Fig. 5 Valve Body Bolt Locations

Fig. 6 Upper Body, Plate And Gaskets

Removing Upper Body From Lower Body

47. Remove two-piece detent spring (Fig. 3). Note po­
    sition of spring sections for assembly reference.

48. Remove manual valve from lower body (Fig. 4).

49. Remove bolts attaching upper body to lower body
    (Fig. S).

50. Carefully lift and remove upper body, plate and
    gaskets from lower body (Fig. 6).

51. Disassemble and overhaul upper and lower body
    sections as outlined in following procedures.

Fig. 4 Removing/Installing Manual Valve

Lower Body Disassembly

47. Remove check valve and spring, pressure relief
    valve and spring and ball check and seat from lower
    body. Note location of each valve for assembly refer­
    ence.

48. Remove the oil strainers (Fig. 2).

49. Note or mark position of valve retainers and pres­
    sure reducing plug clip for assembly reference. Do not
    remove the retainers at this time.

50. Remove solenoid No. 1, 2 and 3. Discard solenoid
    O-rings.

51. Remove release control valve retainer with mag­
    net and remove release control valve and plug (Fig. 4).

52. Remove 1-2 shift valve retainer and remove valve
    plug, valve spring and valve (Fig. 5).

53. Remove primary regulator valve as follows:

Fig. 1 Removing/Installing Lower Body Cheek Valves

Fig. 2 Removing/Installing Lower Body Oil Strainers

WARNING: THE PRIMARY REGULATOR VALVE SLEEVE AND PLUNGER ARE UNDER TENSION FROM THE VALVE SPRING. EXERT COUNTERPRESSURE ON THE SPRING WHILE REMOVING THE VALVE RE­TAINER TO PREVENT COMPONENTS FROM FLYING OUT.

Fig. 3 Valve Retainer And Clip Location

(a) Note position of valve retainer for assembly ref­erence (Fig. 6). Then press valve sleeve inward with your thumb and remove retainer with magnet.

(b) Slowly release thumb pressure on sleeve and re­move sleeve, spring and washer and valve (Fig. 7). Use magnet to remove valve if necessary.
(8) Remove regulator valve plunger from sleeve (Fig.8).

(9) Remove retaining clip and remove pressure re­ ducing plug (Fig. 9). Cover screwdriver blade with tape
to avoid scratching valve body surface.

(10) Remove accumulator control valve retainer and remove control valve assembly (Fig. 10).

(11) Remove spring and control valve from valve sleeve (Fig. 11).

(12) Clean lower body valve components with solvent and dry them with compressed air only. Do not use shop towels or rags. Lint or foreign material from towels or rags can interfere with valve operation.

(13) Inspect condition of lower body components. Re­place lower body if any bores are scored or corroded. Replace valves, plugs or sleeves that are scored or worn. Replace oil strainers if cut, torn or damaged in any way.

Fig. 5 Removing/Installing 1-2 Shift Valve

(14) Inspect the valve body springs. Replace any spring having rusted, distorted, or collapsed coils. Mea­sure the length of each valve body spring. Replace any spring if free length is less than the length specified in the following chart (Fig. 12).

Lower Body Assembly

47. Lubricate lower body components with automatic
    transmission fluid.

48. Install spring and accumulator control valve in
    sleeve (Fig. 11). Then install assembled components in
    lower body (Fig. 10K

Fig. 7 Removing/Installing Primary Pressure Regulator Valve

(31 Press accumulator control valve assembly into valve bore and install retainer (Fig. 10).

47. 

48. Fig. 10 Removing/Installing Accumulator Control Valve Assembly
    

Fig. 9 Removing/Installing Pressure Reducing Plug

Fig. 11 Accumulator Control Valve Components

47. Install pressure reducing plug in plug bore. Then
    

47. secure plug with retaining clip (Fig. 9),

48. Install washer on primary regulator valve plunger
    

49. (Fig. 13).

50. Install primary regulator valve plunger in valve
    sleeve (Fig. 8).

51. Install valve spring and regulator valve sleeve and
    plunger.

(8) Press regulator valve sleeve into bore and install
retainer (Fig. 6 and 7). Be sure retainer is positioned in
sleeve lugs as shown.

VALVE

Fig. 8 Removing/Installing Regulator Valve Plunger

(ß) Install 1-2 shift valve, spring and plug (Fig. 5). Then press valve assembly into bore and install retain­er:

110) Install release control valve and plug in bore and install valve retainer (Fig, 4).

(ID Install replacement O-rings on solenoids and in­stall solenoids on valve body. Tighten solenoid attach­ing bolts to 10 ¹m (7 ft-lbs) torque.

47. Install oil strainers (Fig. 14). Identify strainers
    before installation. The three strainers are all the
    same diameter but are different lengths. Two
    strainers are 11.0 mm (.443 in) long while one
    strainer is 19.5 mm (.76 in) long (Fig. 14).

48. Install check valves and springs/seats (Fig. 1)

Fig. 14 Oil Strainer Identification

Upper Body Disassembly and Inspection

(1) Remove valve body plate and gaskets (Fig. 1).
Discard gaskets.

47. Remove strainer and nine check balls (Fig. 2). Note
    check ball and strainer position for assembly reference

48. Remove valve stop and throttle cam (Fig. 3).

(4J Remove throttle valve pin with magnet and re­move downshift plug, valve spring and throttle valve (Fig. 4)

Fig. 3 Removing/Installing Valve Stop And Throttle Cam

Fig. 1 Removing/Installing Upper Body Plate And Gaskets

Fig. 2 Cheek Ball And Strainer Location

Fig. 4 Removing/Installing Throttle Valve

(5) Turn upper body over and remove throttle valve adjusting iings and spring (Fig. 5). Note number of adjusting rings if valve is equipped with them.

Fig. 5 Throttle Valve Adjusting Ring Location (If Equipped)

47. Remove 3-4 shift valve retainer with magnet and
    remove valve plug, spring and 3-4 shift valve (Fig. 6).

48. Remove second coast modulator valve retainer and
    remove valve plug, spring and valve.

49. Remove lock-up relay valve retainer and remove
    relay valve and sleeve assembly (Fig. 8).

50. Remove lock-up relay valve, spring and plunger
    fromtalve sleeve (Fig. 9).

47. Remove secondary pressure regulator valve re­
    tainer and remove plug, regulator valve and spring
    (Fig. 10).

48. Remove cut-back valve retainer and remove plug,
    cut-back valve and spring (Fig. 11).

49. Remove 2-3 shift valve retainer and remove plug,
    spring and 2-3 shift valve (Fig. 12).

50. Remove low coast modulator valve retainer and
    remove valve plug, spring and low coast modulator
    valve (Fig. 13).

51. Clean the upper body components with solvent
    and dry them with compressed air only. Do not use shop
    towels or rags. Lint or foreign material from towels or
    rags can interfere with valve operation.

52. Inspect condition of the upper body components.
    Replace the upper body if any of the bores are scored or
    corroded. Replace any valves, plugs or sleeves if scored
    or worn. Replace the oil strainer if cut, torn or damaged
    in any way-

Fig. 7 Removing/Installing Second Coast Modulator Valve

Fig. 9 Lockup Relay Valve Components

(16) Inspect the valve body springs. Replace any spring having rusted, distorted, or collapsed coils. Mea­sure length of each spring. Replace any spring if fuse length is less than specified in the chart (Fig. 14).

Fig. 8 Removing/Installing Lockup Belay Valve

Upper Body Assembly

47. Lubricate the valves, springs, plugs, sleeves and
    the valve bores in the upper body with automatic trans­
    mission fluid.

48. Note position of the valve retainers (A) and stop (B)
    for assembly reference (Fig. 15).

49. Install low coast modulator valve, spring and plug
    in valve bore. Press valve plug inward and install re­
    tainer (Fig. 13).

50. Install 2-3 shift valve, spring and plug in valve
    bore. Press plug inward and install retainer (Fig. 12).

51. Install cut-back valve spring, valve and plug (Fig.
    11). Press plug inward and install retainer.

47. Install secondary regulator valve spring, valve
    and plug in valve bore. Press plug inward and install
    retainer (Fig. 10).

48. Assemble lock-up relay valve. Install spring and
    plunger in valve sleeve (Fig. 9). Then install assembled
    valve in sleeve.

49. Install assembled lock-up relay valve in valve bore
    and install retainer (Fig. 81.

50. Install second coast modulator valve, spring and
    plug in valve bore. Press plug inward and install re­
    tainer (Fig. 7).

(10) Install 3-4 shift valve, spring and plug in bore.
Press plug inward and install retainer (Fig. 6).

Fig. 10 Removing/Installing Secondary Pressure Regulator Valve

Fig. 11 Removing/Installing Cut-Back Valve

Fig. 12 Removing/Installing 2-3 Shift Valve

47. Install throttle valve in valve bore. Push valve
    into place and install valve stop (Fig. 16).

48. On models with adjusting rings, turn upper body
    over and install adjusting rings (Fig. 17). Be sure to
    install same number of rings as were removed.

49. Install throttle valve adjusting spring in bore and
    onto end of throttle valve (Fig. 18).

    Fig. 13 Removing/Installing Low Coast Modulator Valve

    
    

50. Install downshift spring and plug in throttle
    valve bore. Press plug inward against throttle valve and
    spring and install the retainer pin (Fig. 19).

51. Install sleeve in throttle cam (Fig. 20).

52. Install spring on cam (Fig. 20). Hook curved end
    of spring through hole in cam as shown.

53. Mount cam on upper body and install cam at­
    taching bolt and spacer (Fig. 20). Tighten bolt to 10 N-m
    (7 ft-Ibs) torque.

54. Be sure straight end of spring is seated in upper
    body slot as shown (Fig. 20).

55. Install check balls in upper body (Fig. 21). Refer
    to illustration for check ball identification and location.

56. Install oil strainer (Fig, 2).

Spring	Flee Length
(A) Downshift Plug	27.3 mm (1.074 in.)
(B) Throttle Valve	20.6 êì (0.811 irv.|
(C| 3-4 Shift Valve	30.8 mm 11.212 inj
|D) Second Coast Modulator Valve	25.3 nun (0.996 in.)
(E) Lockup May Valve	21.4 mm (0.843 in.)
(F) Second Regulator Vain	30.9 mm (1.217 in.|
|G) Cut-Bock Valve	51.8 mm |0 858 in.)
(H) 2-3 Shift Valve	30.8 mm (1.212 in.)
(J) Low Goast Modulator Valve	27.8 mm (1.094 in.)

Fig. 14 Upper Body Spring/Valve Identification

Fig. 17 Install Throttle Valve Adjusting Rings - If Equipped

Fig. 15 Valve Retainer And Stop Locations

Fig. 18 Installing Throttle Valve Adjusting Spring

Fig. 19 Installing Downshift Plug

SIHVE

CheckBoll Diameter ® Rubber Ball 6.35 mm (0.2500 in.) ® Steel Ball 556 mm (0.2189 in,) © Steel Ball 7.14 mm (0.2811 in.)

Fig. 21 Upper Body Cheek Ball Location/Identification

Installing Upper Body On Lower Body

47. Position new No. 1 gasket (Fig. 1) on upper body.

48. Position valve body plate on No. 1 gasket.

49. Position new No. 2 gasket (Pig. 2) on valve body
    plate and align gaskets and plate using bolt holes as
    guides,

50. Install valve body bolts. Three different length
    bolts are used. Refer to the Figure 3 for bolt loca­
    tions. Chart symbols indicate bolt location and
    length in millimeters.

51. Tighten valve body bolts to $.4 N-m (56 in-lbs)
    torque.

47. 
    
    Install manual valve (Fig- 4).

48. Install two-piece detent spring (Fig. 5). Tighten
    spring attaching bolt to 10 *m (7 ft-lbs) torque.

Fig. 4 Installing Manual Valve

Fig. 3 Valves Body Bolt Location/Size

Fig. 5 Installing Detent Spring

Fig. 1 AW-4 Transmission Components

TRANSMISSION ASSEMBLY

(1) During assembly, lubricate components with
transmission fluid or petroleum jelly as indicated.

47. If any of the transmission components are still
    assembled after overhaul checking procedures, disas­
    semble as necessary in preparation for transmission
    assembly.

48. Verify thrust bearing and race installation during
    assembly. Refer to the Thrust Bearing Chart (Fig. 2) for
    bearing and race location and correct positioning.

14) Install rear planetary gear, second brake drum and output shaft as outlined in following steps:

(5) Verify No. 10 thrust bearing and race (Fig. 2). Bearing and race outer diameter is 57.7 mm (2.272 in); inside diameter is 39.2 mm (1.543 in).

16) Coat thrust bearing and race assembly with pe­troleum jelly and install in case (Fig. 3). Race faces down. Bearing rollers face up.

47. Align teeth of second brake drum and clutch pack
    (Fig. 4).

48. Align rear planetary-output shaft àâýåòÛó teeth
    with case slots and install assembly in case (Fig. 5).

49. Install rear planetary snap ring with snap ring
    pliers B.Vi. FM- 29. Chamfered side of snap ring faces
    up and toward caae front (Fig. 6).

47. Check first-reverse brake pack clearance with
    feeler gauge-Clearance should be: 0.6 to 1.74 mm (.024
    to .069 in) on 4-cyl. transmissions and .70 to 2.00 mm
    (.028 to .079 in) on 6-cyl. transmissions. If clearance is
    incorrect, planetary assembly, thrust bearing or snap
    ring is not properly seated in case. Remove and reinstall
    components if necessary -

48. Install second brake piston sleeve (Pig. 8). Sleeve
    lip faces up and toward case front as shown.

49. Install second brake drum gasket with tool B.Vi.
    FM-33 (Fig. 9>. Gasket depth is 43.7 mm (1.720 in).

(13) Install park lock pawl, spring and pin (Fig. 10).

(14) Connect park lock rod to manual valve shift sec­tor (Fig. 11).

(15) Position park lock rod bracket on case and tighten bracket attaching bolts to 10 ¹m (7 ft-lbs) torque (Fig, 12).

(16) Verify park lock operation. Move shift sector to
Park position. Park pawl should be firmly engaged
(locked) in planetary ring gear (Fig. 13).

(17) Install No. 1 one-way clutch (Fig. 14). Short
flanged side of cluteh faces up and toward case front.

47. Install second brake pack (Fig. 15). Install disc
    then plate. Continue installation sequence until correct
    number of discs-plates are installed. Use five discs
    and five plates in 6-cyl. transmissions and four
    discs and four plates in 4-cyl. transmissions.

48. Install second brake pack retainer with rounded
    edge of retainer facing disc.

49. Install second brake pack snap ring.

50. Check brake pack clearance with feeler gauge
    (Fig. 16). Clearance should be: 89 to 2.15 mm (.035 to
    .084 in) on 4-cyl. transmissions and .062 to 1.98 mm
    (.024 to .078 in> on 6-cyl. transmissions If brake pack
    clearance is not correct, brake pack components are not
    seated. Reassemble brake pack if necessary.

Fig. 3 Installing Thrust Bearing And Race (No. 10)

Fig. S Installing Output Shaft/Rear Planetary Assembly

Fig. 4 Align Drum And Clutch Pack Teeth

Fig. 6 Installing Planetary Snap Ring

47. 
    Install planetary sun gear and input drum (Pig.
    17). Be sure drum thrust washer tabs are seated in
    drum. Use petroleum jelly to hold thrust washer in
    position if necessary.

48. Install front planetary gear on sun gear (Fig. 18).

49. Support output shaft with wood blocks (Fig. 19).

50. Install planetary snap ring on sun gear with tool
    B.Vi. FM-30.

51. Install tabbed thrust race on front planetary gear
    (Fig. 21). Washer tabs face down and toward gear. Race
    outer diameter is 47.8 mm (1.882 in); inside diameter is
    34.3 mm (1,350 in).

52. Install second coast brake band (Fig. 22).

(28) Install pin in second coast brake band. Then in­stall retaining ring on pin (Fig. 23).

47. Install thrust bearing and race in forward-direct
    clutch (Fig. 24). Coat bearing/race with petroleum jelly
    to hold them in place-

48. Verify forward-direct clutch thrust bearing size.
    Race outer diameter is 48-9 mm (1.925 in); inside di­
    ameter is 26.0 mm (1.024 in). Bearing outer diameter is
    46.7 mm (1.839 in); inside diameter is 26.0 mm (1.024
    in).

49. Coat front planetary ring gear race with petro­
    leum jelly and install it in ring gear (Fig. 25).

Fig. 8 Installing Second Brake piston Sleeve

Fig. 10 Installing Park Lock Pin/Spring/Pawl

(32) Verify ring gear race size. Outer diameter is 47.0 mm (1.850 in); inside diameter is 26.5 mm (1.045 in).

(33) Align forward-direct clutch disc splines with screwdriver (Fig. 26).

(34) Align and install front planetary ring gear in forward-direct clutch (Fig. 27).

(35) Coat bearing and race with petroleum jelly and install them in ring gear (Fig. 28). Verify bearing/race size. Bearing outer diameter is 47.7 mm (1.878 in); inside diameter is 32.6 mm (1.283 in). Race outer di­ameter is 53.6 mm (2.110 in); inside diameter is 30.6 mm (1.205 in).

(36) Rotate front of transmission case downward and install assembled planetary gear/forward-direct clutch (Fig. 29).

(37) Check clearance between sun gear input drum and direct dutch drum (Fig. 30). Clearance should be 9.8 to 11.8 mm (.386 to .465 in). If clearance is incorrect,

Fig. 11 Installing Pork Lock Rod

Ø

planetary gear/forward-direct clutch assembly is not seated or is improperly assembled. Remove, and correct if necessary.

47. Coat thrust bearing and race assembly with pe­
    troleum jelly and install it on clutch shaft. Bearing faces
    up and toward case front as shown (Fig. 31). Verify
    bearing/race size. Bearing and race outer diameter is
    47.8 mm (1.882 in); inside diameter is 33.6 mm (1.301
    in).

48. Assemble second coast brake piston components

(Fig. 32).

(40) Install assembled second coast brake piston in

case.

Fig. 12 Installing Park nod Bracket

Fig. 14 Installing No. 1 One-Way Clutch

47. 
    
    
    
    Install replacement seals on second coast brake
    piston cover and install cover in case.

48. Install second coast brake piston snap ring with
    tool B.Vi. FM-29 (Fig. 33).

49. Check second coast brake piston stroke as follows:

    Fig. 15 Installing Second Brake Pack

    
    

    Fig. 16 Checking Second Brake Pack Clearance

    
    

50. Make reference mark on brake piston rod (Fig.
    34).

51. Apply 57-114 psi air pressure through feed
    hole (Fig. 34). Alternately apply and release air pres­
    sure to operate piston,

52. Check stroke with gauge (Fig. 35). Use gauge
    B.Vi.FM. 40 with 4-cyl. transmission. Use gauge B.-
    Vi.FM. 41 with 6-cyl. transmission. .

53. If stroke length is incorrect, piston, cover or
    snap ring is not seated. Reassemble and check stroke
    again if necessary.

47. Coat thrust race and tabbed washer with petro­
    leum jelly and install them on overdrive support (Fig.
    36). Verify race siie. Race outer diameter is 50.9 mm
    (2.004 in); inside diameter is 36.2 mm (1.426 in).

48. Install overdrive support in case. Use two long
    bolts to help align and guide support into position (Fig.
    37).

49. Install overdrive support snap ring with tool
    B.Vi. FM-29 (Fig. 38). Chamfered side of snap ring faces
    up and toward case front. Snap ring ends must be

aligned with case opening with ring ends approx­imately 24 mm (0.94 in) from centerline of case opening.

47. Install and tighten overdrive support bolts to 25
    ¹ro (19 ft-lbs) torque (Fig. 39).

48. Check output shaft end play with dial indicator
    (Fig. 40). End play should be .27 to 0.86 mm (.0106 to
    .0339 in).

49. If output shaft end play is incorrect, one or more
    of installed components is not seated. Reassemble as
    necessary and check end play again.

(501 Install overdrive clutch pack (Fig. 41)_Install thickest clutch plate first. Rounded edge of plate faces

up. Install first disc followed by another plate until correct number of discs-plates are installed. Install four discs and three plates in a 6-cyl. transmission and three discs and two plates in a 4-cyl. transmission.

(51) Install stepped ring retainer plate with flat side
facing disc. Then install brake pack snap ring (Fig. 42).

(52) Check overdrive brake piston stroke aa follows:
(a) Mount tool B.Vi. FM-35 in dial indicator and

position gauge tool B.Vi. FM. 35 against overdrive brake piston (Fig. 43).

Fig. 19 Supporting Output Shaft

Fig. 21 Installing Planetary Thrust Race

Fig. 22 Installing Second Coast Brake Band