Overdrive Assembly: Service and Repair

Fig. 5 Removing overdrive unit attaching bolts:

REMOVAL

1. Disconnect battery ground cable, then place selector lever in park.
2. Raise and support vehicle.
3. Loosen oil pan attaching bolts and allow fluid to drain.
4. Mark position of propeller shaft universal joint to pinion yoke for proper position, then remove propeller shaft.
5. On 4WD models, remove transfer case from overdrive unit.
6. On all models, support transmission using a suitable jack.
7. Mark position of crossmember for reference during assembly, then remove crossmember.
8. Disconnect distance sensor and speedometer adapter.
9. Remove overdrive unit to transmission attaching bolts. Ensure overdrive unit is supported when pulled back, Fig. 5.
10. Carefully slide overdrive unit off intermediate shaft.
11. Retain bearing and select fit spacer that may remain on overdrive piston, rear of transmission case, sliding hub or intermediate shaft.
12. Tilt unit to drain any fluid remaining in case. Check for clutch material or metal fragments.

Fig. 6 Gasket size chart:

Fig. 7 Intermediate shaft selector location:

INSTALLATION

1. Remove old gasket material around piston and trim new gasket as necessary, Fig. 6.
2. Install selective spacer in groove on intermediate shaft, just rearward of shaft rear splines, Fig. 7.
3. Install overdrive piston thrust plate on piston hub, then coat thrust plate with petroleum jelly.
4. Install thrust bearing in sliding hub. Coat thrust bearing with petroleum jelly to hold in position.
5. Carefully raise overdrive unit and slide onto intermediate shaft, then insert parking rod in reaction plug.
6. Care must be taken not to tilt unit. Tilting could cause carrier and overrunning clutch splines to rotate out of alignment. If this should occur, it will be necessary to remove overdrive unit and align, using overdrive installation tool No. C-6227-2 or equivalent.
7. Align slip fit governor tubes and push unit forward until it contacts transmission case.
8. Install overdrive unit attaching bolts, then torque in crisscross pattern to specifications.
9. Install crossmember.
10. On 4WD models, install transfer case.
11. On all models, install distance sensor and speedometer adapter. Ensure to index speedometer adapter.
12. Align and install propeller shaft.
13. Fill transmission to proper level with Dexron II transmission fluid.