A/T - Rebuilt Replacement Information
[03]17
BULLETIN NO.
471
DATE:
MARCH, 1995
SUBJECT:
AUTOMATIC TRANSMISSION REPLACEMENT
MODELS:
ALL VEHICLES EQUIPPED WITH A 4-SPEED AUTOMATIC TRANSMISSION
NOTE:
THIS BULLETIN SUPPLEMENTS BULLETINS NO. 371 DATED FEBRUARY, 1990; NO. 415 DATED APRIL, 1991; AND NO. 457 DATED SEPTEMBER, 1993
FLUID LEVEL:
Each rebuilt transmission is shipped with a red or yellow tag attached to the bell housing, depending on the amount of fluid that must be added prior to starting the engine after installation:
Red Tag - Add two (2) quarts of fluid
NOTE:
Failure to add the proper amount of fluid before starting the engine may result in permanent damage to the transmission.
Once the fluid has been added, start the engine and set the fluid level midway between the "add" and "full" marks. Add 150ml (5 fl.oz.) of "Lubegard" (P/N 9735.C2) and road test the vehicle. Make the final fluid level check only after a complete road test, as the fluid level may rise significantly from cold to operating temperature.
ALIGNMENT DOWELS:
Dowel pins are used between the engine block and transmission housing to maintain a precise alignment of these two assemblies. Failure to transfer these dowels to the new transmission may result in undue loads on the torque converter hub, front pump, input shaft, etc., leading to early failure of the replacement transmission.
TORQUE CONVERTER INSTALLATION:
The torque converter must remain fully seated on the input shaft and front pump during transmission installation. Failure to do this can result in broken front pump drive tabs and/or a jammed torque converter. when the transmission is bolted onto the engine block, the converter must be easily rotated by hand to align with the flywheel or flexplate. If the converter is too tight (must be rotated with the assistance of a pry bar or screwdriver), the transmission and torque converter must be removed and the front pump drive tabs inspected for damage. These tabs are visible through the front seal area. If this condition is present, failure of the transmission will occur almost immediately, often within 1 to 2 miles.
In order to properly install the torque converter, hold it level while installing it. Continue to push in slightly while rotating by hand. Two distinct engagements should be felt, first the input shaft and then the front pump tabs.
TRANSMISSION COOLER - 505:
Any time a transmission is removed from a vehicle and replaced, the transmission cooler and lines must be flushed with proper equipment designed to remove contaminants left behind by the failed transmission. Failure to do this may result in shifting complaints and/or premature failure of the replacement transmission. Follow the equipment manufacturer's instructions for proper flushing procedure.
"Sludge Buster" cooling line flusher is available from Kent-Moore under tool number J359454, or through PMA's Tool Loaner Program. This tool requires flusher adapters, P/N 0091A4.
NOTE:
Do not use air pressure to clean the cooler and/or lines. High pressure air can rupture the cooler and, in addition, tends to force the contaminants against the inside walls of the cooler, rather than clean it out.
TRANSMISSION COOLER - 405:
All remanufactured 4HP14 transmissions are shipped with a fully tested and cleaned heat exchanger already installed. In order to avoid possible contamination of the rebuilt transmission, it is important that this cleaned transmission cooler remain on the unit.
However, some transmission cores returned to PMA appear to have the cleaned and tested heat exchanger installed on them. This indicates that the old contaminated cooler is, in some cases, being installed on the replacement remanufactured transmission.
Due to possible contamination by the old cooler, the remanufactured transmission will be exposed to an increased risk of failure. Any future claim on the replacement unit may be subsequently denied due to an improper previous repair.
KICK-DOWN CABLE:
In order to ensure proper shifting of a replacement transmission, the kick-down cable must be properly routed and adjusted, as part of the installation procedure.
Before removing the original transmission, observe the kick-down cable routing. Make sure that the replacement transmission's cable is installed in the same manner. Failure to do this may result in incorrect cable length to throttle opening ratios and poor shifts.
To adjust the kick-down cable, perform the following:
- Before installing the transmission, hold the cable straight from the transmission at the same angle as it exits the case (cable must be straight with no bends).
- Pull the cable from its housing just until resistance can be felt (full throttle position). Measure the distance from the end of the cable housing to the lead plug crimped to the cable; the distance should be 39 mm.
- Pull the cable all the way out (kick-down position). Measure as above; the distance should be 44 mm.
- After installing the transmission, adjust the cable so the lead crimp is 0.5-1.0 mm from the end of the housing at idle.
DRIVESHAFT AND CARDAN JOINT:
whenever a transmission is replaced, always inspect the drive shaft splines for excessive wear. Shiny spots on the sides of the spline are normal; however, if the spline becomes "stepped" (thinner in the middle or at one end of the spline), the driveshaft is worn and must be replaced.
On 505 Station Wagons, the cardan (universal) joint must also be inspected for wear both at the splines and at the rollers. To test the rollers, grasp the ends of the U-joint in either hand. Attempt to twist the joint back and forth with a motion like you were wringing a wet towel. If looseness or play is observed, the joint must be replaced.
NOTE:
It is normal for the braking cups to rotate within the housing.
If a worn driveshaft and/or cardan joint is reinstalled alter a transmission replacement, the customer will have a complaint of noise or vibration when driving, and may even cause premature failure of the replacement transmission.
IMPORTANT:
Warranty transmission cores have been received by Quality Control exhibiting one or more of the above conditions, In some cases, multiple replacements have resulted. Failure to follow proper repair procedures will result in warranty debits being issued. Please inform your personnel accordingly.