Overdrive

Overdrive
g- 1976-
Repairsand
Maintenance
 TP300s8/3
6000.05.84

Printedin U.S.A.
 Y

Contents

Specitications
Specialtools

Problemsand remedies
7
- E.rgagingsoundwhen re-slarl'ng 7
- lmprovedwiring harness .. .. 7
- Modificatronof old lype wiri'1gharness I

On-vehiclerepairs
- C h e c \ i n og i lp r e s s u r.e. . . . . . . . . . . . . . . . . . . . . . . . . 9
- Replacing solenoid I
- Checkrng/replac'ng ,elieivalve . . 10
C l e a n i ncgo n l r ool r i f i c e. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- C h e c k i n g / r e p l a cc ihnegc lv' a l v e. . . . . . . . . . . . .. 12
- Cleaningorlfiltel 12
R e p l a c i nogi l s e a l aol u l p u sl h a f t. . . .
- B e p l a c i n g o n e - w a y c | u.t.c. .h. . . . . . . . . 14

Removingoverdrivetrom vehicle 20

Cleaningand checking 27

Assemblingoverdrive

- Planetarygearassembly
- Clutchslrdingmemberasse-nbly 35
- Froalhousrng 36

Installingoverdrive 39

Group 43
Content
Spec,fcafors

Specifications
Reductionratio 0.8:1
Solenoidcurrentdraw,approx........ 2Ampsat12Volts
Lubricant
M41- Type Gearorl
O u a l i t.y. . . . . . . APIGL-1
V i s c o s i t y. . . . . . . . . . SAE80W/90alt.SAE80/90
Capacity (lransm. included) 1.6lilers 1 7 USqts

M46- Type ATF TypeF oTG

(transm.
Capacity rncluded) 2.3liters 24usqls

o
Theoil levelshouldbe up to the liller plughole
Transmission and overdriveare lubricatedby
the sameorl.Whenoil is drainedlrom transmis'
sion,also removecoveron overdrive and clean
sirainer,

Tighteningtorques
Seespecificoperatrons

Applicalions
Orive
LaycockNo. lntroduced flange l\rainapplicatron
254740-4 115648 Fall1974 1310 6-cylengines
1208014-9 1 1 5 6 5 5 Fall1974 1140 4-cylengrnes
1208015-6 1 1 5 6 5 6 Fall1974 1310 4-cylengines. Beplaced by
1 2 0 8 0 1 4+- 9d r i v e l l a n g1e3 1 0 .
1208101-4 '115657 Fall1976 1l40 4-cylengines
1208109-7 115659 Jan.1978 1310 6-cylengrnes
12081
10-5 115660 Fall1977 1140 4-cylengines
1208191-< 115895 Fall1978 1140 Dieselenqines

Gtoup43
Lansmissio|l
 Speclrbatiors

Specifications

Oil pressures:
Direcldrlve engaged(allengineapplications) 0.15MPa (21psi)

Ovedrive engaged:

Engineapplication Productiondate notes (psi)

821: - June,1980
4-cyl(exceptTurbo) (380-440)
823:- October,1980

828:- October,1980 3.2-3.6 (4ss-s10)

821 (exceptTurbo) June,1980- (469-510)

B23 October,1980- 3.3-3.6 (469-s10)

B2a October,1980- (469-510)

Diesel [4arch,1981- 2.4-3.1 (398-440)

IurDo June,1981- 3.7-4.0 (526-568)

Group43
ffarsmissiot
Specialtools
Specialtools
1797 Drift 5183 Extractor
removingrearbearing for reliefvalve
1801 Standatdhandle 5210 Ring
'1845Presstool assembling/disassembling
driveflange
installing one-wayclutch
2261 Puller
2835 Centeringtool
pullingdriveflange
for centering splinesin planetary
2412 D.in gearcageandone-wayclutch
bearingandseal
installing
2836 Wrench
2715 Dtift
for plugs
clutchbearing
installing
2851 Drift
2806 Drift removing clutchslidingmember
clulchbearing
installing
5069 Extractor
2834 Pressuregauge
for oil seal
checkingoil pressure
5082 Sleeve
5172 Crow-footwrench
5103 Oritt
replacingsolenoidvalve
removing clutchbearing
5149 Wrench
lorquingdriveflangenut

1797 Drift 1801 Standardhandle 1845Presstool

removing
rearbearing driveflange
installing

2412 fr

2261 Pullet 2412 Oritl Drifi

pullingdriveflange bearing
installing installing
clutchbearing
 Spec€/tools

2806 Orifi gauge

2834Pressure 2835 Centeringtool
installing
clutch checkingoil forcenterang
splines
oear|ng pressure

2836 Wrench 2851 Drifi 5069 Exlraclor

for plugs removino
clutch for oil seal
w
1801

5082 Sleeve 5103Drift 5149Wrench

installing
bearing removing
clutch lorquingdriveflange
beannq nut

ry5(@
5172 Crow-toolwrench 5210 Ring
replacing
solenoid assembtingand
dlsassembling
one-wayctutch

5183 Exlraclor
'an1 for reliefvalve
 Prablems and rcmedies

Problems
andremedies
Engagingproblems Engagingsoundwhen re-starting.
A new overdrivewhich has not been used for Upto early1978N/odels.
sornetime mightbe difficultio engage.
The rea- Somelimesa sound could be heardfrom the
sonrsmainlylackof "exercise" whichcausesrne overdrve when re-starting afterdrivng with the
partsto stick.Somereasons: over0nve engaged.
1 Lowoil level The reasons quitenormaland doesnot cause
2. Solenoidstickingor opene ectricalcircuit. any damageor abnormalwear.Duringnorma
3. Clutchslidingmembersticksto theshaft. drivi.q the ove drivera{esup I e 619i.e torque
and assumes a certainposition.lt thencausesa
t. norsewhenjt returnsto the ockedposition.
C h e c k t h a i t h e o i l e v e l i s u p t o t h e p l u g e v e l . It is not necessary to replaceany partsor the
Lowoil levelcancausemanyproblems. overdnve assembly.
2. Thedesignu/aschangedduringthe 1978Model
Checkso enoidoperation. production runto eliminate thesound.
Switchon thelgn iion,
engage4th gear and switch on the overdrive.Wiringharness
Thereshouldbe a clickingsoundfromthe over-
drivesolenoid. A r i m o o v e dw i r i r g h a r r e s c f o r r h e o v e r d r i v e w a s

:C N oc l i c k i n sgo u n d :
Do NOTstartto replace thesotenold.
i n t r o d u c e dd u r n g t h e 1 9 7 8 M o d e l p r o d u c t i o n
r u n .V I N - s :
Checkvoltageto the overdrive connections, then 242 1310A0 264 53000
to relayetc. 244 317040 265 13000
tJsejumper wires directy to the overonvero 245 182040
checkoperation.
Theneww ring harness is longer,softerand bet
3. ier insulated.
lf theclutchslidingmembersticksto thesnan:
Driveat approx.50 mph (80 km/h).Overdrive
I switchedON.
Dlsengage the clutch, increaseenginerpm to
approx.5000,and quickly engagethe ctutch
again.In mostcasesthis shouldfreethe clutch
slidingmember.
Some"exercise is recommended for new cars
with stcking clulch sliding member.Drive at
5G-55mph (80-90km/h).Coastandengage/dis- 6)
engagethe overdrive at least25 times.Thls will
polishthe bearingsurfaces.
4-"-=t
I Operationmalfunction
Overdrivedoes NOTengage,indicator ightdoes
NOT illurrinate
Check:

, Wtring
- Overdriveswitch

Solenoiddoes NOTengage(click),indicatorI ght

illuminates.
Check:
- Switch on transm/ssion
- - S o l e n o i dq r o u n dw t r e
- sotenoro
|

Group43
 --1

Modification of old type

Modification
of old type wiringharness
I
therubberbellowtorthegearlever.
Remove
2.
Cut the wiresapprox.40 mm (1.5inch)lrom the
gearlever. o
3.
Splicetwo 14 gaugewires,approx.250mm (10")
long.

4.
Push on two 50 mm (2") piecesof insulation
ruorn9.

5.
Use tape 1o tie the wires to the gear lever, as
o
6.
Attachtwo spadeconnectorsto the wire ends.

7.
Loop the wires to permit m a x i m u mf l e x i b i l i t y .
Attachto the connector.lt must be in the front
leitcorner.
8.
Reinstall
the rubberbellow.

Group43
Iransmission
 On vehicletepairs
Checkingoil Pressure-
Theoil pressute can be checkedwhendrivingon
test rollersor highway.Testson jack or stands
shouldbe avoided forsafetyreasons.

o 1.
Removethe plugunderthe controlva ve.
connectpressuregauge2834.
2.
2831. Drivein 4th gear,overdrive
NOTengaged, speed
45 mph :70 km/h Pressure sho{rldbe 0.'15MPa
= 2 1p s i .
3.
Same conditions, but overdriveON- Pressures
shouldbe as indicaledin "Specifications"
section.

Disengage Checklimelor pressure

overdrive. to drop
to 0.15 MPa = 21 psi. Time shouldnot exceed
3 seconds-

Testingsolenoid
1. Electrically 2. Mechanical 3. Runningtest
Checklorcurrentalthe yellowwire Removethe solenoid.Ensurethat lf the overdriveoperatesproperly
lgnition
onthesolenoid. mustbeon oil-waysare not blocked. whenthe gearboxis cold but not
and 4th gear plus overdrive Coverthe holes betweenthe O- whenwarm,connectthe solenoid
engaged. ringsand blow throughthe short 1oa powersupplyand leaveuntilii
end.Thevalvemustbelight,noair heats up. Then check in manner
may pass. previously
described.
Connecta 12Vsupplyto solenoid.
Blow again withoutcoveringthe
holes.Thevalvemustbe lightand
no air may pass,

Replacingsolenoid
Solenoidvalve and controlvalve are integraland
replacedas an assembly.Use 25 mm = 1" cfow-
foot wrench(Volvotool 5172)ior femovingand
installing.
1.
Disconneciwires at conneclors.Atlach crow_
foot wrench.Use exlensionand wrenchas appro_
pdale.Removesolenoid.

,0
Group43
On-vehiclercpairs

2.
0 (

ApplyATFoil to the newO-rings.Installsolenoid.

Usecrow-foolwrenchandtorquewrench.
Torqueio: 42-55Nm = 30-40ft.lbs.

g/replacingreliefvalve 0t (

1.
0) I
-^-/-;\ Havean oil collectingpanready.Removeoil pan
andstrainer,
2.
Usetool2836to removethe plugunderthe relief

0l

---:l \--:
*l
t \Tr
E
tl
I
o I
I v{ I \E 3.

o
tl
Vqz. y

{.
: Remove

-
the reliefvalveassernb
1 - Earlyproduction
2 Mid-production
(-75)
(76-5183)
I
*
* 3 - Lateproduction(5/83-)
$ F
A
*
-r T Noteshim arrow)for pressureadjustment.
(at
a ft'l ft
t.l
a ll
Il
- - T
I II
I I
1 2 3

Group43
t On-vehiclercpairc

Usetool5183to pullcyiinderandseat.
Screwout the centerscrewA until the slotted
partB canbe inserted
in theseat.
- Screwin thecenterscrewuntiltight.
-Screw in nut C until seatand cylindercome
loose.
5.
Cleanall partsin solvent.Blowcleananddrywith
compressed alr.
Carefullycheckfor wearanddamage.
I\rakesurethe pistonsruneasilyin the cylinders.
Replacedefectiveparts.
6.
Use compressed air to blow clean the conrrol
orificepriorto installation.
7.
Installnew O-ringson seat,cylinderano prug_
Lubricatewithoil.

: .:..* 8.
K--- _-, Posiiionthe seatin the housing_ Useihe cylinder
to pressit intocorrectposjiion.
NOTE:
-he Lylrnder
O- i19endshourdbe DOW\.
Seat
L
Fii the smallpistonand sprlngsin the largepis-
Cylinder ton.
Inserttheassembly in thecylinder.
eotto,n Nrakesurethe smallpistonfits correctlyin the
I Piston
"no seaL
Spring 10.
lnstallthe plug. Torqueto 19-24'Nm: 14-lB
ft.lbs.
Spring
11.
lMakesure the magnetis cleaned. lJse a new
Piston gasketand insiallstrainerand oil pan. Fill oil to
prugtevet.
NOTE:
Plug Ivakesurethe reliefvalvecylinder is correctly
assembled(seearrow).

Graup43

11
 repatrs
On-vehicle
Cteantngcontrotortitce-

Bemovethe solenoid.
fl (
to
Removethe reliefvalvecylinderto gain access
the controlorifice.
Usecompressedair to blow clean.

i::,1,1:-Checking/replaci ng check valve-

1.
Remove
2.
oil panandstrainer.

Usewrench2836to removethecenterplug.
o (

Remove spring,ballandseal.
3.
Cleana I partsin solvent.Blowdrywithcompres- (
sedalr.
Checkall partsfor wearanddarrage.Replaceas
necessaTy.
4.
InstallanewO-rlngon the plug.lnstallseai,ball,
springand plug.Torqueto 1F24 Nm = 14-18
ft.lbs.
5.
Usea newgasketand installstrainerand oll pan. 0
Do notforgetthe magnetin theoil pan.
Fill with oil (see Specificationsin front of
manuarl.

eaningoil filter
(
1.
RemoveoiLpan and strainer.
2.
Use wrench 2856 to removethe plug. Remove
sealand oil filler.Dlscardseal. (

3.
Cleanallparts n solvent.B owclean and drywith
compressedarr.
4.
Instal ojlfilter,new sealandp ug.

6g Torqueto 19-24 Nm =14-18ft.lbs.

5.
{Jsea new gasketand installstrainerand oil pan.
Do not Jorgetthe magnet.
Fill with oil (see Specifications in front of
manuar)- 0
Gtoup 43

12
 On-vehiclercpais

Replacingoil seal at outputshatt-

o 1.
Disconnectthe driveshaftat the overdriveflange.
2.
Removethe nut. Use puller2261to pull the drive
flange.
3.
lJseextractor5069to removethe oil seal.

4.
Usedrift2412to installthenewseal.
5.
Usepresstool 1845to installthedriveflange.
6.
Installdriveflangenut.Torqueto:
16+180Nm = 120 130ft.lbs.
7.
Reconnect
lhe driveshaft.

Group43

13
On-vehiclerePairs

Replacingone-wayclutch

1.
Jackup rearend.
2.
Unloadtheoverdrive:
0
- Startenoineandenoaqeoverdrive.
- Depresitheclutch-peidal and switch
off theenoine.
3.
Disconnectthe drive shalt at the over-
driveflange.
4.
Disconnect the speedometer cable at
theoverdrive-
5.
Disconnectthe solenoidgroundwire.

6.
Have an oil collecting pan ready.
Removethe nuts retaininglhe oveF
drive housings.Removethe spring
washersand the seals at the two
upperstuds. Q;
7.
Removeoverdriverearhousino,
- Clamo
it in a visewithsoftiaws.

8.
Removesnap ring and oil slinger.
 On-vehiclercpairs

s210

Usering 5210to facilitatedisassembly

andassemblyof one-wayclutch.

ffi
9.
Installring 5210.Lift one-wayclutch
into the ring.Turningclockwise.

W Alternatemethod,if no ring tool is

available:
Carefullyremoveone-wayclutch.The
rollersareloose.

10.
Rotatethe one-wayclutch in the ring
toolso ihatthe rollerscomeout,one by

G
Freewheel
components.

@
i0 ,"
Gtoup43

t6
On-vehiclerePajrs

10.
Disassemble
cturcn.
and clean the one-way I (

11.
Alwaysuse ttre new type hub, with
high cams {see illustration)when
reassembling.
12.
Checkthe rollercagefor damagesand
wear.Beplaceas necessary-

14.
To assemble,installthe springin the 0l I
holesin the cage.

AY
0
Installthe new type cam hub correct
way,see illustration.

I
16.
Instal cage and hub assemblyin ring
tool.

0
Group4S
 On'vehiclerepairs

17.
Turnihe cageassembly
whileinstalling
the rollers.

D
NOTE:
Position opening of the ring tool
toward space between rollers as

c,_--- =-\

frfrilDi7r>rtl\
at\ rli 18.
Makesurethethrustwasheris properly
located. usegreaseto hold
If necessary,
it in place.
NOTE:
Thrustwasherandoutputshaftmustbe
rnatingpafts.

t
Group43

17
On-vehiclerepai's
Il
19.
Positionring tool and one-wayclutch o
Wr
assembly.Turn one-wayclutch hub
qlgqblgise while pressing one-way
clutchintoposition.

I
Earliertype Newtype
(
Alternatemethod:

Assemble theone-way clutch.

t hub
2 - rollercage
3- spring
Botatethe rollercagectockwise to end.
Usethe key(4)to lockit in position.
Installtherollers-Holdthemin position
wiiha rubberband(5)- {r

o (

Alternatemethod,cont.

lrake surethe thrustwasheris properlylocated-

Q; I
Installthe one-wayclutch. Bemovethe rubber
oano.
NOTE:
Thrustwasherand outputshaftmustbe mating
parts.

Group43
fransmission
 On-vehiclerepaits

20.
l n s i a lol i l slingerand snapring.

21.
Cleanthematingsurfaces
of the housings.
Install
newgasket.
22.
surethe gasketin frontof the brakehasnot
l\,4ake
beendaragedwhe'1removtng t']eclLlch.
23.
lfstalloverdrive
rearhousing.

0 24.
Installthesealson theiwo upperstuds.
Installspringwashers andnuts.
Torqueto: 7-16Nm : 5-12ft.lbs.
25.
Reconnect
thesolenoidgroundwire,
26.

{}
t'
-).a
Reconnect the speedometer
drive.4-{ Nm = 3-4 ft.lbs.
27.
cableat the over

Reconnect
thedriveshaftat theoverdrive
flange.
24.
Fillwithcorrecioil (seeSpecifications
in frontof
manual).Startthe engjneand engagethe over-
drivewhendriving.
Recheck oil levelafterdriving.
0
Gtoup43

19
Removingoverdrive

Removing fromvehicle
overdrive
to avoidtorsionalstressesin the
It is irnportant lf this is forgotten,or not possible, the torsional
shaftbetweenthe planetary gearcarrierand the siressescan be removedby engaging/disen-
one-way clutch. gagingthe overdrivein vehicle.This can be ac-
complished by connecting an oil line under2.0-
I
Priorto removingthe overdrive,it is advisable
to = 28G-350psi pressure
2.5 N.4Pa to the connec-
drivethe vehiclewith the overdriveengagedand
tion for the pressure gauge. With this pressure
thendisengage withlheclutchdepressed.
connected,ihe overdrivecan be engaged/dis-
engagedby switchingon ignitionand the over
I
rl
driveswitch. I

1. (
Disconnectthe drive shaft lrom the overdrive
flange.
2.
a supportundertheenglne.
Position
3.
Qr I
Removethe cross memberunder the trans_
mission.

Lowertheenginerearend,
5.
Disconnect
thewiresai thesolenoid.
0 (

6.
Femovethe nuts retainingthe overdriveto the 0 (

transmission-
7.
Pull the overdrive straight backward !ntil (
released
fromthetransmissionoutputshaft.

0
Group43
I/ansm/ss,on
20
 bling overdrive
Disassem

Disassembling
overdrive

rna visewithsofljaws.
Clamptheoverdrive
I Removethesolenoidgroundwire.

_1

Removethe bridges.

Remove the nutsholdingfrontand rearhousings

together.
NOTE:
Loosencrosswiseto avoidtcnsion-

nemovefronthousingandbrakedrum.
Bemovethe springs.Lift out the clutch with
thrustbearingandsungear.

Group43
Di sa9sembIing overdrive

the planetary
Remove gearcarrier.
0 a

Fronthousing
I
pumplinkandpumppiston.
Remove a

o)
Usea copperdriftto taploosethe brakedrum.
O(
Q)C
a
I J

Positionthe front housingwith the front end

DOWN.
Connectcompressed air to the holefor the sole-
noidvalve.Blowoutthepistons.
 ing o verdrive
D isassembl

Clampthefronthousingin a visewithsoftjaws.
Remove theoil pan.

0
Rernove
thestrainer.
0 Usewrench2836to removethethreeplugs.

Removein order:
I - ,+
)q
0
1. Oilfilter.
2. Checkvalvewith spring,balland seat.
i Removepumpcylinder.
0 i
I
)
'I
3. Removereliefvalve.
a. Eadyproduction (-75).
(76-5183)
b. l\4id-production
A E
+ c. Lateproduction (5/83-)
- + Noleshim(al a(ow) for pressureadjustmenl.
'**' 1 2 .ta 3b 3c

5183to pullcylinderandseat.
Useextractor
- Screwout the centerscrewA until the slotted
partB canbe insertedin iheseat.
Screwin the centerscrewuntiltight.
-Screw in nut C until seatand cylindercome
loose.

Group43
Transmission
23
 bling o verdrive
D isassem
GlutchslidingmemberassemblY

Removethe snap ring.Pulloui the sun gear.

0' I

I
2851
Remove the snapring.Usedrift2851and a plas-
tic malletto tapout theclutchdisc
o(

Qr (

Remove the largesnapring.Usedrift 5103and a

plasticmalletto tapoutthebeanng.

0 (

gearassemblY
Planetary I

to pry loosethe oil slinger'

Usea screwdriver

0t (

Group43
fransmrssron
24
 Disassembl i ng ovetd r ive

to pryloosethe lockpins.
Usea screwdriver
NOTEi
Thepinsmayhaveto bedriliedout.

Remove the gearshafts.Removeplanetary

gears
andthrustwashers.
Removeneedlebearingsand spacersfrom the
Lale type planetary
gears.

Rearhousing
0
Removesnap ring, oil slinger,one-wayclutch
assembly
andthrustwasher.
NOTE:
Alsoseepage15 for procedures
0 5210whenremoving one-way
usingring tool
clutchassembly.

rl

Flemovethe speedometergearassembly.

0
Group4S
I/arsmission
25
 bIing overdrive
Di sassem

Attachwrench5149and removethe driveflange

nut.

O) I
Usepuller2261to pullthedriveflange
I

@,

Pressouttheoutputshaft.

C (

Removespacersleeve(1)andspeedometer
drive
gear(2).

Gtoup43
Transmission
 D i sassembl i ng averd rive

PLrlloff the bearingon the outpul shatt.

1801

Use drift 1797and siandardhande 1801when

pressingoutthe bearingin the rearhousing.
Uses eeve5082to supportthehousing.

5082
Cleaning
andchecking
Cleanall partswith solventand blowthemdry with Nlakesure frlterand slrainerare not damaged.

0 compressed
orl
air.Payparticular
passages.
attention
to filtersand

lvlakesuretheorificeinthechannelbetlveen therelief
Check lhe hydrauic syslempistonstor wear and

Check the valvesior wear Make surethe spflngs

and controlvalveis open.lf compressed air is not are not oamageo

o enough,use a pointedwoodenstick.Hardobjects
mustnot be used,sincethis can alterthe boreof
the channel.
Checkall gearsand bal bear ngs ior wear
lf a p anetarygear has lo be replaced ihe other
two musl also be replaced al lhe same tlme
lrake sure the grooveinsidethe ring gear on lhe Olherwise the planelary gear assembly may
outpulshaftis properlycleaned.Dirt easilycollecls
theredue to the centrifugal
force. For the same reason both needlebearingslor a
After cleaning,check all parls carcfullyfor wear, planetarygear should be replacedai the same
cracksor otherdamages. trme

Use a l2-volt batteryto checkthe solenoid.The Check lhe brake drum for scoring. crac*s and
currentdraw shouldbe 1.5-2.0Volts.Checkvalve
movement whenengaging/disengaging. C h e c kt h e c u i c h d i s c l i n i n g sf o r w e a r a n d h e a l

o
Group43
 Assemblingoverdrive

Assemblingoverdrive
Usenewgaskets,O-rings,lockplatesandseals-
Exercise
outmostcleanliness.
temisverysensitiieto dirt.
The hydraulicsys-
I

Rearhousing

Usedrilt2412to installbearingin rearhousing.

o(

o I
Newoutputshaft
Duringthe 1979Model productionrun, a new
outputshaltandthrustwasherwereintroduced.
To holdthe thrustwasherbetweenthe one-way
I
clutchandoutputshaftbetterin position:
- thrustwasherthickness
wasincreasedfrom2.5
m mt o 3 , 8m m ,
the shaftgroovedepthwas increased
from 1.9 0_l
m mt o 3 . 2m m .
Thenewthrustwasher1232644-3
is usedwiththe
newoutput shaft1232646-8.
The old thrustwasher380715-3
is usedwith the
previous type output shalts 380679-1 and
1232105-5.

380715 1232644 0)
Group43

28
 Assemblingoverdrive

2412 Usedrift2412to pressthe bearingon the output

shaft.
I
-(

tr
0
0 Installspeedometer
on theoutputshaft.
drivegear(2)and spacer(1)

Usea pieceof woodto supportthe ouiputshaft

drift2412io presson therearhousing.
LJse

i0

(0

lJsedrift2412to pressin oil sealin rearhousing.

0
Grcup43

29
Assemblingoverdrive

Positionthedriveflangeon theoutputshaft
lnstallwasherandnut.
0. 1
Usewrench5149to hold the driveflangewhile
torquingthe nut.
Nm = 120-130
165-'180 ft.lbs.

I
gearassemoly,
lnstallspeedometer
Bolttorque: Nm = 3-4 ft.lbs.
lH
I

One-way-clutc
I

Alwaysuse the new type hub with high

cams,seeilustratlon,
Checkthe rollercagefor damagesand
0l
wear.Replaceasnecessary.

To assemble,inslallthe spring in the holes in the

w
cage.

0
Group43

30
 Assemblingovetdrive

Installthecamhubcorrectway,seeillustralion.

0
Inslallcage and hub assemblyin ring tool

Turn the cage assemblywhile installingthe

rollers.

i0

NOTE:
Positionopening in ring tool toward space
betweenrollersas shown.

o
Group43
Transmissian
Assemblingovetdive

i-/11/t/l7*\

Makesure the thrust washeris properlylocated

usegreaseto hold it in place.
lf necessary,

Positionring tool and one_wayclutch assembly.

Turn one-wayclutch hub clockwisewhile pres_
sing one-wayclutch into position.
NOTE:
Thrusi washerand outpul shaft must be mating
parts.

Earliertype Newtype
Alternatemethod:

Assemblethe one-wayclutch
'I - hub
2- rollercage
3 -spring
Rotatethe roller cage clockwiseto end.
Usethe key (4) to lock it in positionthe
rollers.Hold them in positionwith a rub-
ber band(5).

Gtoup43
Iransmissro,
32
 Assemblingoverdrive

Alternatemethod,cant.

Makesurethethrustwasherls propedylocated.
Installthe one-wayclutch.Removethe rubber
oano.
NOTE:
Thrustwasherand outputshaftmustbe mating
parts.

I n s t a lol i l s l i n g ear n ds n a pr i n g .

(f
Group43

33
 Assembling
ovetd ve
gearassembly
Planetary

Installneedlebearingsandspacersin the plane-

tary gears.

r%:-
':,i (4,,
Installplanetary
in iheshafts.
gearsandthrustwashers_
Press

R
IJ
i I n s l a ltlh e l o c h i n gp i n s .

Trci"
Positionlhe oil slingeron the planetarygear
carrier.
Usea driftor chiseJ
to secureit.
NOTE:
T h eo i l s l i n g e m
planetary
r u s t b e a t i g h tf i i a g a i n stth e
gearcarrier.
I
(

Positionthe planetarygear assemblyon the

outputshaft.
Usecenieringtool 2835to guidethe sptinesin
planetary
gearcarrierandone-wayclutch.

fr
Gloup43
Trcnsmission
34
 Assemblingoverdrive
Clutchslidingmemberassembly

2806
Usedrift2806to installthe bearingin the bearing
retainer.
lnstallthesnapring.

-
_-_=::, >_\

J"''.'''"''

Installthe bolts. lJse drift 2715 to press o n

bearingand retainer assembly-

Positionthe sun gear in the clulch disc. lnstall

thesnapring.

Position on the outputshaft.

theclutchassembly
Insiallthesprings.

Group43

35
 Assembling
overdrive
Fronthousing

lnslall:
I 1. Oil Filler,sealand plug.
2. Pumpcylinder,seat,ball,springand ptug.
J 3. Pressurereliofvalveand plug.
5
f
€ a. Earlyproduction (-75)
; -- b. Mid-produchon. notethe shims(arrow).
I c. Lateproduction,
& E=
l-J
+
t-,J
notethe shims(arrow).
Noteshim(at arrow)for pressureadjustment.

2 .ta 3b 3c

(
Usewrench2836to iorquetheplugs.
19-24Nm = 14-18ft.lbs.

Installstrainerand oil pan.Do not forgetto clean

themagnet.
Torquetheboltsto:
7-10Nm= 5-7 ft.lbs.

/'l
-1

ff.=:P,
iaal-r{
,-Y:r
,-'F the pistonsin thecylinders
Position
j '-=.''
):
\f1') F.'
"\ l ( l
\- -
a
f :. ll :-1

96- Gtoup43
Iransmission
 Assemblingovetdrive

Position
housrng.

+
Assemble
rearandlronthousing.
NOTE:
Gasketbetween
brakedrumandrearhousing.
Torquethenutscrosswise
to:

o 7-16Nm = 5-12ft.lbs.
NOTE:
Thelwo upperstudshavenylonseals.
Thenarrowendtowardthehousing.

Installthebridgesandtightenthe nuts
7-16Nm : Fl2 ft.lbs.

Inslallsolenoid
andgroundwire
Torquethesolenoidto:
42-55Nm = 3H0 ft.lbs.

Group43
Transmission
37
Assembling
ovetd ve

rn
II1
N Removecenteringtool 2835.
Installpumplinkandpumppiston.

t4

Group4S
Trarsmr'sstott
I Installing
overdrive
lnstallingoverdrive

v
q
trh 1.
Positionthe overdrive on thetransmission
output
shaft.lnstallthe nuts.Torqueto:
7-11Nm= 5-g fi.lbs.
2.
Raisethe transrnission
and install the cross
mernber.

o
3.
Reconnect
thewiresat thesolenoid.
4.
Reconnect
thedriveshaft.

o
O 5.
F i l lw i t ho i l t o p l u gh o l el e v e l .
M 4 1 : S A8E0 W / 9 0
I\,446: Automatic Transmission Fluid
6.
Recheck oil evelafterdrivingapprox
:
1 0m i l e s 1 5k m .

Lf

Gtoup43

39
oi

o
o
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