AUTOMATIC TRANSMISSIONS ZF 4HP 18

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1 AUTO TRANS OVERHAUL - ZF 4HP 18 Article Text 1991 Eagle Premier For Dan's Transmission Service 10 Jefferson Place Fort Walton Beach FL Mitchell Repair Information Company, All Rights Reserved. Tuesday, April 06, :52AM ARTICLE BEGINNING AUTOMATIC TRANSMISSIONS ZF 4HP 18 * PLEASE READ THIS FIRST * NOTE: This article is based on information for Saab vehicles. Procedures for Monaco/Premier are similar. Complete information for Monaco/Premier models was not available at time of publication. APPLICATION APPLICATION & LABOR TIMES ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Vehicle Labor Times Trans. Application (1) R & I (2) Overhaul Model Dodge Monaco ZF 4HP 18 Eagle Premier ZF 4HP 18 Saab 9000 Series ZF 4HP 18 (1) - Removal and installation of transmission from vehicle chassis. (2) - Bench overhaul time for transmission and differential. DOES NOT include removal and installation. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ IDENTIFICATION Automatic Transaxle (A/T) can be identified in 2 ways. A/T sequence number and type is shown on transaxle identification plate which is located on the left side of the case just above oil pan. See Fig. 1. The 7th position of the VIN identifies the transmission type (8 = ZF 4-Speed Automatic).

2 Fig. 1: Locating Transaxle Identification Tag Courtesy of Chrysler Corp. DESCRIPTION The ZF 4HP 18 Automatic Transaxle (A/T) has 4 speeds, providing an overdrive ratio of.74:1. A/T shifting is controlled by a governor valve, line pressure valve, throttle pressure regulator valve and a modulator valve. Valve operation is dependent on shift lever position, vehicle speed and throttle position. The A/T features a lock-up type torque converter and a planetary gear set, consisting of a total of 6 planetary pinions. Ignition TDC sensor is activated by a stamped steel trigger wheel attached to the torque converter drive plate. Two types of one-way clutches are used: roller and sprag. Roller type clutch operates in 4th gear, and a sprag type clutch in 2nd gear. LUBRICATION & ADJUSTMENTS NOTE: NOTE: For lubrication services, refer to the appropriate TRANSMISSION SERVICING - A/T article in the AUTOMATIC TRANS SERVICING section. Transmission and differential sections are not integral in the ZF 4HP 18 transaxle. They are separate and require different lubricants. A/T uses Dexron II/Mercon ATF, while the differential section requires a synthetic SAE grade 75W-140 gear lube. BAND ADJUSTMENT

3 1) Loosen band adjustment screw lock nut. Tighten band adjustment screw to 89 INCH lbs. (10 N.m). Place reference marks on adjuster screw and A/T case. 2) Back off adjusting screw 2 turns. Hold adjusting screw while tightening lock nut to 59 ft. lbs. (80 N.m). THROTTLE VALVE CABLE Ensure throttle lever is at curb idle position. Using vernier calipers or a fabricated gauge that can be slipped over the throttle cable wire, set cable travel to 1.55" (39mm) for the Monaco and Premier and " ( mm) for the See Fig. 4. TROUBLE SHOOTING NOTE: Always check fluid level and shift linkage before trouble shooting any component. Park Does Not Engage Gear selector cable misadjusted, excessive play at parking pawl washer, segment fitted incorrectly, parking pawl mechanism binding or excessively worn. Engine Will Not Start Start inhibitor switch faulty, excessive play at gear selector shaft. Reverse Will Not Engage Gear selector control or selector cable misadjusted, oil filter clogged, clutch "B" damaged, brake "D" damaged (engine will not decelerate in 1st gear), governor sticking, or first and reverse inhibitor valve sticking. Slips Or Vibrates When Accelerating From A Stop Clutch "B" or brake "D" damaged. Turbine shaft "O" ring or pump stator malfunction, or fluid pressure leaking into reverse clutch or piston. Harsh Engagement From "P" To "R" Or From "N" To "R" Accumu-lator inoperative, shift cable misadjusted. Lack Of Power, Poor Acceleration Torque converter malfunction, oil screen plugged, shift linkage out of adjustment, throttle or shift valve sticking. No Reverse Lights; No Electrical Faults Inhibitor switch defective. Vehicle Creeps In Neutral Shift cable misadjusted.

4 Harsh Engagement Shifting From "N" To "D" Accumulator "D" sticking or spring broken. No 1-2 Upshift Or 2-1 Downshift Governor sticking or 1-2 shift valve binding. No 1-2 Shift Brake "C" or band "C" malfunction. No 2-3 Upshift Or 3-2 Downshift Governor sticking or 2-3 shift valve binding. No 2-3 Shift Clutch "E" damaged or oil supply for clutch "E" leaking. No 3-4 Upshift Or 4-3 Downshift Governor sticking or 3-4 shift valve sticking. No 3-4 Shift Brake band "C" inoperative or loose, upshift valve sticking or position 3 valve sticks. binding. Shifting Points Incorrect Throttle cable misadjusted, governor sticking, shift valves Vehicle Takes Off In 2nd Gear (No Downshift To 1st) Governor piston binding, 1-2 shift valve sticking or band "C" not releasing (adjusted too tight). Vehicle Takes Off In 3rd Gear (No Downshift To 1st Or 2nd) Governor malfunction, 1-2 and 2-3 shift valves sticking or closing gap in center plate leaking fluid pressure (reverse clutch stays applied). A/T Shifts From 1st To 3rd 2-3 shift valve sticking, shift valve sticking or shift valve sticking. A/T Shifts From 1st To 4th Valve body malfunction. No Kickdown Throttle valve cable misadjusted. Governor sticking or leaking, or shift valve binding. damaged. A/T Noisy; Will Not Move In "D" Or "R" Converter drive plate damaged or oil pump gears worn or

5 No Overrun Braking Brake band "C" defective. TESTING Preliminary Checks Begin diagnosis by checking easily accessible items such as fluid level and condition and cable adjustments. Check and adjust fluid level with A/T at normal operating temperature, parking brake set and engine at curb idle speed. Correct fluid level is between ADD and FULL HOT marks. Perform appropriate basic procedure. One procedure is for vehicles that are driveable, and an alternate procedure is for disabled vehicles. Vehicle Is Driveable Check fluid level and condition. Adjust throttle and shift cables if complaint was based on delayed, erratic or harsh shifting. Road test and note transmission operating characteristics. Refer to diagnostic charts and tables. Vehicle Is Disabled Check for broken or disconnected throttle or shift cables. Check for cracked or leaking cooler lines. Raise vehicle, start engine, shift A/T into gear and check the following: If axle shafts do not turn and A/T is noisy, stop engine and remove oil pan for inspection. If no debris is found in pan, remove A/T and check converter drive plate, converter, oil pump, input shaft or differential. If axle shafts do not turn and A/T is not noisy, remove and repair or replace unit. ROAD TEST 1) Operate A/T in all gear ranges while checking for slippage and shift variations. Note when shifts are harsh, spongy, delayed, early or if downshifts are sensitive. 2) Check closely for engine flare during shifts. Engine flare usually indicates clutch, band or overrunning clutch malfunctions. Road Test Results Refer to specifications in the CLUTCH & BAND APPLICATION table and the SHIFT SPEED SPECIFICATIONS charts to provide a basis for analyzing road test results. CLUTCH & BAND APPLICATION ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Gear Position Elements In Use 1st Gear... Clutch "A", Brake "D", 1st Gear One-Way Clutch

6 2nd Gear... Clutch "A", Brake "C", Band "C" 2nd Gear One-Way Clutch 3rd Gear... Clutch "A", Clutch "E" 4th Gear... Band "C", Clutch "E" Reverse... Clutch "B", Brake "D" ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ SHIFT SPEED SPECIFICATIONS TABLES NOTE: Shift speed specifications not available for Dodge Monaco and Eagle Premier. SHIFT SPEED SPECIFICATIONS (9000 TURBO, 2-STAGE) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application MPH Upshifts Light Throttle 1-2 Upshift Upshift Upshift Wide-Open Throttle (1) 1-2 Upshift Upshift Upshift Kickdown (Wide-Open Throttle, Maximum Speed) 4-3 Downshift Downshift Downshift (1) - RPM should be between for pre-1988 models and for 1988 and later models. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ SHIFT SPEED SPECIFICATIONS (9000 TURBO, 3-STAGE) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application MPH Upshifts Light Throttle 1-2 Upshift Upshift Upshift Wide-Open Throttle (1) 1-2 Upshift Upshift Upshift Kickdown (Wide-Open Throttle, Maximum Speed)

7 4-3 Downshift Downshift Downshift (1) - RPM should be between for pre-1988 models and for 1988 and later models. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ SHIFT SPEED SPECIFICATIONS (9000/9000i/s, 2-STAGE) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application MPH Upshifts Light Throttle 1-2 Upshift Upshift Upshift Wide-Open Throttle (1) 1-2 Upshift Upshift Upshift Kickdown (Wide-Open Throttle, Maximum Speed) 4-3 Downshift Downshift Downshift (1) - RPM should be between for pre-1988 models and for 1988 and later models. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ SHIFT SPEED SPECIFICATIONS (9000/9000i/s, 3-STAGE) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application MPH Upshifts Light Throttle 1-2 Upshift Upshift Upshift Wide-Open Throttle (1) 1-2 Upshift Upshift Upshift Kickdown (Wide-Open Throttle, Maximum Speed) 4-3 Downshift Downshift Downshift

8 (1) - RPM should be between for pre-1988 models and for 1988 and later models. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ LINE PRESSURE & STALL SPEED TESTS Line Pressure Test 1) Perform line pressure test after A/T has reached operating temperature of 176øF (80øC). Ensure fluid level and condition have been checked and are acceptable. 2) Measure line pressure with gear selector in "N" and engine idling. Measure kickdown line pressure with throttle valve cable withdrawn fully and engine speed at 2000 RPM. 3) Connect Oil Pressure Gauge to pressure port in A/T housing. Use appropriate adapter for vehicles equipped with either fuel injected engines or with turbocharged engines. See Fig. 2. Start engine, obtain pressure readings and refer to specifications. See appropriate LINE PRESSURE & STALL SPEED SPECIFICATIONS table. Fig. 2: Locating Pressure Test Ports Courtesy of Saab-Scania of America, Inc. LINE PRESSURE & STALL SPEED SPECIFICATIONS NOTE: Line pressure and stall speed specifications not available for Dodge Monaco, Eagle Premier and Saab 9000 Non-Turbo. LINE PRESSURE & STALL SPEED SPECIFICATIONS (9000 TURBO) (1) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

9 Pressure Pressure Stall Gear Kickdown Speed Position RPM psi (kg/cmý) psi (kg/cmý) RPM "R" ( ) "N" ( ) ( ) "D" ( ) "1" ( ) (1) - Test At normal operating temperature. ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Stall Speed Test 1) Perform stall speed test with A/T at operating temperature. Check engine and A/T fluid to ensure proper levels and condition. 2) Stall speeds are measured with gear selector in "D" and "1" positions. Parking brake and service brake must be applied fully while performing stall test. Connect an engine tachometer visible to driver. 3) Start engine, apply parking brake and service brake fully, then shift gear selector to "D" position. Ensure no one is in front or behind vehicle and depress accelerator pedal to floor. Obtain engine RPM reading and release accelerator pedal immediately. 4) Allow ATF to cool, then repeat test with gear selector in "1" position. To prevent internal damage to A/T, DO NOT hold stall speed any longer than 10 seconds. See LINE PRESSURE & STALL SPEED SPECIFICATIONS table. ON-VEHICLE SERVICE SPEEDOMETER DRIVE/SPEEDOMETER SENSOR Removal & Installation With a small hammer and pin punch, remove locking pin from A/T case. Pull speedometer cable from A/T case. If equipped with electronic sensor, remove retaining bracket and drive. SERVO PISTON Removal 1) Remove transmission fluid cooler. Compress piston and cover and remove cover snap ring. 2) Remove piston cover and band piston assembly. Remove and discard "O" rings from piston and cover. Clean piston and cover. Inspect for signs of wear or damage.

10 Installation 1) Install new "O" rings on band piston and piston cover. Install piston assembly and cover in case bore and ensure piston rod is seated in band. 2) Compress piston and cover and install cover snap ring. Remove tool and install transmission fluid cooler. Tighten cooler bolt to 37 ft. lbs. (50 N.m). NEUTRAL SWITCH REPLACEMENT Removal 1) Disconnect neutral switch harness connector in engine compartment. Raise vehicle and remove splash shield. 2) Remove bolt attaching switch bracket to A/T case and remove switch from case. Installation 1) While under vehicle, feed switch harness up into engine compartment. Install new "O" ring on neutral switch. 2) Insert neutral switch into A/T case, install switch bracket and tighten bolt to 89 INCH lbs. (10 N.m). 3) Install splash shield and lower vehicle. Connect neutral switch harness connector in engine compartment. VALVE BODY ASSEMBLY Removal Shift A/T to manual 1st gear position. Remove oil pan bolts and oil pan. Remove larger valve body bolts. Remove valve body assembly and oil screen and cover. Installation 1) Move gear selector lever counterclockwise to manual 1st gear position (last detent in counterclockwise direction). Pull throttle cable to wide open throttle position to avoid jamming throttle cam and piston during installation. 2) Set manual valve all the way into manual 1st gear position. Align and install valve body assembly into A/T case. 3) Tighten valve body bolts to 89 INCH lbs. (10 N.m). Tighten small (5mm) oil screen bolts to 44 INCH lbs. (5 N.m) and the larger (6mm) oil screen bolts to 71 INCH lbs. (8 N.m). 4) Install oil pan and tighten clamp nuts to 53 INCH lbs. (6 N.m). Install splash shield, and lower vehicle. Install ATF and adjust throttle cable. THROTTLE VALVE CABLE REPLACEMENT Removal 1) Loosen lock nuts securing throttle valve cable in bracket at throttle body. Disconnect cable from throttle lever and remove from

11 bracket. 2) Remove valve body. See VALVE BODY ASSEMBLY. Disconnect throttle valve cable from pin on throttle cam. 3) Using a 10-mm socket and extension, push throttle valve cable out of A/T case. See Fig. 3. Remove cable. Installation & Adjustment 1) Install new "O" ring on cable and lubricate with ATF or petroleum jelly. Insert cable into A/T case. 2) Connect cable to throttle cam. Install valve body. See VALVE BODY ASSEMBLY. Install splash shield. 3) To set throttle valve cable adjustment, ensure throttle lever is at curb idle position. Using vernier calipers or a fabricated gauge that can be slipped over the throttle cable wire, set cable travel to 1.55" (39mm) for the Monaco and Premier and " ( mm) for the See Fig. 4. Fig. 3: Removing Throttle Valve Cable From Case Courtesy of Chrysler Corp. Fig. 4: Checking Throttle Valve Cable Adjustment GOVERNOR AUTO TRANS

12 Removal 1) Raise vehicle and remove left front wheel. Remove reduction gear cover bolts and cover. Ensure transmission is in park. Remove bolt on driven gear and remove gear with taper roller bearing. 2) Use a heat gun to heat outer race of taper roller bearing. Remove outer race (use a jaw type puller if necessary). Remove governor with governor housing. Thoroughly clean governor if reusing. Installation Apply petroleum jelly to governor seals and install governor (ensure governor is fully seated). Heat case with a heat gun before outer race installation. Install outer race. install clamping sleeve and driven gear. Tighten driven gear bolt to 110 ft. lbs. (150 N.m). Governor Disassembly Remove governor cover and governor valve assembly. Separate governor valves from governor body, and remove seal rings from governor body. See Fig. 5.

13 AUTO TRANS OVERHAUL - ZF 4HP 18Article Text (p. 13)1991 Eagle PremierFor Dan's Transmission Service 10 J Fig. 5: Removing & Installing Governor (Typical) Courtesy of Chrysler Corp. Governor Reassembly 1) Install new oil seals in governor support. Seal position is important. Install small diameter seal with seal lip toward the rear of governor support. 2) Install large diameter seal with seal lip facing out. Install new "O" rings on governor support. Lubricate with petroleum jelly. Install governor valves on governor body and tighten bolts to 89 INCH lbs. (10 N.m). AXLE SHAFTS

14 Removal & Disassembly (Left Side) 1) Remove left front wheel. Remove drive axle from left axle shaft. Remove 5 bolts from bearing housing. Pull output shaft with bearing assembly from case. 2) To disassemble, remove tappet and compression spring from inside of shaft. Remove "O" ring from bearing housing. Remove snap ring from shaft. Separate drive shaft from bearing housing using a plastic mallet. Remove seal and bearing from housing. Assembly & Installation (Left Side) Press new bearing assembly into housing and install seal. Install axle shaft and snap ring. Install "O" ring, spring and tappet. See Fig. 12. Start shaft into housing and install 5 bolts. Tighten bolts to 17 ft. lbs. (23 N.m). Removal (Right Side) Remove right front wheel. Remove drive axle from right axle shaft. Remove dust cover and "O" ring. Remove snap ring. Using a slide hammer and adapter, remove axle shaft. Installation (Right Side) Press axle shaft into case using appropriate driver. Install snap ring, "O" ring and dust cover. PARKING PAWL COMPONENTS Removal & Disassembly 1) With the valve body and reduction gear cover removed, disconnect the throttle valve cable from the throttle cam. Remove the throttle cam assembly. Refer to VALVE BODY ASSEMBLY and GOVERNOR under ON-VEHICLE SERVICE. 2) Disconnect and remove A/T shift lever, and discard shift lever nut (nut is not reusable). Press detent spring to one side with a screwdriver, then remove stop plate with rotating motion. See Fig ) Remove clamp and connecting rod from A/T case. Remove detent spring attaching screws and remove spring. Spring positioning pin will normally remain in case, if not, remove pin with pliers and set aside for reassembly. 4) Remove parking pawl pressure spring, parking pawl pin and parking pawl. Disassemble gear selector assembly if necessary. Reassembly & Installation 1) Install parking pawl and pin in A/T case. Reassemble gear selector if necessary. Hook ends of retainer spring in slots of locking cam and selector disc and seat cam on disc. Set gear selector assembly aside; DO NOT install at this time. 2) Install Detent Spring Alignment Tool (6155) in gear selector shaft hole. Install positioning pin (if removed), and install detent spring on positioning pin. Press and hold spring against

15 alignment tool and install screws. Tighten screws to 89 INCH lbs. (10 N.m) and remove alignment tool. 3) Install gear selector assembly while pushing detent spring aside with screwdriver. Install connecting rod and pawl pressure spring. Place spring on pawl slot pin and install rod. See Fig ) Install connecting rod clamp and push into place using a screwdriver. Install throttle cam and tighten bolt to 44 INCH lbs. (5 N.m). Connect cable to throttle cam. 5) Install A/T shift lever and tighten new lever retaining nut to 12 ft. lbs. (17 N.m). Install reduction gear cover and valve body. See VALVE BODY ASSEMBLY and GOVERNOR under ON-VEHICLE SERVICE. REMOVAL & INSTALLATION See the TRANSMISSION REMOVAL & INSTALLATION - A/T article in the AUTOMATIC TRANS SERVICING section. TORQUE CONVERTER Torque converters used with ZF 4HP 18 transaxles are not serviceable. If damaged in any way or contaminated, converter must be replaced. The transaxle assembly must be removed to access torque converter. TRANSAXLE DISASSEMBLY 1) Mount transmission on work bench and secure with oil pan facing upward. Remove torque converter, oil filter cover and oil dipstick. Remove oil pan and valve body assembly. Remove 18 bolts and torque converter housing on input shaft. Lift out differential assembly. 2) Remove tappet and compression spring from input shaft. Remove intermediate plate with oil pump and clutch "C". Remove angle washer and shims from turbine shaft. Turn turbine shaft back and forth while removing clutch "A", clutch "B" and 2nd gear one-way clutch assembly. 3) Remove brake band and engine shaft with clutch "E". Remove intermediate shaft with 2 axial washers and axial needle bearing. Remove sun gear shaft with axial bearings, washer and angle washer. Remove pot with axial bearing, axial washer, angle washer and sun gear. Lift out planetary spider assembly with axial bearing, washer and angle washer. 4) Turn transmission over, remove spur gear cover and engage parking pawl. Loosen spur gear bolts, but DO NOT remove. Turn transmission over with oil pan side facing upward. Release parking pawl and remove spur gear bolts. Remove spur gear and output shaft. 5) Remove spider pot. Remove hexagon bolt, spur gear and adjusting washer. Remove countershaft. Remove inner race from spur gear (output shaft).

16 6) Remove tapered roller bearing inner shaft of spur gear (countershaft). Tapered roller bearing inner ring on countershaft can be pressed off. Turn transmission housing on end and remove bearing outer race with 2 jaw bearing puller. Remove sleeve and governor assembly. 7) Turn transmission with pan facing upward and remove slotted nut. Remove bearing ring with 1st gear assembly and retainer washer. Depress brake "C" servo cover. Remove retaining ring and piston "C" assembly. Remove adjusting bolt and pin. 8) Lift out brake "D" clutch discs and plate spring. Use compressed air to remove piston "D". Release snap ring and remove discs from clutch "B". Remove clutch "A" and "E" assembly, output shaft and 1st gear one-way clutch. Remove governor and differential assembly. Remove input shaft speedometer from converter housing. Remove selector mechanism and parking interlock from transmission housing. For further information on individual components, see COMPONENT DISASSEMBLY & REASSEMBLY below. COMPONENT DISASSEMBLY & REASSEMBLY BAND SERVO, BRAKE "C" & OIL PUMP Disassembly 1) Press down on servo piston cover and release snap ring with a screwdriver. Remove cover and servo piston "C" assembly. Disassemble piston by removing snap ring and separating plate springs. Remove piston "C" pin from housing by loosening adjusting pin. Remove band from housing. See Fig. 6. 2) Remove intermediate plate bolts and separate pump from intermediate plate. It may be necessary to tap with plastic hammer to remove pump. Rectangular plates and locating pin remain in intermediate plate. Disassemble pump by removing pump gears. Remove com-pression spring and valve with cap from intermediate plate. See Fig. 7. 3) Remove snap ring from groove and remove all clutch discs. Using press and brake "C" together with plate spring. Press out piston "C" by screwing in 2 bolts from pump side.

17 Fig. 6: Exploded View Of Band "C" & Servo Courtesy of ZF Getriebe GMBH Saarbrucken AUTO TRANS OVERHAUL - ZF 4HP 18Article Text (p. 17)1991 Eagle PremierFor Dan's Transmission Service 10 J Fig. 7: Exploded View Of Brake "C" With Intermediate Plate & Oil Pump Courtesy of ZF Getriebe GMBH Saarbrucken Cleaning & Inspection Clean all parts with solvent and dry with compressed air. Inspect all parts for excessive wear and damage. Replace parts (as necessary). Replace all seals and "O" rings. Reassembly

18 1) Install new "O" ring on band anchor pin and insert into housing. Install adjusting bolt with wave washer partially into housing. If piston was disassembled from pin, install thicker washer against collar of pin. See Fig. 14. Install sleeve into servo cylinder housing using appropriate mandrel. 2) Lubricate and install new "O" ring on servo piston. Install springs over piston shaft and slide into housing. Install servo cover. Insert snap ring, remove mounting device and install screw plug. Install brake band. Fit flush with shoulder in transmission housing. 3) Install pump gears into pump housing. Ensure mark at top of pump housing and outer pump gear are visible. Install 2 straight pins into intermediate plate using a plastic hammer. Install assembled torque converter pressure relief valve into intermediate plate. 4) Insert compression spring into pump opening and install intermediate plate onto pump housing. Install intermediate plate and pump housing. Tighten 6 Torx bolts to 89 INCH lbs. (10 N.m). Spin pump shaft to ensure smooth rotation. Install rectangular rings onto hub. 5) Fit "O" ring on clutch piston "C", lubricate piston with petroleum jelly and press piston into intermediate plate. Insert complete set of clutch discs. Install end disc and secure with snap ring. 6) Install measuring bar and dial indicator, position tip on end disc and zero gauge. Manually lift complete set of discs and record readings. Release clearance should be " ( mm). If readings differ from these readings, install correct size snap ring. BRAKE "D" Disassembly Remove snap ring and remove complete set of brake "D" discs and plate spring. Use compressed air to remove piston "D" out of transmission housing oil passage. See Fig. 8. Cleaning & Inspection Clean all parts with solvent and dry with compressed air. Inspect for excessive wear and damage. Replace disc set as a unit. Reassembly 1) Install new "O" rings into piston and insert piston into housing with raised face up. Insert plate spring with convex surface facing plate spring. Insert complete set of brake "D" discs. Begin with spring disc followed by outer disc and lined disc, end with end disc. NOTE: Manufacturer does not provide snap ring thickness information. 2) Install.04" (1.0 mm) snap ring. Install measuring bar and dial indicator and zero dial. Manually lift complete set of discs and

19 record clearance. Release clearance for 5 pairs of discs should be " ( mm) and clearance for 6 pairs of discs should be " ( mm). If readings differ from these readings, install correct size snap ring. Fig. 8: Exploded View Of Brake "D" With 1st Gear One-Way Clutch Courtesy of ZF Getriebe GMBH Saarbrucken CLUTCH "B" Removal Remove snap ring from clutch and clutch discs. Using press and adapter, compress plate spring and release split retaining ring. Remove plate spring. Use compressed air to remove piston out of oil feed bore. Remove piston intermediate ring. Press out overrun clutch inner ring and separate 2 cover washers from outer ring. See Fig. 9. Cleaning & Inspection Clean all parts with solvent and dry with compressed air. Inspect all parts for excessive wear and damage. Replace parts (as necessary). Reassembly 1) Install new "O" ring on hub and lubricate with petroleum jelly. Install intermediate ring with chamfer facing inward. Install new "O" ring on piston, lubricate and install into clutch drum. 2) Using centering ring, insert plate spring. Using press and

20 mounting device, depress plate spring, install thrust washer and secure with split retaining ring. Install clutch discs and secure with snap ring. Fig. 9: Exploded View Of Clutch "B" Courtesy of ZF Getriebe GMBH Saarbrucken CLUTCH "A" Disassembly Use snap ring pliers to remove snap ring and turbine shaft from clutch "A". Remove snap ring from cylinder. Remove complete set of discs and spring disc. Use press and adapter to press down baffle plate and release snap ring. Remove baffle plate and 2 plate springs. Place compressed air gun against one of 2 oil feed bores and, using care, remove piston with compressed air. See Fig. 10. Cleaning & Inspection Clean all parts with solvent and dry with compressed air. Inspect for excessive wear or damage. Replace parts (as necessary). Reassembly 1) Install new "O" rings onto clutch piston and install piston into cylinder. Insert plate spring and plate spring with curved face pointing up. Fit "O" ring into baffle plate and apply petroleum jelly prior to seating baffle plate into clutch housing. See Fig ) Install snap ring and insert clutch discs. Begin with spring disc, followed alternately by steel discs and lined discs. Install end disc and secure with snap ring. Install 2 rectangular rings onto turbine shaft and engage hook. Press turbine shaft onto clutch "A" and install locking ring. Ensure turbine shaft seats with snap ring, otherwise axial reading will be false. 3) Insert clutch "A" assembly, turning back and forth until teeth of discs engage. Ensure plastic thrust washer is centered on engine shaft. If correctly installed, engine shaft projects

21 approximately.9" (22 mm) over turbine shaft. Fig. 10: Exploded View Of Clutch "A" Courtesy of ZF Getriebe GMBH Saarbrucken CLUTCH "E" Disassembly 1) Remove thrust washer off engine shaft. Remove snap ring and lift out complete set of discs. Press down plate spring "E" and remove split retaining ring. 2) Remove plate spring and use compressed air gun to force piston out. Rectangular rings remain on engine shaft. White plastic rings have chamfered ends. See Fig. 11. Cleaning & Inspection Clean all parts with cleaning solvent and dry with compressed air. Inspect all parts for excessive wear or damage. Replace parts as necessary. Reassembly 1) Install new "O" ring onto piston and apply a light coating of petroleum jelly. Press assembled piston onto cylinder of engine shaft. Using press and adapter, compress 2 plate springs. Secure with split retaining ring. 2) Insert clutch discs beginning with steel disc followed alternately by lined disc and steel disc. On models with 5 pairs of discs, end disc is installed with recess to outside. Secure disc sets with snap ring. 3) Install 2 rectangular rings onto engine shaft and engage hook. Coat rings with petroleum jelly. Install thrust washer. Install

22 engine shaft while turning back and forth. If installed correctly, shoulder of clutch "E" is flush with edge of disc carrier on sun gear shaft. Fig. 11: Exploded View Of Clutch "E" With Engine Shaft Courtesy of ZF Getriebe GMBH Saarbrucken OUTPUT SHAFT & 1ST GEAR ONE-WAY CLUTCH Disassembly Remove snap ring from housing and separate hollow gear from output shaft. Remove tapered roller bearing with inner race. Pull overrun clutch inner race from assembly. Remove snap ring from outer race and disassemble. Cleaning & Inspection Clean all parts in solvent and dry with compressed air. Inspect all parts for excessive wear and damage. Replace parts (as necessary). Reassembly Install plate springs and install snap ring. Press in one-way clutch inner race in clutch housing. Press on tapered roller bearing with race. Install hollow shaft into overrun clutch housing and secure with snap ring. GOVERNOR Disassembly Remove bolts and separate 1st and 2nd stage valve assemblies from hub. Pull piston cover plate and remove piston of 1st stage. Using a screwdriver to press down on compression spring, remove retaining plate, compression spring and piston of 2nd stage.

23 Cleaning & Inspection Clean all parts with cleaning solvent and dry with compressed air. Replace complete governor housing if damaged. Stop plate and retaining plate may be replaced separately. Replace parts (as necessary). Reassembly 1) Insert governor piston into valve housing and secure with a washer in 1st stage housing. To assemble 2nd stage, insert governor piston, install 2 compression springs into piston and secure with retaining plate. 2) Install 1st stage and 2nd stage of governor housing into governor flange with each stage covering one straight and one angled oil feed passage. Tighten Torx bolts to 89 INCH lbs. (10 N.m). Fit rectangular ring onto first governor flange and secure hook. Insert 2 rubber rings into middle and rear annular groove. DO NOT distort rubber ring excessively. Lubricate rubber rings with petroleum jelly when installing into transmission housing. DIFFERENTIAL Disassembly Press 2 axle bevel gears and thrust washers out of differential cage. Install differential into soft jaw vise and remove ring gear from differential. Pull tapered roller bearing and race off differential and remove speedometer worm gear. Cleaning & Inspection Clean all parts with solvent and dry with compressed air. Inspect all parts for damage and excessive wear. Replace differential housing if damaged or worn. Reassembly 1) Insert 2 axle bevel gears into differential housing, ensuring both axle bores are aligned. Press tapered roller bearing and race onto housing. Turn differential over. Install tension pin into speedometer worm gear until seated. Install worm gear into differential with tension pin fitting into notch in housing. 2) Press on tapered roller bearing and race using press and adapter. Place differential housing into soft jawed vise. Install ring gear and tighten bolts to 57 ft. lbs. (77 N.m) in a crisscross pattern. AXLE SHAFTS Disassembly 1) Remove retainer speedometer drive sleeve and shaft. Remove "O" ring, seal and snap ring from right axle shaft. Remove right axle shaft and shaft seal with a plastic hammer. Remove shaft seal. Press locking ring and roller bearing from axle shaft. See Fig ) Using a punch and drift, remove shaft seal from converter

24 housing. Remove bearing race from converter housing. Remove left axle shaft by removing bearing cover bolts. Remove shaft from case with a plastic hammer. 3) Remove snap ring from left axle shaft. Using press and adapter, press shaft out of bearing housing and remove shaft seal. Using centering tool, press roller bearing out of bearing housing. Fig. 12: Exploded View Of Final Drive Components Courtesy of ZF Getriebe GMBH Saarbrucken Cleaning & Inspection Clean all parts in cleaning solvent and dry with compressed air. Inspect all parts for excessive wear or damage. Replace parts (as

25 necessary). Reassembly 1) Press outer bearing race into converter housing. Press roller bearing onto right axle shaft and secure with snap ring. Insert axle shaft into converter housing and press shaft seal in place. Secure assembled right axle shaft with snap ring. Slip on "O" ring and install seal until seated. 2) Insert assembled speedometer into converter housing, ensuring hexagon of speedometer sleeve meshes with cast contour of speedometer bore. Press on a new retaining ring. 3) Using a press and adapter, press axle bearing into left axle bearing housing. Turn bearing housing over and press axle shaft seal into housing with adapter. Press left axle shaft into bearing housing using adapter. Secure axle shaft with snap ring. NOTE: Differential preload should be checked when replacing any final drive components including axle shafts or bearings. For preload procedures, see steps 33)-35) under TRANSAXLE REASSEMBLY. SELECTOR MECHANISM & PARKING PAWL Disassembly 1) Detach throttle valve cable from cam and pry out housing with 2 screwdrivers. Remove retaining bolt and remove accel-erator cam axle together with leg spring and accelerator spring. Remove bolts and remove detent spring and pin. See Fig ) Remove screw plug and withdraw support shaft. Use punch to move tension pin enough to remove selector shaft. Remove segment with locking cam and adjusting washer by pressing pawl down slightly. 3) Remove pin at annular groove and remove pawl with leg spring. Remove 2 bearings outer races. Remove shaft seal and selector shaft. Remove dipstick tube and oil tubes. DO NOT damage sealing surface of housing or reuse oil tubes. Remove all screw plugs to clean housing. Leave locating pin and outer turbo feed tube in transmissionhousing. Cleaning & Inspection Clean all parts with cleaning solvent and dry with compressed air. Replace all seals and "O" rings. Inspect all parts for excessive wear and damage. Replace parts (as necessary). Reassembly 1) Coat new selector shaft seal and install in case. Install parking pawl, spring and insert pawl pin. See Fig. 13. Tighten securing bolt to 23 ft. lbs. (32 N.m). Install detent spring and tighten bolts to 89 INCH lbs. (10 N.m). 2) Install selector mechanism gears and shaft. Ensure selector gear teeth mesh. Install assembled accelerator cam axle and

26 tighten bolts to 89 INCH lbs. (10 N.m). Install new accelerator cable into transmission housing and pretension accelerator cam by rotating one revolution and inserting accelerator cam nipple. Fig. 13: Exploded View Of Linkage Components Courtesy of ZF Getriebe GMBH Saarbrucken TRANSAXLE REASSEMBLY 1) On turbo model, install turbo pressure feed tube into transmission housing with a plastic hammer (if removed). Install plugs into housing. Tighten plugs to 11 ft. lbs. (15 N.m). Screw 2 plastic plugs into housing oil cooler line connection hole. Install dowel into transmission housing using a plastic hammer. 2) With a heat gun, heat transmission housing to 158øF (70øC) and install countershaft tapered roller bearing outer ring. Install shaft seal into transmission housing. Assemble pawl and spring and press pin into housing, securing pin with Torx bolt. Tighten bolt to 89 INCH lbs. (10 N.m). Assemble locking cam and install into housing, tightening Torx bolt to 23 ft. lbs. (32 N.m). 3) Insert Detent Adjustment Tool (5P ) and install detent spring. See Fig. 13. Tighten detent spring bolt to 89 INCH lbs. (10 N.m). Install assembled selector mechanism into housing. Use following formula to determine thickness of washer used on selector assembly.

27 S = X -.40" (.10 mm) S = Thickness of washer X = Value to be measured.40" (.10 mm) = Standard clearance Insert correct size washer to meet standard clearance by removing stop plate and withdrawing selector shaft enough to install washer. 4) Assemble and install throttle cam and throttle cable into transmission housing and pretension throttle cam by rotating one revolution and inserting nipple of cable in cam. Install brake "C" band anchor pin into housing and hold in place with adjusting bolt. Assemble piston "C" according to version being used. See Fig. 14. Fig. 14: Identifying Band Servo Piston Variations Courtesy of ZF Getriebe GMBH Saarbrucken NOTE: Certain transmission versions require a sleeve to be inserted with servo piston "C". 5) Install piston "C" into transmission housing. With mounting device, press piston cover slightly and install snap ring to secure piston "C". Turn transmission over and install brake band into housing. Fit lugs of brake band into 2 pins. Ensure brake band seats into transmission housing shoulder. 6) Assemble and install brake "D" clutch discs into transmission housing and secure with snap ring. Install measuring bar and dial indicator. Manually lift complete set of clutch discs and read clearance of discs. Clearance for 5 pairs of clutches should be " ( mm). Clearance for 6 pairs of clutches should be " ( mm). Remove brake "D" disc set and insert 1st gear one-

28 way clutch into gearing in transmission housing. Ensure inner ring of one-way clutch does not fall out. Turn transmission over while holding free-wheel in place. 7) Set tab washer with locking lug into transmission housing. Install slotted nut and tighten to 68 ft. lbs. (50 N.m). Bend lock tab into nut seat. Ensure free-wheel turns freely in clockwise direction. Reinstall brake "D" disc set and secure with correct washers. Install spider bowl into one-way clutch inner ring. Press tapered roller bearing inner ring onto output shaft. Insert output shaft into hollow gear and secure with snap ring. See Fig. 15. Fig. 15: Exploded View Of Planetary Gears & Related Components Courtesy of ZF Getriebe GMBH Saarbrucken 8) Install output shaft/hollow gear assembly into transmission case. Install needle bearing assembly along with flat washer and angle washer in output shaft assembly. Install planetary carrier into hollow gear. Install sun gear into planetary carrier. Fit sun gear pot onto teeth of sun gear. 9) Install needle bearing assembly along with flat washer and angle washer into sun gear pot. Insert sun gear shaft into sun gear pot. Ensure when rotated, sun gear pot rotates in opposite direction

29 from sun gear shaft. Install needle bearing assembly along with flat washer and angle washer over the end of the intermediate shaft. Insert intermediate shaft into sun gear shaft. 10) Fit rectangular rings and thrust washer on engine shaft. Install assembled clutch "E" and engine shaft assembly into case. Ensure shoulder of cylinder "E" is flush with edge of disc carrier on sun gear shaft. 11) Assemble clutch "A" and install 2 rectangular rings onto turbine shaft and engage hook. Press turbine shaft into clutch "A" cylinder and engage locking ring with snap ring pliers. Pull on turbine shaft until it seats with snap ring, otherwise axial clearance will be incorrect. Insert assembled clutch "A", rotating until teeth of discs engage. Plastic thrust washer must be centered on engine shaft. If correctly installed, engine shaft will project approximately.8" (22 mm) over turbine shaft. 12) Assemble clutch "B" and install into case by turning until discs fully engage. Clutch "B" must engage in recesses of pot for a gap of.04" (1.0 mm) to be still visible. 13) Assemble pump housing and torque converter pressure relief valve, and install on intermediate plate. Insert compression spring into opening in pump, place intermediate plate onto pump housing and align. Bolt intermediate plate to pump housing; tighten bolts to 89 INCH lbs. (10 N.m). Inspect torque converter relief valve to ensure it operates freely. Ensure pump operates freely. Install 3 rectangular rings onto hub of intermediate plate. 14) Assemble one-way clutch by inserting cage of one-way clutch into collar with collar facing down. If not installed properly, clamping direction will not be correct. Install cover rings on one-way clutch collar. Insert one-way clutch inner race by turning it clockwise. One-way clutch inner race must rotate freely in clockwise direction with collar pointing out. 15) Install.04" (1.0 mm) selective adjusting washer and angle washer onto shaft. DO NOT install 2nd gear one-way clutch during measurement process. Insert assembled pump and intermediate plate. Rotate back and forth until fully engaged. Hold in place with 2 opposing bolts. Tighten bolts to 89 INCH lbs. (10 N.m). Install measuring tool onto turbine shaft and secure tightly. 16) Measuring tip of dial indicator must rest on impeller shaft. Pull on measuring device to obtain reading. Axial clearance should be " ( mm). If reading differs from this clearance, select correct washer. Remove intermediate plate assembly. Install angle washer and adjusting washer onto hub of intermediate plate. 17) Install 2nd gear one-way clutch into lined discs of brake "C" with inner teeth seated on washer. Ensure all lined discs mesh with one-way clutch inner race. Do this by rotating outer race; lined discs must also turn. 18) Tighten adjusting washer of brake band in order to secure cylinder "B" in place. Insert assembled pump, intermediate plate and 2nd gear one-way clutch into transmission. Rotate back and forth to

30 seat unit. When inserting unit, hold one-way clutch to avoid discs slipping out. When properly installed, plate springs seat into transmission housing when pressure is applied against pump housing. 19) Install 8 bolts into intermediate plate and tighten bolts to 89 INCH lbs. (10 N.m). Loosen brake band and check axial clearance. Assemble governor housing on governor hub. Tighten retaining bolts to 89 INCH lbs. (10 N.m). Install rectangular ring on end groove of governor hub and snap hook. Insert 2 rubber rings into middle and rear groove. DO NOT stretch rings unnecessarily. 20) Coat rubber rings and rectangular ring with petroleum jelly. Carefully insert assembled governor unit into transmission housing. Use care installing rubber rings into annular groove. Install tapered roller bearing inner race onto countershaft. Insert countershaft into engaging gears of governor flange while rotating shaft and holding flange in position to prevent it from falling out. 21) Install retaining tool to hold countershaft in place while turning transmission over. Slip spacer sleeve over countershaft on governor unit. Install outer race of tapered roller bearing with plastic hammer until seated. Outer ring must be seated with no clearance to ensure correct adjustment. 22) Press tapered roller bearing inner race onto spur gear. Install.07" (1.9 mm) washer and spur gear onto countershaft and snugly tighten bolt. See Fig. 16. Drive the 3 tension pins of adjusting ring until they protrude. Install adjusting ring onto tapered roller bearing inner race of output shaft with tension pins facing up and install on spur gear. Fig. 16: Exploded View Of Spur Gears, Countershaft & Governor

31 Courtesy of ZF Getriebe GMBH Saarbrucken 23) Engage parking pawl. Tighten countershaft nut to 44 INCH lbs. (5 N.m) to ensure tapered roller bearings are seated. Release parking interlock, rotate spur gears several times, tighten countershaft nut to 44 INCH lbs. (5 N.m) and rotate again. 24) Loosen nut, remove spur gear and use micrometer to measure thickness of washer at 3 tension pins of adjusting sleeve. Average 3 readings and install correct washer. NOTE: See manufacturer's parts list for correct size washers. 25) Insert correct washer and spur gear onto countershaft. Loosely tighten countershaft bolt. Install Pretension Device (5P ) on differential side of countershaft. NOTE: Always insert thickest washer to assure proper clearance. Engage parking interlock and tighten nut to 110 ft. lbs. (150 N.m). 26) Attach measuring tool with dial indicator. Turn adjusting screw down for gauge pointer to move. Set gauge scale to zero; rotate spur gears several times while doing this. If pointer deflects to end of scale, record readings to determine average reading. Loosen pretensioning device on bottom of transmission. Tighten adjusting screw one turn. 27) Rotate spur gears several times until pointer of dial indicator has settled. Record readings and obtain an average. Use following formula to obtain correct washer thickness. S = Specific thickness of washer X = Reading on dial indicator.03" = Clearance of washer selected S =.07" -.03" S =.04" (1.02 mm) washer is correct size of washer to install. NOTE: If it is necessary to install a washer of different thickness, it is recommended to repeat measurement steps. Nut must be tightened to 110 ft. lbs. (150 N.m). 28) Install spur gears and washer, and tighten bolt to 110 ft. lbs. (150 N.m). DO NOT install end cover and gasket at this time; differential housing must be rotated over countershaft to seat bearings. This step must be repeated for subsequent adjusting of preload. 29) Install shaft seal into converter bellhousing and coat seal with petroleum jelly. Turn over converter bellhousing and install bearing race until it is seated. Press roller bearing onto right axle shaft and secure with snap ring.

32 30) Insert axle shaft into converter bellhousing. Install new shaft seal and assembled right axle shaft. Secure assembled right axle shaft with snap ring. Slip new "O" ring on shaft and install axle seal. Install "O" ring on speedometer sleeve. Insert speedometer pinion into speedometer sleeve and install sleeve. 31) Insert assembled speedometer drive into converter housing ensuring speedometer seats properly into speedometer bore. Install new retaining ring. Install converter housing gasket and converter housing. Tighten bolts to 17 ft. lbs. (23 N.m). 32) Press left axle shaft bearing into bearing housing. Press axle shaft seal into other end of bearing housing. Press left axle shaft into bearing housing and secure axle shaft with locking ring. Install differential bearing race into transmission housing. If necessary, preheat housing with heat gun. 33) Measure shoulder of axle shaft bearing housing and record, this is distance "B". Measure distance "A" between machined surface of converter housing (where axle bearing housing mates) and differential bearing race. Use following formula to determine washer thickness: "A" - "B" = Clearance. Insert correct washer and fit an additional.02" (.5 mm) washer to preload bearing. Use following formula: "A" - "B" +.02" (.5 mm) = X clearance. 34) Bolt axle shaft housing with "O" ring removed to allow axle shaft to fit better. Tighten bolts to 16 ft. lbs. (23 N.m). Turn countershaft nut several times to seat tapered roller bearings. Remove axle bearing housing bolts and measure gap between axle bearing housing and mating surface of converter housing (clearance "H"). Use following formula to find clearance "S". "S" = Thickness of washer required "X" = Distance "A" - distance "B" +.5 mm "H" = Size of gap determined with feeler gauge "V" = Preload selected within specified limits Example: "S" =.04" "X" =.05" (.79" -.76" +.02" =.05") "H" =.01" (determined with feeler gauge) "V" =.004" (preload selected within specified limits) Round up or down numerical size of washer to install washer of closest size needed. 35) Insert selected washer into bearing housing. Install "O" ring on bearing housing and install compression spring and tappet into axle shaft. Tighten bolts to 89 INCH lbs. (10 N.m). Install assembled left axle shaft and tighten bolts to 16 ft. lbs. (23 N.m). Install spur gear cover and gasket. Brake band must be adjusted. 36) Apply a light coat of ATF to cylinder "B". Tighten brake band bolt to 89 INCH lbs. (10 N.m). Turn cylinder "B" during tightening operation to ensure brake band is not twisted. Loosen

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