Chrysler Torqueflite Transmission Overhaul Manual

r Transmissions 21 - 1 GROUP 21 TRANSMISSIONS SERVICE BULLETINS PART I. TRANSMISSION STANDARD 3-SPEED SPECIFICATIONS~----------~----- SPECIAL TOOLS TORQUE SPECIFICATIONS ____________ _ SERVICE DIAGNOSIS --------------- SERVICE INFORMATION- PROCEDURES -------- 1. TRANSMISSION REMOVAL--~------- 2. TO DISASSEMBLE TRANSMISSION ------- 3. CLEANING AND INSPECTION 4. TO ASSEMBLE TRANSMISSION -------- 5. TRANSMISSION INSTALLATION 6. GEARSHIFT LINKAGE ADJUSTMENT_~---- 7. TRANSMISSION REAR BUSHING OIL SEAL PART 2- TRANSMISSION TORQUEFLITE SPECIFICATIONS ---------------- SPECIAL TOOLS ----------------- TORQUE SPECIFICATIONS ------------- SERVICE DIAGNOSIS GENERALINFORMATION -------------- 1. DESCRIPTION 2. OPERATION --------------- 3. POWERFLOW --------------- 4. HYDRAULIC CONTROL SYSTEM ------- 5. OPERATING INSTRUCTIONS SERVICE INFORMATION- PROCEDURES 21 - -:1: 21 - 5 21 - 6 21 - 6 21 - 6 21 - 8 21 - 8 21 - 8 21 - 11 21 - 12 21 - 15 21 - 15 21 - 16 21 - 17 21 - 18 21 - 19 21 - 20 21 - 33 21 - 33 21 - 33 21 - 33 21-38 - 21 - 42 21 - 44 1. GEARSHIFT AND PARKING LOCK CONTROL UNIT._ 21 - 44 2. BACK-UP LAMP SWITCH REPLACE- MENT 21 - 52 3. GEAR SELECTOR LAMP REPLACEMENT 21 - 52

Transmissions 21 - 2 4. GEARSHIFT CONTROL CABLE (TRANSMISSION END) 5. PARKING LOCK CABLE (TRANSMISSION END) MAINTENANCE, ADJUSTMENTS AND TESTS 6. LUBRICATION 7. FLUID LEAKS 8. GEARSHIFT CONTROL CABLE ADJUSTMENT 9. NEUTRAL STARTING SWITCH 10. PARKING LOCK CABLE ADJUSTMENT 11. BAND ADJUSTMENTS 12. THROTTLE LINKAGE ADJUSTMENT 13. HYDRAULIC CONTROL PRESSURE TESTS 14. HYDRAULIC CONTROL PRESSURE ADJUSTMENTS 15. AIR PRESSURE TESTS SERVICING OPERATIONS WITH TRANSMISSION IN VEHICLE 16. SPEEDOMETER PINION --- ------- --- 17. OUTPUT SHAFT OIL SEAL REPLACEMENT ____ _ 18. EXTENSION HOUSING 19. GOVERNOR 20. REAR OIL PUMP 21. PARKING LOCK COMPONENTS--------- - 22. NEUTRAL STARTING SWITCH __________ _ 23. VALVE BODY ASSEMBLY AND ACCUMULATOR PISTON 24. TRANSMISSION AND CONVERTER RECONDITIONING TRANSMISSION OUT OF VEHICLE 25. FLUSHING TORQUE CONVERTER 26. ALUMINIUM THREAD REPAIR 27. FRONT PUMP OIL SEAL 28. REMOVAL OF SUB-ASSEMBLIES 29. RE-CONDITIONING SUB-ASSEMBLIES 30. VALVE BODY ASSEMBLY 31. ACCUMULATOR PISTON AND SPRING 32. EXTENSION HOUSING BUSHING/BEARING AND OIL SEAL 33. PARKING PAWL AND LEVER 34. GOVERNOR AND PARKING SPRAG 35. REAR OIL PUMP 36. FRONT PUMP AND REACTION SHAFT SUPPORT 37. FRONT CLUTCH 38. REAR CLUTCH 39. PLANETARY GEAR ASSEMBLIES, SUN GEAR, DRIVING SHELL,. LOW AND REVERSE DRUM 40. OVER-RUNNING CLUTCH 41. KICKDOWN SERVO AND BAND 42. LOW AND REVERSE SERVO AND BAND 43. INSTALLATION OF SUB-ASSEMBLIES 44. CONVERTER AND TRANSMISSION ALIGNMENT 21 - 52 21 - 53 21 - 53 21 - 55 21 - 55 21 - 56 21 - 56 21 - 57 21 - 58 21 - 59 21 - 61 21 - 62 21 - 63 21 - 63 21 - 64 21 - 66 21 - 67 21 - 67 21 - 69 21 - 69 21 - 70 21 - 73 21 - 73 21 - 74 21 - 74 21 - 77 21 - 78 21 - 82. 21 - 82 21 - 82 21 - 83 21 - 84 21 - 84 21 - 85 21 - 87 21 - 89 21 - 91 21 - 92 21 - 92 21 - 93 21 - 96 " ., ..

Transmissio ns 21 - 3 PART 3 - SERVICE REPLACEMENT BUSHING SPECIAL TOOLS 21 - 99 SERVICE INFORMATION- PROCEDURES 21 - 99 1. GENERAL INFORMATION 21 - 99 2. BUSHING REPLACEMENT ____ 21 - 99 PART 4- STARTER RING GEAR REPLACEMENT SERVICE INFORMATION- PROCEDURES --------- 21 - 102 1. REMOVING RING GEAR _____ 21 - 102 2. INSTALLING RING GEAR____ 21 - 102 t

Transmissions 21 - 4 SERVICE BULLETIN REFERENCE Date Number Subject Changes .. 4 ...,

•' Transmissions 21 - 5 PART I. TRANSMISSION STANDARD 3-SPEED Ratios: First Second Direct Reverse Gears: Type Tolerances: Second speed gear end play Countershaft end play Synchronizer end float SPECIFICATIONS Synchronizer clutch gear snap ring thickness Drive pinion bearing snap ring thickness ... Drive pinion bearing to shaft snap ring thickness Centre mainshaft bearing snap ring thickness ... Centre mainshaft bearing to shaft snap ring thickness Pinion bearing retainer gasket thickness ... Countershaft thrust washers (two sizes) Clutch housing face run-out Clutch housing bore run-out 2.953 1 1. 833 1 1. 00 1 3.797 1 ... Helical . 005" - . 014" . 004" - . 012" . 050" - . 090" . 088'', . 094"' . 061", . 065"' . 069 11 ' . 088"' . 094"' . 061 11 . 063" . 065" . 067" . 069" . 091", . 097''. . 063" . 067" . 091" . 097" - . 088" ,- . 091 11 - . 094" ,- . 097" . 009" . 0135" . 022" "A" - . 062" "B" - . 057" . 006" maximum . 008" maximum

Transmissions 21 - 6 SPECIAL TOOLS CA-452 . . . . . . . . . . .. ... Puller CA-464 . . . . . . . . . . . . ... Arbor (idler gearshift) C-578 . . . . . . . . . . .. ... Arbor (countershaft) DD-1014 . . . . . . . . . . . . ... Repair stand CA-3281 . . . . . . . . . . .. ... Holding tool CA-3751 . . . . . . . . . . .. ... Installer (bushing) CA-3753 . . . . . . . . . . .. ... Puller (extension seal) CA-3754 . . . . . . . . . . .. . .. Installer (oil seal) CA-3755 . . . . . . . . . . .. ... Driver CA-3765 . . . . . . . . . . .. ... Installer (detent ball) CA-3766 . . . . . . . . . . . . ... Installer (seal) CA-3767 . . . . . . . . . . .. ... Protector (shift shaft oil seal) CA-3768 . . . . . . . . . . . . . .. Protector (output shaft oil seal) CA-3789 . . . . . . . . . . . . ... Installer (seal) C-3806 . . . . . . . . . . . . ... Fixture (engine support) CONDITION TORQUE SPECIFICATIONS Mainshaft flange nut . . . . . . . .. Extension to case bolts (5) . . . . .. Extension to case nut (1) . . . . .. Cas e to clutch housing bolts... . .. Transmission cover retaining bolts . Pinion bearing retaining bolts .. . Operating lever retaining bolts .. . Drain plug . . . . . . . . . . . . . .. Filler plug . . . . . . . . . . . . . .. 165 - 185 lbs. /ft. 45 - 55 lbs. /ft. 50 - 60 lbs. /ft. 50 lbs. /ft. 8 - 12 lbs. /ft. 20 - 25 lbs./ft. 16 - 20 lbs. /ft. 20 - 25 lbs. /ft. 20 - 25 lbs. /ft. SERVICE DIAGNOSIS POSSIBLE CAUSE CORRECTION Hard Shifting (a) Incorrect clutch adjustment. (a) Ref er to clutch se ction f or corrections. (b) Improper cross-over adjustm e nt. (c) Sy nchronizer clutch sl e eve damaged. (d) Synchroniz er spring improperly installed. (c) Brok en or worn synchronizer s lop rings. (b) Perform the cross-o\ ·cr adjustment outlined in paragraph "Gearshift Linkage Adjustments". (c - d - c) Causes noted can only be corrected by disassembling th e transmi s sion and replacing da m aged or worn parts. I

I ' . CONDITION Transmission Slips Out of Gear. Transmission Noises. Backlash Noise. POSSIBLE CAUSE (a) Linkage interference. (b) Gearshift rods out of adjustment. (c) Second or direct speed gear synchronizer clutch teeth worn. (d) Clutch housing bore or face out of alignment. (a) Excessive end play in cluster gear. (b) Loose synchronizer hub spline fit on mainshaft. (c) Loose spline fit on low speed sliding gear to mainshift spline. (d) Loose spline fit of rear mainshaft flange. (e) Damaged, broken or excessively worn gear teeth. (f) Drive pinion bearing worn. Transmissions 21 - 7 CORRECTION (a) Inspect and remove all linkage interferences. (b) Adjust the gearshift rods as outlined in paragraph "Gearshift Linkage Adjust- ments". (c) Disassemble the transmission and replace parts as necessary. (d) Refer to Clutch section for correction procedures. (a) Replace worn gear. (b) Inspect the mainshaft and synchronizer hub and replace parts as necessary. (c) Inspect the low speed sliding gear and mainshaft. Replace parts as necessary. (d) Inspect the mainshaft and flange splines. Replace parts as neces~arv. (e) Replace the worn gears. (f) Replace the worn bearing.

Transmissions 21 - 8 SERVICE INFORMATION- PROCEDURES The three speed manual transmission (see Fig. 1) is of the synchromesh type with helical cut gears to provide silent operation. The countershaft gear is in constant mesh and is supported by roller bearings at each end. The mainshaft is supported· by a ball bearing at the centre and a bushing at the rear of the extension housing. The speedometer drive gear is integral with the mainshaft. 1. TRANSMISSION REMOVAL , (1) Drain the lubricant from the transmission. (2) Discormect the propeller shaft, speedometer cable and gearshift control rods. Disconnect hand brake control cable. CAUTION: Re, move the speedometer cable (pinion comes out with cable) by hand so that the housing is not crushed. (3) Remove the back-up light switch leads. (4) Install engine support fixture C-3806, mounting hooks firmly into the holes in the side of the frame members with the support ends up against the underside of the oil pan flange. (5) Adjust the fixture to support the weight of the engine, then raise engine slightly and remove the rear support attaching bolts. Remove the crossmember. (6) Support the transmission, using a suitable jack, then remove the bolts that attach the transmission to the clutch housing. (7) Slide the transmission rearward until the pinion shaft clears the clutch disc before lowering the transmission. (This precaution will avoid damaging the clutch disc). (8) Lower the transmission and remove from under the vehicle. (9) Mount the transmission in repair stand, DD-1014. DRAIN PlUG BAC K·UP LIGHT SWITCH PlUG ~OX852 Fig. 1 - Transmission assembly (typical}. 2. TO DISASSEMBLE TRANSMISSION To disassemble the transmission for cleaning and overhaul, refer to Fig. 1, then proceed as follows: (1) Using flange holding Tool CA-3281, remove the flange retaining nut and washer. (2) If necessary, attach puller Tool CA-452, and remove the flange assembly. Extension Housing (1) Remove the bolts and one nut that attaches the extension housing to the transmission case. Slide the extension off the mainshaft. Discard the gasket. Remove the oil seal using Tool CA-3753. (2) Remove the extension housing bushing using Tool CA-3755. (3) Remove the bolts that attach the cover to the case. Remove the cover and discard the gasket.

Drive Pinion (1) Remove the bolts attaching the main drive pinion bearing retainer, and slide the retainer off the pinion. Discard the gasket and drive the seal out of the retainer using a suitable drift. (2) Grasp the pinion shaft with the hand and pull the assembly out of the case. (It may be necessary to tap the shaft lightly to aid in its removal). A few of the clutch teeth on the main drive gear have been omitted to facilitate the removal of the drive pinion past the mating driven gear of the counter shaft gear. This open space must be positioned at the bottom to allow withdrawal of the drive pinion from the transmission case. Be careful not to bind the inner synchronizer ring on the drive pinion clutch teeth. (3) Remove the snap ring which locks the main drive pinion bearing on the pinion shaft, using snap ring pliers. Remove the pinion bearing washer, then carefully press the pinion shaft out of the bearing using an arbor press. Remove the oil slinger (refer Fig. 2). (4) Remove the 14 roller bearings from the cavity in the end of the drive pinion gear, using a hook or a flat blade. BEARING OIL SLINGER DRIVE PINION KP172B Fig. 2 - Drive pinion assembly. Transmiss ions 21 - 9 Countershaft Gear (I) Using a feeler gauge, chec k end play of the cluster gear (refer Fig. 8). Th e end play should be ftom . 004'' to . 012". Th is measurement will determine if new thru st washers are to be installed at re - as s embly. (2) Remove the locking plate (whi ch is common to countershaft and reve r se idler shaft). Using Tool C-578, drive th e count er - shaft rearward and out of the ca se . Fig. 3 - Synchronizer assembly (typical). SECOND SPEED GEAR INNER STOP RING CLUTCH GEAR SLEEVE THIRD SPEED GEAR OUTER STOP RING Fig. 4 - Synchronizer unit. 59x443B

Transmissions 21 - 10 SPEED GEAl Fig. 5 - Removlng or installlng snap rlng (typlcal). SY NCHRONIZER SPREADER SPRING NY8558 ·- Flg. 6 - Mainshaft assembly. (typical) . LOW AND REVERSE SHIFT FORK LOW AND REVERSE SLIDING GEAR NY8568 Fig. 7 - Removing or installing mainshaft (typical). Hains haft (1) With transmission in reverse, move shaft rearwards until bearing is clear of gearbox housing. (2) Cock the mainshaft, then remove the clutch sleeve, the outer synchronizer rings, the front inner ring and the 2 -3 shift fork (refer to Figs. 3 and 4). (3) Remove the clutch gear retaining snap ring, using snap ring pliers (refer Fig. 5). Slide the clutch gear off the end of the mains haft. (4) Slide the second speed gear, stop ring and synchronizer spring off the mainshaft (refer Fig. 6). (5) Remove the low and reverse sliding gear and shift fork as the mainshaft is completely withdrawn from the case (refer Fig. 7). (6) Lift the countershaf t gear and thrust washers out of the case. Disassemble the countershaft gear by removing the roller bearings (22 each end) and the bearing spacer. Reverse Idler Gear (1) Using a suitable drift, drive the reverse idler gear shaft towards the rear and out of the case. (2) Lift out the reverse idler gear, thrust washers and roller bearings (22) out of the case. Remove the roller bearings from the gear. Gearshift Mechanism (This operation need only be done if the seals are leaking). (1) Remove the operating levers from their respective shafts. (2) Drive out the tapered retaining pin (shown in Fig. 1) from either of the two lever shafts, then withdraw lever shaft from inside the transmission. (The detent balls are spring loaded; as the shaft is being withdrawn, the ball will drop to the bottom of the case). 6' .. ,. ..

Chrysler Torqueflite Transmission Overhaul Manual

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