400/475 AUTOMATIC TRANSMISSION 7A2-1
SECTION 7A2
400/475 AUTOMATIC TRANSM ISSION
CONTENTS
T R A N S M I S S I O N D I S A S S E M B L Y ...........7A2-1
G E N E R A L S E R V IC E
IN F O R M A T IO N ................................................ 7A2-1
D I S A S S E M B L Y ..................................................... 7A2-3
Vacuum M odulator A ssem bly ......................... 7A2-3
Pan & Filter A ssem bly .......................................7A2-4
Control Valve A ssem bly .................................... 7A2-4
Solenoid Assem bly ............................................... 7A2-4
Front and Rear Servo A ssem blies .................. 7A2-4
Band A pply Pin Check ......................................... 7A2-4
Governor A s s e m b ly .............................................. 7A2-5
Front End Play Check ........................................7A2-5
Case Extension A ssem bly ..................................7A2-6
Rear U nit End Play Check ............................... 7A2-6
Oil Pump Assem bly .............................................7A2-7
Parking Lock Pawl and A ctuator
Assem bly ..............................................................7A2-7
Forward Clutch A ssem bly ................................... 7A2-8
D irect Clutch A s s e m b ly ........................................ 7A2-8
Intermediate Clutch A ssem bly ........ ;................ 7A2-8
Center Support and Gear Unit
A ssem bly ................... ....................................... 7A2-10
Transmission Case ......................................... 7A2-11
C O M P O N E N T R E P A IR A N D
T R A N S M I S S I O N A S S E M B L Y ............. 7A2-15
Park Lock Pawl and A ctuator
Assem bly ...... .....................................................7A2-15
Rear Band and Selective Thrust
Washers .................................... .........................7A2-16
Gear U nit and Output Carrier
Assem blies .........................................................7A2-16
Speedometer D rive Gear
Speed Sensor R otor Replacement ............ 7A2-16
Gear U nit A s s e m b ly .......................................... 7A2-17
Reaction Carrier Assem bly ............................. 7A2-18
Intermediate Clutch Piston ................................7A2-20
Low Clutch Roller Assem bly ........................ 7A2-21
Direct Clutch and Intermediate
Roller A ssem bly .............................................7A2-21
D irect Clutch Piston ............................................7A2-22
Direct Clutch Assem bly ......................................7A2-22
Center Support and Gear Unit
Assem bly .............................................................. 7A2-24
Intermediate Clutch Assem bly ........................ 7A2-24
Direct Clutch A ssem bly and Front
B a n d ..................................................................... 7A2-25
Forward Clutch Assem bly .................................7A2-25
Turbine Shaft Rem oval .................................... 7A2-26
Oil Pump A ssem bly .......................................... 7A2-29
Pump Body ...................................................... 7A2-29
Gear Clearance ............................................... 7A2-29
Pump Cover ..................................................... 7A2-30
Rear U nit End Play Check ............................. 7A2-31
Front U nit End Play Check ...........................7A2-32
Governor A s s e m b ly .............................................. 7A2-32
Driven Gear R e p la ce m en t...........................7A2-32
Rear Servo Accum ulator Assem bly ............ 7A2-34
Front Servo A ssem bly .......................................7A2-35
Control Valve A ssem bly ..................................7A2-36
Pan and Filter Assem bly .................................7A2-39
Torque Converter ............................................... 7A2-40
T O R Q U E S P E C IF IC A T IO N S ......................7A2-42
S P E C IA L T O O L S ......................... ..................... 7A2-43
B U S H IN G R E P L A C E M E N T ........................ 7A2-45
TRAN SM ISSIO N D ISA SSEM B LY
GENERAL SERVICE IN F O R M A T IO N
•
Teflon Oil Seal Rings: During disassembly, check
seals for damage and make sure that they rotate
freely in their grooves. Inspect the grooves for
dirt, burrs or other damage.
•
Thrust washers and surfaces: These washers and
the surfaces they engage may appear polished.
This is a normal condition and does not indicate
damage.
•
Thoroughly
clean
the
exterior
o f
the
transmission.
•
A s the unit is disassembled clean the assemblies
or com ponents so that proper inspection can be
made.
■*4-
Install or Connect (Figure 3)
T ools Required:
J 3289-20 Base
J 8763-02 H olding Fixture
1.
J 8763-02 onto transmission case.
9
Important
D o not overtighten the tool as case damage
may result.
2.
Transmission and holding fixture into J 3289-20.
«--► Remove or Disconnect (Figure 1)
Torque converter (1).
3.
Fixture pin.
4.
Drain transmission fluid.
Содержание 1989 Light Duty Truck
Страница 1: ...vr V Light Duty Truck Unit Repair Manual...
Страница 2: ......
Страница 11: ...GENERAL INFORMATION OA 5 Figure 8 RV Models...
Страница 13: ...GENERAL INFORMATION OA 7 Figure 11 ST Models...
Страница 18: ......
Страница 44: ......
Страница 76: ...1B3 18 R 4 AIR CONDITIONING COMPRESSOR N...
Страница 114: ......
Страница 162: ......
Страница 176: ...4B3 14 91 2 INCH RING GEAR...
Страница 192: ...4B5 4 DANA REAR AXLES Figure 4 Spreading the Differential Case Figure 7 Removing the Ring Gear...
Страница 218: ......
Страница 220: ...4B6 2 12 INCH RING GEAR ROCKWELL F 04734 Figure 1 Rear Axle Components...
Страница 229: ...12 INCH RING GEAR ROCKWELL 4B6 11 SPECIAL TOOLS Special Tools...
Страница 230: ...4B6 12 12 INCH RING...
Страница 240: ...4B7 10 LOCKING DIFFERENTIALS SPECIAL TOOLS Special Tools...
Страница 258: ...4C2 4 93 4 INCH RING GEAR FRONT AXLE F 04756 Figure 4 Spreading the Differential Case Figure 7 Removing the Ring Gear...
Страница 259: ...93 4 INCH RING GEAR FRONT AXLE 4C2 5 Figure 10 Removing the Pinion Gears Figure 13 Pinion Flange Removal...
Страница 260: ...4C2 6 93 4 INCH RING GEAR FRONT AXLE Figure 16 Removing the Pinion Inner Bearing...
Страница 273: ...T TRUCK FRONT AXLE 4C3 3 F 05785 Figure 1 Axle Components...
Страница 291: ...K TRUCK FRONT AXLE 4C4 3 Figure 1 Front Axle Com ponents K 15 25 Models...
Страница 293: ...K TRUCK FRONT AXLE 4C4 5 Figure 3 Front Axle Com ponents K35 Models...
Страница 318: ...C4 30 K TRUCK FBOHT AXLE...
Страница 334: ......
Страница 361: ...2 5 LITER L4 ENGINE 6A1 5 Figure 3 Cylinder Head Manifolds and Components...
Страница 363: ...2 5 LITER L4 ENGINE 6A1 7 F 05715 Figure 5 Block and Components...
Страница 395: ...2 8 LITER V 6 6A2 3 Figure 1 Engine Lubrication Diagram...
Страница 396: ...6A2 4 2 8 LITER V 6 Figure 2 Engine Lubrication Diagram...
Страница 424: ...6A2 32 2 8 LITER V 6...
Страница 427: ...I 4 3 LITER V 6 6A3 3 Figure 1 Engine Lubrication Diagram B 07857...
Страница 446: ...6A3 22 4 3 LITER V 6 F 04488 A Forward B Sealant 70 Gasket 71 R einforcem ent Figure 37 Oil Pan Installation...
Страница 451: ...4 3 LITER V 6 6A3 27 SPECIFICATIONS ENGINE SPECIFICATIONS F 6344...
Страница 457: ...4 8 LITER L6 6A4 3 Figure 2 Lubrication Diagram Front View...
Страница 459: ...4 8 LITER L6 6A4 5 11 12 13 9 15 sT iM V le JsJ 1 1 K V 7 B 07997 Figure 4 Cylinder Head Manifolds and Components...
Страница 460: ...6A4 6 4 8 LITER L6 C 1 107 112 fK 108 3 109 165 129 B 05056 Figure 5 Block and Components...
Страница 490: ...Ml...
Страница 493: ...V8 ENGINE 6A5 3 Figure 1 Lubrication Diagram 5 0L and 5 7L Engines...
Страница 494: ...6A5 4 V8 ENGINE Figure 2 Lubrication Diagram 5 0L and 5 7L Engines...
Страница 530: ...6A5 40 V8 ENGINE Figure 81 Exhaust Manifold 7 4L Engines Figure 82 Water Pumps and Components...
Страница 571: ...6 2 LITER DIESEL 6A7 35 Figure 58 Vacuum Pump Installed...
Страница 576: ......
Страница 582: ...6C1 6 MODEL 1MEF CARBURETOR Figure 9 Monojet Model 1MEF...
Страница 604: ...6C2 6 MODEL M4MEF CARBURETOR Figure 9 Model M4MEF...
Страница 640: ...6C4 8 MODEL 700 THROTTLE BODY...
Страница 652: ...nmm...
Страница 672: ......
Страница 693: ...DISTRIBUTORS 6D5 13 Figure 27 Testing the Pickup Coil Figure 28 Testing the Ignition Coil...
Страница 696: ......
Страница 698: ...7A1 2 700 R4 AUTOMATIC TRANSMISSION Figure 1 Case and External Parts J H 0 0 5 3 7 0 0 R 4 R 2...
Страница 707: ...700 R4 AUTOMATIC TRANSMISSION 7A1 11 682 A JH 0 0 7 1 700R4 R2 Figure 20 Transmission Internal Parts...
Страница 745: ...700 R4 AUTOMATIC TRANSMISSION 7A1 49...
Страница 762: ...7A2 2 400 475 AUTOMATIC TRANSMISSION Figure 1 Case and External Parts H H 0021 400 R 3...
Страница 773: ...400 475 AUTOMATIC TRANSMISSION 7A2 13 Figure 29 Internal Parts H H 0 0 4 3 4 0 0 R 2...
Страница 797: ...400 475 AUTOMATIC TRANSMISSION 7A2 37 Figure 93 Control Valve Assem bly...
Страница 803: ...400 475 AUTOMATIC TRANSMISSION 7A2 43 Figure 104 Bushing Replacement Procedure...
Страница 808: ...J c I i sal...
Страница 838: ......
Страница 840: ......
Страница 842: ......
Страница 850: ...7B1 12 HM 290 MANUAL TRANSMISSION J i t i a x V L...
Страница 856: ...7B1 18 HM 290 MANUAL TRANSMISSION...
Страница 892: ...7B1 54 HM 290 MANUAL TRANSMISSION Figure 93 Special Tools...
Страница 897: ...HM 117 TRANSMISSION 7B2 5...
Страница 901: ...HM 117 TRANSMISSION 7B2 9 B 05180 Figure 17 Installing the 1st and 2nd Synchronizer...
Страница 912: ...20 HM...
Страница 917: ...NEW PROCESS TRANSMISSION 7B3 5 Figure 4 Removing the Mainshaft Figure 5 Removing the Reverse Idler Shaft...
Страница 924: ...7B3 12 NEW PROCESS TRANSMISSION SPECIAL TOOLS...
Страница 927: ...BORG WARNER TRANSMISSIONS 7B4 3 Figure 2 77 mm Transmission and Components...
Страница 940: ...i ii iii m i in m i...
Страница 944: ...7D1 4 TRANSFER CASE FO 5688 Figure 3 NP205 Transfer Case...
Страница 952: ...7D1 12 TRANSFER CASE...
Страница 963: ...NEW PROCESS 241 TRANSFER CASE 7D2 11 Figure 17 Oil Pump Pickup Screen Doweled Case Holes...
Страница 964: ...7D2 12 NEW PROCESS 241 TRANSFER CASE Figure 18 NP 241 Transfer Case Cut Away...
Страница 970: ...7D3 4 NEW PROCESS 231 TRANSFER CASE F 05849 L Figure 3 New Process 231 Transfer Case Components...
Страница 978: ......
Страница 981: ...BORG WARNER 1370 TRANSFER CASE 7D4 3 J...
Страница 992: ...7D4 14 BORG WARNER 1370 TRANSFER CASE Figure 26 Installing the Rear Output Yoke...
Страница 993: ...BORG WARNER 1370 TRANSFER CASE 7D4 15 Figure 27 BW 1370 Transfer Case...
Страница 997: ......
Страница 998: ...X 8937...