Exhibit 3 - Transmission Repair Instructions
TRANSMISSION REPAIR INSTRUCTIONSMain Control Valve Body
REMOVAL
1. Raise the vehicle on a hoist so the transmission oil pan is accessible. Refer to the Body, Chassis, Electrical and Powertrain manual, Section 10-04.
NOTE: Some vehicles may require the removal of interfering exhaust system components.
2. Starting at the rear and working toward the front, loosen the oil pan attaching bolts and drain the fluid from the transmission. It may be necessary to use a 3/8-inch or 1/4-inch drive ratchet and a 10 mm universal socket to remove the oil pan bolts.
3. Remove the transmission oil pan attaching bolts, pan and gasket. Discard gasket.
4. Remove three filter-to-valve body attaching bolts and remove the filter, grommet and gasket. Discard gasket.
5. Remove the detent spring attaching bolt and spring.
6. Remove the valve body-to-case attaching bolts. Remove the valve body. Discard valve body-to-case gasket.
DISASSEMBLY
1. Loosen and remove 11 bolts from reinforcement plates and detent spring guide bolt from the separator plate using a 10 mm socket.
NOTE: When removing the 11 bolts, note the location of the two shoulder bolts. They must be installed in the same locations when assembling the valve body
2. Remove reinforcement plates, separator plate and separator plate gasket. Discard gasket.
3. Remove the 3-4 shuttle valve and replace with the valve contained in the kit.
4. Remove the throttle control valve spring and replace with the spring from the kit.
ASSEMBLY
1. Verify that the seven-check balls are in their proper locations.
NOTE: The location of the orange ball. This ball is larger than the others and must be positioned as shown.
NOTE: The check ball locations are labelled one through eight. Check ball seven was eliminated. There are a total of seven check balls.
2. Verify that the pressure relief valves are in their proper locations.
3. Install Valve Body Guide (Alignment) Pins T80L-77100-A or equivalent. Note the location of the pins. These two holes are smaller than the other bolt holes to ensure proper alignment of the gasket and separator plate with valve body These two holes also align the valve body gasket and valve body assembly with the case.
CAUTION: The two shoulder bolts must be installed at alignment pin locations only.
4. Install the lower separator plate gasket from the kit. Do not use a lower separator plate gasket other than the one-supplied in this kit. Slide the gasket and the new separator plate over the two alignment pins. Position the three reinforcement plates and loosely install the 11 bolts. Loosely install the detent spring guide bolt. (This bolt is the same as the short valve body assembly-to-case attaching bolts.)
CAUTION: Do not use a shoulder bolt at the detent spring guide or damage to valve body casting will result.
5. Starting at the center (large) reinforcement plate and working outward, tighten the 11 attaching bolts to 9-11 N-m (80-100 lb.in). Tighten the detent spring guide bolt to 9-11 N-m (80-100 lb.in.). Remove the alignment pins.
INSTALLATION
1. Install new upper valve body-to-case gasket.
2. Using Valve Body Guide Pins T80L-77100-A or equivalent, position the valve body to the case, making sure that the inner manual lever and inner TV levers are engaged.
3. Install valve body-to-case attaching bolts. Tighten to 9-11 N-m (80-100 lb.in.).
4. Install detent spring and attaching bolt. Tighten to 9-11 N-m (80-100 lb.in.).
5. Remove the guide pins and install and tighten the remaining two attaching bolts.
6. Load TV lever torsion spring against the separator plate.
7. Using three filter attaching bolts, install the filter and gasket to the valve body Tighten attaching bolts to 9-11 N-m (80-100 lb.in.).
8. Clean the transmission oil pan and gasket surfaces thoroughly
9. Using a new oil pan gasket, secure the pan to the transmission case. It may be necessary to use a 3/8-inch or 1/4-inch drive ratchet with a 10 mm socket to install the oil pan bolts. Tighten the attaching bolts to 8-13.5 N-m (6-9 lb.ft.).
10. Lower the vehicle and fill the transmission to the correct level with the specified fluid. Start the engine and shift the transmission to all ranges, then recheck the fluid level. Refer to Transmission Fluid Level Check procedure. Refer to the 1989 or 1990 Lincoln Town Car, Crown Victoria/Grand Marquis Shop Manual.
11. Adjust the linkage rod or cable system as outlined under Linkage Adjustment. Refer to the 1989 or 1990 Lincoln Town Car, Crown Victoria/Grand Marquis Shop Manual.