Overhaul - 180c/3l30 GMC Cab & Chassis R2500

APPLICATION

TRANSMISSION APPLICATION (CHEVROLET)

TRANSMISSION APPLICATION (GEO)

TRANSMISSION APPLICATION (GMC)

TRANSMISSION APPLICATION (PONTIAC)

TRANSMISSION APPLICATION (SUZUKI)

IDENTIFICATION

The transmission identification code is stamped on a tag located on left side of transmission case near rear edge of torque converter housing.

TRANSMISSION MODEL CODES

DESCRIPTION

The 180C transmission is a fully automatic unit consisting primarily of a 4-element hydraulic torque converter and a compound planetary gear set. Three multiple-disc clutches, a roller clutch and a band provide the 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.

LUBRICATION & ADJUSTMENTS

See appropriate TRANSMISSION SERVICING - A/T article in the AUTOMATIC TRANS SERVICE section

1. For 1987 S10/S15 2.5L & 2.8L, see TRANSMISSION SERVICING - A/T
2. For 1987 S10 Blazer/S15 Jimmy 2.5L & 2.8L, see TRANSMISSION SERVICING - A/T
3. For 1982-87 Chevette/T1000 1.6L, see TRANSMISSION SERVICING - A/T
4. For 1989-92 Tracker/Sidekick 1.6L, see TRANSMISSION SERVICING - A/T

SERVICE (IN VEHICLE)

The following components may be removed from transmission for inspection or repair, without removing transmission from vehicle

1. Governor Cover, Seals & Assembly
2. Intermediate Servo Cover, Seal & Assembly
3. Oil Pan & Screen Assembly
4. Control Valve Assembly
5. Check Balls & Valve Body Space Plates & Gaskets
6. Inside Detent Range Lever
7. Manual Detent Roller & Spring Assembly
8. Throttle Lever & Bracket Assembly
9. TV Detent Cable & "O" Ring
10. Parking Pawl Actuator Rod
11. Parking Pawl & Bracket
12. Manual Shift & Seal
13. Manual Valve
14. Manual Valve Link
15. Extension Housing, Gasket & Rear Seal
16. 1-2 Accumulator Assembly
17. Vacuum Modulator
18. Cooler Fittings
19. Oil Filter Pipe & "O" Ring
20. Speedometer Driven Gear & Assembly
21. Converter Clutch Solenoid
22. Solenoid Wire Clips
23. Electrical Connectors
24. Governor Feed Screen
25. Modulator Valve
26. Low Band Adjustment

For removal and installation procedures on these components, see TRANSMISSION DISASSEMBLY and TRANSMISSION REASSEMBLY.

TROUBLE SHOOTING

See appropriate TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.

Drive Range ("D")

With selector lever in "D" range, accelerate vehicle from a standstill. A 1-2 and 2-3 shift should occur at all throttle openings (shift points will vary with throttle openings). As vehicle speed decreases to zero MPH, a 3-2 and 2-1 downshift should occur.

Intermediate Range ("L2")

Place selector lever in "L2" and accelerate vehicle from a standstill. A 1-2 shift should occur at all throttle openings. No 2-3 shift can be obtained in this range. The 1-2 shift point will vary with throttle opening. As vehicle speed decreases to zero MPH, a 2-1 downshift should occur.

Low Range ("L1")

Place selector lever in "L1" and accelerate vehicle from a standstill. No upshift should occur in this range.

2nd Gear ("L2") Overrun Braking

With selector lever in "D" range and vehicle moving in high gear, lift foot off accelerator and move selector lever to intermediate range ("L2"). An increase in engine RPM and an engine braking effect should be noted.

1st Gear ("L1") Overrun Braking

With selector lever in "L2" range, and vehicle speed approximately 30 MPH at constant throttle, move selector lever to "L1" range. An increase in engine RPM and an engine braking effect should be noted.

CLUTCH & BAND APPLICATIONS

Scheme 54

CONTROL PRESSURE TEST

1. Remove transmission crossmember side bolts and lower transmission slightly to gain access to line pressure take-off point. Connect a tachometer to engine and a pressure gauge to line pressure take-off point on left side of transmission case. See Item 91 in (Scheme 55).
2. Replace rear crossmember and side bolts. With transmission fluid at correct level and operating temperature, pressure can be checked by road testing or by running engine with vehicle on a hoist as follows.

Stationary Test (Modulator Disconnected)

Make test with vehicle stationary, service brakes applied, engine speed set at 1500 RPM, vacuum modulator line disconnected, and pressure gauge installed. Transmission line pressure should be approximately as shown in STATIONARY CONTROL PRESSURES .

STATIONARY CONTROL PRESSURES

Coasting Check (Modulator Connected)

With vehicle coasting at 30 MPH (foot off throttle), pressure gauge installed and vacuum modulator line connected, transmission line pressure should be approximately as shown in COASTING CONTROL PRESSURES .

COASTING CONTROL PRESSURES

Control Pressure Too Low

1. Low oil level.
2. Clogged suction screen.
3. Leak in oil pump suction circuit.
4. Leak in oil pressure circuit.
5. Pressure regulator valve malfunction.
6. Sealing ball in valve body dropped out.

Control Pressure Too High

1. Modulator vacuum line leaking or interrupted.
2. Failed vacuum modulator.
3. Vacuum leak in engine or accessory vacuum system.
4. Pressure regulator valve malfunction.

REMOVAL & INSTALLATION

See appropriate article in AUTOMATIC TRANS SERVICE

1. For 1987 S10/S15 2.5L & 2.8L, see TRANSMISSION REMOVAL & INSTALLATION - A/T
2. For 1987 S10 Blazer/S15 Jimmy 2.5L & 2.8L, see TRANSMISSION REMOVAL & INSTALLATION - A/T
3. For 1982-87 Chevette/T1000 1.6L, see TRANSMISSION REMOVAL & INSTALLATION - A/T
4. For 1989-92 Tracker/Sidekick 1.6L, see TRANSMISSION REMOVAL & INSTALLATION - A/T

TORQUE CONVERTER

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

LEAKAGE CHECK

See procedure given in AUTO TRANS OVERHAUL - TURBO HYDRA-MATIC 400 article.

Note. For information on the converter clutch system used in the THM 180C, see GENERAL MOTORS TORQUE CONVERTER CLUTCH article.

TORQUE CONVERTER & CONVERTER HOUSING OIL SEAL

1. Remove oil filter tube. Remove converter by pulling straight out. Install transmission in a holding fixture with oil pan up.
2. If converter housing oil seal replacement is necessary, remove oil seal using puller and slide hammer.

INPUT SHAFT END PLAY

See SELECTING TRANSMISSION END PLAY SELECTIVE THRUST WASHER .

Scheme 55

LEGEND FOR (Scheme 55)

Scheme 56

Scheme 57

1. Remove attaching bolts and lift off oil pan. Remove oil pan gasket. Remove manual detent roller and spring assembly. Remove and discard oil strainer and gasket.
2. Disconnect governor pressure switch electrical connector and solenoid wiring harness. Remove governor pressure switch, converter clutch solenoid and solenoid pipes. DO NOT bend solenoid pipes when removing.
3. Remove transfer plate reinforcement attaching bolts and remove reinforcement. Remove servo cover attaching bolts and remove cover and gasket. Remove remaining bolts attaching valve body to case. Identify bolts for replacement in correct location during reassembly. Carefully remove valve body with gasket and transfer plate. (Scheme 56) NOTE: Care must be taken so that manual valve and link are not damaged or lost during valve body removal.
4. Remove 2 bolts holding transfer plate to valve body, then remove plate and gasket. Remove 2 check balls located in oil passages in transmission case. NOTE: Location of these 2 check balls must be noted to ensure that they are reinstalled correctly.
5. Using Compressor (J-23075), compress servo piston and remove retaining snap ring. Remove compressor and servo piston assembly.

Scheme 58

MODULATOR ASSEMBLY

Remove vacuum modulator from transmission case. Use care not to lose the modulator plunger. Remove modulator valve and sleeve from case. Remove "O" ring seal, by using internal snap ring pliers.

Scheme 59

1. Remove lock nut securing inner lever to selector shaft, then remove inner lever. Remove selector lever shaft spring pin by pulling upwards with pliers. (Scheme 59)
2. Remove selector lever shaft. Remove selector lever shaft oil seal. Discard oil seal. Remove electrical connector from transmission case. Remove vacuum modulator as previously described.
3. Remove detent valve spring pin using pliers. Push on spring seat of detent valve assembly from front of case and remove detent valve, sleeve, spring, and spring seat from rear of case.

EXTENSION HOUSING & SPEEDOMETER DRIVEN GEAR

1. Remove bolt holding speedometer driven gear housing retainer. Carefully remove retainer and pull driven gear assembly from extension housing bore.
2. Remove extension housing attaching bolts. Slide extension housing and gasket from case, while noting position of parking pawl in housing. Remove parking pawl actuator lever and actuator rod from transmission case.

SPEEDOMETER DRIVE GEAR, GOVERNOR BODY & HUB

1. Depress speedometer drive gear retaining clip and slide gear off output shaft.
2. Remove 4 attaching bolts from governor body, slide governor body off output shaft. Remove governor hub retaining snap ring, and slide hub from output shaft.

CONVERTER HOUSING, OIL PUMP, REVERSE CLUTCH & 2ND CLUTCH

ASSEMBLY

Scheme 60

1. Turn transmission in holding fixture so that converter housing is facing up. Remove the 7 converter housing attaching bolts. Loosen, but do not remove, the 5 oil pump attaching bolts. (Scheme 60) NOTE: Outer bolts are converter housing bolts. Inner bolts are oil pump attaching bolts.
2. Remove "O" ring seal from input shaft. Remove converter housing with oil pump, oil pump flange gasket and reverse clutch assemblies. DO NOT lose selective thrust washer, located between oil pump hub and 2nd clutch drum.
3. Remove 2nd clutch and 3rd clutch assemblies by lifting up on input shaft. Separate 2nd clutch and 3rd clutch assemblies. Remove reverse clutch plates and aluminum pressure plate from transmission case.

3RD CLUTCH, PLANETARY CARRIER, REACTION SUN GEAR & LOW BAND

1. Remove inside selector lever and parking lock actuator rod from transmission case. Lift out 3rd clutch assembly and input shaft. Remove planetary carrier and output shaft by sliding out. NOTE: Care should be taken not to lose the 2 thrust bearings and one thrust washer from planetary carrier assembly.
2. Pull reaction sun gear and drum straight out of case. Remove thrust bearing from rear of transmission case. Remove low band by slightly compressing band and pulling straight out. If necessary, remove transmission case vent.

Note. If transmission case vent is removed, a new vent must be installed. DO NOT attempt to reinstall old vent.

Disassembly

1. Remove 2nd clutch assembly from oil pump shaft. Remove selective washer from oil pump shaft.
2. Remove oil pump outer seal. Remove oil pump bolts from converter housing. Separate oil pump from housing. Remove oil pump wear plate. (Scheme 61)
3. Remove converter housing oil seal, and if necessary, remove housing bushing using a bushing driver. Mark relative location of oil pump gears and remove gears from oil pump body.
4. Using Spring Compressor (J-2327), compress reverse clutch return springs and remove snap ring. Remove reverse clutch retaining ring and 24 return springs. Remove reverse clutch piston.

Note. Pressure regulator valve and boost valve should not be removed unless it was determined by oil pressure checks to have been malfunctioning.

Scheme 61

Scheme 62

1. Clean converter housing thoroughly. Check converter pump hub for nicks, burrs or other damage. Remove nicks and burrs. Inspect the pressure regulator boost valve, the pressure regulator valve and the converter clutch actuator valve for nicks or damage.
2. Thoroughly clean the pressure regulator boost valve, pressure regulator valve and converter clutch actuator valve. Immerse valves in transmission fluid before installing in their bores. Inspect oil pump hub oil seal rings. Replace if damage or side wear is found.
3. Inspect reverse clutch piston for damage and replace if necessary. Inspect reverse clutch piston springs for wear or distortion and replace as necessary.
4. Inspect oil pump and gears for any signs of wear or damage, and replace as necessary. Install gears into oil pump and check end clearance of both gears.
5. Use a straightedge and feeler gauge and measure clearance between face of gears and pump face. Clearance should be .0005-.0035" (.013-.083 mm).
6. Next, measure clearance between drive gear and crescent while rotating gears one complete revolution. Clearance should be .005-.009" (.127-.229 mm).
7. Measure clearance between outside of driven gear and housing. Clearance here should be .003-.007" (.076-.178 mm). Finally, measure between inside of driven gear and crescent segment. Rotate gear one revolution. Clearance should be a minimum of .005" (.127 mm).

Scheme 63

1. Inspect oil pump hub bushing for wear or damage and replace as necessary. If replacement is needed, thread a 3/4" standard pipe tap into bushing. Using a drift on tap, press oil pump bushing out with arbor press. NOTE: Use rag or cloth to protect oil pump face when pressing out bushing.
2. Clean pump body, including all holes and pockets thoroughly. With oil pump shaft hole "A" facing downward, scribe an alignment mark on oil pump shaft inner diameter at the center of oil groove to right of hole "A". (Scheme 63)
3. Scribe mark on outer edge of bushing through centers of small and large drilled holes "B". Place bushing into oil pump shaft with small hole up, and align scribe marks on bushing with those made in oil pump shaft.
4. Use arbor press to drive bushing into oil pump shaft until seated in bore. Care must be taken so that bushing is pressed in straight, using scribe marks as a guide until firmly seated.

Scheme 64

1. If removed, install a new converter housing bushing using a driver. Install bushing flush with front face of housing. Install new converter housing oil seal.
2. Immerse pressure regulator valve in transmission fluid, install valve in oil pump body bore. Install pressure regulator spring, 2 spring seats, boost valve and sleeve into pump bore. Depress regulator boost valve sleeve until back end lines up with pin holes. Install retaining spring pin.
3. Install 2 new oil seals on reverse clutch piston. Install reverse clutch piston onto rear face of oil pump using a liberal amount of transmission fluid.
4. Install 24 reverse clutch piston return springs, then install retaining seat. Compress return springs and seat and install retaining snap ring. NOTE: DO NOT air check reverse clutch as the clutch is not complete and damage to return spring retaining seat may occur.
5. Turn oil pump and reverse clutch assembly so that oil pump face is up. Install oil pump gears using location marks made at disassembly. Install oil pump wear plate onto oil pump.
6. Insert guide pin into oil pump for alignment of converter housing and lower housing onto pump. Loosely install bolts into converter housing.
7. Use Aligner (J-23082-01) to align converter housing to pump. (Scheme 64) Aligner should bottom on oil pump gear.
8. Tighten oil pump attaching bolts in 2 stages to specified torque. Remove aligner. Install new converter housing-to-case rubber oil seal.

1. Remove ring gear retaining ring from 2nd clutch drum, then pull ring gear from drum. Remove 2nd clutch spacer plate retaining ring, then remove spacer plate, steel and composition clutch plates from clutch drum. NOTE: Keep clutch plates in same sequence as they were installed in clutch drum.
2. Remove 2nd clutch-to-3rd clutch thrust washer. Using Spring Compressor (J-23327), compress 2nd clutch return springs and remove retaining snap ring. Remove compressor and withdraw spring retaining seat and return springs. Remove clutch piston from drum.

Inspection

1. Inspect clutch piston. If piston is damaged or if check ball falls out upon inspection, replace piston. Inspect piston lip seals and replace if worn or damaged.
2. Inspect piston return springs for wear and distortion and replace as necessary. Inspect clutch hub bushing. If necessary, use a driver to replace bushing.
3. Inspect clutch plates for wear, damage or signs of burning or glazing. If the surface of steel clutch plate; is smooth and an even color smear is indicated, plate should be reused. If severe heat spot discoloration or surface scuffing is indicated, plate should be replaced.

Scheme 65

Scheme 66

1. Lubricate piston seals with transmission fluid, then install piston into drum using Seal Protector (J-23080-A) to keep from damaging lip seals.
2. Install 22 piston return springs and spring seat on piston. Compress return springs and seat and install retaining snap ring. NOTE: Ensure that spring seat does not catch in snap ring groove.
3. Install 2nd clutch-to-3rd clutch thrust washer so that tang seats in slot of 2nd clutch hub. Retain washer with petroleum jelly.
4. Lubricate clutch plates with transmission fluid. Install plates into drum starting with cushion plate (wave washer), alternating steel and composition plates until all clutch plates are installed.
5. Install 2nd clutch spacer plate into drum. If necessary, expand spacer plate with screwdriver until ends are evenly butted together seating tightly into drum. Install spacer plate retaining snap ring. Install ring gear into drum with grooved edge facing up, then install retaining snap ring.

Scheme 67

1. Mount 3rd clutch assembly in vise at a 90 degree angle. Position the 5 pins of Sprag Retaining Ring Remover (J-29351) into elongated slots of 3rd clutch drum. (Scheme 67) NOTE: DO NOT put a pin into slot if the internal retaining ring is not visible in that slot.
2. Slide compressing ring of remover over pin cage to compress retaining ring. Pull up on remover to withdraw sprag assembly from clutch drum. Remove input shaft-to-input sun gear thrust washer and thrust bearing from clutch drum. NOTE: If sprag retaining ring hangs up on one side causing clutch hub to cock, insert a punch in slot to compress ring.
3. Lift clutch plates from drum, noting the number and installation sequence for reassembly reference.
4. Remove input sprag race and retainer assembly from clutch hub and input sun gear assembly. Push sprag assembly and retaining rings from sprag race and retainer.
5. Using Spring Compressor (J-23075), compress 3rd clutch piston return springs and remove snap ring. Remove retaining seat and 12 piston return springs. Remove piston from drum.

1. Inspect piston return springs for wear and distortion. Replace as necessary. Inspect clutch piston for wear, damage and condition of check ball. If check ball is missing or falls out upon inspection, replace piston.
2. Inspect steel thrust washer on front face of 3rd clutch drum. Replace if scored or damaged. Inspect all other thrust washers and thrust bearing for wear or damage and replace as necessary.
3. Inspect condition of composition and steel clutch plates. Replace as necessary. Inspect sprag assembly for wear, damage or sprags that fall freely out of cage. Inspect input sun gear for chipped or nicked teeth or abnormal wear. Replace as necessary.

Scheme 68

1. Lubricate and install new lip seals on clutch piston. Carefully install new oil seal on input shaft inside 3rd clutch drum, with lip pointing downward.
2. Install piston into drum using care not to damage lip seals. Install 12 piston return springs onto piston, then install spring seat over springs. Compress return springs and seat. Install retaining snap ring. NOTE: Ensure that spring seat does not catch in snap ring groove when compressing springs.
3. Install 3rd clutch plates on hub in following order: steel plate, composition plate, steel plate, composition plate, steel plate, and conical steel plate. When installed correctly, the I.D. of conical plate will touch steel plate below it but, O.D. will not. NOTE: Install same number of clutch plates as were removed. Lubricate plates with transmission fluid before installing.
4. Install thrust washer and thrust bearing onto input shaft, with inner lips of bearing toward washer. Retain in place with petroleum jelly.
5. Install sprag onto clutch hub with flared shoulder on cage outer diameter toward input sun gear. Install sprag race and retainer assembly over sprag assembly. When correctly assembled, sprag should rotate when turned counterclockwise and lock up when turned clockwise. (Scheme 68)
6. Slightly turn clutch hub and sprag assembly to engage it to clutch plate splines until sprag race rests on clutch drum.
7. Align teeth of sprag race with splines of clutch drum. Using a small screwdriver, press retaining ring all around into ring groove, at the same time applying pressure on sprag race. Slide sprag into clutch drum until retaining ring snaps into clutch drum groove.

Scheme 69

1. Inspect reaction sun gear for chipped or nicked teeth and inspect sun gear for scoring. If necessary, replace complete assembly.
2. Inspect reaction sun gear drum bushing for wear or damage. If bushing requires replacement, use a chisel and remove bushing at bushing joint from sun gear.
3. Thoroughly clean drum. Install new bushing using a driver. Bushing should be installed flush with rear face of sun gear drum hub.

1. Inspect planetary carrier and output shaft for distortion or damage. Inspect planetary pinions for excessive wear or damage, such as chipped teeth.
2. Check end play of all planetary pinions using a feeler gauge at points "A" and "B". (Scheme 70) End play should be.005-.035" (.127-.89 mm). If end play is not as specified, replace complete planetary carrier.
3. Tighten planetary carrier lock plate retaining screws to 20-35 ft. lbs. (27-48 N.m)

Checking Planetary Carrier & Pinion End Play. Scheme 70

Depress secondary valve spring with small screwdriver and remove secondary valve spring retainer. Remove secondary valve spring, secondary valve and primary valve from governor body.

1. Inspect primary and secondary valves for nicks, burrs and other damage. If necessary, use crocus cloth to remove small burrs. NOTE: DO NOT remove the sharp edges of the valve since these edges perform a cleaning action within the valve bore.
2. Inspect secondary valve spring for distortion or breakage. Clean governor body in solvent and blow out all passages with compressed air. Replace governor body if damaged or worn. Lubricate governor valves with transmission fluid before installation.

Reassembly

Install primary valve in governor, small end first. Install secondary valve (small end first) into governor body. Install secondary valve spring, then depress spring and install retainer.

Scheme 71

1. Inspect governor hub oil seal rings for wear or damage, and replace if necessary. Remove governor hub oil screen, using care not to lose or damage screen.
2. Inspect screen and clean with solvent and air dry. Install governor screen flush with hub. Inspect governor hub splines for cracks or chipped teeth in splines. Replace governor hub if required.

1. Inspect extension housing for damage and replace housing if necessary. Check parking pawl and spring for damage and replace as necessary.
2. If extension housing rear seal requires replacement, use a screwdriver and pry seal from housing. If bushing requires replacement, use a driver and drive bushing from housing.
3. Clean housing of dirt and foreign matter. Install new housing bushing into housing using a bushing driver until bushing is flush with shoulder of extension housing. Install new oil seal into rear of housing.

1. Remove servo piston apply rod. Holding servo piston sleeve at flat portion of sleeve with wrench, loosen adjusting bolt lock nut and remove.
2. Depress servo piston sleeve and remove piston sleeve retaining ring. Push sleeve through piston and remove cushion spring and spring retainer. Remove servo piston ring.

Inspection & Reassembly

Inspect cushion spring, adjusting bolt, and piston sleeve for damage. Inspect piston for damage and piston ring for side wear. Replace if necessary. Reverse disassembly procedure to reassemble.

Scheme 72

VALVE BODY ASSEMBLY

Note. As valve trains are removed from each valve body bore, place individual parts in correct order and in relative position to valve body to simplify reassembly. Valves and springs are not interchangeable. Parts must be reinstalled in correct order in proper valve body bore. Use valve body exploded view illustration as a disassembly and reassembly guide.

Scheme 73

1. Remove manual valve and link from valve body. Turn valve body so that transfer plate is facing upward and remove the 2 bolts attaching plate to valve body. Remove transfer plate and gasket.
2. Using a small "C" clamp, compress accumulator piston and remove retaining ring. (Scheme 73) Carefully loosen "C" clamp as accumulator is under spring tension, then remove accumulator piston, oil ring and spring.
3. Remove retaining pin then slide out 1-2 shift control valve sleeve, control valve, 1-2 shift valve spring and valve. (Scheme 74) NOTE: It may be necessary to remove burrs in valve body bores made by retaining pin prior to removal of sleeves and valves.
4. Remove 2-3 shift control valve retaining pin and sleeve, then slide out 2-3 shift control valve, spring seat, spring and 2-3 shift valve.
5. Remove 3-2 control valve retaining pin and plug. Remove 3-2 control valve spring and control valve.
6. Remove detent pressure regulator valve retaining pin. Remove spring and detent pressure regulator valve.
7. Remove high speed downshift timing valve retaining pin, then remove spring and valve.
8. Remove downshift timing valve plug retaining pin and remove plug. Remove low speed downshift timing valve and spring.
9. Remove manual low and reverse control valve retaining pin. Remove spring and manual low control valve and reverse control valve.
10. Remove the 1-2 accumulator valve retaining pin and remove 1-2 accumulator valve plug, accumulator valve and spring.

1. Inspect each valve for free movement in its respective bore. Use crocus cloth to remove small burrs on valves. NOTE: DO NOT remove sharp edges of valves as these edges perform cleaning action within bore.
2. Inspect valve springs for distortion or collapsed coils. Replace complete valve body assembly if any part is damaged. Inspect transfer plate for dents or distortion. Replace transfer plate if necessary.

Reverse disassembly procedure using a liberal amount of transmission fluid on all valves, plugs and springs.

Scheme 74

1. Inspect case for damage. Clean oil passages with solvent and air. Check for good retention of band anchor pins. Inspect all threaded holes for thread damage.
2. Inspect detent valve and modulator valve bores for scratches or scoring. Inspect case bushing inside case at rear. If damaged, remove and install bushing using a driver. Install bushing flush with rear of case.
3. Inspect reaction sun gear drum bushing sleeve inside case at rear for scoring. If necessary, replace sleeve before installing new case bushing.

Note. Care must be used when removing sleeve in order that aluminum case is not damaged.

SELECTOR LEVER & SHAFT

1. Install new selector lever shaft oil seal in case, with grooved end (with metric threads) outside of case. Insert selector shaft through case from outside. NOTE: Use care not to damage oil seal when installing shaft.
2. Insert spring pin in case to secure selector lever shaft. Guide selector lever over shaft and secure with lock nut. Insert parking pawl actuator rod from front of case and through hole in rear of case, then install retaining ring.

LOW BAND & REACTION SUN GEAR & DRUM

1. Turn transmission case so that front of case is upward. Place band in case and locate onto anchor pins.
2. Place thrust bearing into case and retain with petroleum jelly. Case bushing acts as a guide to center bearing.
3. Insert reaction sun gear and drum into low band with reaction sun gear facing upward. Install thrust bearing onto sun gear and hold in place with petroleum jelly.

OUTPUT SHAFT & PLANETARY CARRIER

1. Install thrust washer and Torrington bearing into planetary carrier. Retain in place with petroleum jelly.
2. Insert output shaft and planetary carrier from front of case. Ensure planetary carrier engages reaction sun gear.

Scheme 75

2ND & 3RD CLUTCH ASSEMBLIES

1. With 2nd clutch assembly on bench, align drive plates in drum. Insert 3rd clutch drum and input shaft through top of 2nd clutch drum, seating 3rd clutch drum splines with 2nd clutch plate splines.
2. Holding clutch assemblies by input shaft, lower into transmission case, indexing 2nd clutch drum ring gear with long planetary pinion gear teeth.

Scheme 76

REVERSE CLUTCH PLATES

1. Install aluminum pressure plate into transmission case with flat side up. Ensure lug on pressure plate engages one of the narrow notches in case.
2. Lubricate steel and composition reverse clutch plates with transmission fluid. Install clutch plates into transmission case starting with a steel plate and alternating composition and steel clutch plates until all plates are installed.
3. Install reverse clutch cushion plate (wave washer) into case, so all three of its lugs are engaged into narrow notches in case.

Scheme 77

1. Place Gauge (J-23085) on case flange and against input shaft. (Scheme 77) Loosen thumb screw to allow inner shaft of gauge to drop onto 2nd clutch drum hub.
2. Tighten thumb screw and remove gauge. Compare thickness of selective thrust washer No. "1" removed during transmission disassembly with protruding portion of gauge inner shaft.
3. Selective thrust washer used in reassembly should be the thickest washer available without exceeding dimension of shaft protruding from gauge. Dimension of thrust washer selected should be equal to or slightly less than inner shaft dimension for correct transmission end play.
4. Selective thrust washers for end play are available in the following thicknesses:.069-.074",.075-.079",.080-.084",.085-.089",.090-.094", and.095-.100" (1.7-1.8 mm, 1.9-2.0 mm, 2.0-2.1 mm, 2.2-2.3 mm, 2.3-2.4 mm, and 2.4-2.5 mm). Transmission end play should be.014-.031" (.36-.79 mm).

CONVERTER HOUSING, OIL PUMP & REVERSE CLUTCH ASSEMBLY

1. Install new oil pump flange gasket. Place transmission end play thrust washer, as previously determined, onto oil pump shaft and retain with petroleum jelly.
2. Install guide pin in case and lower converter housing and oil pump into case. Use Oil Pump Aligner (K-23082) to align converter housing with oil pump and case. Install and tighten converter housing attaching bolts.
3. Check for correct assembly by turning input shaft by hand. Shaft should rotate freely without binding.

GOVERNOR ASSEMBLY & SPEEDOMETER DRIVE GEAR

1. Turn transmission so that rear of case is upward. Lubricate governor hub seal rings with transmission fluid. Slide hub onto output shaft until it seats in case. Install snap ring into output shaft groove to lock hub in place.
2. Install new governor body gasket. Install governor body to governor hub. Install and tighten attaching bolts. NOTE: Ensure governor valves move freely after governor body is installed on hub.
3. Install speedometer drive gear retaining clip into hole in output shaft. While depressing retaining clip, slide drive gear over output shaft and onto retaining clip.

Scheme 78

1. Install new extension housing gasket. Slide housing over output shaft and align bolt holes. Align parking pawl shaft into extension housing. Install and tighten attaching bolts.
2. Install speedometer driven gear and housing into extension housing bore. Install speedometer driven gear housing retainer and tighten retainer bolt.

DETENT VALVE, MODULATOR VALVE & MODULATOR ASSEMBLY

1. Install detent valve, sleeve, spring and spring seat into case bore using a liberal amount of transmission fluid. Depress detent valve spring and insert spring pin to secure valve assembly. NOTE: Detent valve sleeve must be installed with slot facing oil pan. Ensure that spring pin is inserted into groove provided in sleeve and not into oil passage slots in sleeve.
2. Install modulator valve and sleeve into case with small end of valve installed first. Use a new "O" ring on modulator. Install plunger and thread modulator into case and tighten.

SERVO ASSEMBLY

1. Install servo apply rod, spring and piston into case using a liberal amount of transmission fluid. Compress servo piston spring and install retaining ring while lightly tapping piston until piston is seated.
2. To adjust servo, use a 3/16" hex head wrench on servo adjusting bolt and tighten bolt to 40 INCH lbs. (4.5 N.m.). Back off bolt EXACTLY 5 turns. Hold adjusting bolt stationary and tighten lock nut.

1. Position steel check balls into case oil passages. (Scheme 57) Locate guide pin in case. (Scheme 56) Install new transfer plate-to-case gasket. Install bolts holding transfer plate to valve body.
2. Install manual valve into valve body bore using liberal amount of transmission fluid. Install long side of manual valve link into valve, then install short end of link into selector lever as valve body and transfer plate are installed over guide pins.
3. Install attaching bolts in original positions. Tighten valve body attaching bolts by starting at the center and working outward. Install selector lever roller spring and retainer. Install reinforcement plate bolts to case and tighten.

Installation

1. Install governor pressure switch. Install solenoid valve and piping. Connect electrical wires. Negative wire connects to governor pressure switch and positive wire connects to case electrical connector.
2. Install oil strainer assembly using new gasket. Install servo cover using new gasket. Bolt oil pan to transmission using new gasket.
3. Slide torque converter over stator shaft and input shaft. Make sure that the converter pump hub keyway is seated into the oil pump drive lugs. With converter properly seated, distance between engine mounting face of case and the front face of converter cover straps should be 1".

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• TRANSMISSION DISASSEMBLY