Valve Body
BODY-VALVEDISASSEMBLY
CAUTION: Do not clamp any valve body component in a vise. This practice can damage the component resulting in unsatisfactory operation after assembly and installation. Do not use pliers to remove any of the valves, plugs or springs and do not force any of the components out or into place. The valves and valve body housings will be damaged if force is used. Tag or mark the valve body springs for reference as they are removed. Do not allow them to become intermixed.
1. Disconnect wires from governor pressure sensor and solenoid.
2. Remove screws attaching governor body and retainer plate to transfer plate.
3. Remove retainer plate, governor body and gasket from transfer plate.
4. Remove governor pressure sensor from governor body.
5. Remove governor pressure solenoid by pulling it straight out of bore in governor body. Remove and discard solenoid O-rings if worn, cut, or torn.
6. Remove small shoulder bolt that secures solenoid harness case connector (1) to 3-4 accumulator housing (2). Retain shoulder bolt. Either tape it to harness or thread it back into accumulator housing after connector removal.
7. Unhook overdrive/converter solenoid harness (1) from 3-4 accumulator cover plate (2)
8. Turn valve body over and remove screws that attach overdrive/converter solenoid assembly (1) to valve body.
9. Remove solenoid and harness (6) assembly from valve body.
10. Remove boost valve cover (1).
11. Remove boost valve retainer (1), valve spring (6), and boost valve (5).
12. Secure detent ball and spring with Retainer Tool 6583 (1).
13. Remove park rod E-clip (2) and separate rod (3) from manual lever (1).
14. Remove E-clip and washer (2) that retains throttle lever shaft (1) in manual shaft (3).
15. Remove manual lever (2) and throttle lever (3). Rotate and lift manual lever off valve body and throttle lever shaft. Then slide throttle lever out of valve body.
16. Position pencil magnet (4) next to detent housing to catch detent ball and spring. Then carefully remove Retainer Tool 6583 and remove detent ball (3) and spring (2).
17. Remove screws (2) attaching pressure adjusting screw bracket (3) to valve body and transfer plate. Hold bracket (5) firmly against spring tension while removing last screw (5).
18. Remove adjusting screw bracket (4), line pressure adjusting screw (2), pressure regulator valve spring (5), and switch valve spring (1). Do not remove throttle pressure adjusting screw from bracket and do not disturb setting of either adjusting screw during removal.
19. Turn upper housing (1) over and remove switch valve (3), regulator valve (2) and spring (4), and manual valve (8).
20. Remove kickdown detent (6), kickdown valve (5), and throttle valve and spring (7).
21. Loosen left-side 3-4 accumulator housing (3) attaching screw (1) about 2-3 threads. Then remove center and right-side housing attaching screws (2).
22. Carefully rotate 3-4 accumulator housing upward and remove 3-4 shift valve spring and converter clutch valve plug and spring.
23. Remove left-side screw and remove 3-4 accumulator housing (3) from valve body.
24. Bend back tabs on boost valve tube brace (2).
25. Remove boost valve connecting tube (1). Disengage tube from upper housing port first. Then rock opposite end of tube back and forth to work it out of lower housing.
CAUTION: Do not use tools to loosen or pry the connecting tube out of the valve body housings. Loosen and remove the tube by hand only.
26. Turn valve body over so lower housing (1) is facing upward. In this position, the two check balls in upper housing will remain in place and not fall out when lower housing and separator plate are removed.
27. Remove screws attaching valve body lower housing (1) to upper housing and transfer plate (3). Note position of boost valve tube brace for assembly reference.
28. Remove lower housing and overdrive separator plate (2) from transfer plate (3).
29. Remove the Number 10 check ball (1) from the transfer plate. The check ball is approximately 4.8 mm (3/16 inch) in diameter.
30. Remove transfer plate (2) from upper housing (1).
31. Turn transfer plate (1) over so upper housing separator plate (2) is facing upward.
32. Remove upper housing separator plate (2) from transfer plate (1). Note position of filter screen (3) in separator plate for assembly reference.
33. Remove rear clutch (1) and rear servo check balls (2) from transfer plate (3). Note check ball location for assembly reference.
VALVE BODY UPPER HOUSING
1. Note location of check balls (1, 2) in valve body upper housing. Then remove the one large diameter (2) and the five smaller diameter (1) check balls.
2. Remove E-clip (1) that secures shuttle valve secondary spring (2) on valve stem (3).
3. Remove governor plug and shuttle valve covers (8).
4. Remove throttle plug (12), primary spring (10), shuttle valve (9), secondary spring (7), and spring guides (5).
5. Remove boost valve retainer, spring and valve if not previously removed.
6. Remove throttle plug and 1-2 and 2-3 governor plugs.
7. Turn upper housing (1) around and remove limit valve (6) and shift valve covers.
8. Remove limit valve housing (5). Then remove retainer, spring, limit valve (7), and 2-3 throttle plug (4) from limit valve housing (5).
9. Remove 1-2 shift control valve and spring (9).
10. Remove 1-2 shift valve and spring (2).
11. Remove 2-3 shift valve and spring (3) from valve body.
12. Remove pressure plug cover (10).
13. Remove throttle pressure plug and spring (12).
VALVE BODY LOWER HOUSING
Lower Housing Shift Valves and Springs
3-4 ACCUMULATOR HOUSING
1. Remove end plate from housing.
2. Remove piston spring.
3. Remove piston. Remove and discard piston seals.
4. Remove timing valve cover.
5. Remove 3-4 timing valve and spring.
6. Remove 3-4 quick fill valve, spring and plug.
7. Remove 3-4 shift valve and spring.
8. Remove converter clutch valve, spring and plug.
9. Remove converter clutch timing valve, retainer and valve spring.
VALVE BODY
CLEANING
Clean the valve housings, valves, plugs, springs, and separator plates with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution.
Do not immerse any of the electrical components in cleaning solution. Clean the governor solenoid and sensor and the dual solenoid and harness assembly by wiping them off with dry shop towels only.
Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages.
Wipe the governor pressure sensor and solenoid valve with dry, lint free shop towels only. The O-rings on the sensor and solenoid valve are the only serviceable components. Be sure the vent ports in the solenoid valve are open and not blocked by dirt or debris. Replace the valve and/or sensor only when DRB scan tool diagnosis indicates this is necessary. Or, if either part has sustained physical damage (dented, deformed, broken, etc.).
CAUTION: Do not turn the small screw at the end of the solenoid valve for any reason. Turning the screw in either direction will ruin solenoid calibration and result in solenoid failure. In addition, the filter on the solenoid valve is NOT serviceable. Do not try to remove the filter as this will damage the valve housing.
INSPECTION
Inspect the throttle and manual valve levers and shafts. Do not attempt to straighten a bent shaft or correct a loose lever. Replace these components if worn, bent, loose or damaged in any way.
Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure.
Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced.
CAUTION: Many of the valves and plugs, such as the throttle valve, shuttle valve plug, 1-2 shift valve and 1-2 governor plug, are made of coated aluminum. Aluminum components are identified by the dark color of the special coating applied to the surface (or by testing with a magnet). Do not sand aluminum valves or plugs under any circumstances. This practice could damage the special coating causing the valves/plugs to stick and bind.
Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore.
Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils.
Check the two separator plates for distortion or damage of any kind. Inspect the upper housing, lower housing, 3-4 accumulator housing, and transfer plate carefully. Be sure all fluid passages are clean and clear. Check condition of the upper housing and transfer plate check balls as well. The check balls and ball seats must not be worn or damaged.
Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores.
Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling.
The only serviceable valve body components are listed below. The remaining valve body components are serviced only as part of a complete valve body assembly. Serviceable parts are:
^ dual solenoid and harness assembly
^ solenoid gasket
^ solenoid case connector O-rings and shoulder bolt
^ switch valve and spring
^ pressure adjusting screw and bracket assembly
^ throttle lever
^ manual lever and shaft seal
^ throttle lever shaft seal, washer, and E-clip
^ fluid filter and screws
^ detent ball and spring
^ valve body screws
^ governor pressure solenoid
^ governor pressure sensor and retaining clip
^ park lock rod and E-clip
ASSEMBLY
CAUTION: Do not force valves or plugs into place during reassembly. If the valve body bores, valves and plugs are free of distortion or burrs, the valve body components should all slide into place easily. In addition, do not overtighten the transfer plate and valve body screws during reassembly. Overtightening can distort the housings resulting in valve sticking, cross leakage and unsatisfactory operation. Tighten valve body screws to recommended torque only.
LOWER HOUSING
1. Lubricate valves, springs, and the housing valve and plug bores with clean transmission fluid.
2. Install 3-4 timing valve spring and valve (13) in lower housing.
3. Install 3-4 quick fill valve (18) in lower housing.
4. Install 3-4 quick fill valve spring (18) and plug (12) in housing.
5. Install timing valve end plate (11). Tighten end plate screws to 4 Nm (35 inch lbs.) torque.
3-4 ACCUMULATOR
1. Lubricate accumulator piston, seals and housing piston bore with clean transmission fluid.
2. Install new seal rings (3) on accumulator piston.
3. Install piston (1) and spring (4) in housing.
4. Install end plate on housing (5).
TRANSFER PLATE
1. Install rear clutch (1) and rear servo (2) check balls in transfer plate (3).
2. Install filter screen (2) in upper housing separator plate (1).
3. Align and position upper housing separator plate (3) on transfer plate (2).
4. Install brace plate (1). Tighten brace attaching screws to 4 Nm (35 inch lbs.) torque.
5. Install remaining separator plate attaching screws. Tighten screws to 4 Nm (35 inch lbs.) torque.
UPPER AND LOWER HOUSING
1. Position upper housing so internal passages and check ball seats are facing upward. Then install check balls in housing (1, 2). Seven check balls are used. The single large check ball (2) is approximately 8.7 mm (11/32 inch) diameter. The single small check ball is approximately 4.8 mm (3/16 inch) in diameter. The remaining 5 check balls are approximately 6.3 mm (1/4 inch) in diameter.
2. Position assembled transfer plate and upper housing separator plate (2) on upper housing. Be sure filter screen (1) is seated in proper housing recess.
3. Install the Number 10 check ball (1) into the transfer plate. The check ball is approximately 4.8 mm (3/16 inch) in diameter.
4. Position lower housing separator plate (3) on transfer plate (2).
5. Install lower housing (2) on assembled transfer plate (4) and upper housing (3).
6. Install and start all valve body screws by hand except for the screws to hold the boost valve tube brace. Save those screws for later installation. Then tighten screws evenly to 4 Nm (35 inch lbs.) torque. Start at center and work out to sides when tightening screws (1).
UPPER HOUSING VALVE AN D PLUG
Refer to the following graphics, and to perform the following steps.
1. Lubricate valves, plugs, springs with clean transmission fluid.
2. Install the boost valve plug (4), boost valve (3), spring (1), and retainer (2) into the housing.
3. Install the boost valve cover (14). Tighten cover plate screws to 4 Nm (35 inch lbs.) torque.
4. Install shuttle valve as follows:
a. Insert plastic guides (5) in shuttle valve secondary spring (7) and install spring on end of shuttle valve (9).
b. Install shuttle valve (9) into housing.
c. Hold shuttle valve in place.
d. Compress secondary spring (7) and install E-clip (6) in groove at end of shuttle valve.
e. Verify that spring and E-clip are properly seated before proceeding.
5. Install shuttle valve cover plate (8). Tighten cover plate screws to 4 Nm (35 inch lbs.) torque.
6. Install 1-2 (9) and 2-3 (12) valve governor plugs in valve body.
7. Install shuttle valve primary spring (13) and throttle plug (11).
8. Align and install governor plug cover (11). Tighten cover screws to 4 Nm (35 inch lbs.) torque.
9. Install the switch valve (3).
10. Install the throttle valve and spring (7), kickdown (5), and kickdown detent (6).
11. Install the manual valve (8).
12. Assemble regulator valve (2) and spring (4). Insert assembly in upper housing.
13. Install 1-2 (2) and 2-3 (3) shift valves and springs.
14. Install 1-2 shift control valve and spring (9).
15. Install retainer (8), limit valve and spring (7), and 2-3 throttle plug (4) into the limit valve housing (5).
16. Install the throttle pressure spring and plug (12) and plug sleeve (11).
17. Install pressure plug cover (10) and cover plate (6). Tighten screws to 4 Nm (35 inch lbs.).
18. Install limit valve housing (5) and cover plate (6). Tighten screws to 4 Nm (35 inch lbs.).
BOOST VALVE TUBE AND BRACE
1. Position valve body assembly so lower housing (2) is facing upward.
2. Lubricate tube ends and housing ports with transmission fluid or petroleum jelly.
3. Start tube in lower housing port first. Then swing tube downward and work opposite end of tube into upper housing port.
4. Insert and seat each end of tube in housings.
5. Slide tube brace (2) under tube and into alignment with valve body screw holes.
6. Install and finger tighten three screws that secure tube brace to valve body housings.
7. Bend tube brace tabs up and against tube to hold it in position.
8. Tighten all valve body housing screws to 4 Nm (35 inch lbs.) torque after tube and brace are installed. Tighten screws in diagonal pattern starting at center and working outward.
3-4 ACCUMULATOR
1. Position converter clutch valve (4) and 3-4 shift valve (3) springs in housing.
2. Loosely attach accumulator housing (2) with right-side screw (1). Install only one screw at this time as accumulator must be free to pivot upward for ease of installation.
3. Install 3-4 shift valve and spring (3).
4. Position plug (2) on end of converter clutch valve spring. Then compress and hold springs and plug in place with fingers of one hand.
5. Swing accumulator housing upward over valve springs and plug.
6. Hold accumulator housing firmly in place and install remaining two attaching screws. Be sure springs and clutch valve plug are properly seated. Tighten screws to 4 Nm (35 inch lbs.).
VALVE BODY FINAL
1. Insert manual lever detent spring in upper housing.
2. Position detent ball on end of spring. Then hold detent ball and spring in detent housing with Retainer Tool 6583 (1).
3. Install throttle lever (1) in upper housing. Then install manual lever (2) over throttle lever and start manual lever into housing.
4. Align manual lever with detent ball and manual valve (3). Hold throttle lever upward. Then press down on manual lever until fully seated. Remove detent ball retainer tool after lever is seated.
5. Then install manual lever seal, washer and E-clip.
6. Verify that throttle lever is aligned with end of kickdown valve (4) stem and that manual lever arm is engaged in manual valve.
7. Lubricate solenoid case connector (1) O-rings and shaft of manual lever with light coat of petroleum jelly.
8. Attach solenoid case connector to 3-4 accumulator with shoulder-type screw. Connector has small locating tang that fits in dimple at top of accumulator housing (2). Seat tang in dimple before tightening connector screw.
9. Install solenoid assembly and gasket. Tighten solenoid attaching screws to 8 Nm (72 inch lbs.) torque.
10. Verify that solenoid wire harness is properly routed. Solenoid harness must be clear of manual lever and park rod and not be pinched between accumulator housing and cover.
11. Position line pressure adjusting screw in adjusting screw bracket.
12. Install switch valve spring on tang at end of adjusting screw bracket.
13. Position adjusting screw bracket on valve body. Align valve springs and press bracket into place. Install short, upper bracket screws first and long bottom screw last. Verify that valve springs and bracket are properly aligned. Then tighten all three bracket screws to 4 Nm (35 inch lbs.) torque.
14. Perform Line Pressure and Throttle Pressure adjustments.
GOVERNOR BODY, SENSOR AND SOLENOID
1. Turn valve body assembly over so accumulator side of transfer plate is facing down.
2. Install new O-rings on governor pressure solenoid and sensor.
3. Lubricate solenoid and sensor O-rings with clean transmission fluid.
4. Install governor pressure sensor in governor body.
5. Install governor pressure solenoid in governor body. Push solenoid in until it snaps into place in body.
6. Position governor body gasket on transfer plate.
7. Install retainer plate on governor body and around solenoid. Be sure solenoid connector is positioned in retainer cutout.
8. Align screw holes in governor body and transfer plate. Then install and tighten governor body screws to 4 Nm (35 inch lbs.) torque.
9. Connect harness wires to governor pressure solenoid and governor pressure sensor.
10. Install fluid filter and pan.
11. Lower vehicle.
12. Fill transmission with recommended fluid and road test vehicle to verify repair.