Overhaul - 200c Chevrolet Camaro II

APPLICATION

TRANSMISSION APPLICATION (BUICK)

TRANSMISSION APPLICATION (CHEVROLET)

TRANSMISSION APPLICATION (GMC)

TRANSMISSION APPLICATION (OLDSMOBILE)

TRANSMISSION APPLICATION (PONTIAC)

IDENTIFICATION

Transmission model may be identified by the production code number, located on an identification plate attached to right side of transmission case, near modulator. Number consists of a year code, 2 letter model code, and a build date code. Transmission model codes are listed in the following table.

Scheme 54

DESCRIPTION

The Turbo Hydra-Matic 200C automatic transmission is a fully automatic unit consisting primarily of a 3-element hydraulic torque converter with the addition of a converter clutch and a compound planetary gear set. Three multiple-disc clutches, a roller clutch and a band provide friction elements required to obtain the desired function of the compound planetary gear set. A hydraulic system pressurized by a gear type pump provides the working pressure required to operate the friction elements and automatic controls.

The 3-element torque converter consists of a pump or driving member, a turbine or driven member, and a stator assembly. The stator assembly is mounted on a one-way roller clutch which will allow stator to turn clockwise but not counterclockwise. The converter clutch is splined to the turbine assembly, and when operated, applies against the converter cover, providing mechanical direct drive coupling of the engine to the transmission planetary gears. When converter clutch is released, the assembly operates as a normal torque converter.

LUBRICATION

See appropriate TRANSMISSION SERVICING article.

ADJUSTMENTS

See appropriate TRANSMISSION SERVICING article.

SERVICE (ON VEHICLE)

The following components may be removed from transmission without removing transmission assembly from vehicle.

1. Governor Assembly.
2. Governor Pressure Switch (Diesel Only).
3. Intermediate Servo Assembly.
4. Front and Rear Servo.
5. Auxiliary Valve Body.
6. Extension Housing and Gasket.
7. Oil Pan and Oil Screen (Intake Pipe) Assembly.
8. 3rd Accumulator Check Valve Assembly.
9. 3-4 Accumulator.
10. Parking Pawl, Actuator and Bracket.
11. Reverse Boost Valve and Bushing.
12. Stop Valve.
13. Control Valve Body Assembly.
14. Check Balls and Valve Body Spacer Plate and Gaskets.
15. Pressure Regulator Parts.
16. Manual Valve and Link.
17. Inside Detent/Range Lever.
18. Intermediate Band Anchor Pin.
19. 4-3 Pressure Switch.
20. 4th Clutch Pressure Clutch.
21. Vacuum Modulator.
22. Manual Detent and Roller Assembly.
23. Low-Reverse Clutch Cup Plug.
24. Throttle Lever and Bracket Assembly.
25. T.V. Cable and "O" Ring.
26. T.V. Boost Valve and Bushing.
27. Rear Seal.
28. Down Shift Solenoid.
29. Converter Clutch Valve, Springs and Solenoid.
30. 1-2 Accumulator and Spring.
31. Cooler Fittings.
32. Governor Feed Screen.
33. Pump Pressure Screen.
34. Oil Filter Pipe & "O" Ring.
35. Speedometer Driven Gear Assembly.
36. Speedometer Drive Gear.
37. Modulator Valve.
38. Intermediate Band Adjustment.
39. Solenoid Wire Clips.
40. Electrical Connector.

For removal and installation procedures for the above listed transmission components, refer to TRANSMISSION DISASSEMBLY and TRANSMISSION REASSEMBLY .

Scheme 55

Scheme 56

TROUBLE SHOOTING

See appropriate DIAGNOSIS article.

Drive Range

Position selector lever in Drive range and accelerate vehicle. A 1-2 and 2-3 shift should occur at all throttle openings (shift points will vary with throttle opening). Check part throttle 3-2 downshift at 30 MPH by quickly opening throttle approximately three-fourths, transmission should downshift 3-2. Check for 3-2 downshifts at 50 MPH, by depressing accelerator fully.

Intermediate Range

Position selector lever in Intermediate range and accelerate vehicle. A 1-2 shift should occur at all throttle openings (shift point will vary with throttle opening). No 2-3 shift can be obtained in this range. Check detent 2-1 downshift at 20 MPH. Transmission should downshift 2-1.

Low Range

Position selector lever in Low range and accelerate vehicle. No upshift should occur in this range.

Intermediate Range Overrun Braking

Position selector lever in Drive range and with vehicle speed at approximately 50 MPH, with closed throttle, move selector lever to Intermediate range. Transmission should downshift to 2nd. An increase in engine RPM and an engine braking effect should be noticed.

Low Range Overrun Braking

At 40 MPH, with throttle closed, move selector lever to Low. A 2-1 downshift should occur in speed range of approximately 40-25 MPH, depending on axle ratio and control valve assembly calibration. The 2-1 downshift at closed throttle will be accompanied by increasing engine RPM and an engine braking effect should be noticed.

Reverse Range

Position selector lever in Reverse range and check for reverse operation.

Preliminary Checking Procedure

Check prior to making control pressure test

1. Check transmission fluid level.
2. Check and adjust T.V. cable.
3. Check and adjust outside manual linkage.
4. Check engine tune-up.
5. Install oil pressure gauge. (Scheme 57)
6. Connect tachometer to engine.
7. Check electrical system.
8. Check vacuum modulator.

Scheme 57

Minimum T.V. Pressure Check

With T.V. cable adjusted to specifications and brake applied, check line pressure in ranges and at engine RPM indicated in CONTROL PRESSURE SPECIFICATIONS .

Full T.V. Pressure Check

With T.V. cable at full extent of its travel and brakes applied, check line pressure in ranges and at engine RPM indicated in CONTROL PRESSURE SPECIFICATIONS .

CONTROL PRESSURE SPECIFICATIONS

CLUTCH & BAND APPLICATION (ELEMENTS IN USE)

High Or Low Oil Pressures

1. T.V. cable misadjusted, binding, unhooked or broken.
2. Throttle lever and bracket assembly binding, unhooked or mispositioned.
3. Throttle valve or plunger binding.
4. Shift T.V. valve binding.
5. No. 1 check ball missing or leaking.
6. Pressure regulator valve binding.
7. Wrong pressure regulator valve spring installed.
8. Oil pressure control orifice in pump cover plugged (causes high oil pressure).
9. Pressure regulator bore plug leaking.
10. Manual valve not connected.
11. Intermediate boost valve binding (pressure will be incorrect in intermediate and low ranges only).
12. Orifice in spacer plate at end of intermediate boost valve plugged.
13. Reverse boost valve binding (pressures will be incorrect in reverse only).
14. Orifice in spacer plate at end of reverse boost valve plugged.

REMOVAL & INSTALLATION

See appropriate TRANSMISSION REMOVAL & INSTALLATION article.

TORQUE CONVERTER

Note. Torque converter is a sealed unit and cannot be disassembled for service.

TORQUE CONVERTER LEAKAGE CHECK

See procedure given in GENERAL MOTORS TURBO HYDRA-MATIC 400 article.

TORQUE CONVERTER END CLEARANCE CHECK

See procedure given in GENERAL MOTORS TURBO HYDRA-MATIC 400 article.

TORQUE CONVERTER FLUSHING

See procedure given in appropriate SERVICING article.

Scheme 58

1. Mount transmission in holding fixture and remove torque converter by pulling straight out. Remove oil pan and discard gasket. Remove oil screen and discard gasket. NOTE: The 2 oil screen attaching bolts are about 3/8" (10 mm) longer than valve body attaching bolts, and they are not interchangeable.
2. On Diesel models, remove governor pressure switch lead wire from switch and wire clips. Remove pressure switch using a 1 1/16" oil sending unit socket. (Scheme 58)
3. On all models, remove throttle lever and bracket assembly, using care not to bend throttle lever link. T.V. exhaust valve lifter and spring may separate from lever and bracket assembly.
4. Remove manual detent roller and spring assembly and remaining valve body attaching bolts. Holding manual valve with finger, remove valve body assembly, spacer plate, and gaskets together, to prevent dropping the 4 check balls located in valve body.
5. Remove 1-2 accumulator spring. Remove fifth check ball from bore in transmission case. Using a small screwdriver, remove governor cover retaining ring, then remove cover using pliers and discard cover seal rings. Remove governor assembly and governor-to-case washer. NOTE: It may be necessary to rotate output shaft counterclockwise while removing governor. DO NOT use any type of pliers to remove governor.
6. Remove lead wire from case electrical connector and solenoid wire clip, then compress fingers on connector sleeve and withdraw connector.
7. Depress intermediate servo cover and remove retaining ring. Using pliers, pull servo cover from case and discard cover seal ring. Remove intermediate servo piston and band apply pin assembly.

Note. Before continuing with transmission disassembly, check for proper intermediate band apply pin as follows.

Scheme 59

1. Install Band Apply Pin Selection Gauge (J-25014-2) in intermediate servo bore and retain with intermediate servo cover retaining ring aligning retaining ring gap in case slot. Install Selection Gauge Tapered Pin (J-25014-1) into gauge (Scheme 59)
2. Make sure tapered pin end is properly located against band apply lug. Also, make sure band anchor pin is properly located in case and band anchor lug.
3. Install dial indicator and position indicator pointer on top of selection gauge zero post.
4. Set indicator to zero. Make sure selection gauge is squarely seated against servo retaining ring and stepped side of tapered pin is aligned with torquing arm of gauge. Arm must stop against step in tapered pin.
5. If band selection pin does not register between the high and low limits, look for possible problem with intermediate band, direct clutch or case. (Scheme 59): Intermediate Band Apply Pin Selection INTERMEDIATE BAND APPLY PIN SELECTION Indicator Reading: In. (mm) (1) Apply Pin ID.0-.029 (.0-.72) 1 Ring.029-.057 (.72-1.44) 2 Rings.057-.086 (1.44-2.16) 3 Rings.086-.114 (2.16-2.88) Wide Band (1) Identification ring(s) or band is located on band end of apply pin.
6. Apply 100 INCH lbs. (11 N.m) torque to hex nut on side of gauge. Slide dial indicator over tapered pin and read dial indicator travel. Select correct band apply pin. See «INTERMEDIATE BAND APPLY PIN SELECTION»(/chevrolet/camaro/ii-1970-1987/remont/automatic-trans/#overhaul-200c). NOTE: Dial indicator travel is reversed, making the indicator readings backwards. On an indicator that ranges from 0-100, a.020" (.51 mm) travel will read.080" (2.03 mm), a.060" (1.52 mm) travel will read.040" (1.02 mm).
7. Remove apply pin selection tools. Inspect third accumulator valve for the following: Missing check ball, check ball binding or stuck in tube, oil feed slot in tube missing or restricted, improperly assembled, loose fitting or not fully seated in case. (Scheme 60)

Scheme 60

Third Accumulator Check Valve Replacement

1. Using a No. 4 screw extractor, remove check valve assembly from case by turning and pulling straight out. (Scheme 61)
2. Install new check valve assembly, small end first, into case. Position oil feed slot in tube so it faces servo cover. Using a 3/8" diameter metal rod and hammer, drive assembly in until it is flush or below surface of third accumulator case hole.

Scheme 61

OIL PUMP & FRONT UNIT COMPONENTS

Note. Prior to removing oil pump and front unit components, check front unit end play to determine correct end play thrust washer for use at reassembly. See Front Unit End Play Check under TRANSMISSION REASSEMBLY .

1. Turn transmission so oil pump faces upward. Remove and discard pump oil seal (if necessary). Remove oil pump-to-case attaching bolts and washers. Using Oil Pump Remover (J-24773-A), remove oil pump and gasket from case.
2. Grasp turbine shaft and pull direct and forward clutch assemblies from transmission case. Pull direct clutch assembly off forward clutch assembly. Direct-to-forward clutch thrust washer may stick to end of direct clutch housing.
3. Remove intermediate band assembly and anchor pin from case. Withdraw output shaft-to-turbine shaft front selective thrust washer. Output shaft-to-turbine shaft selective thrust washer may be stuck to end of turbine shaft.

FRONT INTERNAL GEAR

Note. At this time, check rear unit end play to determine correct end play thrust washer for use at reassembly. See Rear Unit End Play Check under TRANSMISSION REASSEMBLY .

Using snap ring pliers, remove output shaft-to-selective washer snap ring. Remove front internal gear, rear selective thrust washer, and thrust washer. Remove front carrier assembly and front internal gear-to-front carrier roller bearing assembly. Remove front sun gear snap ring, sun gear and front sun gear-to-front carrier thrust bearing assembly. Remove the input drum and rear sun gear. (Scheme 62)

Scheme 62

INPUT DRUM, REAR SUN GEAR & LOW-REVERSE CLUTCH HOUSING

1. Remove input drum and rear sun gear from case. Remove the 4-tanged input drum-to-reverse clutch housing thrust washer from rear of input drum or from reverse clutch housing.
2. Grind approximately 3/4" from end of a No. 4 screw extractor to remove housing-to-case cup plug. Remove cup plug assembly by turning screw extractor 2 or 3 turns and pulling straight out. (Scheme 63)
3. Remove low-reverse clutch housing-to-case beveled snap ring. Flat side of snap ring should have been against housing with beveled side up.
4. Using Reverse Clutch Housing Remover (J-25012), remove low-reverse clutch housing assembly from case. Remove clutch housing-to-case spacer ring. The front sun gear-to-front carrier thrust bearing may come out with front carrier.

Removing Low-Reverse Clutch Housing-To-Case Cup Plug. Scheme 63

REAR GEAR COMPONENTS

1. Ensure governor has been removed before removing rear gear components. Grasp output shaft and lift out rear unit parts and lay them down in a horizontal position. (Scheme 64)
2. Slide roller clutch and rear carrier assembly off output shaft. Remove 4-tanged rear carrier-to-rear internal gear thrust washer off end of rear carrier or inside rear internal gear.
3. Remove low-reverse clutch plates from output shaft. Remove rear internal gear-to-rear sun gear thrust bearing assembly from rear internal gear. Remove rear internal gear from output shaft.

Scheme 64

MANUAL SHAFT & PARKING LINKAGE

1. Remove manual detent spring and roller assembly. Remove hex nut holding inside detent lever to manual shaft, then remove parking actuator rod and detent lever.
2. Remove manual shaft retaining pin from case and slide manual shaft out. Pry manual shaft seal from case (if necessary). Remove parking lock bracket.
3. Remove parking pawl shaft retaining pin. Grind approximately 3/4" from end of a No. 4 screw extractor. Remove parking pawl cup plug and discard.
4. Using sheet metal screw or No. 3 screw extractor, remove parking pawl shaft. Remove parking pawl and return spring. (Scheme 65)

Scheme 65

VALVE BODY

As valve trains are removed from each valve body bore, place individual parts in correct order in relative position to valve body to simplify reassembly.

Valves and springs are not interchangeable, and all parts must be installed in correct order in proper valve body bore. Remove all coiled pins by pushing through from rough case surface of body, except the 2 pins which retain throttle valve and throttle valve plunger.

Scheme 66

Disassembly

1. Position valve body with cored face upward and 1-2 accumulator pocket at lower left. (Scheme 67) Remove 4 check balls from cored passages of valve body (5th check ball is in case), then remove 1-2 accumulator piston. From upper bore, remove manual valve. CAUTION: Some coiled pins in valve body assembly have pressure against them. Hold a shop towel over bore while removing pin to prevent losing bore plug or spring.
2. From upper right side bore, remove 2-3 valve train. From next bore down, remove the 1-2 valve train. From next bore down, remove reverse boost valve train. Some valves and springs may be inside valve bushings.
3. Remove shift T.V. valve train (if necessary). Remove coiled pin and place valve body with rough casting surface up. Use needle nose pliers and push in on valve, then hold in place with a small screwdriver.
4. Position a 1/4" diameter rod, 3/8" long against end of valve, pry on rod with a screwdriver, remove small screwdriver, and remove plug, spring, and valve.
5. From lower right side bore, remove outer coiled pin. Remove throttle valve bushing, plunger and spring. Remove throttle valve detent pin. Using 1/16" Allen wrench, with sides ground to fit inside pin, remove inner coiled pin, and then withdraw throttle valve.
6. From upper left side bore, remove intermediate boost valve train. From next bore down, remove low overrun clutch valve train. From next bore down, remove direct clutch exhaust valve train. From lower left side bore, remove 1-2 accumulator valve train.

Scheme 67

Inspection

Wash all parts in solvent and air dry. Inspect 1-2 accumulator piston and seal for damage; DO NOT remove seal unless replacement is required. Check valve body for cracks, damage, or scored bores. Inspect valves and plugs for scores, cracks, and free movement in valve body bores. Inspect springs for distortion and collapsed coils.

Reassembly

1. Reverse disassembly procedure using illustration as a guide. (Scheme 67) Install all flared coiled pins (zinc coated) flare end out, and away from machined surface of valve body.
2. Install the 2 tapered coiled pins (Black finish) that retain throttle valve and throttle valve bushing, tapered end first. Coiled pins do not fit flush on rough casting face.
3. Make sure pins are flush at machined face. When installing 1-2 throttle bushing and 2-3 throttle bushing, align in bores, so that coiled pins can be installed in pin slot. (Scheme 68) Install manual valve with inside detent lever pin groove to the right.

Scheme 68

1. Remove pump-to-case seal ring. Position pump on bench with cover side facing up. Remove pump-to-direct clutch thrust washer, and if replacement is necessary, remove 3 Teflon oil seal rings.
2. Remove solenoid wires from wire clips. Remove attaching bolts and lift torque converter clutch solenoid assembly from pump cover. Remove "O" ring from solenoid and discard.
3. Remove converter clutch valve bushing retaining pin and remove bushing, apply valve and actuator valve from pump cover bore. (Scheme 69)
4. Using a small screwdriver, push in on pressure regulator bore plug and remove retaining ring. Release spring tension slowly and remove pressure regulator valve train.
5. Remove attaching bolts and separate pump cover from body using care not to drop check ball from body. Remove check ball. Remove pump gears, marking them for reassembly in same position.

Note. Keep pump check ball separate from the 5 check balls used in case and valve body. Pump check ball diameter is .281" (7.14 mm), while case and valve body check ball diameter is .250" (6.35 mm).

Scheme 69

Scheme 70

1. Check drive and driven gears for scoring, galling, or other damage. Inspect gear pocket and crescent in body for scoring or damage.
2. Check pump cover and body for nicks, open oil passages, and overall flatness. Using a straightedge and feeler gauge, measure pump body face-to-gear face clearance. Clearance should be .0007-.0021" (.020-.055 mm).
3. Inspect torque converter clutch solenoid wires for loose connections and damaged or cut insulation. Inspect solenoid assembly ball check valve for nicks or damage.
4. Check for defective ball or ball seat. Blow air into ball seat with solenoid de-energized. Air should pass through ball seat. Noting polarity, energize solenoid with +12 volts D.C. and again blow air into ball seat. Air should not pass through ball seat. NOTE: DO NOT use compressed air to check ball and ball seat. The use of compressed air may cause a false reading.
5. Inspect converter clutch apply and actuator valves for nicks or damage. Check valves for free operation in bushing bore.
6. Grind approximately 1/2" from end of a No. 4 screw extractor. Using modified screw extractor, remove and discard cup plug from pump body. Discard cup plug. Withdraw screen from plug bore.
7. Clean screen in clean solvent and air dry, then reinstall screen in pump body bore. Install new cup plug, small diameter end first, into hole in pump body. Using a 5/16" diameter metal rod and hammer, drive cup plug until just below surface of hole.
8. Inspect pressure regulator valve bore in pump cover and pressure regulator valve assembly for wear or damage and make sure parts operate freely in bore. Inspect the 6 cup plugs in pump cover for damage or leaks. If necessary, replace cup plug.

Pump Cover Cup Plug Replacement

Remove old cup plugs using care not to damage pump cover. Drive new cup plugs to 1/32" below top of hole, using a 1/4" diameter rod on smaller plug and a 5/16" rod on the 5 larger plugs. Stake top of hole in 2 places, directly opposite each other, to retain plugs.

Scheme 71

Scheme 72

1. Install driven gear into pump body with identification mark down against gear pocket. (Scheme 72) Install drive gear into pump body with identification marks on tangs up. (Scheme 73) Place check ball into pocket in pump body (Scheme 71) Retain with petroleum jelly.
2. Assemble pump cover and body using Alignment Strap (J-25015) and lace bolt or screwdriver through pump-to-case bolt hole. Install and tighten pump cover attaching bolts and remove strap.
3. Install pressure regulator spring, spring guide, valve (stem end out), and bore plug (hole end out) into pump cover bore. Compress pressure regulator valve assembly and install retaining ring.
4. Install actuator valve into bushing bore of pump cover. Install apply valve into bushing, then install bushing into cover. Install apply valve bushing retaining pin and pin clip and bolt. (Scheme 69)
5. Install new pump-to-case gasket on pump and retain with petroleum jelly. Lubricate with petroleum jelly and install new "O" ring on solenoid assembly. Install solenoid on pump and tighten attaching bolts. Install solenoid wires into wire clip.
6. If removed, install 3 new oil seal rings on pump cover stator shaft, making sure cut ends are assembled in the same relationship as cut. Also, make sure rings are seated in grooves to prevent damage during transmission reassembly. Retain rings with petroleum jelly.
7. Install pump-to-case seal ring (chamfered side out), making sure ring is not twisted. Install pump-to-direct clutch thrust washer and retain with petroleum jelly.

Scheme 73

1. Remove clutch pack snap ring. Remove backing plate from clutch housing. Remove clutch plates from housing and keep them separate from the forward clutch plates. (Scheme 74)
2. Using Clutch Spring Compressor (J-23327), compress retainer and spring assembly and removed snap ring. Remove tool and lift retainer and spring assembly from clutch housing.
3. Remove release spring guide from clutch housing. Remove clutch piston from housing. Remove inner and outer seals from piston and center seal from housing.

Note. DO NOT separate apply ring from clutch piston unless ring or piston requires replacement.

Scheme 74

1. Inspect composition plates, steel plates, and backing plate for wear, burning, or scoring. Check release springs and retainer for damage or a collapsed condition. Inspect clutch piston for distortion, cracks and free operation of check ball.
2. Check clutch housing for cracks, wear, and open passages, and for free operation of check ball. Inspect snap ring grooves and bushing in housing for wear or damage.

1. Install apply ring on clutch piston. Install new inner and outer seals on piston, with seal lips facing away from clutch apply ring side. Install new center seal into direct clutch housing, with seal lip facing upward. Install Seal Protector (J-25010) over oil seals, lubricate seals with transmission fluid, and install clutch piston. CAUTION: Use care when installing piston past larger snap ring groove in clutch housing as groove could cut outer seal on piston.
2. Install release spring guide with omitted rib over check ball in piston (Scheme 75) Install retainer and spring assembly into housing, making sure all parts are positioned correctly.
3. Using clutch spring compressor, compress release springs and install retaining snap ring. Lubricate clutch plates with transmission fluid.
4. Install them into clutch housing starting with a flat steel plate and alternating composition plates and flat steel plates until all clutch plates are installed.
5. See «DIRECT CLUTCH PLATE USAGE»(/chevrolet/camaro/ii-1970-1987/remont/automatic-trans/#overhaul-200c). Install backing plate with chamfered side up and clutch pack retaining snap ring. After reassembly is completed, ensure that composition faced clutch plates turn freely.

DIRECT CLUTCH PLATE USAGE

Scheme 75

1. Remove forward clutch-to-direct clutch thrust washer. If replacement is required, remove Teflon oil seal rings from turbine shaft. Remove clutch pack snap ring. Remove backing plate, clutch plates and waved steel plates. (Scheme 76) NOTE: Keep forward clutch plates separate from direct clutch plates.
2. Using Forward Clutch Spring Compressor (J-25018), Compressor Press (J-25024) and Clutch Spring Compressor (J-23327), compress retainer and spring assembly and remove retaining snap ring.
3. Release compressor slowly, then remove retainer and spring assembly. Remove piston with apply ring from clutch housing, then remove inner and outer seals from piston.

Note. DO NOT remove clutch apply ring from piston unless piston or apply ring requires replacement.

Scheme 76

1. Inspect composition, steel and backing plates for wear, scores or other damage. Check spring retainer and release springs for distortion or collapse. Inspect piston and housing for cracks, distortion, open oil passages, or other damage. Inspect snap ring grooves for wear or damage, and make sure ball check in housing operates freely.
2. Check turbine shaft for open passages on both ends of shaft, and check journals for damage. Inspect clutch housing cup plug and if damaged, remove using No. 3 screw extractor (grind to fit). Install new cup plug to .039" (1.0 mm) below surface (grind to fit).

1. Install clutch apply ring on piston. Install new inner and outer seals on piston, with seal lips facing away from apply ring side. Lubricate seals with transmission fluid. Install piston into housing. Install retainer and spring assembly into housing. Compress retainer and springs, and install retaining snap ring. CAUTION: Use care when installing piston past large snap ring groove as groove could cut outer piston seal.
2. Lubricate with transmission fluid then install forward clutch plates into housing starting with waved steel plate then alternating flat steel plates and composition plates until all clutch plates are installed.
3. See «FORWARD CLUTCH PLATE USAGE»(/chevrolet/camaro/ii-1970-1987/remont/automatic-trans/#overhaul-200c) . Install backing plate (chamfered side up) and clutch pack snap ring. Install new turbine shaft seal rings (if removed) and forward clutch-to-direct clutch thrust washer.

Note. After reassembly is completed, ensure composition faced clutch plates turn freely.

FORWARD CLUTCH PLATE USAGE

Check all parts for pitting, scoring, damaged gear teeth and cracks. Make sure all lubrication holes are open. Check front internal gear thrust washers for wear or other damage and front carrier roller thrust bearing for roughness and pitting. Check pinion end play of front carrier. End play should be.009-.027" (.23-.69 mm). (Scheme 77)

Scheme 77

Check rear sun gear for cracks, splits, spline damage, gear or journal wear, and for plugged lubrication holes. Remove snap ring (if necessary) and separate sun gear from input drum. Inspect drum splines for damage. Check input drum-to-low-reverse clutch housing thrust washer for scoring or distorted tangs.

Scheme 78

Compress low-reverse clutch spring retainer, remove snap ring and retainer. Check for damage and distortion. Remove waved spring and clutch piston. Remove inner and outer seals, and clutch apply ring. (Scheme 79)

Check clutch housing for scoring or wear, damaged bushing, and plugged oil feed hole. Inspect splines and snap ring groove for damage or burrs. Check piston assembly for distortion, cracks, or damage. Inspect clutch plates for signs of scoring or burning. Check retainers and spring for damage or distortion. Check housing to case spacer for damage.

1. Install clutch apply ring on low and reverse hub clutch piston. Install new inner and outer seals on clutch piston (seal lips facing away from apply ring side). Lubricate clutch seal with transmission fluid.
2. Install Seal Protector (J-25011) into clutch housing hub. Using a flat tip screwdriver to start seal into housing, install clutch piston, rotating while pushing down into bore. Remove seal protector. Install waved spring, retainer (cupped side down) and snap ring.

Scheme 79

1. Check rear internal gear splines, teeth, bearing surface and parking pawl lugs for wear, cracks or other damage. Inspect roller clutch race and spline for scoring or wear, and roller bearings, cage and springs for wear, scoring, distortion or collapse.
2. Inspect thrust washers for excessive wear or damaged tangs. Check rear carrier roller clutch cam ramps and bushing for scoring or other damage. Inspect planet pinions for damage, rough bearings, tilt and correct end play. End play should be .009-.027" (.23-.69 mm).

Scheme 80

1. Inspect journals and snap ring grooves for wear or damage. Check for plugged or damaged lubrication holes. Inspect shaft splines and governor drive gear for rough or damaged surfaces.
2. Check speedometer drive gear and retaining clip for wear or damage. Replacement output shaft has one speedometer drive gear clip hole at the front speedometer gear location which is about 1/4" diameter.
3. Opposite this hole is another clip hole which is about 5/32". The shaft also has same size holes at rear speedometer gear location.

Speedometer Drive Gear Replacement

1. If equipped with a nylon gear, depress gear clip and slide drive gear and clip off output shaft. To install, place gear clip with tanged end in correct hole in shaft. Align slot of gear with slip and install gear. (Scheme 81)
2. Using Gear Puller (J-8433 and J-21427-01), remove steel gear (if equipped). To install, position front end of shaft on a block of wood to prevent damaging shaft during installation.
3. Position gear (large chamfered inside diameter first) over rear end of output shaft. Using driver, drive gear onto shaft until distance from rear end of shaft to rear face of gear is 6 5/32" (156.37 mm).

Scheme 81

Compress intermediate servo piston spring. Using small flat blade screwdriver, remove servo pin-to-piston snap ring. Separate band apply pin, spring and washer from servo piston. (Scheme 82)

1. Check intermediate servo pin for wear, damage and proper fit in case bore. Inspect inner and outer seal rings for damage and proper fit in seal ring grooves of piston. CAUTION: DO NOT remove seal rings from piston unless replacement is required.
2. Check servo piston and cover for cracks or other damage. Inspect servo spring for collapsed coils or distortion. Check intermediate servo cover and piston assembly for proper combination and usage. See «INTERMEDIATE SERVO COVER & PISTON USAGE»(/chevrolet/camaro/ii-1970-1987/remont/automatic-trans/#overhaul-200c) .

INTERMEDIATE SERVO COVER & PISTON USAGE

1. Install retainer on band apply pin and install snap ring. Install band apply pin (retainer end first) through servo pistons. Install new inner and outer seal rings on piston (if removed).
2. Ensure seal ring ends are assembled in the same relationship as cut and seal rings are seated in grooves. Lubricate with petroleum jelly and install new seal ring on intermediate servo cover. Install servo piston assembly into servo cover.

Scheme 82

1. Inspect governor cover for damage, scored or worn bore and plugged oil passage. Wash governor assembly in cleaning solvent and blow out oil passage. Inspect governor driven gear, weights, springs, shaft and washer for wear or damage.
2. Check governor shaft seal ring for cuts, damage and free fit in groove. If damaged, cut ring off shaft and install new seal ring. Lubricate seal with petroleum jelly. Inspect for presence of 2 check balls.

1. Check case assembly for cracks, porosity and interconnected oil passages. Inspect reverse clutch lugs, governor bore, intermediate servo bore, speedometer bore and snap ring grooves for wear and other damage. Make sure all vents and passages are open and clear.
2. Inspect vent assembly in case for damage. DO NOT remove unless replacement is required. Check cooler line connectors for damage. DO NOT remove unless replacement is required.

Scheme 83

1. Place transmission in horizontal position, oil pan side up. Install new manual shaft seal into case with seal lip facing inward. Place parking pawl and return spring into case, making sure pawl tooth faces inside of case. Be sure spring is positioned under pawl tooth and spring ends locate against case pad.
2. Align pawl and spring with shaft bore in case and install pawl shaft (tapered end first). Using a 3/8" diameter rod, install a new shaft cup plug (open end out) into shaft bore, past retaining pin hole. Install parking pawl shaft retaining pin.
3. Install parking lock bracket into case, with parking pawl positioned between guides of bracket. Install and tighten 2 attaching bolts. Install parking lock actuator rod into inside detent lever (on pin side) locating lever between actuator rod tangs. (Scheme 84)
4. Install rod and lever assembly into case with lever pin toward center of transmission and actuator plunger between parking pawl and parking lock bracket. File off any burrs or raised edges on manual shaft that could damage seal during installation of shaft.
5. Install manual shaft (small I.D. ring groove first) through case. Install manual shaft-to-case retaining pin, indexing with larger groove on manual shaft.
6. Align inside detent lever with flats on manual shaft, position lever on shaft. Install and tighten nut on manual shaft.

Scheme 84

OUTPUT SHAFT & REAR INTERNAL GEAR

Install new rear internal gear-to-output shaft snap ring into groove on output shaft (if removed). Install rear internal gear (hub end first) onto shaft. Position rear internal gear-to-rear sun gear roller thrust bearing assembly over shaft by placing small diameter race against rear internal gear.

ROLLER CLUTCH & REAR CARRIER

1. Install rear internal gear, hub end first, on output shaft. Install internal gear-to-rear sun gear roller thrust bearing assembly into internal gear by placing small diameter race over output shaft.
2. Install roller clutch-to-rear carrier thrust washer into rear carrier. Install rollers that may have come out of roller clutch cage, by compressing energizing spring with forefinger and inserting roller from outer edge.
3. Install roller clutch assembly into rear carrier assembly. Install roller clutch race, spline side out and rotate clutch race counterclockwise into position.
4. Install 4 tanged rear carrier-to-rear internal gear thrust washer onto carrier and align tangs into slots of carrier. Retain washer with petroleum jelly. Install roller clutch and carrier assembly into rear internal gear on output shaft.
5. Install Output Shaft Support (J-25013) on rear of transmission as follows: place Support Sleeve (J-25013-1) into rear of case, open end first. Bolt Bracket (J-25013-5) into rear mount bolt holes on extension housing. (Scheme 85)
6. Turn case to vertical position, with pump end upward. Install rear unit parts (output shaft, rear internal gear, and rear carrier previously assembled) into transmission case and into support sleeve, indexing rear internal gear parking pawl lugs to pass by parking pawl tooth.
7. Using adjusting screw on bracket and looking through parking pawl case slot, adjust height of the rear internal gear parking pawl lugs to align flush with the parking pawl tooth.

Scheme 85

LOW-REVERSE CLUTCH

1. Lubricate with transmission fluid then install low-reverse clutch plates, starting with a flat steel plate, and alternating composition and flat steel plates until all clutch plates are installed. See «LOW-REVERSE CLUTCH PLATE USAGE»(/chevrolet/camaro/ii-1970-1987/remont/automatic-trans/#overhaul-200c) . Install waved steel clutch plate on top of last flat steel plate.
2. Install low-reverse clutch housing-to-case spacer ring into case. Install low-reverse clutch housing assembly, aligning housing oil feed hole with case oil feed passage.
3. If housing does not seat past snap ring groove, proceed as follows: Install input drum and rear sun gear assembly into case and rotate back and forth to align roller clutch race and low-reverse clutch hub splines. Remove input drum and sun gear. LOW-REVERSE CLUTCH PLATE USAGE Model Application (1) Flat Steel Composition All Models (2) 7 6 (1) Plate thickness is 0.077" (1.96 mm). (2) Plus 1 WAVED steel plate 0.077" (1.96 mm) thick, installed last.
4. Repeat step 3) if low-reverse clutch housing still is not seated past case snap ring groove. With parts properly seated, install low-reverse clutch housing-to-case snap ring, with flat side of ring against housing (beveled side upward). Locate snap ring gap opposite parking pawl rod.

Note. It may be necessary to loosen adjusting screw on output shaft support tool to install low-reverse clutch housing-to-case snap ring.

REAR SUN GEAR, INPUT DRUM & FRONT SUN GEAR

1. Position thrust washer (four tangs) on input drum over sun gear end, align washer tangs with slots in drum, and retain with petroleum jelly.
2. Install rear sun gear and input drum assembly into case. Install front sun gear, with drill spot or groove on face against input drum-to-rear sun gear snap ring.
3. Install front sun gear-to-front carrier thrust bearing and race assembly with roller thrust bearing against front sun gear. The front sun gear-to-front carrier thrust bearing requires only one thrust race.

Scheme 86

FRONT CARRIER

Position front carrier-to-front internal ring gear thrust bearing assembly on front carrier, with small diameter race against carrier and retain in place with petroleum jelly. Install front carrier and thrust bearing assembly into case, engaging front sun gear.

1. Install thrust washer on front internal gear and retain with petroleum jelly. Install front internal gear into case.
2. Install rear unit selective thrust washer on top of internal gear thrust washer. Install output shaft-to-thrust washer snap ring and make sure snap ring is fully seated in output shaft groove.
3. At this time, measure rear unit end play to ensure correct selective thrust washer has been installed.

Rear Unit End Play Check

1. Loosen adjusting screw on Output Shaft Support (J-25013-5) and push output shaft fully downward. Mount dial indicator and extension on transmission case (Scheme 87) Position indicator button on output shaft. DO NOT clamp indicator to any machined surface.
2. Zero dial indicator. Move output shaft upward by turning adjusting screw on output shaft support tool, until White or scribed line on tool sleeve begins to disappear. Read resulting end play on indicator.
3. Rear unit end play should be.004-.025" (.10-.64 mm). If not, selective thrust washer located between front internal gear thrust washer and output shaft snap ring must be changed.
4. See «REAR UNIT SELECTIVE THRUST WASHER»(/chevrolet/camaro/ii-1970-1987/remont/automatic-trans/#overhaul-200c). Install correct thickness thrust washer (with I.D. number toward front of case). Reinstall output shaft snap ring making sure it is fully seated in groove.
5. Remove dial indicator assembly and loosen adjusting screw on output shaft support tool. Install output shaft-to-turbine shaft front selective thrust washer, locating it on output shaft and retain with petroleum jelly.

Scheme 87

REAR UNIT SELECTIVE THRUST WASHER

Scheme 88

1. Align direct clutch composition clutch plate teeth one above the other to make forward clutch assembly easier to install. Position direct clutch over hole in bench with clutch plate end upward.
2. Make sure forward clutch-to-direct clutch thrust washer is still in place on forward clutch. Install forward clutch (turbine shaft first) into direct clutch.
3. Hold direct clutch housing and rotate forward clutch back and forth until forward clutch is seated. When properly seated, end of forward clutch drum will be approximately 5/8" (15.8 mm) from tang end of direct clutch housing.
4. Position intermediate band into case, locating band apply lug and anchor pin lug in case slots. Install direct and forward clutch assemblies into case as a unit, rotating into position.
5. When correctly seated, the direct clutch housing will be approximately 1 5/16" (33.34 mm) from pump face in case.

OIL PUMP

1. Install new pump-to-case gasket on pump and retain with petroleum jelly. Install 2 pump-to-case alignment pins in case, opposite each other. NOTE: Before installing pump, ensure intermediate band anchor pin lug is aligned with band anchor pin hole in case.
2. Install pump assembly and finger start pump-to-case bolts and new washers, except one bolt which will be used to make front unit end play check. CAUTION: If turbine shaft cannot be rotated as pump is pulled into place, forward or direct clutch housings are not properly indexed with all clutch plates. This condition must be corrected before pump is pulled fully into place.
3. Remove alignment pins and install 2 pump attaching bolts and new washers. Tighten pump-to-case bolts evenly and make sure turbine shaft rotates freely.

Scheme 89

1. With transmission in vertical position (pump side up), install an 11" long bolt into pump attaching bolt hole. Push turbine shaft downward.
2. Output Shaft Support (J-25013-5 and J-25013-1) should still be attached to rear of transmission; if not, reinstall using procedure given in «ROLLER CLUTCH & REAR CARRIER»(/chevrolet/camaro/ii-1970-1987/remont/automatic-trans/#overhaul-200c__roller-clutch-rear-carrier) section of TRANSMISSION REASSEMBLY.
3. Install End Play Gauging Fixture and Adapter (J-24733-A and J-25022-A) on end of turbine shaft. (Scheme 89) Mount dial indicator on bolt and position indicator button against cap nut of gauging fixture.
4. Move output shaft upward by turning adjusting screw on output shaft support tool until White or scribed line on sleeve begins to disappear, then zero dial indicator.
5. Pull turbine shaft upward and read end play on indicator. Front unit end play should be.022-.051" (.56-1.30 mm). Selective thrust washer controlling front unit end play is located between output shaft and turbine shaft.
6. If more or less washer thickness is required to bring end play within specifications, remove oil pump and forward and direct clutch assemblies, and install correct thickness washer on end of output shaft. See «FRONT UNIT SELECTIVE THRUST WASHER»(/chevrolet/camaro/ii-1970-1987/remont/automatic-trans/#overhaul-200c).
7. Remove front unit end play checking tools. Install remaining pump-to-case bolt and tighten. Remove output shaft support.

FRONT UNIT SELECTIVE THRUST WASHER

GOVERNOR

1. Install new seal ring on governor shaft (if removed) and place seal ring end into governor cover to size seal. Lubricate seal with petroleum jelly. Lubricate and install 2 new seal rings on governor cover. Ensure 2 check balls are in governor before installation.
2. Install governor assembly (seal end first) into cover. Install governor assembly and cover into case, aligning governor shaft with shaft hole in case.
3. Rotate assembly and output shaft slightly to ease installation. Install governor retaining ring and align ring gap with an end showing in case slot. If retaining ring cannot be installed, governor shaft is not aligned with case hole. Governor cover fits tight in case bore the last 1/16" (1.59 mm).

BAND ANCHOR PIN & INTERMEDIATE SERVO

Install anchor pin (stem end first) into case. Make sure stem locates in hole of intermediate band lug. Install servo assembly into case and make sure tapered end of band apply pin is properly located against band apply lug. Compress servo cover and install retaining ring. Align ring gap with an end showing in case slot.

Scheme 90

Scheme 91

Scheme 92

1. Install new low-reverse clutch housing-to-case cup plug and seal assembly, with seal end first, into hole in case. (Scheme 90) Using a 3/8" diameter metal rod and hammer, drive plug and seal assembly into case until it seats against low-reverse clutch housing.
2. Lubricate with petroleum jelly and install new "O" ring seal on torque converter clutch electrical connector. Connect solenoid lead wire to electrical connector. Install connector into case with lock tabs facing into case and locator tab in notch on side of case.
3. Install 1-2 accumulator spring into case pocket. Install 5th check ball into case. Install 2 guide pins into case to align valve body parts. Install remaining four check balls into ball seat pockets in valve body and retain with petroleum jelly. (Scheme 66)
4. Position valve body-to-spacer plate gasket (marked "VB") on valve body, then place spacer plate on top of gasket. Place spacer plate-to-case gasket (marked "C") on top of spacer plate.
5. Insert 2 valve body attaching bolts through valve body, gaskets and spacer plate. Install valve body assembly, aligning manual valve with detent lever pin.
6. Make sure check balls, 1-2 accumulator piston and manual valve do not fall out during valve body installation. Start valve body attaching bolts, except throttle lever, bracket assembly and oil screen attaching bolts. (Scheme 91)
7. Remove guide pins and replace with bolts, inside manual detent roller, and spring assembly. Locating tang in valve body and roller on inside detent lever.
8. Install spring on top of throttle lever (if removed) and bracket assembly lifter. Place lifter and spring into throttle bracket. Install link on throttle lever, making sure link is hooked. (Scheme 92)
9. Install lever and bracket assembly, locating slot in bracket with coiled pin, aligning lifter through valve body hole and link through T.V. linkage case bore. Install attaching bolts. Tighten all valve body attaching bolts evenly.
10. On Diesel models, install governor pressure switch using a 1 1/16" oil pressure sending unit socket. Connect long solenoid lead wire to governor pressure switch terminal. Press solenoid lead wires into wire clip.

Scheme 93

OIL SCREEN, OIL PAN & SPEEDOMETER DRIVEN GEAR

Install new screen gasket on oil screen, retain with petroleum jelly. Install screen on valve body. Install and tighten attaching bolts. Position new pan gasket on case. Install oil pan and attaching bolts and tighten. Install new "O" ring seal on speedometer driven gear housing (if necessary). Install housing into case. Install retainer and attaching bolt, aligning slot in housing with retainer.

Install torque converter into pump assembly. Ensure converter hub drive slots are fully engaged with pump drive gear tangs. Converter must be fully installed towards rear of transmission.

Note. When properly installed, the distance between engine mounting face of transmission case and front face of converter cover drive lugs will be at least 1" (25.4 mm).

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TRANSMISSION DISASSEMBLY
• ROLLER CLUTCH & REAR CARRIER