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Automatic Transmission

|4r70w Transmission |

|[pic|[pic| |[pic|A4LD Transmission |

|] |] | |] | |

|[pic|[pic| |[pic|C3 Transmission |

|] |] | |] | |

|[pic|[pic| |[pic|C5 |

|] |] | |] | |

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|PATH:  Drive Train > Automatic Transmission > Transmission Removal & Installation > 4r70w Transmission |Print[pic] |

4r70w Transmission

1. Disconnect the negative battery cable.

2. Raise and safely support the vehicle.

3. Disconnect the driveshaft from the rear axle assembly and slide the shaft rearward from the transmission. To maintain driveshaft balance, mark the rear driveshaft yoke and rear axle universal joint flange so the driveshaft can be installed in its original position.

4. Remove the exhaust system.

5. Place a suitable drain pan under the transmission oil pan. Starting at the rear of the pan and working forward, loosen the retaining bolts and allow the fluid to drain. Remove all of the transmission pan retaining bolts except the two at the front, to allow the fluid to further drain. With the fluid drained, install two bolts on the rear side of the transmission pan to temporarily hold it in place.

6. Remove the converter drain plug access cover from the lower end of the converter housing.

7. Remove the torque converter-to-flexplate retaining nuts. Place a wrench on the crankshaft pulley retaining bolt to turn the torque converter to gain access to the nuts.

8. Place a suitable drain pan under the torque converter. With the wrench on the crankshaft pulley retaining bolts, turn the torque converter to gain access to the converter housing plug and remove the converter housing access plug. After the fluid has been drained, install the converter housing access plug.

9. Disconnect the cable from the terminal on the starter motor. Unfasten the retaining bolts, and remove the starter. Detach the park/neutral position start switch wires at the plug connector.

10. Remove the rear mount-to-crossmember retaining bolts and the two crossmember-to-frame retaining bolts.

11. Remove the two engine rear support-to-extension housing retaining bolts.

12. Carefully disconnect the shift cable from the transmission manual control lever at the transmission by removing the adjusting nut.

13. Detach the wiring connectors from the wiring harness assembly.

14. Raise the transmission with a suitable jack to provide clearance to remove the rear engine support. Remove the rear engine support insulator from the rear engine support and remove the rear support from the side support.

15. Carefully lower the transmission to gain access to the transmission oil cooler inlet tube.

16. Disconnect the transmission oil cooler inlet tube from the fittings on the transmission.

17. Detach the vehicle speed sensor from the extension housing.

18. Remove the bolt that retains the oil filler tube to the cylinder block. Lift the oil filler tube and the oil lever indicator from the transmission.

19. Secure the transmission to the jack with a chain.

20. Remove the converter housing-to-cylinder block retaining bolts.

21. For 1994 vehicles, remove the transmission pad from the left side of the converter housing using a hacksaw.

|[pic] |

|For 1994 vehicles, you must use a hacksaw to cut the transmission pad off the left side of the converter housing |

|Click to Enlarge |

22. Carefully move the transmission and torque converter away from the engine and, at the same time, lower the jack to clear the underside of the vehicle.

To install:

23. Tighten the converter housing plug to 21–23 ft. lbs. (28–30 Nm).

|NOTE |

|Lubricate the pilot with suitable chassis grease. |

24. Position the torque converter on the transmission, ensuring the converter drive flats are fully engaged in the pump gear by rotating the torque converter.

25. With the torque converter properly installed, place the transmission on a jack. Secure the transmission to the jack with a chain.

26. Rotate the torque converter until the studs and converter housing access plug are in alignment with the holes in the flexplate.

27. If present, align the orange balancing marks on the converter stud and flexplate bolt hole.

28. Move the torque converter and transmission assembly forward into position, using care not to damage the flexplate and the converter pilot. The torque converter face must rest squarely against the flexplate. This indicates that the converter pilot is not binding in the engine crankshaft.

|NOTE |

|Before installing the crankshaft to the flexplate retaining nut, a check should be make to ensure that the torque converter is |

|properly seated. The torque converter should move freely with respect to the flexplate. Grasp the stud. Movement back and forth |

|should result in a metallic clank noise if the torque converter is properly seated. If the torque converter will not move, the |

|transmission must be removed and the torque converter repositioned so that the impeller hub is properly engaged in the pump gear. |

29. Connect the EGR tube to the torque converter assembly.

30. Position the transmission to the engine and install the retaining bolts. Tighten the bolts to 40–50 ft. lbs. (50–68 Nm).

31. Install the nuts retaining the torque converter to the flexplate. Tighten the nuts to 20–34 ft. lbs. (27–46 Nm).

32. Install the starter and the oil fill tube.

33. Connect the transmission shift selector mounting bracket.

34. Install the transmission rear engine support assembly. Tighten the bolts to 64–81 ft. lbs. (87–110 Nm).

35. Install the vehicle speed sensor and electrical connector.

36. Remove the transmission jack from under the vehicle.

37. Position the driveshaft yoke inside the extension housing.

38. Connect both transmission oil cooler inlet tube and oil cooler tube. Tighten to 15–19 ft. lbs. (20–26 ft. lbs.).

39. Raise the rear axle housing, and install the retaining nuts.

40. Install the driveshaft and secure with the retaining bolts.

41. Install the exhaust system components.

42. Carefully lower the vehicle, then connect the negative battery cable.

43. Fill the transmission with the proper type and amount of fluid.

44. Start the engine and check transmission operation.

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|PATH:  Drive Train > Automatic Transmission > Transmission Removal & Installation > A4LD Transmission |Print[pic] |

A4LD Transmission

1. Disconnect the negative battery cable.

2. Raise and safely support the vehicle.

3. Place a drain pan under the transmission fluid pan. Starting at the rear of pan and working towards the front, loosen the attaching bolts and allow the fluid to drain. Remove all the pan attaching bolts except two at the front, to allow the fluid to further drain. With fluid drained, install two bolts on the rear side of the pan to temporarily hold it in place.

4. Remove the converter access cover and adapter plate bolts from the lower left side of converter housing.

5. Remove the four flexplate-to-converter attaching nuts by placing a 22mm socket and breaker bar on the crankshaft pulley attaching (center) bolt. Rotate the pulley clockwise (as viewed from front) to gain access to each of the nuts.

|NOTE |

|Never rotate a 2.3L engine in the counterclockwise direction (as viewed from the front) serious engine damage can occur! |

|[pic] |

|Rotate the pulley clockwise to access each flexplate-to-converter nut |

|Click to Enlarge |

6. Scribe a mark indexing the driveshaft to the axle flange, disconnect the driveshaft from the rear axle and slide the shaft rearward from the transmission. Install the Extension Housing Seal Replacer T74P-77052-A or equivalent in the extension housing to prevent fluid leakage.

|[pic] |

|Remove the driveshaft and install a suitable seal installation tool to prevent fluid from leaking out |

|Click to Enlarge |

7. Disconnect and remove the speedometer sensor from the extension housing.

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|Detach, and remove the speedometer sensor |

|Click to Enlarge |

8. Disconnect the shift cable from transmission manual lever and retainer bracket (mounted at extension housing). Disconnect the downshift cable at the transmission downshift lever. Depress the tab on cable downshift retainer and remove the downshift cable from the bracket.

9. Remove the starter-to-converter housing attaching bolts and position out of the way.

10. Tag and detach the neutral start switch wires, converter clutch solenoid and the 3–4 shift solenoid connector.

|[pic] |

|Tag and disconnect the neutral start switch, converter clutch and the 3–4 shift solenoid wiring |

|Click to Enlarge |

11. Remove the vacuum line from the transmission vacuum modulator.

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|Detach the vacuum line from the modulator |

|Click to Enlarge |

12. Position a transmission jack under the transmission and raise it slightly.

13. Remove the engine rear support-to-crossmember bolts.

|NOTE |

|Certain models require the removal of some or all exhaust system components, before the transmission can be removed from the |

|vehicle. Check for clearance and remove the exhaust pipe or catalytic converter before removing the crossmember. |

14. Remove the crossmember-to-frame side support attaching bolts. Remove the crossmember insulator support and damper.

|[pic] |

|Remove the crossmember-to-frame side support attaching bolts. Remove the crossmember insulator support and damper |

|Click to Enlarge |

15. Lower the jack under transmission and allow the transmission to hang.

16. Position a jack under the front of the engine. Raise the engine to gain access to the two upper converter housing-to-engine attaching bolts.

17. Disconnect the oil cooler lines from the fittings at the transmission and plug all openings to keep the dirt out.

|[pic] |

|Detach and plug the transmission oil cooler lines |

|Click to Enlarge |

18. Remove the lower converter housing-to-engine attaching bolts and remove the transmission filler tube.

19. Secure the transmission to the jack with a safety chain or strap.

20. Remove the two upper converter housing-to-engine attaching bolts. Slide the transmission to the rear so it disengages from the dowel pins and the converter is disengaged from the flexplate.

21. Lower and remove the transmission from vehicle. If necessary, remove the torque converter from vehicle.

|[pic] |

|Carefully lower the transmission from the vehicle |

|Click to Enlarge |

|[pic] |

|If necessary, remove the torque converter |

|Click to Enlarge |

To install:

|NOTE |

|Proper installation of the converter requires full engagement of the converter hub in to the pump gear. To accomplish this, the |

|converter must be pushed in and at the same time, rotated through what feels like two "notches" or bumps. Rotation of the converter |

|when fully installed will result in a "clicking" noise which is caused by the converter hitting the housing-to-case bolts. This is |

|an indication of proper installation since, when the converter is attached to the flexplate, it will be pulled slightly forward away|

|from the bolt heads. |

22. With the converter properly installed, place the transmission on the jack and secure it with a safety chain or strap.

23. Rotate the converter so the drive studs are aligned with the holes in the flexplate.

24. Move the transmission assembly forward into position, being careful not to damage the flexplate and converter pilot.

|CAUTION |

|To avoid damage during this move, do not allow the transmission to get into a nose down position, as this will cause the converter |

|to move forward and disengage from the pump gear. The converter housing is piloted into position by dowels on the rear of the engine|

|block. The converter must rest squarely against the flexplate. This indicates the converter pilot is not binding in the end of the |

|crankshaft. |

25. Install the two converter housing-to-engine attaching bolts at the engine dowel locations and tighten to 28–38 ft. lbs. (38–51 Nm).

26. Install the remaining housing-to-engine attaching bolts and tighten to 28–38 ft. lbs. (38–51 Nm).

27. Remove the safety chain or strap from the transmission.

28. Insert the filler tube into the stub tube and secure it to the cylinder block with the attaching bolt and tighten to 28–38 ft. lbs. (38–51 Nm).

|NOTE |

|If stub tube becomes loose or dislodged, it should be replaced. |

29. Install the fluid cooler lines into the retaining clip at cylinder block. Then connect the fittings to the transmission case.

30. Raise the transmission. Position the crossmember, insulator, support and damper to frame side supports. Install the attaching bolts and tighten to 20–30 ft. lbs. (30–41 Nm).

31. Align and lower the transmission to install the rear engine support nut, and tighten to 60–80 ft. lbs. (81–108 Nm).

32. Install the vacuum hose onto the vacuum unit and into its retaining clip.

33. Connect the plug to the neutral start switch. Connect the converter clutch solenoid wires and 3–4 shift solenoid wires.

34. Install the starter and tighten the attaching bolts to 15–20 ft. lbs. (20–27 Nm).

35. Install the four flexplate-to-converter attaching nuts and tighten to 20–34 ft. lbs. (27–46 Nm).

36. Install the converter access cover, adapter plate bolts and tighten to 12–16 ft. lbs. (16–22 Nm).

37. Reconnect any exhaust system components that were disconnected for the transmissions removal.

38. Position the selector cable in the bracket on the transmission extension housing. Press the end of cable onto the ball stud on lower portion of the selector lever and install the retaining clip on the bracket.

39. Connect the downshift cable to the downshift lever. Install the speedometer sensor and connect the wiring.

40. Align the scribe marks on driveshaft to the rear axle companion flange and tighten the attaching nuts to 70–95 ft. lbs. (95–129 Nm).

41. Adjust the manual and downshift linkage as required. Lower vehicle.

42. Fill the transmission to the correct level with Mercon® or equivalent fluid. Start the engine and shift the transmission through all ranges, then recheck the fluid level.

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|PATH:  Drive Train > Automatic Transmission > Transmission Removal & Installation > C3 Transmission |Print[pic] |

C3 Transmission

1. Disconnect the negative battery cable.

2. Raise and safely support the vehicle.

3. Place a drain pan under the transmission fluid pan. Starting at the rear of the pan and working toward the front, loosen the attaching bolts and allow the fluid to drain. Then remove all of the pan attaching bolts except two at the front, to allow the fluid to further drain. After all the fluid has drained, install two bolts on the rear side of the pan to temporarily hold it in place.

4. Remove the converter drain plug access cover and adapter plate bolts from the lower end of the converter housing.

5. Remove the four flexplate-to-converter attaching nuts. Crank the engine to turn the converter to gain access to the nuts, using a wrench on the crankshaft pulley attaching bolt. On 2.3L engines, never turn the engine backwards.

6. Crank the engine until the converter drain plug is accessible and remove the plug. Place a drain pan under the converter to catch the fluid. After all the fluid has been drained from the converter, reinstall the plug and tighten to 20–30 ft. lbs. (28–40 Nm).

7. Remove the driveshaft and install the extension housing seal replacer tool in the extension housing.

8. Remove the speedometer cable from the extension housing.

9. Disconnect the shift rod at the transmission manual lever using Shift Linkage Grommet Remover T84P-7341-A or equivalent. Disconnect the downshift rod at the transmission downshift lever.

10. Remove the starter-to-converter housing attaching bolts and position the starter out of the way.

11. Disconnect the neutral start switch wires from the switch.

12. Remove the vacuum line from the transmission vacuum unit.

13. Position a transmission jack under the transmission and raise it slightly.

14. Remove the engine rear support-to-crossmember nut.

15. Remove the crossmember-to-frame side support attaching bolts and remove the crossmember.

16. Remove the inlet pipe mounting brackets from the inlet pipe and rear engine support; then disconnect the muffler inlet pipe at the exhaust manifold and secure it.

17. Lower the jack under the transmission and allow the transmission to hang.

18. Position a jack to the front of the engine and raise the engine to gain access to the two upper converter housing-to-engine attaching bolts.

19. Disconnect the oil cooler lines at the transmission. Plug all openings to keep out dirt.

20. Remove the lower converter housing-to-engine attaching bolts.

21. Remove the transmission filter tube.

22. Secure the transmission to the jack with a safety chain.

23. Remove the two upper converter housing-to-engine attaching bolts. Move the transmission to the rear and down, to remove it from under the vehicle.

To install:

24. Tighten the converter drain plug to 20–30 ft. lbs. (28–40 Nm). if not previously done.

25. Position the converter to the transmission making sure the converter hub is fully engaged in the pump gear. The dimension given in the accompanying illustration is for guidance only. It does not indicate engagement.

|[pic] |

|Converter hub-to-flange position—C3 transmission |

|Click to Enlarge |

26. With the converter properly installed, place the transmission on the jack and secure with the safety chain.

27. Rotate the converter so the drive studs and drain plug are in alignment with their holes in the flexplate.

28. With the transmission mounted on a transmission jack, move the converter and transmission assembly forward into position being careful not to damage the flexplate and the converter pilot.

29. During this move, to avoid damage, do not allow the transmission to get into a nosed down position as this will cause the converter to move forward and disengage from the pump gear. The converter must rest squarely against the flexplate. This indicates that the converter pilot is not binding in the engine crankshaft.

30. Install the two upper converter housing-to-engine attaching bolts and tighten to 28–38 ft. lbs. (38–51 Nm).

31. Remove the safety chain from the transmission.

32. Insert the filler tube in the stub tube and secure it to the cylinder block with the attaching bolt. Tighten the bolt to 28–38 ft. lbs. (38–51 Nm). If the stub tube is loosened or dislodged, it should be replaced.

33. Install the oil cooler lines in the retaining clip at the cylinder block. Connect the lines to the transmission case.

34. Remove the jack supporting the front of the engine.

35. Position the muffler inlet pipe support bracket to the converter housing and install the four lower converter housing-to-engine attaching bolts. Tighten the bolts to 28–38 ft. lbs. (38–51 Nm).

36. Raise the transmission. Position the crossmember to the frame side supports and install the attaching bolts. Tighten the bolts to 30–40 ft. lbs. (41–54 Nm).

37. Lower the transmission and install the rear engine support-to-crossmember nut. Tighten the nut to 30–40 ft. lbs. (41–54 Nm).

38. Remove the transmission jack.

39. Install the vacuum hose on the transmission vacuum unit. Install the vacuum line into the retaining clip.

40. Connect the neutral start switch plug to the switch.

41. Install the starter and tighten the attaching bolts.

42. Install the four flexplate-to-converter attaching nuts.

43. Install the converter drain plug access cover and adaptor plate bolts. Tighten the bolts to 15–20 ft. lbs. (20–30 Nm).

44. Connect the muffler inlet pipe to the exhaust manifold.

45. Connect the transmission shift rod to the manual lever.

46. Connect the downshift rod to the downshift lever.

47. Connect the speedometer cable to the extension housing.

48. Install the driveshaft. Tighten the companion flange U-bolt attaching nuts to 30 ft. lbs. (41 Nm).

49. Adjust the manual and downshift linkage as required.

50. Carefully lower the vehicle, then connect the negative battery cable.

51. Fill the transmission to the proper level with Dexron®II. Pour in 5 qts. (4.7L) of fluid; run the engine and add fluid as required.

52. Check the transmission, converter assembly and oil cooler lines for leaks.

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|PATH:  Drive Train > Automatic Transmission > Transmission Removal & Installation > C5 |Print[pic] |

C5

1. Open the hood and install protective covers on the fenders.

2. Disconnect the battery negative cable.

3. On Cougars equipped with a 3.8L engine, remove the air cleaner assembly.

4. Remove the fan shroud attaching bolts and position the shroud back over the fan.

5. On Cougars equipped with a 3.8L engine, loosen the clamp and disconnect the Thermactor® air injection hose at the catalytic converter check valve. The check valve is located on the right side of the engine compartment near the dash panel.

6. On Cougars equipped with a 3.8L engine, remove the two transmission-to-engine attaching bolts located at the top of the transmission bell housing. These bolts are accessible from the engine compartment.

7. Raise and safely support the vehicle.

8. Remove the driveshaft.

9. Disconnect the muffler inlet pipe from the catalytic converter outlet pipe. Support the muffler/pipe assembly by wiring it to a convenient underbody bracket.

10. Remove the nuts attaching the exhaust pipe(s) to the exhaust manifold(s).

11. Pull back on the catalytic coverts to release the converter hangers from the mounting bracket.

12. Remove the speedometer clamp bolt and pull the speedometer out of the extension housing.

13. Separate the neutral start switch harness connector.

14. Detach the kick down rod at the transmission lever.

15. Disconnect the shift linkage at the linkage bellcrank using Shift Linkage Grommet Remover T84P-7341-A or equivalent. On vehicles equipped with floor mounted shift, remove the shift cable routing bracket attaching bolts and disconnect the cable at the transmission lever.

16. Remove the converter dust shield.

17. Remove the torque converter to drive plate attaching nuts. To gain access to the converter nuts, turn the crankshaft and drive plate using a ratchet handle and socket on the crankshaft pulley attaching bolt.

18. Remove the starter attaching bolts.

19. Loosen the nuts attaching the rear support to the No. 3 crossmember.

20. Position a transmission jack under the transmission oil pan. Secure the transmission to the jack with a safety chain.

21. Remove the through bolts attaching the No. 3 crossmember to the body brackets.

22. Lower the transmission enough to allow access to the cooler line fittings. Disconnect the cooler lines.

23. On Cougars, remove the (4) remaining transmission-to-engine attaching bolts (2 each side). On all models, remove the (6) transmission-to-engine attaching bolts.

24. Pull the transmission back to disengage the converter studs from the drive plate. Lower the transmission out of the vehicle.

To install:

25. Raise the transmission into the vehicle. As the transmission is being slowly raised into position, rotate the torque converter until the studs and drain plug are aligned with the holes in the drive plate.

26. Move the converter/transmission assembly forward against the back of the engine. Make sure the converter studs engage the drive plate and the transmission dowels on the back of the engine engage the bolts holes in the bellhousing.

27. On Cougars equipped with a 3.8L engine, install four transmission-to-engine attaching bolts (2 each side). On all other models, install the (6) transmission-to-engine attaching bolts. Tighten the attaching bolts to 40–50 ft. lbs. (55–67 Nm).

28. Connect the cooler lines.

29. Raise the transmission and install the No. 3 crossmember through bolts. Tighten the attaching nuts to 20–30 ft. lbs. (30–41 Nm).

30. Remove the safety chain and transmission jack.

31. Tighten the rear support attaching nuts to 30–50 ft. lbs. (41–68 Nm).

32. Position the starter and install the attaching bolts.

33. Install the torque converter to drive plate attaching nuts. Tighten the attaching nuts to 20–30 ft. lbs. (30–41 Nm).

34. Position the dust shield and on vehicles with column mounted shift, position the linkage bellcrank bracket. Install the attaching bolts and tighten to 12–16 ft. lbs. (16–22 Nm).

35. Connect the shift linkage to the linkage bellcrank. On vehicles equipped with floor mounted shift, connect the cable to the shift lever and install the routing bracket attaching bolt.

36. Connect the kick down rod to the transmission lever.

37. Connect the neutral start switch harness.

38. Install the speedometer and clamp bolt. Tighten the clamp bolt to 35–54 inch lbs. (3.9–6.1 Nm).

39. Install the catalytic converts using new seal(s) at the pipe(s) to exhaust manifold connection(s).

40. Install the pipe(s) to exhaust manifold attaching nuts. Do not tighten the attaching nuts.

41. Remove the wire supporting the muffler/pipe assembly and connect the pipe to the converter outlet. Do not tighten the attaching nuts.

42. Align the exhaust system and tighten the manifold and converter outlet attaching nuts.

43. Install the driveshaft.

44. Check and if necessary, adjust the shift linkage.

45. Carefully lower the vehicle.

46. On Cougars equipped with a 3.8L engine, install the two transmission-to-engine attaching bolts located at the top of the transmission bellhousing.

47. On Cougars equipped with a 3.8L engine, connect the Thermactor® air injection hose to the converter check valve.

48. Position the fan shroud and install the attaching bolts.

49. On Cougars equipped with a 3.8L engine, install the air cleaner assembly.

50. Connect the battery negative cable.

51. Start the engine. Make sure the engine cranks only when the selector lever is positioned in the neutral (N) or Park (P) detent.

52. Fill the transmission with type H fluid.

53. Raise the vehicle and inspect for fluid leaks.

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