transmission to the
correct level with the specified fluid. Start the 1. Thoroughly clean and inspect the 3-4
engine and shift the transmission to all ranges. accumulator piston and cover.
Refer to Section 17-01 for the Transmission
Fluid Level Check procedure. 2. Install new seals on the 3-4 accumulator piston
and cover.
20. Adjust the TV linkage rod or cable system as
outlined under cable adjustment. 3. Thoroughly clean and inspect the accumulator
pocket in the case.

19
(~ATSG] Technical Service Information

4. Lubricate the rubber cover seal and the cover 19. Lower the vehicle and fill the transmission to the
pocket of case with either clean transmission proper level with the specified fluid . Start the
fluid or a petroleum jelly. engine and shift the transmission to all ranges,
then recheck the fluid level. Refer to Section
5. Reinstall the 3-4 accumulator piston (and return 17-01 for the Transmission Fluid Level Check
spring) into the case . Install the cover. procedure.

6. Depress the cover into piston pocket sufficiently 20. Adjust TV linkage rod or cable system as
to allow clear access to the snap ring groove outlined under linkage adjustment.
in the ID of the pocket.

7. Install the retaining snap ring. IMPORTANT:

Cover must then be reseated snug against
retaining ring. Inspect the outer edge of the 3-4
accumulator piston pocket for nicks or burrs
which might have been raised during the
removal or installation of the retaining snap ring.
Remove nicks or burrs with a fine honing stone
and clean the effected surfaces thoroughly .
Failure to do so may cause improper seating 2-3 Accumulator Piston
of the valve body separator plate to the
hydraulic passages in the case and subsequent Removal
cross leakage.
1. Raise the vehicle on a hoist so the transmission
8. Clean and inspect the valve body if necessary. oil pan is accessible. Refer to Pre-Delivery
Refer to Section 17-01 . manual, Section 50-04.

9. Position a new valve body gasket to the NOTE: Some vehicles may require the removal
separator plate. of interfering hardware.

10. Using Valve Body Guide Pins T80L-77100-A or 2. Starting at the rear and working toward the
equivalent, position the valve body to the case, front, loosen the oil pan attaching bolts and
. making sure that the inner manual lever and in- drain the fluid from the transmission . It may be
ner TV lever are engaged. necessary to use a 3/8-inch or 1/4-inch drive rat-
chet with a 10mm universal socket to remove
11. Install and tighten 24 valve body-to-case the oil pan bolts. If the same fluid is to be used
attaching bolts to 9-11 N·m (80-100 lb-in). again, filter the fluid through a 100 mesh
screen. Reuse the fluid only if the fluid is in good
12. Install and tighten the detent spring and at- condition.
taching bolt to 9-11 N·m (80-100 lb-in).
3. Remove the transmission oil pan attaching
13. Remove the Valve Body Guide Pins bolts, pan and gasket. Discard gasket.
T80L-77100-A or equivalent and install the two
remaining valve body attaching bolts. 4. Remove the three filter-to-valve body atttaching
bolts and remove the filter, grommet and
14. Position the TV lever torsion spring against the gasket. Discard gasket. If the fluid is con-
separator plate. taminated, discard the filter (do not clean the
filter).
15. Using three filter attaching bolts install the filter
and gasket to the valve body and tighten the 5. Remove the detent spring and attaching bolt.
attaching bolts to 9-11 N·m (80-100 lb-in).
6. Remove the 24 valve body-to-case attaching
16. Clean the transmission oil pan and gasket sur- bolts. Remove the valve body. Discard the valve
. faces thoroughly. body-to-case gasket.
17. Using a new oil pan gasket, secure the pan to 7. Depress the 2-3 accumulator piston cover.
the transmission case . It may be necessary to Remove the retaining snap ring, cover the
use a 3/8-inch drive ratchet with a 10mm univer- spring.
sal socket to install the oil pan bolts. Tighten
the attaching bolts to 16-22 N·m (12-16 lb-ft). 8. Remove the 2-3 accumulator piston .
18. Install any exhaust system components that 9. Remove the seals from the 2-3 accumulator
might have been removed. piston and 'discard.

20
(~RTSG) Technical Service Information

Installation 18. Install any exhaust system components that

might have been removed.
1. Clean and inspect the 2-3 accumulator piston.
Replace piston if damaged. 19. Lower the vehicle and fill the transmission to the
proper level with the specified fluid . Start the
2. Clean and inspect the 2-3 accumulator pocket engine and shift the transmission to all ranges,
in the case for nicks, burrs or porosity. then recheck the fluid level. Refer to Section
17-01 for the Transmission Fluid Level Check
3. Install new seals on the 2-3 accumulator 1-1iston. procedure.
4. Install the 2-3 accumulator piston into the case. 20. Adjust TV linkage rod or cable system as outlin-
ed under linkage adjustment.
5. Install the return spring and cover.

6. Install the retaining snap ring.

Extension Housing Bushing and Rear Seal
7. Inspect the outer edge of 2-3 accumulator
piston pocket for nicks or burrs which might
have been raised during the removal or installa- Removal
tion of the retaining snap ring.
1. Raise the vehicle and disconnect the driveshah
8. Remove nicks or burrs with a fine honing stone at the transmission . To maintain driveline
and clean the effected surfaces thoroughly. balance, mark the rear driveshaft yoke and axle
Failure to do so may cause improper seating companion flange su the driveshaft can be in-
of the valve body separator plate to the stalled in its original position . Refer to Section
hydraulic passages in the case and subsequent 15-60 or 15-66.
cross leakage.
2. When only the rear seal needs replacing,
9. Clean and inspect the valve body. Refer to Sec- carefully remove it with Extension Housing Seal
tion 17-01. Remover T74P-77248-A or equivalent.

10. Position a new valve body-to-case gasket to the 3. Remove the bushing. Use the Extension
separator plate. Housing Bushing Remover T??L-7697-A or
equivalent carefully so that the output shah
11. Using Valve Body Guide Pins T80L-77100-A or spline is not damaged.
equivalent, position the valve body to the case,
making sure that the inner manual lever and in-
ner TV lever are engaged. Install and tighten
24 valve body-to-case attaching bolts to 9-11 Installation
N·m (80-100 lb-in).
1. When installing a new bushing use Extension
12. Install and tighten the detent spring and at- Housing Bushing Replacer T80L-77034-A or
taching bolt to 9-11 N·m (80-100 lb-in). equivalent.

13; Remove the Valve Body Guide Pins 2. Before installing a new seal. inspect the seal-
T80L-77100-A or equivalent and install and ing surface of the universal joint yoke for scores.
tighten the two remaining valve body attaching If scores are found, replace the yoke .
bolts.
3. Inspect the counterbore of the housing for
14. Position the TV lever torsion spring against the burrs. Remove burrs with crocus cloth .
separator plate .
4. Install the seal into the housing with Extension
tS. Using three filter attaching bolts, install the filter Housing Seal Replacer T61 L-7657-A or
and gasket to the valve body and tighten the equivalent. The seal should be firmly seated in
attaching bolts to 9-11 N·m (80-100 lb-in). the bore. Coat the inside diameter of the rub-
ber portion of the seal with Multi Purpose Long-
16. Clean the transmission oil pan and gasket sur- Life Lubricant C1AZ-19590-B or equivalent.
faces thoroughly .
5. Install the driveshaft so that the index marks,
17. Using a new oil pan gasket, secure the pan to made during removal, are correctly aligned .
the transmission case. It may bP. necessary to Refer to Section 15-60 or 15-66.
use a 3/8-inch or 1/4-inch drive ratchet with a
10mm universal socket to install the oil pan NOTE: Lubricant yoke splines with Multi-
bolts. Tighten the attaching bolts to 16-22 N·m Purpose Long Life Lubricant C 1AZ-19590-B or
(12-16 lb-ft). equivalent.

21
(~ATSG) Technical Service Information

Extension Housing 3. Raise the transmission high enough to position

the engine rear support on the crossmember.
Removal
4. Secure the support to the crossmember with the
1. Raise the vehicle on a hoist or stands. Refer to attaching bolt and nut. Tighten the bolt to
Pre-Delivery manual, Section 50-04. specification . Reier to Group 21 for
specifications.
NOTE: Remove any interfering exhaust system
components . 5. Lower the transmission and remove the jack.
Install engine rear support-to-extensililn hous-
2. Disconnect the parking brake cable from the ing attaching bolts. Tighten the bolts to
equalizer, if so equippep. specification. Reier to Group 21 for
specifications.
3. Disconnect the driveshaft from the rear axle
flange and remove it from the transmission. To 6. Secure the speedometer cable to the extension
maintain driveline balance, mark the rear housing with the attaching bolt.
driveshaft yoke and axle companion flange so
the driveshaft can be installed in its original 7. If so equipped, connect the parking brake cable
position . to the equalizer.

4. Disconnect the speedometer cable from the 8. Install the driveshaft in the transmission and
extension housing. connect shaft to rear axle flange. Install
driveshaft so that index marks, made during
5. Remove the engine rear support-to-extension removal, are correctly aligned . Refer to Section
housing attaching bolts. 15-60 or 15-66.

6. Place a jack under the transmission and raise NOTE : Lubricate yoke splines with Multi-
it just enough to remove the weight from the Purpose Long Life Lubricant C1AZ-19590-B or
engine rear support. equivalent.

7. Remove the bolt that secures the engine rear 9. Install any exhaust system components that
support to the crossmember and remove the might have been removed .
support.
10. Lower the vehicle. Fill the transmission to the
8. Place a drain pan under the rear of the proper level with the specified fluid. Start the
transmission case. engine and shift the transmission through all
ranges, then recheck the fluid level. Refer to
9. Lower the transmission and remove the exten- Section 17-01 for the Transmission Fluid Level
sion housing attaching bolts. Slide the exten- Check procedure.
sion housing off the output shaft and allow the
fluid to drain.

NOTE: The lower three extension housing bolts

have been coated with a sealant. More break Governor
torque may be required to remove these bolts.

10. Remove and discard extension housing gasket. Removal

1. Remove the extension housing as outlined.

NOTE: If the governor body only is to be

removed, skip Steps 2 and 3.
lnstalltition 2. Remove the governor-to-output shaft retaining
snap ring.
1. Clean the mounting surface on the transmission
and on the extension housing. Remove any 3. Using a soft-faced hammer, tap the governor
sealant from the bolts and the case bolt holes. assembly off the output shaft. Remove the
Position a new gasket on the transmission. Coat governor driveball.
the lower three bolts with Ford Threadlock and
Sealant EOAZ-19544-A or Ford Pipe Sealant 4. Remove the governor-to-counterweight at-
DBAZ-19554-A Teflon® Tape or equivalent. taching screws. Lift the governor from the
counterweight.
2. Hold the extension housing in place and secure
it with the attaching bolts. Tighten to 22-27 N·m
(16-20 lb-ft).

22
l~RTS6) Technical Service Information

8. Place a drain pan under the transmission oil

Installation
pan. Starting at the rear of the pan and work-
ing toward the front, loosen the attaching bolts
1. Lubricate the governor valve parts with clean
transmission fluid . Make certain that the valve and allow the fluid to drain. Remove all of the
moves freely in the valve body bore. attaching bolts except two at the front to allow
the fluid to further drain. It may be necessary
to use a 3/8-inch or 1/4-inch drive ratchet with
2. Position the governor valve body on the
a 10mm universal socket to remove the oil pan
counterweight with the cover facing toward the
bolts. After all fluid has drained, remove the two
front of the vehicle. Install the two attaching
remaining bolts and the oil pan and gasket.
screws. and tighten to 6-7 N·m (50-60 lb-in).
Discard the gasket. If the same fluid is to be
3. Position the governor drive ball into the pocket used again , filter the fluid through a 100 mesh
screen. Reuse the fluid only if it is in good
of the output shaft.
condition.
4. Align the keyway in the counterweight to the
governor drive ball. Slide governor assembly 9. Remove the transmission oil filter grommet and
onto the output shaft. If necessary, gently tap gasket. Discard the gasket. If the fluid is con-
governor into position with a soft-faced hammer. taminated, discard the filter. (Do not clean the
filter).
5. Reinstall the governor to output shaft retaining
snap ring. Clean the mounting surface on the 10. Remove the manual lever detent spring and
transmission and on the extension housing. roller assembly.
Position a new gasket on the transmission.
11. Remove the manual lever retaining pin by pry-
6. Install the extension housing as outlined. ing with a narrow sharp screwdriver. Use care
when removing the pin.

12. Note assembled position of the TV lever torsion

spring, then remove spring.

13. Slide a 5/8-inch box end wrench over the inner

Internal and External Shift Linkage manual lever close to the bottom of the lever.
Do not allow the wrench to contact the "rooster
Removal comb" area. Using a 21 mm wrench, remove the
manual lever attaching nut. Securely hold the
1. It may be necessary to remove the fan shroud inner manual lever with the box end wrench
bolts and move the shroud away from the fan while applying break torque to the manual lever
on models that require lowering the transmis- attaching nut.
sion for access to the manual lever.
14. Remove the outer manual lever from the case.
2. Raise vehicle on a hoist so that transmission
oil r,an is accessible. Refer to Pre-Delivery 15. Remove inner throttle lever and shaft assembly.
111ur11u1I, Sf1clio11 ~0-04 .
16. Rornovo tho lnnor munuul luvur und purk puwl
:J . Rumuvu uny l11IorlurI11u uxlluu:il ::iy::1l11111 11cluuling rod ossombly.
components.
17. Disconnect the park pawl actuating rod from the
4. On vehicles that require additional clearance to inner manual lever.
remove the manual lever, lower the
transmission. 18. Remove the manual lever oil seal with a
screwdriver or Shift Shaft Seal Remover
5. Apply penetrating oil to the outer throttle lever T58L-101-A and Slide Hammer TS0T-100-A or
attaching nut to prevent breaking the inner equivalent. Discard the seal.
throttle lever.

6. Grasp the outer throttle lever and hold firmly.

Then, remove the outer throttle lever attaching
nut and lockwasher. Swing lever and TV rod or Installation
cable assembly out of the way for clearance.
1. Install a new manual lever seal into the case
7. Carefully disconnect the manual rod from the using Shift Shaft Seal Replacer T74P-77498-.A
transmission manual lever at the transmission or equivalent.
using the Shift Linkage Grommet Removal Tool
T84P-7341-A or equivalent. For tool usage in- 2. Check the manual lever, shaft and threads for
structions, refer to Section 17-02. damage.

23
(~ATSG) Technical Service Information

3. With the manual lever attaching nut on the in- oil pan bolts. On some vehicles it is easier ~o
ner throttle lever and shaft assembly, slide the install the oil pan after the crossmember Is
inner throttle lever through the inner manual installed.
lever.
18. Install exhaust system components and
4. Slide the outer manual lever in the case. Make crossmember as appropriate. Install the fan
sure the lever is properly positioned either up · shroud bolts (if removed) .
or down depending on application.
19. Lower vehicle and add three quarts of specified
5. Allow the inner throttle lever and shaft assembly tra:ismission fluid .
to slide through the ID bore of the outer manual
lever.
20. Start vehicle in PARK and with brake pedal
6. Snug up the manual lever attaching nut against depressed, cycle gear selector several times.
the inner manual lever making sure the flats are Recheck oil level. Refer to Section 17-01 . Check
properly aligned . First tighten the nut to remove for leaks.
free play, then tighten the nut to specification. 21 . Check and adjust manual linkage. Refer to Sec-
The torque can be approximated by tightening tion 17-02.
the nut to remove free play, then turning the nut
an additional 30 degrees. This is equivalent to 22. Check/adjust the TV linkage at the carburetor.
rotating one point of the nut 1/4 turn.

7. Position TV lever torsion spring on the inner

throttle valve shaft and align into notch.

8. Push manual lever all the way into the case.

Make sure inner manual lever pin is engaged
in manual valve detent slot and inner throttle
lever is acting on the TV valve. Neutral start
switch plunger must also be riding on cam sur-
face of inner manual lever.
Neutral Start Switch
9. Install new manual lever retaining pin in case.
Pin must be flush or slightly below pan surface. Lincoln Town Car, Ford Crown Victoria/Mercury
Grand Marquis
10. Install a new throttle lever seal.
Removal
11 . Install detent spring. Make sure detent spring
roller is centered on "rooster comb" area.
Tighten to 9-11 N·m (80-100 lb-in). 1. Set parking brake.

12. Install the throttle valve outer lever. Do not push 2. Place the selector lever in the manual low
inner throttle valve lever past throttle valve. position.

13. Install throttle lever lockwasher and attaching 3. Open hood and remove the air cleaner
nut. Tighten nut to 16.5-21 .5 N·m (12-16 lb-ft). assembly.

14. Check PARK function and operation of TV lever 4. Disconnect the negative battery ground cable.
and manual lever before further assembly.
5. Disconnect the neutral start switch electrical
15. Connect the manual linkage rod to the manual harness from the neutral switch by lifting the
lever at the transmission using the Shift Linkage harness straight up off the switch without side-
Grommet Installation Tool T84P-7341-B or to-side motion.
equivalent. For tool usage instructions, refer to
Section 17-02. 6. Remove the neutral switch and O-ring seal us-
ing a 24-inch extension, universal adapter and
16. Install the oil filter gasket and oil filter. Tighten the Neutral Start Switch Socket T74P-77247-A
to 9-11 N·m (80-100 lb-in). or equivalent (access path is the area by the left
side dash panel.
17. Install oil pan with a new gasket and tighten
bolts to 16.5-21 .5 N·m (12-16 lb-ft). It might be NOTE: Use the Neutral Start Switch Socket
necessary to use a 3/8-inch or 1/4-inch drive rat- T74P-77247-A or equivalent for both removing
chet with a 10mm universal socket to install the and installing the switch. Other tools could
crush or puncture the walls of the switch.

24
f~RTSCi) Techni cal Service Inform ation

Installation 5. Remove the neutral start switch and O-ring us-

ing Neutral Start Switch Socket T74P-77247-A
1. Install the neutral start switch and O-ring. or equivalent, assembled to a ratchet 24cm
{9½-inch) in length. Once the socket and rat-
CAUTION: Exercise care not to damage the chet are on the switch, sufficient clearance for
switch terminals. Tighten to 11-15 N·m (8-11 tool movement can be gained by reaching from
lb-ft) using a clicker type torque wrench, a the rear of the transmissio n over the extension
24-inch extension, a universal adapter, and housing area while standing on a stool.
the neutral start switch socket tool.
NOTE: Use the Neutral Start Switch Socket
2. Connect the neutral start switch electrical T74P-77247-A or equivalent for both removing
harness to the neutral start switch . and installing the switch . Other tools '-Ould
crush or puncture the walls of the switch .
3. Connect the negative batt~ry ground cable.

4. Check the operation of the neutral start switch

in each position with the parking brake
engaged .

5. Install the air cleaner and close the hood.

Installation

1. Install the neutral start switch and O-ring.

Mark VII/Continental, Thunderbir d/Cougar, LTD/
Marquis, Mustang/Ca pri CAUTION: Exercise care not to damage the
switch terminals. Tighten to 11-15 N·m (8-11
Removal lb-ft) using a clicker type torque wrench, the
neutral start switch socket tool and by
1. Place the selector lever in the manual LOW following the method in Step 4 of the
position. removal procedure for tool clearance.

2. Disconnect the negative battery ground cable. 2. Connect the neutral start switch electrical
harness to the neutral start switch .
~- Raise the vehicle on a hoist. Refer to Pre-
Delivery manual, Section 50-04. 3. Lower the vehicle from the hoist.

4. Disconnect the neutral start switch electrical 4. Connect the negative battery ground cable.
harness from the neutral start switch by pushing
the harness straight up off the switch using a 5. Check the operation of the neutral start switch
long blade screwdriver underneath the rubber in each position with the parking brake
plug section of the harness. engaged.

CLUTCH ANO BAND APPLICATION

lnterm. Planetary Low-
lnterm.
One-Way Overdrive Reverse Forward One-Way Reverse
Friction
Clutch Band Clutch Clutch Clutch Band Direct Clutch
Clutch
Applied Holding Applied
Isl Gear
Mar,ual 1-ow
·2nd Gear Apphed Holding Applied Applied
Manual Low
Applied Holding
1sI Gear -
(O)(OVEROAIVE) or
0(3)
2nd Gear- Applied Holding Applied
{O)(OVERDAIVE) or
0(3)
Applied Apphed
Jrd Gear- Applied
{O)(OVERDAIVE) or
0(3)
Applied Applied
4th Gear - Applied
{O)(OVEROAIVE)
Applied Applred
Reverse {R)

25
( ~ RTS6) Technical Service Information

NOTE: Before beginning the transmission overhaul, • Whenever a seal is removed from a piston, shaft
review the following guidelines. These general rules or servo, note the type of seal and when
are provided to emphasize the need for attention to applicable, the direction of the sealing lip.
detail and care when servicing an automatic
transmission. • Always use the specified transmission fluid
when lubricating seals or other components
• If the transmission is being removed for major prior to assembly (refer to Specifications for the
overhaul. it is important to completely clean all proper oil).
transmission components, including converter,
cooler, cooler lines. main control valve body,
governor, all clutches and all check balls after
any transmission servicing that generates con-
tamination. These contaminants are a major Transmission
cause for recuring transmission troubles and
must be removed from ·the system before the
transmission is put back into service. Disassembly

The cleaning of debris from the direct clutch 1. Mount the transmission in Bench Holding Fix-
check ball is often omitted. This omission can ture T57L-500-B or equivalent.
lead to a repeat servicing of the transmission.

Cleaning and flushing procedures for transmis-

FROM COOLER
sion components, including the direct clutch
check ball, can be found under Cleaning and
Inspection, Section 17-01.

• Refer to Section 17-01 for procedures detailing

the cleaning and inspection of individual
components.

• Thorough cleaning of the transmission exterior

will reduce the possibility that damaging con-
taminants might enter the subassemblies dur-
ing disassembly and assembly.

• All fasteners must be tightened to the torque in- ,___ _ _ _ HOLDING FIXTURE
dicated in the text. In addition to appearing in T57L•SOO•B
the text, the necessary torques can be found
in Specifications.

• When building-up subassemblies, each compo-

nent part should be lubricated with clean
transmission fluid. It is also good practice to 2. Grasp the torque converter firmly and pull
lubricate the subassemblies as they are install- straight out of the transmission .
ed in the case.
NOTE: The torque converter is relatively heavy.
• Needle bearings. thrust washers and seals Be prepared to handle the weight.
should be lightly coated with petroleum jelly dur-
ing subassembly buildup or transmission
assembly.

• Many components and surfaces in the transmis-

sion are precision machined. Careful handling
during disassembly, cleaning inspection and
assembly can prevent unnecessary damage to
machined surfaces.

• When building-up subassemblies or assembl-

ing the transmission, always use new gaskets
and seals.

• The transmission service area should be kept

clean, well organized and supplied with clean
lint-free shop cloths.

26
(~RTSG) Technical Service Information

3. Remove the 14 oil pan attaching bolts, the oil Remove the filter, grommet and gasket and
pan and the pan gasket. discard .

Discard the gasket. NOTE: If fluid was contaminated be sure to use

a new filter. Never attempt to clean or reuse a
dirty filter.

4. Remove the three oil filter attaching bolts. 5. Remove the manual lever detent spring and
roller assembly.

FIL TEA A TT ACHING BOLTS

DETENT SPRING AND
ROLLER ASSY

27
(~ATSG) Tech nica l Serv ice Infor mati on

6. Remove the remaining 24 valve body-to-case 3-4 Accum ulator

attaching bolts, the valve body assemb ly and
the valve body gasket. Removal
NOTE: The four front, one center and three rear 8. Push down on the accumu lator cover and
attachin g bolts are shorter than the others. remove the retaining ring using a thin-bladed
screwdr iver.

0 INDICATES A LONGER BOLT

□ INDICATES A SHORT BOLT

7. This illustration shows the position of the 3-4

accumu lator, the overdrive servo, the low
reverse servo, and the 2-3 accumu lator.

Remove these compon ents from the transmis - 9. Remove the accumulator cover and, if so equip-
sion using the following procedures. ped, the piston return spring.

LOW-REVERSE SERVO OVERDRIVE SERVO

~ ACCUMULATOR

28
(~RTSG) Technical Service Information

Some AOD applicatio11s will have an inverted 10. Remove the accumulator piston .
3-4 accumulator piston design. The inverted
piston has a pocket in the piston . The piston uses a scarf-cut Teflon'•· seal and
comes out with very little resistance .

3-4 ACCUMULATOR
PISTON WITH POCKET

NOTE: Depending on model application, one of

three accumulator designs will be present: there
will be a spring between the cover and piston
as shown, there will be a spring beneath the
piston, or there will be no spring. The ap-
pearance of the piston and spring will also vary
from model to model.
If the cover sticks in the bore use Servo Piston
Remover TS0L-77030-8 or equivalent and air
pressure to aid removal. 2-3 Accumulator
CAUTION: Make certain a QOrtion of the Ser-
vo Piston Remover TBOL-77O3O-B or Removal
equivalent extends over the bore to prevent
the cover from flying out of the bore. 11. Using a wide-bladed screwdriver or wooden
dowel, push down on the accumulator cover
and remove the retaining ring.

29
(~ATSG) Technical Service Information

NOTE : If necessary, a magnet can be used to 17. Remove the cover and piston as a unit.
lift the piston from the bore.

NOTE : USE A MAGNET TO

AID REMOVAL OF THE
SERVO PISTON

\
NOTE : The length of the rod attached to the
piston may vary in length from transmission to
transmission . Three possible lengths may be If the cover sticks in the bore, use Servo Piston
encountered. A single groove cut into the piston Remover TS0L-77030-8 or equivalent and air
rod indicates the shortest possible length while pressure to aid removal.
two and three groove piston rods indicate suc-
cessively longer rods . For assembly purposes,
111s important to determine which length piston CAUTION: Make certain a portion of the
rod was used in the manufacture of the Servo Piston Remover TB0L-77030-B or
transmission . equivalent extends over the bore to prevent
the cover from flying out of the bore.

Remove spring.
Overdrive Servo

Removal

16. Using a hammer handle or wooden dowel, push

down on the servo cover and remove the retain-
ing ring.

I ' )

30
(~RTSG) Technical Service Information

18. Remove the direct driveshaft. 20. Remove the pump assembly using Impact Slide
Hammer T59L-100-B and Front Pump Remover
Adapters TB0L-77103-A, or equivalent.

SLID E HAMMER
T59L· I00·B

19. Remove the seven 10mm pump body attaching

bolts. All bolts have been coated with a sealant.
More break torque might be required to remove
the bolts. Before installation, clean bolts and
bolt holes in case and pump. Coat bolts with
Threadlock and Sealer EOAZ-19554-A or Pipe
Sealant with Teflon® DBAZ-19554-A or 21. Remove the pump-to-case gasket.
equivalent.

P UMP -TO-CASE GASKET

31
(~ATSG) Technical Service Information

22. Grasp the turbine shaft firmly and pull these 24. Remove the forward clutch hub and the No. 3
components out of the case as an assembly: needle bearing as an assembly.

a. Intermediate clutch pack

b. Intermediate one-way clutch
c. Reverse clutch
d. Forward clutch

NOTE: Remove the assembly carefully to pre-

vent damage to the overdrive band friction
material by the reverse clutch drive lugs.

/ /

·23_ Disengage the overdrive band from the anchor 25. Remove the toward sun gear, the No. 5 needle
pins and remove from the case. bearing, the reverse sun gear and drive shell
and the No. 4 needle bearing as an assembly.

32
(~RTSG) Technical Service Information

26. Remove the center support retaining ring. 28. Remove the center support and planetary
carrier as an assembly.
Note position of tabs for assembly.

PLANETARY
CARRIER
,-- --- ··-- - - AND
ClNIEA
SUPPORT
ASSY

\ I

27. Using a screwdriver, pry the anti-clunk spring 29. Remove the reverse band.
out from between the center support and the
case.
Note the location for assembly.

REVERSE
BAND

33
(~ATSCi) Technica l Service Informat ion

30. If the direct clutch hub did not come out with 32. Remove the retaining ring and governor
the planetary carrier, reach in and lift it out of assembly.
the direct clutch.
NOTE: If the transmission is positioned with the
output shaft pointing up, do not allow the shaft
assembly to fall through the case when the
governor is removed .
DIRECT
CLUTCH
HUB NOTE: TO LOOSEN EXPANDING
GOVERNOR FROM TYPE SNAP
SHAFT, IT MAY BE RING PLIERS
NECESSARY TO TAP
GOVERNOR ASSEMBl Y WITH
A PLASTIC TIP HAMMER.

31. Remove the six extension housing attaching 33. Remove the governor drive ball from the out-
bolts and the extension housing. put shaft. A magnet may be used to aid
removal.
Remove and discard the extension housing
gasket.

EXTENSION
HOUSING

EXTENSION
HOUSING
GASKET
(DISCARD
AFTER
REMOVAL!

34
(~ATSG) Technical Service Information

34. Remove the output shaft, the ring gear and the 36. Remove the intermediate clutch pack from the
direct clutch as an assembly, through the front intermediate one-way clutch.
of the case.

INTERMEDIATE
CLUTCH PACK

FORWARD - - - I
CLUTCH

35. Remove the output shaft No. 9 needle bearing 37. Remove the reverse clutch assembly from the
from the rear of the case. forward clutch assembly.

REVERSE
CLUTCH

FO R W ARD
CLUTCH ---1,

35
(~ATSG) Technical Service Information

Transmission 3. Install the output shaft, the ring gear and the
direct clutch as an assembly.
Assembly

1. Install the output shaft needle bearing No. 9 in

the transmission case .

'

2. Install the bearing support, No. 7 needle bear- 4. Install the governor drive ball and the governor
ing and direct clutch hub in the direct clutch . assembly.

__-:;;:::::--
NO . 7
NEEDLE
BEARING~ ~- -·

BEARING
SUPPORT---,.,.,_,.,..::...;~'-l.a""'-",..__.,

DIRECT
CLUTCH

36
(~ATSG) Technical Service Information

Install the governor retaining ring. Make sure the band is seated on the anchor
pins.
Make sure that the face of the governor body
is about flush with the counterweight. The cover
and attaching screws must face toward the case
(forward) .

RETAINING
EXPANDING RING
TYPE SNAP
RING PLIERS

NOTE: When properly installed, the center of

the band actuating rod seat can be seen
5. Install the low-reverse band. through the servo piston bore.

/I

~
REVERSE\,
BAND \
\

37
(~ATS6) Techni cal Service Inform ation

6. Install the center support and planetary 7. Install the center support anti-clunk spring using
assembly. Rotate the output shaft, if necessary, a hammer handle or wooden dowel.
to align the planet carrier splines with the direct
clutch hub splines. NOTE: Spring tabs must face outward.

\
PLANETARY
CARRIER
AND
CENTER
SUPPORT
ASSY

/
I
I
_)
')

NOTE: The planet carrier and center support

assembly cannot be installed unless the notch 8. Install the center support retaining ring.
cut in the center support is aligned with the
overdrive band anchor pin.

~. .
I

CENTER
SUPPORT
NOTCH
I
l
C!)
I

38
(~ATSG) Tech nical Servi ce Infor matio n

9. To determin e the correct length of the low- e. Thread the bolt out of the selector tool until
reverse servo piston, proceed as follows: the piston stops against the bottom of the
tool.
a. Lubricate the low-reverse piston seal to
facilitate assembly and to prevent damage f. Read the amount of piston travel on the dial
to the seal. indicator.

b. Install the low-reverse servo piston and • If the travel is 2.845-6.020mm (0.112-
return spring. Do not install the piston cover 0.237 inch), the piston length is within
or retaining ring. specifica tion .

c. Install Servo Piston Selectio n Tool • If the travel is not within specification,
TB0L-77030-A or equivalent, and tighten the selective pistons are available in the
band apply bolt on Servo Piston Selection following lengths:
Tool TB0L-77030-A or equivalent to 5.6 N·rn
(50 lb-in). ID
2.936 1 groove
2.989 2 grooves
SERVO
3.043 3 grooves
,· PISTON SELECTION
TOOL Length of rod measured from piston surface
TBOL -77030-A
to end of rod .
Select the proper rod to bring the servo
piston travel within specification.

g. Lubricate the cover seal to facilitate

assembly and to prevent damage to the seal.

h. Remove the servo selection tool and dial

indicator.
i. Install the servo cover and retaining ring.

10. Install the reverse clutch on the forward clutch.

d. Attach Dial Indicator TOOL-42 01-C or

equivalent and position the indicator stern on
the flat portion of the piston. Zero the dial
indicator.

REVERSE
CLUTCH

FORWARD
CLUTCH ------"

39
f~ATSG) Technical Service Information

NOTE: Make sure the No. 2 thrust washer is in 12. Position the No. 4 needle bearing on the for-
position. ward clutch hub and install the drive shell.

DRIVE
NO . 2 THRUST WASHER NO . 4 NEEDLE SHELL
BEARING

• 11 . Install the No. 3 needle bearing and forward 13. Install the No. 5 needle bearing and forward sun
clutch hub in the forward clutch. gear on the drive shell.

FORWARD
CLUTCH

DRIVE
SHELL

40
(~ATSG) Technical Service Information

14. Install the drive shell, forward clutch and 16. Lubricate the overdrive servo cover seals to
reverse clutch as an assembly. Rotate the out- facilitate assembly and to prevent damage to
put shaft, as necessary, to aid the engagement the seal.
of the sun gear with the planetary gears.
Install the overdrive servo.

DRIVE
• SHELL

c. NOTE USE A SCREW

DRIVER TO HOLD
BAND IN POSITION
WHILE INSTALLING
SERVO

15. Install the overdrive band. Make sure the band 17. With the overdrive servo installed, inspect the
anchor is properly positioned on the anchor pin. apply pin and band for proper position and
engagement. If the band anchor and apply pin
are not properly engaged, remove the servo and
reposition the band as necessary.

41
,~ATSGI Techn ical Servic e Inform ation

18. Install the intermediate clutch pact< components 19. Measure the intermedia te clutch clearance us-
in the following order: ing a Depth Micromete r DB0P-4201-A and End
Play Gauge Bar TB0L-77003-A or equivalent.
a. Pressure plate Set the end play tool across the pump case
mounting. Locate the micromete r end play
gauge bar and read the depth. The depth at the
intermedia te clutch separator plate is:

5.8l (351 CID), 5.0L (302 CID

41 .5-41 .Bmm (1 .634-1.636 inch)

3.8L (232 CID)

41.4-41. 7mm (1.629-1 .640 inch)

Check the clearance again 180 degrees op-

posite to assure the average depth is within
tolerance.

NOTE: Maintain a downward pressure on the

PRESSURE clutch pack while measuring depth .
PLATE
/
If the depth is not within tolerance , the follow-
b. Clutch pack ing size selective steel separator plates are

•
. /

- -:::_,---.::n -----,... ~
available:

•
•
0.071-0.06 7
0.081-0.07 7
inch
inch
I • 0.091-0.087 inch
• 0.101-0.097 inch
Install the correct plate and recheck the
clearance .

Q
\

SELECTIVE PLATE

42
(~AT56) Technical Service Information

20. Position the Depth Micrometer DS0P-4201-A on 21. Install the selective washer determined in Step
End Play Bar TS0L-77003-A or equivalent so 20 on the pump. Use petroleum jelly to hold it
that the depth is measured at the reverse clutch in place.
drum thrust face . Check the end play 180
degrees opposite to determine the average
depth._ The following chart shows the proper
selective thrust washer for various depth
measurements.

Washer Washer
Depth Washer Size
No. Color
37 668-38.113mm
1 0.050-0.054 inch Green
(1.483-1500 inch)
38.114-38.540mm
2 0.068-0.O72 inch Yellow
(1501 -1517 inch)
38 541-38.970mm
3 0.085-0.089 inch Natural
(1 518-1534 inch)
PUMP
38 971-39 408mm Red
THRUST
4 0.102-0.106 inch WASHER
11 535-1 .551 inch)
NO TE POS ITION
39 409-39.827mm OF ALIGNMENT TAB
5 0.119-0.123 inch Blue
11 552-1 568 inch)

22. Install pump alignment dowel. The alignment

dowel can be fabricated by removing the head
from a MS-1 .25 bolt. Install the dowel only a few
threads in the position shown.

23 . Install a new pump gasket.

I i
!;
0
,/ ,r-;: "
; )~

DOWEL MUST
/QW,C
-~,.:._. ,;_:f'-•-e-·- - ----, =~.~~MENT

BE INSTALLED IN
POSITION SHOWN

'

43
(~RTSG) Technical Service Information

24. Using Impact Slide Hammer T59L-100-B and 25. Remove the alignment dowel and install the
Front Pump Remover Adapters TS0L-77103-A seven pump attaching bolts. Alternately tighten
or equivalent, lower the pump assembly into the the bolts a few turns at a time to draw the pump
case. into the case. Tighten the attaching bolts to
22-27 N·m (16-20 lb-ft).
NOTE: Clean attaching bolts with a wire brush
SLIDE HAMMER to remove loose particles. Apply a coating of
T59L -100·8 Threadlock and Sealer EDAZ-19554-A or
equivalent, to bolt threads before installation .

•~ , l 1
~ -
_,,. - Q ----

--fta~-- ---------- .......,. --- ~

NOTE: The dowel must appear at this position

in the bolt pattern for proper alignment of the
bolt holes and oil passages.
26. Assemble the 3-4 accumulator. Install the piston
(and spring, if so equipped) . Lubricate the rub-
ber seal on the cover and the top of the bore
to help cover installation. Install cover.
- ---~ ~I"' ~
--~~Ji~~
-;- IMPORTANT NOTE: After assembly, the
\ / ____ ,_ .~ ~ ()J;;' "-- cover must be fully up and seated against re-
\
~/~
I :· _,/ /
ti~
//j/1 /•
• ~
·.
~
~
taining ring to avoid exposing a pressure
passage. Use air pressure if necessary to
ti
'
,-

, i
/ .!
\
,
' / •.
11 1 ,··
~, , ____./
_ _ ,.,~- ~ T~\_
-:1 • ✓,,
_.. /
/ •',
\ seat cover up against retaining ring.
LOW-REVERSE SERVO
2·3 ACCUMULATOR
OVERDRIVE SERVO
! '\ / - -~ '

----1-------1---
~ /,M
· ·1 \ "'- / ~
'\\\'\ 1'•,.
1

• • \ I
l
-~
'// / , \ -
' \ '
1
,/ ;1
_II

~
I
< q:;,-= , _ •l
// ,•

NOTE: THE OOWEL'--.,

MUST APPEAR AT
THIS POSITION IN
~ \

~
--......._
~
'·
l[ __,J~~/ .
-:-_:--:J\ ~
,:.:.._
.r., \
/ ''~'~,

· -- - - ' '
0

THE BOLT PATTERN ·- • --

FOR PROPER
ALIGNMENT OF THE
BOLT HOLES AND OIL ALIGNMENT DOWEL
PASSAGES.

3-4 ACCUMULATOR

44
(~RTSG) Technical Service Information

27. Assemble the 2-3 accumulator. 29. Install the valve body gasket and the valve body
assembly over the pins.

NOTE: Make sure the manual and throttle

levers are properly positioned before installing
the valve body attaching bolts.
LOW-REVERSE SERVO OVERDRIVE SERVO

2-3 ACCUMULATOR._,_-.\---- ---+----...

3-4 ACCUMULATOR

28. Install Valve Body Guide Pins TB0L-77100-A or 30. Loosely install 22 valve body attaching bolts us-
equivalent in the positions shown. ing an 8mm socket. Starting at the center and
working outward, tighten the bolts to 9-11 N·m
(80-100 lb-in.)

45
(~ATSCi] Technical Service Information

NOTE: Two different length bolts are used. The 32. Position the TV lever torsion spring against the
shorter bolts are used at the four front, one separator plate V-notch . This spring pushes the
center and three rear locations. Refer to the throttle lever in the direction of wide open
illustration. throttle.

_,.

TORSION
l-
------ c, SPRING
0 0 . - !1
0 INDICATES A LONGER BOL .;:- - ~ ·
□ INDICATES A SHORT BOLT

31. Remove the alignment pins and install bolts 33. Install the filter grommet.
(short). Install the detent spring and roller
assembly (long bolt). Tighten the bolts to 9-11
N·m (80-100 lb-in).

FILTER
GROMMET
DETENT SPRING AND
ROLLER ASSY

46
(~RTSG) Technical Service Information

34 . Install a new filter gasket and the filter on the 36. Position a new pan gasket and install the oil pan
valve body. (10mm socket) . Tighten the attaching bolts to
8-13.5 N·m (6-10 lb-ft) .
NOTE: If the fluid was contaminated , be sure
to use a new filter. Never attempt to clean or
reuse a dirty filter.

37. Position a new gasket and install the extension

housing . Tighten the attaching bolts to 22-27
N·m (16-20 lb-ft).
35. Install the filter attaching bolts. Tighten the at-
taching bolts to 9-11 N·m (80-100 lb-in).

TIGH TEN ATTACHING

BOL TS TO 9-1 \ N ·m
(80-100 LB -IN)

38. Install the direct driveshaft.

FILTER ATTACHING BOLTS

47
(~RTSG) Technical Service Information

39. Install the torque converter. Make sure the con- Installation
verter is fully seated in the pump.
Install the seal using Front Pump Seal Replacer
T63L-77838-A or equivalent.

Sub Assemblies Pump Bushing

Pump Seal Removal

Removal Remove the bushing using Bushing Remover

TB0L-77268-8 or equivalent.
Remove the pump seal using Front Pump Seal
Remover TOOL-1175-AC and Impact Slide Hammer
T59L-100-B or equivalent.

SEAL REMOVER
TOOL 11 75-AC

SLIDE HAMMER
T59L -100-B

48
(~RTSG) Technical Service Information

Installation Installation

Install the bushing using Bushing Installer 1. Position the replacement bushing on Bushing
TB0L-77268-A or equivalent. Installer TB0L-77110-A or equivalent and install
in the bushing bore through the front of the
case .

2. Thread Impact Slide Hammer TS0T-100-A or

equivalent into the bushing installer through the
back of the case and install the bushing.

SLIDE HAMMER
TSOT-100-A

BUSHING INSTALLER
TB0L-77110-A

BUSHING
INSTALLER
TBOL-77268-A

Case Bushing
Removal

To remove the transmission case bushing use Im- Extension Housing Seal
pact Slide Hammer TS0T-100-A and Seal Remover
TOOL-1175-AC or equivalent. Removal

Remove the extension housing seal using Impact

Slide Hammer T59L-100-8 and Extension Housing
Seal Remover T74P-77248-A or equivalent.

SEAL REMOV~A
T74P -77248-A
SLIDE HAMMER
T59L-100-B

IJ.---,----;r--:r'-r-,.1.,.._,,-_-_-_-_:-_-_-_

EXTENSION
HOUSING

49
(~RTSG) Technical Service Information

Assembly

1. If removed. install the clip and spring on the

governor valve.

2. Install the governor valve in the governor body.

3. Install the sleeve in the governor body with the

points outward.

4. Install the plug in the sleeve with the knurled

face inward.

5. Position the cover and install the attaching

screws. COUNTERWEIGHT
ATTACHING
Tighten the attaching screws to 2.3-2.4 N·m SCREWS
(20-30 lb-in).

6. Install the screen in the body. NOTE: The steel

SPRING
band (brass colored) goes inward and the top RETAINING
of the screen faces outward. CLIP

7. Position the governor body on the SLEEVE

counterweight and install the attaching screws.
COUNTERWEIGHT
Tighten the attaching screws to 6-7 N·m (50-60
lb-in).

NOTE: The finished face of the body should be

flush with the face of the counterweight. (If it is
not, the body is installed backwards).

Governor

Disassembly

1. Remove the screws attaching the

counterweight to the governor body.

3. Remove the plug, the sleeve, and the governor

valve from the governor body.
PARI(
PAWL
4. Remove the screen from the governor body. SHAFT

NOTE: Externally, the AOD governor is very

similar in appearance to the FMX governor.
However, the internal components are not the Parking Pawl
same. The AOD governor can be distinguished
from the FMX by examining the governor valve. Removal
The AOD governor valve has a circular shoulder
on the end of the valve . 1. Slide the park pawl shaft out the rear of the case
and remove the parking pawl.

2. Remove the return spring.

50
(~RTSG) Technical Service Information

Installation

1. Hook the squared end of the spring into the RETURN

SPRING
notch on the park pawl.
PARKING
PAWL
2. Hold pawl and spring in place and hook curved
end of spring into the recess in the case.

3. Install the park pawl shaft.

Neutral Start Switch Installation

Removal 1. Install a new seal on the neutral start switch.

1. Using the Neutral Start Switch Socket 2. Install the switch in the case using the Neutral
T74P-77247-A or equivalent, remove the switch Start Switch Socket T74P-77247-A or
from the case. equivalent. Tighten to 11-14 N·m (8-11 lb-ft).

2. Remove the O-ring seal and discard .

. ((i

O-RING
SEAL

\
~

51
l~RTSG) Technical Service Information

Intermediate One-Way Clutch

REVERSE CLUTCH ORUM

CLUTCH
RETAINING CLUTCH OUTER RACE
PL.ATE ANO INTERMEOIA TE
CLUTCH HUB

CLUTCH
RETAINING
RING

Disassembly and Assembly

1. Using snap ring pliers, remove the clutch retain-

ing ring.

52
(~RTSG) Technical Service Information

2. Remove the clutch retaining plate.

RETAINING
PLATE

3. Remove the clutch outer race by lifting on the 4. Carefully lift the one-way clutch from the inner
race while turning counterclockwise. race.

ONE-WAY
CLUTCH
ASSY

5. To assemble the intermediate one-way clutch,

reverse Steps 1 through 4.

53
(~RTSG) Technica l Service Informat ion

Output Shaft

OUTPUT
SHAFT
NO. 8 HUB HUB TO
NEEDLE RING GEAR
BEARING RETAINING
RING
DIRECT
CLUTCH

SEAL RINGS-
OUTPUT
SHAFT
TO DIRECT
OUTPUT CLUTCH
SHAFT
TO HUB
RETAINING
RING

Disassembly and Assembly

1. Remove the ring retaining the output shaft hub 2. Separate the output shaft and hub assembly
to the ring gear. from the ring gear.

NO 8
NEEDLE
BEARING

DIRECT
CLUTCH
RING
GEAR

54
(~RTSCi) Technical Service Information

3. Remove the direct clutch from the ring gear and DIRECT CLUTCH
TO HUB NO. 8
the No. 8 needle bearing from the back of the NEEDLE BEARING
direct clutch .

RING
GEAR

4. Remove the four output shaft seal rings (7, 8, 5. Remove the two direct clutch seal rings (5 and
9 and 10) and the hub-to-output shaft retaining 6) from the output shaft.
ring . Separate the hub from the output shaft.

6. To assemble the output shaft, reverse Steps 1

through 5.

55
f~RTSG) Technical Service Information

INNER
d Throttle Linkage THROTTLE
Manual an observe LEVER

. mbling the linkage,

levers.
NOTE:
the locat1on of d~sa~!~ious
Before t e

MANUAL
LEVER
RETAINING
PIN

OUTER
MANUAL
LEVER

OUTER
THROTTLE
LEVER

PARKING PAWL
INNER ACTUATING ROD
MANUAL
LEVER

TORSION
INNER THROTTLE
SPRING
LEVER ANO SHAFT
ASSY

I MANUAL LEVER

RETAINING PIN
OUTER
MANUAL LEVER
ANO SHAFT ASSY

THROTTLE LEVER
SHAFT SEAL

OUTER
THROTTLE
LEVER

MANUAL LEVER
ATTACHING NUT

MANUAL
LEVER
SHAFT
SEAL

SHIFT ROD THROTTLE ROD

TO LEVER TO LEVER
INSULATOR INSULATOR

56
(~RTSCi) Techn ical Servic e Inform ation

Disassembly 2. Using a small screwdriver or awl, remove the

seal from the outer manual lever counterbore.
1. Grasp the outer throttle lever firmly and loosen
the lever attaching nut. Discard seal.
NOTE: The outer throttle lever must be held in
the position shown to prevent the inner throttle
lever from rotating against the machined valve
body surface. Failure to observe this precaution
could result in damage to the valve body
surface.

LEVER MUST NOT BE

ALLOWED TO CONTACT
VALVE BODY
SURFACE

3. Using a narrow, sharp screwdriver, carefully

remove the manual shaft retaining pin from the
case.
Remove the attaching nut, the lockwasher, and
throttle lever.

57
(~RTSG) Technical Service Information

4. Slide a 5/8-inch box end wrench over the inner 5. Remove the inner throttle lever and TV lever tor-
manual lever, close to the bottom of the lever. sion spring .
Do not allow the wrench to contact the "rooster
comb" area. Using a 21 mm wrench, remove the
manual lever attaching nut while securely
holding the inner manual lever.

6. Remove the inner manual lever and parking

pawl actuating rod as an assembly.
Thread the nut off the shaft and remove the
lever.

PARKING
PAWL
ACTUATING
ROD

OUTER MANUAL
LEVER AND SHAFT
ASSV

58
(~RTSG) Technical Service Informatio n

After removal, the rod may be disengaged from Assembly

the lever.
To assemble the manual throttle linkages. reverse
the disassembly except for the following:

1. Install a new manual lever seal using Shift Shaft

Seal Replacer T74P-77498-A or equivalent.

7. Remove the manual lever shaft seal from the 2. Before installing the outer throttle lever. install
case using Shift Shaft Seal Remover a new seal in the outer manual lever. To seat
T58L-101-A and Impact Slide Hammer the seal, a 13mm thin wall socket may be used.
T59L-100-B or equivalent.
Position the ratchet end of the socket against
Discard seal. the seal.

NOTE: The seal identification number must face

outward .

SEAL REMOVER
T58l·101 -A

59
(~RTSG) Technical Service Information

Direct Clutch

CLUTCH
PRESSURE PISTON
PLATE
PISTON RElUHN
CLUTCH SPRING AND
PACK f1ETAINLII
ASSY

DIRECT CLU I CH
HUB

DIRECT
CLUTCH
DAUM

CLUTCH
PACI\ PISTON
SEALS

Disassembly

1. Remove the No. 7 direct cutch hub inner needle 2. Remove bearing support.
bearing.

NO 7 NEEDLE
BEARING

60
(~RTSG) Technic al Service Informa tion

3. Remove the clutch pack selective retaining 5. Using Clutch Spring Compressor T65L-77515-A
snap ring. or equivalent, compress the piston return
springs. Remove the piston retaining ring us-
ing expanding type snap ring pliers.

CLUTCH SPRING
COMPRESSOR
T65L -77 515-A

EXPANDING
TYPE SNAP
RING PLIERS

4. Remove the clutch pack from the drum. 6. Remove the spring retainer assembly and
piston from the drum.

NOTE: USE AIR PRESSURE,

IF NECESSARY TO REMOVE
PRESSURE CLUTCH PISTON
PLATE

61
(~RTSG) Technical Service Information

Note the position and direction of the lip seals d. Push the seal down until it snaps off the end
and then remove . of the protector onto the clutch hub.

e. Remove the seal protector from the clutch

hub.
f. Slide the seal up until it seats in the seal
groove.

INNER PISTON
SEAL. INSTALLED
PISTON RETURN
NOTE DIRECTION
SPRING AND
OF SEALING LIP
RETAINER ASSY

---~~:TAl~o
RING

Assembly

Install the inner piston seal on the clutch drum

hub as follows:

a. Position Direct Clutch Lip Seal Protector

TS0L-77234-A or equivalent over the clutch 2. Inspect the piston check ball. Make sure the ball
drum hub. is present and moves freely. Check for leakage
by performing the direct clutch piston check ball
b. Lubricate the seal and the seal protector with leakage procedure as outlined in Section 17-01.
petroleum jelly.

c. Position the seal over the installer tool with

the sealing lip lacing down.

SEAL PROTECTOR
TB0L -77234-A

DIRECT
CLUTCH
DRUM
0
CHECK
BALL
PISTON
SEAL

62
(~RTSG) Techn ical Servic e Inform ation

3. Install the outer clutch piston seal. Note the c. Position the tool in the clutch drum and push
direction of the sealing lip before installation. the piston to the bottom of the drum using
The lip points away from the spring posts. even thumb pressure.

PUSH PISTON
TO BOTTOM
OF DRUM
USING EVEN
THUMB PRESSURE

4. Install the clutch apply piston as follows: 5. Install the piston spring and retainer assembly
and retaining ring using Clutch Spring Com-
a. Coat the piston seals, the clutch drum seal- pressor T65L-77515-A or equivalent.
ing area, and the piston inner seal area with
petroleum jelly.
b. Install the piston in the Lip Seal Protector
TBOL-77254-A or equivalent.
CLUTCH SPRING
COMPRESSOR .
T65L-77515-A

EXPANDING
TYPE SNAP
t_- RING PLIERS
SEAL
PROTECTOR
TB0L -77254-A

CLUTCH
PISTON

---

63
(~RTSG) Technical Service Information

6. Install the clutch pack.

PRESSURE
PLATE

7. Install the clutch pack selective retaining ring The clearance should be:
and check the clearance between the ring and
the pressure plate using a feeler gauge. 5.0L HO, 5.0L SEFI, 5.8L

The pressure plate should be held downward 1.3-1.77mm (0.050-0.067 inch).

as the clearance is checked.
3.8L

1.0-1.44mm (0.040-0.057 inch).

/
If the clearance is not within limits, selective
snap rings are available in the following
thicknesses:
SELECTIVE
RE1AINING
RING • 0.050-0.054 inch
• 0.064-0.068 inch
• 0.078-0.082 inch
• 0.092-0.096 inch

Install the correct size snap ring and recheck

the clearance.

64
(~RTSG) Technical Service Information

8. Check the clutch for proper operation using air

pressure. The clutch should be heard and felt
to apply smoothly and without leakage.
CHECK ASSEMBLED
CLUTCH FOR PROPER
OPERATION USING
AIR PRESSURE

Forward Clutch

PISTON
SEAL
RINGS

65
(~ATS6) Technical Service Information

Disassembly 3. Remove the clutch pack.

PRESSURE
1. Remove the clutch hub and No. 3 needle bear- PLATE

ing, if not already removed.

FORWARD
HUB

CLUTCH PACK

FORWARD
CLUTCH
4. Compress the piston return spring using Clutch
Spring Compressor T65L-77515-A, and For-
ward Clutch Spring Compressor Adapter
TB0L-77515-A or equivalent.

EXPANDING TYPE
SNAP RING PLIERS

COMPRESSOR
T65L-77515-A
AND ADAPTER
TB0L-77515-A

2. Remove the clutch pack selective retaining ring.

NOTE: To aid handling, the clutch may set in

the extension housing or a 51mm (2-inch)
diameter hole may be cut in the work bench.

Remove the retaining ring and spring retainer.

SPRING
RETAINER

PISTON
RETURN
RETAINING SPRING
RING

66
(~RTSG] Technical Service Information

5. Remove the clutch piston . Assembly

Note the position and direction of th ,• ;;p 5c, als 1. Install new seals on the clutch piston . Note the
and remove . direction of the sealing lip before installation .
PIS TO N CLIJ TC H
RE TURN PISTON
SPRI N G

~
~
RET A1t;I NG
PI_AIE RE TAINING
RIN G

•o,e o>e "" oaessoae

IF NE C ESSAR Y TO REM O VE
THE C LU TC H PI STO N
~ O UTER PI STO N SEAL
THE SEAL MUST BE
INST ALL ED WITH
THE SEALING LIP
TOWARD YOU AS
SHOWN

NOTE: Make sure check balls in clutch piston

are free.

INNER PISTON SEAL

THE SEAL MUST BE
IN STALLED WITH
SEALING UP
TO WARD YO U AS
SHOWN

67
(~RTSG) Techn ical Servic e Inform ation

2. Install the clutch piston as follows : 3. Install the piston return spring, the spring re-
tainer and the retaining ring.
a. Coat the piston seals and the clutch drum
sealing area with petroleum jelly.

b. Install the Forward Clutch Lip Seal Protect

or (inner), TB0L-77140-A or equivalent, over
SPRING
the clutch cylinder hub . Rtl AINER

PI STON
RETURN
SPRING

Compress the piston return spring using Clutch

Spring Compressor T65L-77515-A and Forward
Clutch Spring Compress or Adapter
TS0L-77515-A or equivalent.
c. Install the piston in the Forward Clutch Lip
Seal Protector (outer), T68P-7O158-A or
equivalent.
d. Position the seal protector and piston in the
clutch drum. Push the piston to the bottom
of the drum using even thumb pressure . E XPANDING TYPE
SNAP RING PUERS

CO MPRESSOR
T65L-77515-A
AND ADAPTER
TS0L- 77 515-A

APPLY EVEN
THUMB PRESSURE
WHEN INST ALLING
PISTON IN ORUM

68
(~RTSG) Technical Service Informatio n

4. Install the clutch pack. 5. Install the clutch pack retaining ring and check
the clearance between the ring and the
pressure plate using a feeler gauge.

The pressure plate should be held downward

as the clearance is checked.

SH[C: IIVl
Ill I /\ININ!,
IUNl.;

NOTE: The wave plate must be installed first.

The clearance should be:

3.8L (232 CID)

1.02-1.S0mm (0.040-0.071 inch)

5.0L HO (302 CID), 5.0L SEFI (302 CID),

5.8L (351 CID)

1.27-2.26mm (0.050-0.089 inch)

CLUTCH PACK
If the clearance is not within specification, selec-
WAVE PLATE tive snap rings are available in the following
(MUST BE thicknesses:
INSTALLED FIRST)

• 0.060-0.064 inch
• 0.074-0.078 inch
• 0.088-0.092 inch
• 0.102-0.106 inch
Install the correct size snap ring and recheck
the clearance.

69
(~RTSG) Technical Service Information

6. Check the clutch for proper operation using air Disassembly

pressure. The clutch should be heard and felt
to apply smoothly and without leakage. 1. Remove the No. 2 thrust washer.

NO 2 THRUST WASHER

USE AIR PRESSURE TO

CHECK CLUTCH
ASSEMBLY FOR
PROPER OPERATION

REVERSE CLUTCH

2. Remove the clutch pack retaining ring.

Reverse Clutch

CLUTCH
BELLVILLE
DRUM
RETURN
SPRING
CLUTCH
PACK

NO 2 THRUST
WASHER

3. Remove the clutch pack.

CLUTCH
PISTON

THRUST
RING WAVE
SNAP
RING
PLATE
CLUTCH PACK
RETAINING RING

CLUTCH PACK

70
l~RTSG) Technical Service Information

4. Remove the wave snap ring using Clutch Spring 5. Remove the piston return spring and the thrust
Compressor T65L-77515-A and Reverse Clutch ring.
Spring Compressor Plate TS0L-77405, or
equivalent.

COMPRESSOR
T6~L 77515-A
AND COMPRESSOR
PLATE TB0L -77 405 -A

RETURN
SPRING

6. Remove the clutch piston .

WAVE SNAP RING

NOTE: To aid removal, it may be necessary to

apply air pressure to the drum. Block the
opposite hole wit_
h a finger.

NOTE USE AIR PRESSURE

IF NECESSARY TO REMOVE
CLUTCH PISTON

71
(~RTSG) Technica l Service Informat ion

Assembly 2. Install the clutch piston as follows:

1. Install new seals on the clutch piston. Because a. Coat the piston seals and clutch drum
the seals are square cut, the direction of in- seating area with petroleum jelly.
stallation is not important.
b. Install Reverse Clutch Seal Protector (inner)
NOTE: The piston check ball must be present TS0L-77403-B and Reverse Clutch Seal Pro-
and moving freely. tector (outer) TS0L-77403-A or equivalent in
the clutch drum .

OUTER SEAL
INNER SEAL
PROTECTOR
PROTE CTOR
T80L•77403-A
T80L •77 403-B

OUTER
PISTON
SEAL

c. Coat the piston seals, the clutch drum seal-

ing area and the seal protector with
petroleum Jelly.
NOTE: THE SEALS ARE SQUARE AND /
THEREFORE CAN BE INSTALLED IN EITHER
DIRECTION.
d. Position the piston and push it to the bottom
of the drum using even thumb pressure.

CHECK
BALL-

INNER
PISTON
SEAL

PUSH PISTON TO
BOTTOM or BORE
USING EVEN
THUMB PRESSURE

72
r ,~RTSG) Technical Service Information

3. Install the piston thrust ring and the piston

return spring.

THl1UST
RING
RETURN
SPRING

4. Install the wave snap ring (with points down) us-

ing Clutch Spring Compressor T65L-77515-A
and Reverse Clutch Spring Compressor Plate
TB0L-77405-A or equivalent.

COMPRESSOR
T65L-77515-A
AND COMPRESSOR
PLATE TB0L-77405-A

73
(~RTSG) Technical Service Information

5. Install the clutch pack . 6. Install the clutch pack retaining ring and check
the clearance between the ring and the
pressure plate using a feeler gauge. The
pressure plate should be held downward as the
clearance is checked .

CLUTCH PACK

NOTE: The apply plate must be installed first.

Note that the dished side of the plate must face
the piston.

The clearance should be:

5.0L (302 CID), 3.8L (232 CID)

.76-1.42mm (0 .030-0.056 inch)

5.8L (351 CID)

1.02-1 .91 mm (0 .040-0.075 inch)

If the clearance is not within specification, selec-

tive snap rings are available in the following
thicknesses:
APPLY PLATE • 0.060-0.064 inch
(DISHED SIDE
OF PLATE MUST • 0.074-0.078 inch
FACE PISTON) • 0.088-0.092 inch
• 0.102-0.106 inch
Install the correct size snap ring and recheck
the clearance .

74
(~RTSG) Technic al Service Informa tion

7. Check the clutch for proper operation using air Center Support and Planetary One-Way
pressure . The clutch should be heard and felt Clutch
to apply smoothly and without leakage.

USING AIR PRESSURE

CHECK ASSEMBLED PLANETARY CENTER
CLUTCH FOR PROPER ONE-WAY SUPPORT
OPERATION CLUTCH

PLANETARY
ASSY

8. Install the No. 2 thrust washer. Disassembly

1. Remove the center support from the planetary
carrier. Rotate the center support counterclock-
wise and lift.

NO 2 THRUST WASHER

CENTER
SUPPORT

REVERSE CLUTCH

75
(~ATSG) Techni cal Service Inform ation

2. Carefully remove the planetary one-way clutch 2. Install the one-way clutch in the planetary
from the planetary assembly. carrier.

PLANETARY
PLANETARY ONE -WAY
ONE -WAY CLUTCH
CLUTCH

3. Install the center support into the one-way

clutch by rotating the center support
counterclockwise.

Lubricate the clutch races and the clutch

Assembly assembly with petroleum jelly to aid in
assembly.
1. If necessary, assemble the one-way clutch.

NOTE: THE HOOKED ENO

OF THE SPRING MUST
FIT TIGHT ON THE FRAME

SPRING

NOTE : THE CURVED

ENO OF THE SPRING
MUST FACE THE ROLLER

76
(~RTSCi) Technic al Service Informa tion

Sun Gear and Drive Shell 2. Remove the forward sun gear and No. 5 needle
bearing from the drive shell.

DRIVE
NO 4 SHELL NO 5 NEEDLE
NEEDLE BEARING
BEARING FORWARD
SUN
GEAR
' --
b FORWARD
SUN
GEAR
NO 5 NEEDLE
BEARING

DRIVE
SHELL

Disassembly
3. Remove the No. 5 needle bearing from the for-
1. Remove the No. 4 needle bearing from the drive ward sun gear.
shell.

DRIVE
NO 4 NEEDLE SHELL
BEARING

Assembly
The sun gear and drive shell is assembled as part
of the transmission assembly procedure.

77
l~ATSCi) Technical Service Information

Pump and Intermediate Clutch Piston

Pllf-..ff'
lh..l\l\ l 'lJMI' 11\J ll l
Ill CASE SEAL

IN 1L HM LDII\ I l Sl'I-I IN ( _;
C LUIC H P IS TON RE TA INE R
ASS Y

Disassembly 2. Remove the four pump seal rings (1, 2, 3 and 4).

1. Remove the No. 1 thrust washer. The reverse clutch rings (1 and 2) are larger
than the forward clutch rings (3 and 4).

f OAWARLl
l- 1 tr TCH
HIN l; S ~ -,0 SL A L RIN G '.>

RF:VERSE
C LUTCH
RINGS

78
(~RTSG) Techn ical Servic e Inform ation

3. Remove the pump body-to-case seal and 5. Remove the clutch piston .
discard.

4. Remove the spring retainer assembly by 6. Remove the five 10mm stator support bolts.
carefully dislodging the tabs.

FIVE
A Tl ACHING
BOLTS

0
0
0~
0

79
(~RTSG) Technical Service Information

7. Remove the stator support. Assembly

1. Install the drive and driven pump gears in the
pump body.

STATOR
SUPPORT

DRIVEN
GEAR

NOTE: Chamfers on both gears face into the

pump body.
8. Remove the drive and driven pump gears from
the pump body.

THE CHAMFERS
ON BOTH GEARS
MUST BE FACE
DOWN AFTEl'I INSTALLATION

80
[~RTSG) Technic al Service Informa tion

2. Position the stator support to the pump body 4. Install new seals on the clutch piston. Note the
and install the bolts. Tighten to 16-22 N·m direction of the sealing lip before installation .
(12-16 lb-ft). The lips point away from the spring posts.

STATOR
SUPPORT

PUMP
BODY

3. Install new pump-to-case seal.

81
(~RTSG) Techn ical Servic e Inform ation

5. Install the clutch piston as follows: 6. Snap the spring retainer assembly into place on
the pump body. Use even pressure.
a. Coat the piston seals and the pump body
sealing area with petroleum jelly.
b. Install the piston in seal protector SPRING RETAINER
TB0L-77005-A or equivalent. APPL Y EVEN PRESSURE
TO INSTALL

7. Install the pump seal rings.

NOTE: Stator support seal rings (1 and 2) are

c. Install the piston in the pump body and push the largest rings and are for the reverse clutch .
to the bottom of the bore by exerting even These rings are closest to the pump. Stator sup-
thumb pressure on the piston. port seal rings (3 and 4) are for the forward
clutch. These rings are furthest from the pump
IMPORT ANT NOTE: The piston bleed body.
must be located at 12:00 o'clock position
(toward top of transmission.)

FORWARD
CLUTCH
RINGS

PUSH PISTON TO
BOTTOM OF BORE
USING EVEN THUMB
PRESSURE

82
(~RTSG) Technical Service Information

Accumulators and Servos Low Reverse Servo

Disassembly and Assembly Inspect the sealing edge on both the servo cover and
the apply piston. Replace the cover or piston, if
3-4 Accumulator necessary.

Install new seals on the accumulator piston and the NOTE: The length of the rod attached to the piston
piston cover. may vary in length from transmission to transmis-
sion. Three possible lengths may be encountered.
NOTE: Be sure the diagonal cuts on the piston seal A single groove rod indicates the shortest possible
are aligned properly. length, while two and three groove piston rtids in-
dicate successively longer rods. For assembly pur-
NOTE: Some transmissions may be built with a poses, it is important to determine which length
spring. Depending on model application the spring piston rod was used in the manufacture of the
may or may not be present. The appearance of the transmission.
piston and spring may also vary from model to SERVO
model. RETAINING PISTON
RING

J.4 ACCUMULATOR
SPRING (SOME MODELS)

PISTON
COVER

PISTON
RETURN
SPRING

PISTON
SEAL SERVO
(SCARF -CUT COVER
TEFLON SEAL)

RETAINING SEAL
RING (SQUARE CUT
RUBBER SEAL)

Overdrive Servo

1. Pull the overdrive servo piston out of the piston

cover.
2-3 Accumulator
2. Install new seals on the piston and cover .
Install new seals on the accumulator piston. Be sure
3. Lubricate the piston seal to prevent damage
the diagonal cuts are properly aligned.
and to facilitate assembly.

4. Install the piston in the cover.

RETAINING
RING COVER
2-3 ACCUMULATOR
SEAL
SPRING
PISTON
COVER
RET1t.lNING
RING

PISTON
SEAL

PISTON
SEAL

PISTON
2·3 ACCUMULATOR SEAL
COVER
COVER
SEAL

83
(~RTSCi] Tech nical Servi ce Infor matio n

Valve Body 3. Remove the two relief valves and si>,en check
balls from the valve body. Note the ,ocation of
Disassembly the orange ball. It is not interchan geable with
the six black balls.
1. Remove and discard valve body gasket. Loosen
and remove 11 bolts from reinforce ment plates NOTE : The check balls are numbere d one
and detent spring guide bolt from the separator through eight. Check ball number seven was
plate using a 10mm socket. eliminate d in a previous productio n year. There
are a total of seven check balls.

0 IN DIC A TES RE LI EF VALV E

2. Remove separato r plate, reinforce ment plates

and separato r plate gasket. Discard gasket.

RELIEF VALVE CONVE RTER PRE SSU RE

P.ELIEF VAL VE

4. The following procedur al steps detail the

removal and installation of the individual valves.
Each valve body bore has been assigned a
reference number on the assemble d view . The
illustrations have been assigned a correspo nd-
ing reference number. Each set of illustratio ns
contains the views necessary to remove and in-
REINFORCEM ENT PLATES stall the compone nts contained in a particula r
valve body bore .

84
(~RTSG) Technical Service Information

12

LEGEND:
1 MANUAL VALVE
2. THROTTLE SYSTEM VALVES
3. 2-3 BACKOUT VAL VE
4. ORIFICE CONTROL VALVE/2 -3 CAPACITY
MODULATOR VALVE (FUNCTIONS ARE
SEPARATED BY A SPRING RETAINING PLATE)
5. 3-4 SHIFT AND 3-4 MODULATOR \/ALVES
6. Tl/ LIMIT 1/AL\/E
7. 1-2 SHIFT 1/AL\/E
8 00 SERVO REGULATOR 1/AL\/E
9 3-4 SHUTTLE 1/ALIIE
10. 1-2 ACCUMULATOR 1/AL\/E
11. 1-2 CAPACITY MODULATOR 1/ALIIE
12. MAIN REGULATOR AND PRESSURE BOOST
\/ALI/ES
13. 2-1 SCHEDULING VALVE/LOW SERVO
MODULATOR 1/AL\/E (FUNCTIONS ARE
SEPARATED BY A SPRING RETAINING PLATE)
14 . 3- ◄ BACKOUT 1/AL\/E
15. 2-3 SHIFT. 3-2 CONTROL AND
2-3 Tl/ MODULATOR \/ALI/ES

85
(~ATSG) Techni cal Service Inform ation

VALVE BODY - REAR OF VEHICLE SIDE

BORES 1, 2 AND 3

BORE
NO. 2

BORE NO. 1 BORE NO. 2 BORE NO . 3

0 Chp
© Chp 0 Chp

® Manual Valve @ Thronle Sleeve 0 Bore Plug

© Preload Spring 0 Spnng

0 Throllle Plug G) © 2 -:J Backoul Valve

® Thronle Conlrol Valve and Spring @

0 ThroUle Plunger

NOTES :
easier plug
Some Bore Plugs have a tapped hole rn the center . use a M-t me1nc screw ,n lapped hole lor
removal. These plugs must be installed with lhe tap hole lacing outward .

(0 The notch rn the throtlle plug faces the boltom of lhe thronle sleeve bore
(v The chamfered stem of the throttle control valve laces the throllle plunger

86
(~ATSG) Technical Service Information

VALVE BODY - PASSENGER SIDE

BORES 4 THROUGH 7

BORE NO. 4 BORE NO. 5 BORE NO. 6 BORE NO. 7

@ Spring Rela iner Plate ® Clip ® Retainer Plate @) Clip

(e) Bore Plug 1 © Sleeve © TV l1m11 Valve and

Sprong @ Bore Plug

(9 Orifice Control Valve

® Plug 2 @) 1-2 Shih Valve and
and Spring Spring

@ Spnng Retainer Plate 1

Ci) 3-4 Shih Valve and
Spring
2-3 Capacity
® Modulato, Valve and Q) 3-4 TV Modulator
Vatve and Spring
Sprona
NOTES:
Some Bore Ptugs have a tapped hole in the center, use a M4 metric screw in tapped hole for easier plug
removal. These plugs must be 1ns1alled wilh the lap hole facing outward.

1 The 2-3 Capacity Modulator Valve Retainer Plate is thicker and longer than lhe other plates. II must
be ins1aned ,n lhis slot

2 The notch iri 1he plug laces the bonom ol the sleeve bore.

87
(~RTSG) Technical Service Information

VALVE BODY - PASSENGER SIDE

BORES 8 THROUGH 11

HUF<[

BORE NO 8 BORE NO . 9 BORE NO 10 BORE NO . 11

0 Sprin~ Re tainer Pla1e

© S~rmg Relamer Pla1e (~ C!1;,
0 Clip

® Bure Plulj t
0 Bore Pluy
0 8u1t' Pluq G ~ore P luq

© Spring
@ J ..i Shu Ille V dive and (j) 0 r1r1~ SecJI ~'
G 1 ;• C .1pc.w1r·,
Spring MPtJutaiur V.:.il:f> :.Jfld
@ OD
Valvt>
Servo Regu1a101
0 I ~· At..: t.: UfllUIJJUf
, llld Sp1111~ _I
\I alve Sµ11ni;

NOTES :
Some 801 P Plugs have a lapped hu1P 111 !h t> c t>111t• r 11":f' ,1 f\n rn1•1rn· •;i-r,~w 111 !;-:;iprc1 tlnl c 10, •~.,:;,,,, plu~J
lt'OIOval Th~se plugs musl be ,nstalleo With lh l:;! l,Jt} r1 u11,,• lc1 cir1q (IUIW.Jl(J

0 To install the OD Ser,10 Regulator Valve Bure Plug turn [hf-' 1etdi11~1 pJ~tt> 11110 lln-• pll•q s101

@ When 1ns1alhng lhe 1-2 Accumula1or Valve Bort?- Pluy 1n10 rtie oo,e, ttit> 0-rmy !:iea1 musl ldCe ou1s1de
ol ine valve booy

(J) Tritt 1•2 Accumulator Valve and valve body d1.;1111t.>le1 a• t' nut 111e S<'Ullt' lo, ull muot! IS

88
(~ATSG) Technical Service I nformat·10n

NO 12 ~1
BORE -------''--' ,

@
JG NO TE POLI CE
LOW GEAR LOCM OOEL S WITH

f} 0 ®
(P -R-N - D -D 2
HAVE THE . I
KOUT

VAL VE c o :OLLOWING

BO
FIG U RA TI O
N
RE lJ POLICE MODELS

0~
~
~
MANUAL LOW
~~~TSRPOL-VALVE
RING

@
LOW SERVO
MODULATOR--
VALVE
\
G
___,.@
© SPRING
AET AINING ~
PLATE

89
(~ATSG) Technical Service Information

Assembly 3. Install Alignment Pins TB0L-77100-A or

equivalent. Note the location of the pins. These
1. Install the seven body check balls. two holes are smaller than the other bolt holes
to assure proper alignment of the gasket and
Note the location of the orange ball. This ball separator plate with valve body. These two
is larger than the others and must be positioned holes also align the valve body gasket and valve
as shown . body assembly with the case.

NOTE: The check balls are labelled one through

eight. Check ball seven was eliminated in a
previous production year. There are a total of
seven check balls.
ALIGNMENT
PINS
□ INOICA,ES RELIEF VALVE
TB0L-77100-A
0 INDICATES CHECK BALLS

4. Use a new separator plate gasket. Slide the

gasket and the separator plate over the two
alignment pins. Position the three reinforcement
plates and loosely install the 11 bolts . Loosely
install the detent spring guide bolt. (This bolt is
the same as the short valve body assembly-to-
case attaching bolts).
TV PRESSURE
RELIEF VALVE CONVERTER PRESSURE
RELIEF VALVE

2. Install the pressure relief valves.

SEPARATOR
GASKET

90
f~ATSCi) Techn ical Servic e Inform ation

5. Starting at the center (large) reinforcement plate

and working outward, tighten the 11 attaching
bolts to 9-11 N ·m (80-100 lb-in). Tighten the de- REINFORCEME NT
tent spring guide bolt to 9-11 N·m (80-100 lb- PLATE

in). Remove the alignment pins. BOLTS

ALIGNMENT PIN
!Hill 77100·A
I
I

I
I
~1:==:::::---i-r- ~t- ~'
0

ALIGNMENT PIN
TB0L -77 100-A

Thrust Bearing Locator

,L J.• ) f )r )

91
(~ATSG] Techni cal S erv1ce
. I n f ormat·10n

0
NO 4 NEE
BEARING OLE

NO 2 THR UST WASHER

REVERSE CLUTCH

,I ___,
,

0 FORWARD
SUN
GEAR

FORWARD
HUB

DRIVE
NO 3 SHELL
NEEDLE
BEARING

FORWARD
CLUTCH

92
© 0
NO . 8
NEEDLE
BEARING

DIRECT
CLUTCH
RING
GEAR

0)
BEARING SUPPORT

NO. 9 NEEDLE
BEARING

-- -·
D4953-A

NO . 7 NtEDLE
BEARING

93
(~ATS6) Technical Service Information
SPECIFICATIONS
FORWARD CLUTCH
Selective Snap
Transmission Model Steel Friction Clearance
Rings-Thickness
Models w1lh 3 SL 1232 CID) 4• 4 1 02-1 .S0mm 10 040-0 071 inch) 0 060-0 064
U U/4-U U/U
Models Wllh 5.0L HO. 5.0L S.E.F .I.
s· 5 1.27-2.26mm (0.050-0.089 inch) 0.088-0 .092
or 5.8L (302 or 351 CID) 0 102-0 106

"Plus a waved plale (1nslalled next 10 piston).

REVERSE CLUTCH
Setecllve Snap
Transmission Model Steel Friction Clearance
Rings-Thickness
Models w11h 3 BL (232 CID) 2 3 0.76-1 .42mm (0 030-0 .056 inch) 0 060-0.064
0.074-0 .078
Models wrlh 5 0L HO, 5.0L S.E.F.L
3 4 1.02-1.91 mm (0.040-0.075 inch) 0 088-0092
or 5.BL (351 CID) 0 102-0.106

DIRECT CLUTCH
Selective Snap
Transmission Model Steel Friction Clearance
Rings-Thickness
Models with 5.0L HO. 5.0L S.EFI. 0.050-0.054
5 5 1.3- 177mm (0 050-0 .06 7 inch)
or 5 BL 0.064-0.068
0.078-0 082
Models w1lh 3 BL 1232 CID) 4 4 1.02-1 44mm (0 040-0 057 inch) 0 092-0 096

INTERMEDIATE CLUTCH
Selective S1eel
Transmission Model Steel Friction Gauge Dim.
Plates-Thickness

Models with 5.BL or 0 067-0 .071

3 3 41.504-41808mm (1 .634-1.646 inch)
5 0L 1351 or 302 CID) 0 077-0 .081
0.087-0 .091
Models Wllh 3 BL 1232 CID) 2 2 41.4-41 7mn1 I1 628-1.640 inch) 0 097-0 101

LOW-REVERSE SERVO PISTON TRAVEL- 2.845-6.020mm (0.112-0.237 Inch)

Nole: Piston travel can be ad1usled using one of the selective servo pistons available for service.
SELECTIVE SERVO PISTONS - All MODELS
Rod leng1h" 1.0. Rod length" I.D. Rod length" 1.0.
2 936 1 Groove 2.989 2 Groove 3 043 J Groove

"Measured from the piston surface to the end of the rod .

FLUID CAPACITY
Liters Imperial Quarts Quarts
11.6 10.2 12.3

SELECTIVE THRUST WASHER" - ALL MODELS

Depth Thickness Color Code Depth Thickness Color Code

37 668-J8113mm 38.971-39.408mm
0 050-0.054 Green 102- 106 Red
( 1 483-1 500 1nchl (1 535-1.551 inch)
3S.J 14-38.540mm
0.068-0.072 Yellow
(1 S0i-1 517 rnch) 39 409-39 827mm
119- .123 Blue
38 541-38 970mm ( 1552-1.568 inch)
0.085-0.089 Natural
(1 518-1.534 inch)
"The thrust washer Is localed on the s1ator suppor1 which rs anached to the back of lhe pump housing .

'l'ORQUE SPECIFICATIONS
Description N•m lb-Ft Description N•m lb-Ft
Staler Support lo Pump Body 16-22 12-16 Converter 10 Flywheel 27-46 20-34
Fronf Pump lo Case 22-27 16-20 Converter Housing Access Cover 10
Converter Housing 16-22 12- 16
Re,nforcing Plate 10 Valve Body 9-14 80-120 lb-1n
Defent Spring Anach1ng Bolt 9-14 80-120 lb-1n
Separ aIor Plafe to Valve Body 9-11 80-100 lb-1n
Inner Manual Lever lo Shah 26-37 19-27
Valve Body to Case 9-11 80-100 lb-1n
Outer Thronle Lever to Shah 16-22 12-16
Filter to Valve Body 9- 14 80-120 lb-1n
Push Connect Fining lo Case 24-31 18-23
011 Pan to Case 8-13.5 6-10
Converter Plug lo Converter 11-38 8-28
E rfens,on to Case 22-27 16-20
Neu1raI Stan Switch to Case 11 · 15 8-11
Governa.r Body to Coun1erwe1ghl 6-7 50-60
Pressure Plug to Case 8-16 6-12
Governor Body Cover to
Governor Body 2.3-3.4 20-30 Transmission to Engine 55-68 40-50

94
( ~ RTSG) Technical Service Information

TRANSMISSION - AUTOMATIC - • Reverse clutch pack plate count increased by one

AOD - DESCRIPTION OF friction plate and one steel plate (was three friction.
CHANGES 2 steel; now four friction. three steel).
• Cable TV control system released on all vehicles.
FORD Installation in engine compartment varies among
1986 FORD. THUNDERBIRD. MUSTANG car lines.

LINCOLN-MERCURY • TV cable adjustment toggle lever at throttle body

1986 MERCURY. COUGAR. CAPRI, LINCOLN, lever on driver side of engine compartment for
CONTINENTAL MARK VII Lincoln Town Car. Crown Victoria . and Grand
Marquis vehicles.
LIGHT TRUCK
1986 E & F-SERIES. BRONCO • TV cable adjustment toggle lever at throttle body
lever on passenger side of engine compartment for
Twenty-four transmission calibrations are currently Mark VII. Continental. Mustang, Capri, Thunder-
released for the 1986 Automatic Overdrive Trans- bird. and Cougar vehicles.
mission (AOD) program : Eighteen for passenger car and
six for truck. • New cable TV adjustment procedure using TV
control pressure and a special service tool.
New to AOD will be the release of the 5.OL SEFI
(sequential electronic fuel injection) engine for all 5.OL • For Continental, Thunderbird, and Cougar vehicles.
and 5 .OL HO passenger cars. Fourteen of the twenty- there is also a bellcrank assembly mounted on the
four calibrations are new and have been programmed transmission bell housing in the area of the TV
for 5.OL SEFI passenger car application. lever and bracketry holding the cable in the upper
bell housing area.
The 5.OL Econoline application will be released with the
5.OL EFI engine. The AOD transmission calibration will • New TV outer control lever at the transmission.
be combined with the F-Series 5.OL EFI calibration. • New main control valve bodies not compatible for
There will be no more 5 .OL-2V carbureted engine past model service.
applications with the AOD transmission.
Major Design Changes Affecting Serviceability for
Major Design Changes Affecting Serviceability for the New 5.OL EFI Econoline Application
All Passenger Car and Truck Applications
• Forward clutch pack plate count increased to five
• Lube hole added to the reverse sun gear to improve friction. five steel (was four friction. four steel).
planetary lubrication (incorporated mid- 1985).
• Reverse clutch pack plate count increased to four
• Transmission fluid changed to H Fluid (Ford Specifi - friction. three steel (was three friction, two steel).
cation ESP-M2Cl 66-H); was Dexron®II.
• Cable TV system released . Adjustment procedure
• New manual lever retaining pin. similar to 5.OL EFI truck application.
• Galvanized oil pan to improve corrosion protection • New filler tube and dipstick.
(incorporated mid-1985).
All F-Series, Econoline. and Bronco applications will
• 1.5mm longer passenger car cooler line quick have new TV control outer levels.
connect fittings to insure full seating of the cooler
line metal tube wall.
Major Design Changes Affecting Serviceability for
the 5.0l SEFI and the 5.0L HO SEFI Passenger Car
Applications
• Forward clutch pack plate count increased by one
friction plate and one steel plate (was four friction.
four steel; ~ five friction. five steel).
-
95
Ir'1II ATSG I Technical Service Information

PRESSURE SPECIFICATIONS

Tap Range Idle Pressure WOT Pressure

Main line Reverse 75-90 psi. 241-290 psi.
Forward Clutch Drive 55-65 psi. 176-215 psi.

TV pressure Drive 0-3 psi. * 70-91 psi.

* = Idle pressure with no gage block

NOTE: Connect pressure gage to desired pressure port shown below.
Pressure should indicate readings shown above.
Pressure should be within 10-15 psi of Main line pressure
when checking the Direct or Forward Clutch.

Pressure Port Locations

Copyright © 2006 ATSG

AUTOMATIC TRANSMISSION SERVICE GROUP

96