Alison

Allison TT, TTB, TRT 2001 -Transmissions Series Service Manual ©IMPORTANT SAFETY NOTICE ITIS YOUR RESPONSIBILITY to be completely familiar with the warn- ings and cautions described in this service manual. These warnings and cautions advise against the use of specific service methods that can result in personal injury, damage to the equipment, or cause the equipmentto be unsafe. Itis, however, important to understand that these warnings and cautions are not exhaustive. Detroit Diesel Allison could not possibly know, evaluate and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way. Consequently, Detroit Diese! Allison has not undertaken any such broad evaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY DETROIT DIESEL ALLISON MUST first be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized by the service methods selected. Proper service and repair is important to the safe, reliable operation of the equipment. The service procedures recommended by Detroit Diese! Allison and described in this service manual are effective methods for performing service operations. Some of these service operations require the use of tools specially designed for the pur- pose. The special tools should be used when and as recommended. WARNINGS, CAUTIONS, AND NOTES Three types of headings are used in this manual to attract your attention. WARNING is used when an operating procedure, practice, etc., which, if not correctly followed, could result in personal jury or loss of life. CAUTION is used when an operating procedure, practice, etc., which, if not strictly observed, could result in damage to or destruction of equip- ment. NOTE is used when an operating procedure, pra highlight. ice, etc., is essential toLIST OF WARNINGS Do not burn discarded Teflon seals, Toxie gases are produced by burning. Never dry bearings by, spinning them with compressed air. spinning bearing can disintes grate, allowing balls or rollers to become lethal flying projec tiles. This manual contains the following warnings. IT IS YOUR RESPONSIBILITY to be familiar with all of them. During disassembly, do not al- low second-turbine drive gear and freewheel unit to remain with the converter housing. ‘The second-turbine drive gear could fall unexpectedly and cause damage ot injury. Copyright 1984 General Motors Corp.SA 2003 Service Manual Allison Transmissions POWERSHIFT MODELS TT 2221-1, TTB 2221-1 TT 2421-1, TTB 2421-1 TRT 2211-3, TRT 2411-3 TRT 2221-1, TRT 2421-1 TRT 2221-3, TRT 2421-3 NOVEMBER 1984 QD sera aseramison nalanapots. ndena 46206 rie nS. © 1804 Genet Mate Can,NOTE: This publication is revised periodically toinclude improvements, new models, specialtools, and procedures. Revisionisindciated by lettersufixto publica: tion number. Check with your Detroit Diese! Allison service outlet for currently applicable publication. Additional copies of this publication may be purchased from authorized Detroit Diesel Allison service outlets. See your yellow pages under Engines--Diesel or Transmissions~Truck, Tractor, etc.TABLE OF CONTENTS Para Page Para Page Section 1, GENERAL INFORMATION Section 2. DESCRIPTION AND OPERATION 1-1, SCOPE OF MANUAL DeVe) SOOEB ee eee tt ee tool a. Coverages see ee eee AD b. Illustrations... ... 1-1 2-2, GEARING, CLUTCHES, HYDRAULIC c+ Maintenance Information . 1-1 SYSTEMS, TORQUE PATHS... . 2-1 1-2. SUPPLEMENTARY INFORMATION . . 1-1 2-3, POWER TAKEOFF (TT) a. Converter-driven PTO. . . 2-1 1-3. ORDERING PARTS >. Output-driven Power a. Transmission Nameplate. . 1-2 Takeoff... ee ee ee DL b. Parts Catalog... . . . 1-3 2-4, IMPLEMENT PUMP, ACCESSORY 1-4, DESIGN FEATURES DRIVE PADS a. Model Differences . . . . 1-3 a. Implement Pump Drive b. Mounting, Input Drive . . 1-3 Pode ee eee ee ee BL c. Twin-Turbine Torque b. Accessory Drive Pad... 2-1 Converter... +. ++ + 1-3 4. Range Gearing, Clutches .1-3 2-5. OIL PUMP,» 2 ee ee ee 23 e. Transfer Gears... .. . 1-3 f. Output Shafts... ... 1-4 | 2-6, INTERNAL BRAKE (TTB) g- Converter-driven Power Brake Components. . . . . 2-3 Takeoff... ee ee 1-4 b. Brake Operation... . . 23 hh. Output-driven Power Takeoff... ee ++. 1-4 247, PARKING BRAKE. 2. 2... . 23 4. Internal Brake. «2... 1-4 3+ Accessory Drive Pad... 1-4 2-B. CONTROL VALVE BODY ASSEMBLY kk. O82 Pumps se ad Control Valve Body. . . . 2-4 1. Control Vaive Body Main-pressure Regulator, Assembly. 2... ee es 1-4 Selector Valves... «+ 2-4 m, Parking Brake... . . . 1-4 cs Clutch Cutoff Valve . . . 2-4 n. Oil Filter, Cooler... . 1-4 4. Inching Control Valve . . 2-4 1-5. OPERATING INSTRUCTIONS 2-9, HYDRAULIC SYSTEM (A11 Models) a. Related to Vehicle. . . . 1-4 a. System Functions. . . . « 2-4 b. Range Selection... . . 1-5 b. System Schematics . . . . 2-4 c. Changing Direction of Travel... 2 ee ee ee 15 2-10. HYDRAULIC SYSTEM (TT, TTB) 4. Clutch Cutoff Control . . 1-5 11 Pump, Filter Circuit. 2-5 e. Inching Control... . . 1-5 Main-pressure Regulator f. Output Disconnect . . . . 1-5 Valve, Converter-in B Towing... 2... 15 Circuit... ee OS h, Temperatures, Pressures . 1-5 cs Torque Converter. . . «+ 2-5 4. Converter-out, Cooler, 1-6. SPECIFICATIONS, DATA. . . . . 1-6 Lubrication Circuit . . . 2-5 Copyright 1984 General Motors Corp. iTABLE OF CONTENTS (CONT) Pera Page Para Page e. Clutch Cutoff Valve 2-14. CONVERTER GEARING TO PORWARD- Circuit... eee ee OS AND-REVERSE SUN GEAR-- £. Inching Control Valve TORQUE PATH Circuit. ee ee ee OD a, First Turbine... . . 217 8+ Manual Selector Valve b. Second Turbine... . . - 2-19 fetreutt epg a). 2-9) h, Trimmer Circuit... . 2-9 4. Internal Brake Coolant 2-15, TT, TTB 2221-1, 2421-1 Lubrication Circuit . . . 2-10 TORQUE PATHS a, Neutral and Power 2-11, HYDRAULIC SYSTEM (TRT 2221, Takeoff... s+ ee + + 2-20 ‘TRT 2421) >. Forward-1 (low-range) . . 2-21 a. O41 Pump, Filter Circuit. 2-10 c. Forward-2 (high-range). . 2-22 . Main-pressure Regulator d. Reverse Range... « « 2-23 Valve, Converter-in Circuit... 1 ee ee 210 © 2-16, TRI 2221-1, 2421-1 TORQUE PATHS c. Torque Converter. . . . . 2-10 a. Neutral and Power 4. Converter-out, Cooler, Takeoff... ee ee + 224 Lubrication Circuit . |. . 2-10 b. Forward-1 es ee es 225 €. Clutch Cutoff Valve ce Forward-2.. 6... 5 + 226 Cireutt se... ee + 210 a. Reverse-l ss. eee es 226 £. Inching Control Valve e. Reverse-2. 1. ee + 226 Circuit... ee» 220 e 8. Manual Selector Valve Cireuit se. ee +. 210 © 217, TRI 2221-3, 2421-3 (Underdrive h, Trimmer Circuit... . . 2-12 Models) TORQUE PATHS a. Neutrals... ee es 2°27 2-12. HYDRAULIC SYSTEM (TRT 2211, b. Forward-l ss +e ee + 2°28 ‘TRT 2411) c. Forward-2....-4 44 2-29 a. O11 Pump, Filter Circuit, 2-12 a. Reverses see ss 230 b. Main-pressure Regulator e. Reverse-2.... 4.4. 2-30 Valve, Converter-in Circuit... 1. 6. +. 212 2-18, TRT 2221-3, 2421-3 (Overdrive e+ Torque Converter... . 2-12 Models) TORQUE PATHS 4. Converter-out, Cooler, fae Neuttaly- eee eteg ee | 21) Lubrication Cireuit .”. . 2-12 b. Forward-l ss ee. 23d e. Clutch Cutoff Valve ec. Forward-2. ee... 6 231 Circuit... ee ee. 213 4. Reverse-L ss ss 2°32 £. Inching Control Valve e. Reverse-2.. 6 6. 2033 Circuit... eee ee 213 g- Manual Selector Valve Cireuit .. 1... +. 213 2-19, TRT 2211-3, 2411-3 TORQUE PATHS h, Trimmer Circuit... . . 2-13 a, Neutral... +... + 2-34 b. Forward see ee ee 234 2-13, TRANSMISSION TORQUE PATHS c. Reverses. ee ee ee 235 a. Component Functions . . . 2-14 b. Cross-section Illustrations... . . . 2-15 Section 3, PREVENTIVE MAINTENANCE e. Torque Converter, e@ Freewheel Clutch... .. 2-16 3-1. SCOPE... 2. eee 554 $1 at Copyright 1984 General Motors Corp.+4, 3-10. an. TABLE OF CONTENTS (CONT) PERIODIC INSPECTIONS, CLEANING a. Inspecting Exterior . . . b. Cleaning Breather. . . . OIL CONTAMINATION a. Examine at O11 Change b. Coolant Leakage . . « c. Metal Particle... . 4. suciliary Filter. . CHECKING OIL LEVEL a. Gold Check (check plug) b. Hot Check (check plug). + Cold Check (dipstick) . d. Hot Check (dipstick). . MAINTENANCE INTERVALS a. Frequency... ee ees b. O41 and Filter Change . CHANGING OIL, FILTER a. Draining Oil... .... b. Refilling Oil System. . BLEEDING INTERNAL BRAKE (7B Models)... 2... ee PRESSURES, TEMPERATURES . . « LINKAGE CHECKS, ADJUSTMENTS a. See Vehicle Manual Instructions. . 2... + b. Selector, Inching Linkeget| ces) c- Front Output Disconnect . d. Parking Brake (external, mechanical)... 2. TRANSMISSION STALL TEST Mo iitoododdoda ibe Procedures 228 or es emilee PRESERVATION, STORAGE a. Storage, New Transmissions»... . « b. Preservation Methods. . c. Storage, 1 Year--Without Cn Page 33 33 343 34 +6 3-6 36 Para 312. +13. d. Storage, 1 Year--With ieee ee e. Restoring Units to Service. see eee ee FLANGE RETAINER... 1s ss ‘TROUBLESHOOTING a. Importance of Troushooting. .. ss. b. Troubleshooting Table . - Section 4. GENERAL OVERHAUL “INFORMATION — SCOPE ge MODEL CHANGES... 1. es TOOLS, EQUIPMENT a. Special Tools... ~~~ b. Mechanic's Tools, Shop Equipment... 6. ses REPLACEMENT PARTS a. Ordering Information. . . bd. Parts Normally Replaced . CAREFUL HANDLING. . 6... + CLEANING, INSPECTION a. Dirt-free Assembly... « bd. Cleaning Parts... ..~ c. Cleaning Bearings... - d. Inspecting Bearings . . . e. Keeping Bearings Clean. « £. Inspecting Cast Parts, Machined Surfaces... « 8. Inspecting Bushings, Thrust Washers... . hh, Inspecting 011 Seale, Gaskets. eee ee eee i. Inspecting Gears. . ss . j. Inspecting Splined Parts. k, Inspecting Clutch Plates. 1, Inspecting Threaded Parte. eee ee ee ee m, Inspecting Snaprings. . - n. Inspecting Springs. . . . Copyright 1984 General Motors Corp. PagePara 4-7. 4-8. 4-10. a. Sl. av TABLE OF CONTENTS (CONT) o. Inspecting Seal Contact Surfaces. sss eee P. Inspecting Swaged, Interference-fit Parts. . q+ Inspecting Balls in Clutch Pistons... ... Inspecting Pump Gears . « ASSEMBLY PROCEDURES a. Clutches, Pistons... . b. Parte Lubrication... . 4 c. External Pipe Plugs, Hydraulic Fittings... . 4, Ofl-soluble Grease... e. Sealing Compounds, Noo~ soluble Greases... . « f£, Metal-Encased Oil Seals . g- Interference-fit Parts. . h. Sleeve-type Bearing . . i, Bearings (ball or roller) REMOVING, INSTALLING TRANSMISSION a, Drain Oil... .-.e, b. Check Linkages, Lines . c+ Remove, Clean Transmission... .. . + (dep Licting hee ee e. Reconnect at Installation. ».... + TIGHT-FIT FLANGES a. Removal of Flanges . . . >. Installation of Flanges « WEAR LIMITS, SPRING DATA a. Wear Limits Inspection. . b. Spring Inspection. . . « TORQUE SPECIFICATIONS . . . . Section 5. DISASSEMBLY OF iSMIS: CCR eee Page Sa Para 5-2, 5-3. 5-5. 5-7. 5-8, PREPARATION FOR DISASSEMBLY a. General Information . « b. Lifting, Handling... SERVICING OF VEHICLE-MOUNTED ‘TRANSMISSION a. Some Servicing Without Removal... +--+ bd. Accessibility... .. REMOVAL OF EXTERIOR COMPONENTS (411 Models) a. External Thermostat . . >. O11 Pump Drive Coupling c. Oil Strainer Assembly . d. Output Flanges, Parking Brake e. Control Valve Assembly. REMOVAL OF INPUT COMPONENTS a. Direct Mount (flex disk)... 2. . Direct Mount (drive ring). . +. + ce. Remote Mount... +. REMOVAL OF TORQUE CONVERTER COMPONENTS AND HOUSING a. Torque Converter Components... +++ + - Torque Converter Housing. REMOVAL OF TORQUE CONVERTER TURBINE GEARING AND OIL SUCTION TUBE a. Turbine Gears and Freewheel Clutch. . . . b, Accessory Drive Shaft - c+ O41 Suction Tube. . . . REMOVAL OF REAR COVER AND HIGH-RANGE CLUTCH PISTON HOUSING (TT 2221-1, 2421-1) a. Rear Cover Assembly (without converter— driven PTO)... 1. Copyright 1984 General Motors Corp.Para 5-9, 5-10. sl. S12. TABLE OF CONTENTS (CONT) Page b. High-range Clutch Piston Housing (without converter-driven PT0) . . 5-8 c. Rear Cover Assembly (with converter-driven PIO). ee eee ee ee 58 4. High-range Clutch Piston Housing (with converter driven PTO)... 1 es 599 REMOVAL OF REAR COVER, INTERNAL BRAKE, AND HIGH-RANGE CLUTCH PISTON HOUSING (ap 2221-1, 2421-1) a. Rear Cover Assembly (with converter-driven PIO). eee ee ee 59 Rear Cover Assembly (without converter- driven PTO). se. eee 5-9 c. Internal Brake Couponents.... +. 4, High-range Clutch Piston Housing... 6 ee ee - S10 + 5-10 REMOVAL OF HIGH-RANGE AND FORWARD CLUTCH, GEARING (TT, TTB 2221-1, 2421-1) a. “High-range Clutch Assembly and Transfer Drive Gear... 2... + Sell b. Forward Clutch and Planetary... 2... + Sell REMOVAL OF REAR HOUSING, HIGH- AND LOW-RANGE CLUTCHES, PLANETARY, AND ADAPTER CRT -1, TRT -3) a, RT 2221-1, 2421-1. . « b. TRT 2221-3, 2421-3, Models With Underdrive. ce. TRI 2221-3, 2421-3, Models With Overdrive . . 4. TRT 2211-3, 2411-3... . + S12 + S15 5-18 5-20 REMOVAL OF REVERSE CLUTCH AND PLANETARY (A11 Models). . 5-21 Copyright 1984 General Motors Corp. Para 5-13, S14, Section ol. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. Page REMOVAL OF OIL PUMP... . . 5-21 REMOVAL OF OUTPUT COMPONENTS AND TRANSFER DRIVEN GEAR (IT, TTB, TRT 2221-1, 2421-1) a. One-piece Output Shaft. . 5-22 b. Two-piece Output Shaft. . 5-23 c. Rear Output Shaft (no front output) . . . . 5-26 REBUILD OF SUBASSEMBLIES SCOPE... eee ee ee ee OD GENERAL INFORMATION FOR SUBASSEMBLY REBUILD... . « CONTROL VALVE BODY ASSEMBLY a, Disassembly... ..- b. Assembly... se ee ee ‘TRANSMISSION FRONT COVER Disassembly... ~~ + b. Assembly... eee ah TORQUE CONVERTER DRIVE COVER a. Disassembly... .. ++ b. Assembly... -.. ~~. FIRST- AND SECOND~TURBINE ASSEMBLY a. Disassembly... ... b. Assembly... +... ‘TORQUE CONVERTER PUMP a. Disassembly... . bd, Assembly... 2. e+ 1 + 6+ TORQUE CONVERTER HOUSING a. Disassembly»... - b. Assembly... 2... 0. TURBINE-DRIVEN GEARS AND FREEWHEEL CLUTCH a. Disassembly... .. ~~ b. Assembly... se ee eePara 6-10, 6-1. 6-12, 6-13. os. 6-15. 6-16. 6-17. 6-18. 6-19. 6-20, 6-21. vi TABLE OF CONTENTS (CONT) FIRST~TURBINE DRIVE GEAR AND BEARING ASSEMBLY a. Disassembly... . b, Assembly... 1+... CLUTCH PISTON HOUSING a. Disassembly... . (be Assembly oe CLUTCH PISTON ASSEMBLIES a. Disassembly... . +. b. Assembly... - 2. HIGH-RANGE CLUTCH AND HUB (aT, TTB) a, Disassembly. . +... b. Assembly... ee ee ee CLUTCH ANCHOR (TRT 2221-1, 2421-1, 2221-3, 2421-3) a. Disassembly... . +. te Soins ouaoocd ADAPTER ASSEMBLY (RT) a, Disassembly. .....- b. Assembly... . 2. eee INTERNAL BRAKE DIAPHRAGM (TTB) a. Disassembly... ... b. Assembly...) se ee ‘TRANSFER DRIVE GEAR (TT, TTB) a. Disassembly... ... b. Assembly... ee ‘TRANSFER DRIVE GEAR (TRT ~1) a. Disassembly... . b. Assembly... .-/e eee TRANSFER DRIVE GEAR SLEEVE ASSEMBLY (IRT ~1) a. Disassembly... .... b, Assembly... ee. eee REAR PTO COVER ASSEMBLY (TT) a, Disassembly. ...... b. Assembly. . REAR COVER ASSEMBLY (TTB) a. Disassembly... . +. b. Assembly... . 2... e Page 6-16 6-16 6-16 o-17 6-17 6-19 Para Page 6-22. TRANSMISSION REAR HOUSING ASSEMBLY (TRT 2221-1, 2421-1) a. Disassembly... .. . - 6-20 b. Assembly... 2... - 6-20 6-23, TRANSMISSION REAR HOUSING ASSEMBLY (TRT 2221-3, 2421-3) a. Disassembly... .. . . 6-20 b. Assembly... . + + 6-21 6-24, TRANSHISSION REAR HOUSING ASSEMBLY (TRT 2211-3, 2411-3) a. Disassembly... . + + 6-21 b. Assembly...) 1. ee 5 6-21 6-25. PLANETARY CARRIER ASSEMBLY a. Disassembly... ~~. - 6-21 b. Assembly... 2... 5. 6-22 6-26. OIL PUMP a. Disassembly... . + 6-24 b. Assembly... 2... «+ 6-26 6-27. TRANSMISSION HOUSING (oT, TTB, TRE -1) a. Disassembly... . . . - 6-26 bd, Assembly... 6 1. ee + 6-27 6-28, TRANSMISSION HOUSING (TRT -3) Disassembly... + +. - 6-27 b. Assembly.» 5... 5. . 6-27 Section 7. ASSEMBLY OF TRANSMISSION Tl. SCOPES. eee ee eee PL 7-2. GENERAL INFORMATION FOR ASSEMBLY OF TRANSMISSION 7-3. INSTALLATION OF OUTPUT COMPONENTS, ‘TRANSFER- DRIVEN GEAR (-1 Models) a. One-piece Output Shaft. . 7-1 b. ‘Two-piece Output Shaft. . 7-2 c. Rear Output Shaft (no front output)... . 7-5 Copyright 1984 General Motors Corp.Para 7-4, 7-5. 7-6. TABLE OF CONTENTS (CONT) Page INSTALLATION OF REVERSE AND FORWARD CLUTCHES, GEARING (A11 -1 Modeis) a. Reverse Clutch, Planetary >. Forward Clutch and Planetary ss ee ee ee 7-5 INSTALLATION OF TRANSFER DRIVE GEAR, HIGH-RANGE CLUTCH (TT, TTB) a, Transfer Drive Gear... Db. High-Range Clutch and Hub Assembly... 2 es + 7-8 7-8 INSTALLATION OF HIGH-RANGE CLUTCH PISTON HOUSING, INTERNAL BRAKE, REAR COVER (TTB) a. High-range Clutch Piston Housing»... b. Internal Brake Components... 1s + c. Rear Cover (without converter-driven PTO) . - Rear Cover (with converter-driven PTO) . . te 79 7-10 7-1. 7-1 INSTALLATION OF HIGH-RANGE CLUTCH PISTON HOUSING, REAR covER (TT) a. iligh-range Clutch Piston Housing (with converter- faetvenyPTO) oe etecte b. Rear Cover Assembly (with converter-driven c. High-range Clutch Piston Housing (without converter-driven PTO) . . d. Rear Cover (without converter-driven PTO) . . 7-13 7-12 7-12 7-12 INSTALLATION OF TRANSFER DRIVE GEAR, HOUSING ADAPTER, LOW- RANGE CLUTCH, HIGH-RANGE CLUTCH (aR -1) a. Transfer Drive Gear, Wousing Adapter... . . 7-13 Para 7-10. Low-Range Clutch, High Range Planetary... + ~ c. High-Range Clutch, Rear Housing... +. - + ASSEMBLY OF TRT-3 MODELS a. Reverse Clutch and Planetary (IRT-3 models). >. Forward Clutch, Planetary and Adapter Assembly (aRT 2221-3, 2421-3 overdrive models) . c. Installation of Low-Range Clutch, High-Range Planetary (IRT 2221-3, 2421-3 overdrive models). 4. High-range Clutch, Rear Housing (IRT 2221-3, 2421-3 overdrive models). e. Forward Clutch, Planetary, and Adapter Assembly (TRT 2221-3, 2421-3 underdrive models)... eee ee £. High-range Clutch, Low- Range Planetary (IRT 2221-3, 2421-3 underdrive models)... +e. eee + Low-range Clutch, Rear Housing Assembly (TRT 2221-3, 2421-3 underdrive models)... . h. Forward Planetary, Clutch, Rear Housing (oRT 2211-3, 2411-3). . INSTALLATION OF TURBINE GEARING, OIL SUCTION TUBE, AND STRAINER a. Accessory Drive Shaft Assembly... - . . b, Turbine Gears, Freewheel ClucchS tee c, 041 Suction Tube, (tl strainers) Copyright 1984 General Motors Corp. Page 7-14 7-15 7-18 7-20 72a 7-25 7-25 7-26 7-26 7-27 vitPara vu. 7-12. 7-13. 7-14, vil ‘TABLE OF CONTENTS (CONT) INSTALLATION OF CONVERTER HOUSING, CONVERTER COMPONENTS a. Converter Housing . . . « b. Converter Components. . . INSTALLATION OF INPUT COMPONENTS a. Direct Mount (flex disk). b. Direct Mount (drive egueoodsocd c. Remote Mount... 5. INSTALLATION OF EXTERIOR COMPONENTS a. External Thermostat . . . b. O11 Pump. . : 011 Pump Drive Coupling . 4. Control Valve Body. . . . Parking Brake, Output Flanges se eee ee ee ASSEMBLY TECHNIQUES FOR VEHICLE-MOUNTED TRANSMISSIONS a, Similar Procedures. . . b. Clutch Installation . . - Specifications and Data . . . Model Differences... .. + Choice of Proper C-3 Oil. . « O11 System Refill Amounts . . Page Para 7-29 Ba. 7-29 7-30 7-31 7-31 82. 7-31 7-31 7-32 7-32 oa. 7-33 9-2. 7-34 7-35 9-3, ‘TABLES Page Table 1-6 1. 22 34 Ba. 34 Section 8. WEAR LIMITS AND SPRING DATA WEAR LIMITS DATA a, Maximum Variations... . b, Cleaning, Inspection. . . c. Bearings, Bearing Journals, Bores . « Gears fot Splinese ec) £. Hook-type Sealrings SPRING DATA... ee eee Section 9. OWNER ASSISTANCE IND_SERVICE LITERATURE OWNER ASSISTANCE. . 2... SERVICE LITERATURE... . - FACTORY SERVICE "INFO"... Piston Housing Assemblies . . Planetary Assemblies. . . . - Wear Limits... eee ee Spring Data: ee Copyright 1984 General Motors Corp. Page Page 6-12 6-22 8-2TABLE OF CONTENTS (CONT) FOLDOUTS (back of manual) Exploded Views TT 2001 and TTB 2001 Series transmissions ‘TRI 2421-1 Transmission RT 2221-3 Transmission (with underdrive) ‘TRT 2221-3 Transmission (with overdrive) ‘TRI 2211-3 Transmission ‘Transmission front cover and remote-mount input drive Transmission direct~mount input drive Torque converter Torque converter housing and turbine drive gears Turbine driven gears and freewheel clutch Transmission housing (-1 models) Transmission housing (-3 models) Reverse clutch and planetary Forward clutch and planetary (-1 models) Forward clutch and planetary (TRT 2221-3, 2421-3) Forward clutch and planetary (TRT 2211-3, 2411-3) High-range clutch and piston housing (TT models) Low-range clutch and transfer drive gear (TRT-1 models) High-range clutch and planetary (TRT-1 models) High-range clutch, low-range ring gear (TRT 2221-3, 2421-3 with underdrive) Low-range clutch and planetary (-3 models with underdrive) Low-range clutch, high-range planetary (-3 models with overdrive) High-range clutch, planetary sun and ring gears (-3 models with overdrive) High-range clutch and piston housing (17 models) Internal brake and rear cover (TTB models) Rear housings and output shafts (TRT models) Rear covers and PTO shaft (TT models) Output shafts and disconnect assembly (-1 models) Parking brake 011 pump assemblies Control valve assemblies Copyright 1984 General Motors Corp. ixSection 1. GENERAL INFORMATION 1-1, SCOPE OF MANUAL a, Coverage. This Service Manual de- seribes the operation, maintenance, and over haul procedures for the following Powershift transmissions (fig. 1-1 through 1-5): ‘TT 2221-1 TTB 2221-1 TT 2421-1 TTB 2421-1 TRT 2211-3 TRT 2221-1 TRY 2221-3 TRT 2411-3 TRT 2421-1 TR 2421-3 ‘The function and operation of the hydraulic systems, torque paths, wear limits, inspection procedures, and torque specifications are included. b. Mlustrations. Transmission features and overhaul procedures are illustrated main- ly by photographs. Line drawings are used to illustrate the hydraulic systems and to sup- plement detailed assembly procedures; cross sections show torque paths and the relation- ship of assembled parts. Exploded views illustrate the relationship of transmission parts. The cross section and exploded views appear on foldouts at the back of the manual, ‘The foldouts may be opened for reference while studying the text. ¢, Maintenance Information, Each task outlined in this Service Manual has been sue- cessfully accomplished by service organiza- tions and individuals, It is not expected that every service organization or individual will possess the required special tooling, training, or experience to perform all the tasks out— Tined. However, any task outlined herein may be performed if the following conditions are met: (1) The organization or individual has the required knowledge of the task through: - Formal instruction in a DDA or Distributor training facility. - "On-the-job" instruction by a DDA or Distributor representative. ~ Experience in performing the task. (2) The work environment is suitable to prevent contamination or damage to trans- mission parts or assemblies. (3) Required tools and fixtures are available as outlined in the Service Manual. (4) Reasonable and prudent mainte- nance practices are utilized. NOTE Service organizations and indi viduals are encouraged to con- tact their loeal DDA Distribu- tor for information and guid- ance on any of the tasks out- lined herein. 1-2, SUPPLEMENTARY INFORMATION Supplementary information will be issued when significant design changes occur. The supplements w i 11 pertain only to specific changes and, therefore, must be used in con- junetion with this Service Manual. CONVERTER, HOUSING TRANSMISSION. HOUSING Torgharic ‘COUPLING our. DISCONNECT. ‘CONTROL Fig. 1-1, Model TT 2221-1 (or TT 2421-1) transmission—right-front view Copyright 1984 General Motors Corp. 1-1‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS: on pup assy ACCESSORY MOUNTING PAD aR COVER BRAKE LID LI, AE von IE rancort ance PARKING BRAKE Fig. 1-2, Model TTB 2221-1 (or TTB 2421-1) ‘transmission—left-rear view CONTROL VALVE ASSY CONVERTER HOUSING parking BRAKE OIL DRAIN PLUG Fig. 1-3. Model TR 2221-1 (or 2421-1) transmission—left-rear view ow BREATHER PUMP. accessony [MOUNTING PAO: cconreo. VAWE BOW ASSY —_— EAR ouput PARKING FLANGE RAKE: OL STAANER COVER Fig. 1-4, Model TRT 2211-3 (or 2411-3) transmission-—right-rear view conTRo. ave ASSEMBLY FLEXI ORVE EAR HOUSING TRANSMISSION HOUSING couvenren ROUSING Fig. 1-5. Model TRT 2221-3 (or 2421-3) transmission-left-front view 1-3, ORDERING PARTS 8, ‘Transmission Nameplate. The name- plate (fig: 1-0), located on the lower left side of the transmission housing, has the serial number, part number (sembly number), and 1-2 Copyright 1984 General Motors Corp.GENERAL INFORMATION O/Allison Transmission \@ Mensached By GQ setettcset amon Fig. 1-6. ‘Transmission nameplate model number all of which must_be supplied when ordering parts or requesting service in- formation. b. Parts Catalog. All replacement parts and Serviee Kits should be ordered from ‘your dealer. These parts are listed in the current Parts Catalog SA 1248, Do not_order parts by illustration item numbers used in this Ser~ viee Manual. 1-4, DESIGN FEATURES a Model Differences. Refer to foldout 1, 2, 3, 4, or 5 for the model that is to be ser- viced or rebuilt. The various features de-~ scribed in this section will not all be on any one model. For detailed deseription of speci- fie models, refer to Section 2. Basie differ- ences are indicated by the model designation: TT - Twin turbine with two forward ranges, one reverse range TRT - Twin turbine with equal ranges forward and reverse B_ - Internal service brake 2. ~ 2000 Series transmission 2 (or 4) - Converter series 2 (or 1) - Number of drive ranges 1 ~ Major model change 1 = Long drop transfer housing -3 - Short drop transfer housing b. Mounting, Input Drive (1) The transmission may be direct mounted or remote mounted. A direct-mount transmission is coupled to the engine through a modified SAE 3 mounting face on the torque converter housing, whieh is bolted to the engine flywheel housing. A flex disk drive assembly is bolted to the engine fly- wheel. Another direet-mount configuration consists of a splined converter drive cover which is driven by the engine flywheel (or adapter plate) through a splined drive ring. (2) The remote-mount transmission is equipped with a front cover. An input shaft, connected to the converter drive cover, ex~ tends through the front cover and receives the customer-selected flange. The input flange is driven by the engine through a drive shaft and universal joints. ¢. Twin-Turbine Torque Converter Q) A fourelement t wi mturbine torque converter transmits power from the engine to the transmission gearing through two sets of turbine gears. (2) When torque demand is high, the freewheel clutch is engaged and the first tur bine, assisted by the second turbine, drives the range gears. When the speed of the ve~ hicle inereases and torque demand decreases sufficiently, the second turbine assumes the entire load and the freewheel cluteh disen- gages. The transition from both turbines to second turbine only (high torque to high speed) is automatic, and oceurs when the load demand has reduced to @ level that can be supplied by the second turbine. @. Range Gearing, Clutehes. The trans- missions have two or three planetary gear sets and two, three, or four clutches. Each of the clutches is applied seperately. Two forward ranges (Fl and F2) and reverse (R and R2) are derived from the range gearing and clutches, All clutches are multiplate, hydraulically applied, and spring released. All gearing is in constant mesh. ¢, Transfer Gears. Tw o transfer spur gears are in constant mesh and in conjunetion with the turbine gear, provide either a 19- inch (483 mm) (-1 models) vertical drop or a T-ineh (178 mm) (-3 models) vertical dr op from the input shaft to the output shaft. The transfer gears drive the output shaft. Copyright 1984 General Motors Corp. 1-3‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS f, Qutput Shafts (1). The transmission may be equipped with either a one-piece shaft or a two-piece shaft. (2) A one-piece shaft may provide for identical operation at the front and rear out- puts or may provide for operation at the rear output only. ‘The two-piece shaft and discon neet coupling allow the front output shaft to be disconnected f ro m the driveline while Grive at the rear output shaft is maintained. g; Converter-driven Po wer Take Some models include a converter-driven power takeoff (PTO) which consists of a PTO shaft which extends through the rear cover. An output flange is splined to the rear end of the PTO shaft. The forward end of the PTO shaft is splined to the reverse-and-low-range sun gear, which is driven by the torque con- verter. Thus, regardless of the range selee- tor position, t he PTO rotates at the same rpm as the torgue converter output. ‘bh, Qutput~driven Po wer Takeoff (TT models). Some TT models include an output- driven power takeoff (PTO) which consists of an access to the splines in ther e ar of the high-range piston housing through the re ar cover. With the addition of an OEM fur- ied hydraulic pump, this PTO-driven pump nis provides hydraulic pressure f or steering in the event of engine failure, as long as the ve~ hiele is still moving. i, Internal Brake, A 11 TTB models in- clude ‘a multidisk, self-adjusting, hydrauli cally-applied dynamic brake. This brake is connected to the vehicle driveline through the transfer drive gears and the transmission output shaft(s). i Accessory Drive Pad (1) An SAE size A, two-bolt mounting pad is located at the upper-right rear of the transmission housing to accommodate a steer pump or other accessory (in addition to that Mounted at the rear of the oil pump). Rote- tion at this pad is clockwise (as viewed from the rear). Lubrication is supplied to the splined drive, and a customer-supplied gasket is required at the mounting surface. (2) If no requirement exists for an accessory drive at this location, the drive gear, shaft assembly, and related parts are omitted, and the opening in the housing is closed with a plug. k, O11 Pump. A positive displacement, gear-type oil pump furnishes the oil flow and pressure necessary for hydraulic operation, lubrication, and cooling of the transmission components. Rotation of the pump is in a clockwise direction (viewed from rear) and is proportional to the speed of the engine. A mounting pad is provided at the rear of the oil pump to accommodate an implement. pump. Lubrication is supplied to the splined output drive and a customer-supplied gasket is required at the mounting surface. 1. Control Valve Bo dy Assembly. The control valve body assembly is located on the left side of the transmission housing (fig. 1-2, 1-3, 1-5). Movement of the valves within the valve body controls the functions of the transmission, All shifts are trimmed for a soft-shift capability. The control valve body assembly contains, in addition to the pressure regulator valve, range selector valve, and re~ lated components, either a clutch cut- off valve or an inching control valve. m. Parking Brake. The transmission may be equipped with an expanding-shoe parking brake. The brake is mechanical and is man- ually operated. , Oil Filter, Cooler. Provision is made for connecting @ Femote-mount, full-flow oil filter and an oil cooler to the transmission (both customer-furnished). Refer to figure 3-1 for the points at which these items are attached. 1-5. OPERATING INSTRUCTIONS NOTE Refer to Operators Manual SA 1336. & Related to Vehicle. For information on controls and linkage provided by the ve- hiele manufacturer, refer to the vehicle ser- viee manual. 1-4 Copyright 1984 General Motors Corp.GENERAL INFORMATION >. Range Selection (1) Position the range selector con- trol in neutral position before starting the engine. A neutral start switeh (if used) will prevent the engine from starting if the shift lever is in any other position. (2). When a shift is made from neutral to any driving range, the engine should be at idle speed. Any shift to a higher speed range, in the same direction, can be made at full throttle, under load. Downshift to the next lower speed range may be made at full throt- tle, under load, providing the vehicle is not exceeding the maximum speed attainable in the lower range. ¢. Changing Direction of Travel. Direc- tionin shifts canbe Tade under TulF-power or full-speed conditions in the working ranges (P1 to R1 and Ri to Fl). Shifts from reverse should be made to Fl drive range--not F2. Direct shifts from Ri to F2 will adversely affect clutch service life. d, Cluteh Cutoff Control. When the ‘transmission is equipped with the cluteh cut- off control, the driving eluteh is completely released whenever the vehicle brakes are ap- plied. Air or hydraulic pressure which applies the brakes also actuates the clutch cutoff. ‘Thus, with the cluteh released, full engine power is available for PTO-driven equipment without shifting the range selector control to neutral. @ Inching Control CAUTION Use of inching control in high range will © aus e premature failure of the high-range cluteh because no cooling o i] is pres- ent at the cluteh during inching. (1) Applying the inching control re- leases the driving clutch. The inehing control may be used during operation in any renge except that its use in high range (F2) is not recommended. (2) Ful application will completely release the driving cluteh, Lesser application will slip the cluteh while it is driving. Very slight and slow movements of the vehicle can be made with this control. f, Output Disconnect. The transmission front output may be aisconeeted by moving the control (at the front of the dropbox) which moves the disconnect coupling for- ward. Rearward movement connects the front and rear output shafts through the splines of the coupling. Two spring-loaded ball detents retain the coupling in either posi- tion. The control should never by shifted while the vehicle is moving; however, slight shaft rotation may be required to obtain cor- rect spline alignment for engagement. g- Towing. All lubrication and clutch apply oil is provided by the engine-driven oil pump. Because of the pump location, ahead of the transmission gearing and clutches, the 011 pump cannot be motored by towing or pushing the vehicle, THEREFORE, ANY ‘TIME THE VEHICLE MUST BE TOWED OR PUSHED FOR MORE THAN A HALP MILE (HALE KILOMETER), THE DRIVELINE MUST BE DISCONNECTED. h, Temperatures, Pressures (1) When a transmission is equipped with @ temperature gage, the bulb or sending unit is mounted in the converter-out oil circuit (fig. 3-1). Temperature should never be permitted to exceed 275°F (135°C). EX- tended, severe operating conditions may cause th e temperature to exceed this maximum. If so, t h e transmission should be shifted to neutral and the engine should be operated at approximately 1000-1500 rpm for several minutes until the normal temperature of 180-220°F (82-104°C) is restored. If the temperature reaches a maximum of 275°F (135°C) during normal operation of the trans- mission, st 0p the engine and locate the trouble. Refer to the Troubleshooting Chart (ara 3-13), (2) When a transmission is equipped with a clutch (main) pressure gage, it is con- nected to the front of the control valve body Copyright 1984 General Motors Corp. 15TT, TTB, TRT 2001 SERIES TRANSMISSIONS: assembly (fig. 3-1). The pressure shown is that which is effective in the operating range cluteh. Shifting or use of the cluteh cutoff or inching control will cause a drop in the pressure indicated. If abnormal pressures are evident, refer to the Troubleshooting Chart (para 3-13), 1-6. SPECIFICATIONS, DATA The following table of specifications and data are applicable to all models within the scope of this Service Manual. SPECIFICATIONS AND DATA Item ‘Transmission type... . « Rating: input speeds see ee eee eee Anput torque (net*) se input horsepower. Rotation, viewed from fron! inpote ee ‘i output (forward operation)... 2... (reverse operation)... ... . Mounting, drive: side. front, direct mounted... ++... front, remote mounted... ... 05. Gear ranges, selector positions: Reverse High Reverse Low Neutral, Forward Forward Low High * Net as installed: inlet restriction, idle steer pump, idle implement pump, when applicable, 1-6 Description torque converter and planetary gear 3000 rpm (max) 310 1b ft (420 Nem) (max) 175 hp (130 kW) (max) =a -3 clockwise clockwise clockwise counterclockwise counterclockwise clockwise four 5/8-11 tapped holes in side pads, each side todified SAE-3 flange on converter hous~ ing bolts to engine flywheel housing, flex plate attaches to engine flywheel (optional splined drive) front unmounted, converter enclosed, in- put flange for shaft and universal joint coupling TT 2221-1 © TRI 2221-1 TTB 2221-1 © TRT 2221-3 ‘TRT 2211-3 TT 2421-1 TRT 2421-1 TRT 2411-3 TTB 2421-1 © TRT_ 2421-1 - - RQ R R RL N N N F FL FL - F2 F2 exhaust restrictioa, alternator, fan, and air compressor should be deducted Copyright 1984 General Motors Corp.GENERAL INFORMATION SPECIFICATIONS AND DATA (cont) Item Weight, dry (approx): Basic Model. TT 2001-1 TTB 2001-1 ‘TRT 2001-1 TRT 2001-3 RT 2011-3 Add Weight Remote mount 2401 Model, (larger converter) Torqmatic® coupling Flange Parking brake (-1 models) Parking brake (~3 models) Torque converter... +... +++ +s + two-stage, four-element, twin-turbine 26:1 Tz Converters* ‘TT 220 TT 240 ‘Tr 260 TT 270 TT 425 TT 444 TT 445 TT 465, 1b 760 935 910 755 660 40 1b 36 6 20 35 Description ae 345, 424 413 (342 299 18 7 16 3 9 16 5.09. 3.32: 4.81 4.78: 3.40 3.3421, Grorquatic is the registered trademark of Detroit Diesel Allison, Indianapolis, IN and Detroit, MI. *To obtain overall transmission torque ratios, converter ratio times the gear ratio. Copyright 1984 General Motors Corp. multiply the applicable torqueTY, TTB, TRT 2001 SERIES TRANSMISSIONS SPECIFICATIONS AND DATA (cont) item Description Range gearing. 6.0 e eee eee + +s constant mesh, straight spur, planetary Transfer gearing... +++. +++ ++ + constant mesh, straight spur, in-line ‘Gear ratios: 0.826:1 Ty Converters 1,211:1 Tp Converters ‘Low High Tow High TTB) 2221-1, 2421-1 Fr 2.663:1 0,699:1, 3.902:1 1.02421. Rt 1.96421 - 2.878:1. - Fr: 2.02931 0.69921 2.973:1 1.024: R: \* 2.878:1 0 === Fi R: TRT 2211-3, 2411-3 F: 2.39811 == R: 2.3211 0 == TRT 2221-1, 2421-1 Fr 2.029:1 0.73621 2.973:1 1,079:1 Ri 1.96421 0.71221, 2.878:1 1.043:1. TRT 2221-3, 2421-3 : 9.689:1 Rr 9.37521 Clutch data: types see eee ee eee ee ee + multidisk, hydraulic-actuated, spring released, oil-cooled; automatically compensates for wear material... .....+..+ +... + external-tanged reaction plates--polished steel internal-splined friction plates forward, reverse--resin-graphite high range-~sintered bronze Freewheel clutch... ....... + +. standard or heavy duty, depending on application * To obtain overall transmission torque ratios, multiply the applicable torque converter ratio times the gear ratio. 1-8 Copyright 1984 General Motors Corp.GENERAL INFORMATION SPECIFICATIONS AND DATA (cont) Item Description Parking brake: Type and Size Burnished Rating -1 Models expanding~shoe, 30,000 Ib in. (3389 Nem) mechanically-applied, at 1500 1b (6672 N) 10 x 1-1/2 in. apply force (254 x 38 om) 3 Models expanding-shoe, 45,000 1b in. (5084 Nem) mechanically-applied, at 2100 1b (9342 N) 13-3/8 x 2 in. apply force (340 x 51 mm) Internal brake (TTB model): TYPE ee ee ee ee ee ee «+ multidisk, hydraulic-applied, self- adjusting, oil cooled rating (static capacity)... . . . . 3000°1b ft (4068 Nem) at transmission output shaft with 1500 psi (10 342 kPa) max. brake-apply pressure hydraulic brake fluid... .... . . SAE J70, type 70RL or 70R3 Flanges: input and output... ........ . Mechanics 4C, 5C, 6C, 7C3 Rockwell 5N plain, 6N plain; Spicer 1480 Torqmatic coupling. .. 1... + +. Mechanics 5C (TT,TTB,TRT 2221-1) Mechanics 6¢ (TT,TTB,TRT 2421-1) O41 system ofl pump. ss... +... 2... ss dnput driven, positive displacement, gear type ofl pump output pressure... . . . . . 255 psi (1758 kPa) max (with clean fil- ter) (measure at 10 FILTER port) SUP eee ee ee ee ee single, integral Oe ee ee Type 63 Fluid Viscosity and Grade Which Preheat is Required SAE 30... . soe 32°F (0°C) SAE 15W-40. oa 32°F (0°C) SAE 10W-30, . 10°F (-12°C) 10°F (-12°C) 10°F (-23°C) SAE 10W. le SAE 5W-20.) 1 Copyright 1984 General Motors Corp. 1-9TT, TTB, TRT 2001 SERIES TRANSMISSIONS SPECIFICATIONS AND DATA (cont) Item Description 011 system (cont): oil capacity: 1 model “(less external circuits). . initial f111--8-1/2 US gal (32 liters) -3 model (less external circuits). . initial fil1--6-1/2 US gal (25 liters) oil filter (customer furnished) . . . . remote mounted filtration... eee ee eee + + 44 micron (max) pressure drop across filter... . . clean 35 psi (241 kPa) max; dirty 45 psi (310 kPa) max converter-out ofl temperature . . . . . 275°F (135°C) max continuous main pressure, at full throttle, dn all ranges... +. sss +s + « #135 to 170 psi (930 to 1171 kPa)-- vehicle weight to 28,000 1b (22-701 kg) *160 to 195 psi (1102 to 1343 kPa)-~ vehicle weight over 28,000 1b (22-701 kg) lubrication pressure, at full throttle stall... . +... +. + + 10 to 30 psi (68 to 206 kPa) converter-out pressure, at full throttle stall... ~~... . 40 psi (275 kPa) (min) converter-out pressure, at full throttle, no-load. . . . . . . « 65 psi (447 kPa) (max) Control valve body assembly: clutch cutoff... ......... « hydraulic- or pneumatic-actuated inching control. .......... . manual-actuated Engine-driven power takeoffs: implement pump drive (pad at rear of ofl pump): ratio~-standard . ... ~~... + 0,91 x engine speed ~voptional......... . 1,00 x engine speed maximum rating? Continuous Intermittent horsepower, at 2000 — to 3000 rpm. we. ee ss 90 (67 KH) 110 (82 kw) torque, up to 2000 rpm... . . 236 1b ft (321 Nem) 288 1b ft (391 Nem) mounting pad... ........ . SAE size C, two-bolt or four-bolt; SAE size B, two-bolt spline size... ........ . SAE size B, SAE size C, SAE size B-B (1.00:1 PTO Ratio only) * Main pressure in high range may be as much as 10 psi (33 kPa) lower than in other ranges. These pressures are established for a converter-out temperature range of 140 to 165°F (60 to 73.8°C). As converter-out temperature approaches 250°F (221°C), main pressure can drop as much as 15 psi (103 kPa). 1-10 Copyright 1984 General Motors Corp.GENERAL INFORMATION SPECIFICATIONS AND DATA (cont) Item Description Engine-driven power takeoffs (cont): accessory drive: ratio-~standard . .. s+. ++. « . 0.91 x engine speed optional... +... + + 1,00 x engine speed ‘maximum rating: horsepower. torque. . « mounting pad. spline size 30 hp (22 kW) at 2000-3000 rpm 79 1b ft (107 Nem) up to 2000 rpm SAE size A, two-bolt SAE size A or SAE size B Converter-driven power takeoff: ratio~-standard ...... «+++ + + 1e21 x converter output speed optional»... + + + + 0,83 x converter output speed rating, continuous. ....... + + full input (engine) hp (kW) Output-driven power takeoff (emergency-steer PTO): Tato ee ee ee ee ee ee + 0,846 x output speed or 0.684 x output speed, depending on transmission gear ratio maximum rating. «66... + + +» 30 hp (22 kW) at 2000-3000 rpm mounting pad... +... ...... SAE size A, tworbolt (gasket required) Speedometer drive pad (some models) TYP ee ee ee ee eee ee eo SAE 5/32, heavy duty Tato. see ee ee eee ee ee + 0,846 x transmission output speed or 0.684 x transmission output speed depending on transmission gear ratio Magnetic speed pickup provision (later models)... . . «+ +. s+ + 3/4-16 UNF-3B tapped port in main housing * If both drive pads are used simultaneously, their combined duty requirements should not exceed the duty rating for the implement pump P10. Copyright 1984 General Motors Corp. 1-11-12,Section 2. DESCRIPTION AND OPERATION 2-1, SCOPE ‘This section describes the functions of the transmission components. ‘The hydraulic sys~ tems are explained and schematically illus- trated. The transmission torque paths are also explained for each gear range. 2-2, GEARING, CLUTCHES, HYDRAULIC SYSTEMS, TORQUE PATHS Table 2-1 shows the relationship of clutehes, planetaries, and ranges for the various TT, TTB, and TRT 2001 Series ‘Trans~ missions. It also references the paragraphs which explain the hydraulic systems and torque paths. 2-3. POWER TAKEOFF (TT MODELS) Converter-driven PTO (foldout 1) Q)_ The converter-driven power take off consists of PTO shaft 49 which is driven at converter output speed by forward-and- reverse sun gear 26, The PTO shaft extends through the rear cover. Output flange 48 is splined to the rear end of the PTO shaft. The converter-driven PTO is designed so that full engine horsepower ean be utilized. (2) Driving, Winehing. Although it is permissible to drive and winch at the same time, this mode of operation splits the torque path. Thus, to aehieve full power at the con- verter-driven PTO, shift the range selector to neutral position. ‘b. Qutput-driven Power Takeoff () Some TT models include an out- put-driven PTO which consists of a 2-bolt SAE type-A pad located in the center of the rear cover. A vehicle-furnished pump mounted on this pad will provide hydraulic pressure for emergency steering in the event of engine failure. (2) As long as the vehicle is moving (without engine running), torque from the ve~ hicle wheels is transmitted back through the Griveline to the transfer gears in the drop- box. Rotation of the transfer gears drives the forward clutch piston. Splines in the rear hub of the piston transmit the torque to the PTO pad. 2-4. IMPLEMENT PUMP, ACCESSORY DRIVE PADS NOTE Refer to Specifications and Data (para 1-6) for duty ratings. a. Implement Pump Drive Pad. ‘The im- plement pump drive pad, located on the rear face of oil pump body 10 (foldout 18,4), may be any one of four configurations—four-bolt, SAE size C; two-bolt, SAE size C; 2- and 4 bolt SAE size C; or a two-bolt, SAB size B. Aceessory-driven gear 2 (foldout 7,B) is en- gine-driven through accessory drive gear 19 (foldout 7,4) at one of two customer-selected ratios—1 to 1 or 0.91 to 1. Regardless of the range selector position, the shaft rotation is clockwise as viewed from the rear. Adapter drive coupling 18 (foldout 18,A) may be used to accommodate a Brsize spline to the C-size splines in gear 2 (foldout 7,B). b, Accessory Drive Fad. A two-bolt, SAE size A pad IS located at the upper right rear face of the transmission housing. The drive at the pad is provided by accessory drive gear 1 (foldout 7,B) and drive shaft 8, which rotate at a 1 tol or 0.91 to 1 ratio. Shaft 8 provides either a size A or size B internal spline at its rear end. Regardless of the range selector position, the shaft rotation is clockwise as viewed from the rear. If no requirement exists for a PTO at this loca~ tion, the drive gear, shaft, and related parts are omitted, the opening closed by cup plug 12 (foldout 8,B), and the ofl passage closed by ‘cup plug 10. Copyright 1984 General Motors Corp. a1TT, TTB, TRT 2001 SERIES TRANSMISSIONS TABLE 2-1. Model Differences TRANSMISSION TT 2221-1 TRT 2221-1 TRT 2211-3 MODELS TTB 2221-1 TRT 2221-3 TRT 2411-3 TT 2421-1 TRT 2421-1 TTB 2421-1 ‘TRT 2421-3, POLD- FOLD- our FOLDOUT our T 2T3]4 3 CLUTCHES Reverse 17 | Reverse [39 [36/37] Reverse 5 Low (forward) | 19 | Forward |38|33|34 | Forward 23 High 24 | Low 21 |20 |i9 Internal High 23 |18 fo brake (TTB) | 60 FOLD-| FOLD- our FOLDOUT, our T 2[3[q 3 PLANETARIES | Reverse 18 | Reverse [15 {14]T5 | Reverse IT Low (forward) | 21 | Forward {18 {29/32 | Forward 22 High (over- drive) |28|—] 29 Low (under drive) 26|— Clutehes Clutehes Cluteh | Applied A Hle |R H | |e [R FIR 1]o|E 1 Jo jo |E ole G]R|V IG |w IR |v R|v HIWIE H| [wfe wie AIR AR AIR R|s R|s R|s DIE D JE DE RANGES. Reverse KX | Reverse-2 |X E] Reverse Neutral |—|—|— | Reverse-1 | |x] |X| Neutral | —|— Forward-1 | |X Neutral x Forward | X Porward-2 | x Forward-1 | |X |x Porward-2 |x| |X HYDRAULIC | Para. 2-8, Para. 2-8 Para, 2-8, SYSTEMS. 2-9, and 2-10 2-9, and 2-11 2-9, and 2-12 TORQUE Para, 2-13, Para. 2-13, Para, 2-13, PATHS 2-14, and 2-15 2-14, and 2-16 2-14, and 2-19 through 2-18 22 Copyright 1984 General Motors Corp.DESCRIPTION AND OPERATION 2-5. OIL PUMP Oil pump assembly 2 (foldout 18,A) con sists mainly of two spur gears 5 and 7, body assembly 9, and ¢ overt 3. The oil pump assembly furnishes the entire oil flow and pressure for all transmission operations (ex- cept brake apply pressure on TTB models). ‘The pump is driven by accessory drive gear 19 (foldout 7,A) and rotates any time the en- gine output shaft rotates. The transmission oil is drawn, through oil strainer 22 (foldout 8,B), into the lower end of suction tube 2 which directs it to the pump assembly. The oil is then directed, under pressure, through passages in the transmission housing to the control valve assembly and other locations for lubrication and cooling. 2-6, & Brake Components. The brake con- sists’ miaily oF hub T3 (oldout 15,0), tive in- ternal-splined plates 15, six external-tanged plates 14, diaphragm assembly 2, apply plate assembly 20, three pistons 26, and cover as- sembly 37. Th e hub of high-range cluteh piston housing 22 or 35 (foldout 15,A) is ex- tended to receive brake hub 13 (foldout 15,B). Diaphragm assembly 2 and cover 38 are mounted on the rear of t he transmission, ‘These parts house the brake assembly. INTERNAL BRAKE (TTB MODELS) b. Brake Operation (1) When the vehicle hydraulic brake master cylinder is actuated, Drak e fluid pushes three pistons 26 (foldout 15,B) for- ward. The pistons push apply plate 23 for- ward, compressing brake plates 14 and 15 against diaphragm 4. (2) Internal-splined plates 15 are com- pressed between external-tanged plates 14. Rotation of plates 14 is prevented by anchor pins 6. Plates 15 are slowed or stopped by friction against stationary plates 14. (3) Adjusting ring 21 has two fune- tions. It continually adjusts the brake to a predetermined clearance, and it controls the flow of brake coolant. ‘The ring is attached to apply plate 23 by six spring pins 22. Rings 21 can move lengthwise on the pins when suf- ficient force is applied. Ring 21 can move a predetermined distance forward and rearward on the inner hub of cover 38, It is restrained from further forward movement by snapring 19. (4) When the brake is released, springs 11 push apply plate 23 rearward. Plate 23 carries ring 21 rearward until it bottoms on the flat face of the inner hub of cover 38 At this point, the ring and apply plate stop, because springs 11 do not have sufficient force to move pins 22 in ring 21. Also, in this position, ring 21 closes @ large opening through which cooling ofl (returning from the oil filter) is supplied. A small hole in ring 21 continues to supply sufficient oil for lubrication while the brake is released. (5) When the brake is applied, plate 23 and ring 21 move forward together. ‘The brake applies when plate 23 compresses the brake plates. Ring 21, in the forward posi- tion, uncovers the large oil passage and the brake is flooded with coolant. If there is excess clearance in the brake plate pack (due to weat), ring 21 is stopped by snapring 19 while plate 23 continues to move forward to apply the brake. Pins 22 are pushed forward through the pin holes in ring 21 the distance plate 23 moves in excess of ring 21 move~ ment. This is the automatic adjustment ac~ tion. (6) When released, plate 23 and ring 21 move rearward until ring 21 is stopped by the face of the cover inner hub. Thus, brake plate clearance is continually maintained at a dimension equal to the movement permitted the adjusting ring in its travel from the cover inner hub face to snapring 19. 2-1. PARKING BRAKE An expanding shoe-type brake may be mounted at the lower-rear output location on the transmission housing. Brake backplate 2, 8, or 13 (foldout 17,B) is bolted to the trans- mission housing, a nd brake drum 9 or 18 is bolted to a customer-selected output flange. ‘The brake is manually operated. Copyright 1984 General Motors Corp. 2-3‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS 2-8 CONTROL VALVE BODY ASSEMBLY & Control Valve Body (foldout 18,B). The ce ontrol valve body contains a manually operated range selector valve 29 for reverse, neutral, low-, or high-range operation, plus main-pressure regulator valve 8, and either cluteh cutoff v al v e 20 or inching control valve 42. b. Main-Pressure Regulator, Selector Valves (otdout 165) (1) Main-pressure regulator valve components and trimmer valve components are contained in the upper bore of the body; clutch cutoff valve (or inching control valve) components in the middle bore; and the se- lector valve components in the lower bore. ‘The main-pressure regulator valve group in- cludes items 6, 7, 8, 13, and 14. The selector valve group contains items 26 through 35. (2) Main-pressure regulator valve 8 is spring loaded and regulates the pressure for all hydraulic functions except brake apply pressure for TTB models, The selector valve is @ spool-type valve which is manually moved lengthwise to the various range posi- tions. Spring-loaded detent balls 30 position the valve in each range. Clutch Cutoff Valve (foldout 18,B) (1) Cluteh cutoff valve 20 is located between the main-pressure regulator valve an selector valve 29, It is a spool-type valve which is moved rearward by spring 19 force and forward by plug 21 when brake hy- draulic pressure acts on the plug. ___ (2) If the valve is actuated by brake air pressure, a miniature air cylinder is mounted at the rear of the valve body. A stem of the air cylinder moves plug 49 for- ward within retainer plug 50. (3) During normal operation, valve 20 is rearward. ‘This allows main pressure to flow to the selector valve and trimmer plug 16. When vehicle brakes (hydraulic or air) are applied, valve 20 moves against spring 19. This interrupts the flow of main pressure to the selector valve and exhausts clutch apply pressure, releasing the applied clutch, d. Inching Control Valve (foldout 18,B) CAUTION Do not use the inching control while operating in high range. No provision is made for lubri- cating and cooling the high- range cluteh during inching operation. Q) Inching control valve 42 replaces the cluten cutoff valve in the valve body when this feature is used, This is a spool type valve that is manually controlled by the vehicle operator through mechanical linkage attached to one end of the valve. Pressure from spring 41 and main oil pressure hold the valve in the CLUTCH-ON (non-inching) posi- tion. In the CLUTCH-ON position, full main oil pressure is directed to the range selector valve. (2) When the inching control is moved, main pressure applying the driving clutch is bled off through an oil passage to the driving cluteh plate area. This reduces main pressure available to apply the clutch, allowing it to slip. At the same time, the oil being bled off cools and lubricates the slip~ ping clutch. The degree of inching valve movement determines the degree of slippage, from full apply to full release. Inching reg- ulator valve 39 and spring 38 maintain a uniform clutch apply pressure at any given position of the inehing valve. 2-9. HYDRAULIC SYSTEM—ALL MODELS 8 System Functions, The _ hydraulic system generates, directs, and controls the pressure and flow of the hydraulic fluid within the transmission. The hydraulic fluid is the power-transmitting medium in the torque converter. Its flow lubricates and cools the transmission components, its pres~ sure applies the clutches, and its velocity drives the converter turbines. b. System Schematies (f i g. 2-1 through 2-11), ‘Color-coded schematics are presented which illustrate the hydraulic systems of the models covered by this manual. 4 Copyright 1984 General Motors Corp.DESCRIPTION AND OPERATION 2-10, HYDRAULIC SYSTEM--TT, TTB MODELS (fig. 2-1, 2-2, and 2-3) & Oil Pump, Filter Circuit () TT _models (fig. 2-1, 2-2). Oil is drawn from the transmission sump, through a wire-mesh strainer, into the oil pump. The pump delivers its entire output to a full-flow oil filter which is customer-supplied. ‘The oil filter is mounted external from the transmis- sion, From the filter, the entire oil supply is returned to t he transmission and control valve assembly. (2) TTB models (fig. 2-3). The oil pump and filter circuit is the same as that described for the TT models, except an addi- tional cireuit is required for cooling and lubri- cation of the brake components. This circuit is external and extends from the oil filter re- turn circuit to the tapped b o s s in the rear cover. b. Main-Pressure Regulator Valve, (1). At the control valve assembly, oil fro m the oil filter (red) enters the valve body, and flows around the main-pressure regulator valve. The oil also flows through a Giagonal passage (orifice A) to the left end of the valve, ‘The resultant pressure at the left end of the valve pushes the valve rightward against @ spring until the oil pressure is bal- anced by spring force. (2) The rightward movement of the valve against the spring exposes the port to the converter-in circuit (yellow). Oil in ex- cess of that required to maintain main pres- sure is allowed to escape into the converter in cireuit. Under certain conditions, the con- verter-in circuit ean be charged with more oil than can be exhausted by the converter pressure regulator valve, When this is the ease, the main-pressure regulator valve moves farther to the right and allows oil to flow directly into the exhaust port (blue) at the left end of the valve. This flow occurs between the two short lands at the left end of the regulator valve. (3) Oil flowing into the converter-in (yellow) circuit is directed to the torque con- verter. A pressure regulator valve in the cir- cuit limits eonverter-in pressure to 80 psi (552 kPa). ¢, Torque Converter, ‘The torque con- verter is continuously filled with oll. during transmission operation. Rotation of the converter pump imparts energy to the oil whieh, in turn, drives the turbines. The oil then flows between the stator vanes which redireet it to the pump. Converter-Out, Cooler, Lubrication Circuit NOTE On TTB models, an additional circuit is required to cool and lubricate the brake components. (Refer to para 2-10i,) (1) Oil flowing out of the torque con- verter (orange) is directed into the oil cooler. The oil cooler, like the oil filter, is customer supplied and vehicle mounted. ‘The oi) cooler is @ heat exchanger in which the oil flows through water- or air-cooled passages. (2) On transmissions equipped with a thermostat, a bypass tube provides adequate lubrication’ when the thermostat is closed. The bypass tube permits a constant low-vol- ume flow from the converter-out cireuit to the lubrication circuit. When the oil is warm, the thermostat opens and permits converter out oil to flow through the cooler. (3) From the cooler, oil flows to the lubrication circuit (green) for distribution to the transmission components. All oil in ex- cess of that required to maintain lubrication pressure is exhausted to sump (blue) through the lubrication regulator valve. Cluteh Cutoff Valve Cireuit ig. 2-1, 2-3) (1) Main pressure oil (red), supplied from the left end of the main-pressure reg- ulator valve, flows through orifice B to the cluteh cutoff valve bore and then to the man- ual seleetor valve. From the selector valve the flow is directed back through the clutch cutoff valve bore to the trimmer. The ori- fice funetions in connection with the trim- mer. (Refer to para 2-10h.) Copyright 1984 General Motors Corp. 25TT, TTB, TRT 2001 SERIES TRANSMISSIONS \wanicarow converter ressune \LUBRICK ow codten REGULATOR VALVE (tyes FROM OW FILTER ‘Maln-PRESSURE REGULATOR VALVE: ORIFICE A Mann PRESSURE (HECK POINT oH CLUTCH oRtFCe 1 PUMP Tren raed ontrice Lt cuutex [Link] (AiR OF HYDRAULIC) crew | cuuten 1 | | Pstanat SIGNAL Jam Fire | TAP TAP aNuAL sevecTdR vaWE TO REvERse saNGE cu” To WiGH RANGE (2) CLUTCH: am sue WB ain pressure Pig. 2-1. PY 2221-1, TT 2421-1 hydr (2) The eluteh cutoff valve is normal- ly in t h e position shown and functions only when the vehicle brakes are applied. A 2-6 7 convertenw WH converren-our TO LOW RANGE (Fi) CLUTON: {ANDIGATES EXHAUST TO SUMP WE BAIcaTION -aulie system with clutch eutoff control spring holds the valve rightward, allowing main oil pressure to flow through the valve bore to the manual selector valve and trim- mer. Copyright 1984 General Motors Corp.DESCRIPTION AND OPERATION ‘CONVERTER-OUT ox-coneh : won 3 ae 3] || comenensnessine 2] || conemenes curren coout mamonessune | EGULATOR VALVE 7 reso awe feat ramen us \, TANNER, a oneice D over VALVE onraces IIL wc como tt — i vamonesune cxuron ote cauroxccoust |Lan Sens LL e ome reuuon || aaa secon Lge euros Sha ae = som mm vam pressure 1 cowvertensn ‘me convenreR-our TOO RANGE CUTER —| a cuuro omc ACUTE NDIGATES EXHAUST TO SUMP = wenicaron Fig. 2-2. TY 2221-1, TT 2421-1 hydraulic system with inching control (3) When the vehicle has hydraulic brakes, hydraulic brake pressure aets directly against a plug which moves the eluteh cutoff valve leftward during br a k e application. When the vehicle is equipped with air brakes, air brake pressure actuates a miniature air cylinder. The air cylinder piston rod pushes Copyright 1984 Gener the clutch cutoff valve leftward. When left- ward against its spring, t he clutch cutoff valve interrupts the flow of main pressure oil to the manual selector valve. In this posi- tion, the oil in t he trimmer circuit is re~ tained, and the charged clutch is allowed to exhaust to sum p (blue) through the port “al Motors Corp. aTT, TTB, TRT 2001 SERIES TRANSMISSIONS STRAINER nom oraxe Masten CYLINDER) FROM OIC TILTER An PRESSURE REGULATOR YALE once a UERICATION aman ou ecuuaron /T™MMER BUG CLUTCH CUTOFE 7) von oRAuLC) Mann pRessunE HECK POIKT citer || crew signal | Epsionat mo 10? oH cute ORIFICE "To REVERS RANGE ( CLUTOW TO OW RANGE TF) CLUTCH TORIGH RANGE Fa CuuTOR™ X- INDICATES EXHAUST 0 SUMP masuNe (converter A LUBRICATION Mmusn pressure WE ConventeR-out Fig. 2-3. TTB 2221-1, TTB 2421-1 hydraulic system with clutch cutoff control shown at the top-center of the valve. Thus, (4) When the brake is released, the when the vehicle brake is applied, the driving clutch cutoff valve returns to its normal cluteh is released. position (as shown). This allows the oil re- 28 Copyright 1984 General Motors Corp.DESCRIPTION AND OPERATION tained at the trimmer to enter the exhausted clutch cireuit. This additional volume from the trimmer assists in the quick application of the eluteh, Inching Control Valve Circuit (fig. 2-2) (1) Main pressure (red) from the main= pressure regulator connects to t he inching control valve at two points. One is at orifice B directly below t he regulator valve. The other is through a line running toward the right end of the inching control valve. Pres- sure at the left passes on to the manual se- lector valve. Pressure at the right helps re- tract the valve against its tendency to move rightward because of main pressure at the inching regulator valve. A spring keeps the valve retracted when the engine is stopped. (2) Main pressure at the left pushes the inching regulator valve rightward against a spring which seats in the left end of the in- ching control valve. When the inching con- trol valve is released (retracted), main pres- sure and spring force at its right end are suf~ ficient to hold it leftward. This exerts suffi- cient pressure on the regulator spring to hold the inching regulator valve leftward far enough to prevent oil escaping to the clutch coolant passage. Thus, main pressure is re~ tained at the left end of the inching regulator valve. (3) When the inching control is ac tuated, the valve is pulled rightward (ex- tended). ‘This reduces the force of the spring acting against the inching regulator valve, permitting the valve to move rightward. ‘This uneovers @ port which directs cooling oil to the cluteh whieh slips or releases during in- ching. The amount of oil which goes to the slipping clutch depends upon the degree of movement of the inching control valve. ‘The escape of oil into the clutch coolant line reduces main pressure, which causes the driving clutch to slip. Orifice B, directly below the main-pressure regulator valve, restricts the flow of oil and causes a lower pressure downstream from the orifice. (4 Pull rightward movement of the inching control valve will completely release the driving eluteh. Any degree of clutch en- gagement is possible by allowing the control to retract, & Manual Selector Valve Cireuit () Main-pressure oil from the clutch cutoff (or inching control) valve flows into ‘the manual selector valve bore and surrounds the valve in the area of the detent notches. Main oil then flows, regardless of valve posi- tion, to another surrounding area toward the right end of the valve. Here it is available for forward ranges and for operation of the trimmer. (2) Three clutch apply lines leave the bottom of the selector valve bore. From left to right these are reverse range, forward-2, and forward-l. In neutral all three cluteh lines are exhausted, and the neutral start switeh is actuated. Moving the selector valve one notch rightward will charge the forward (low-range) line and thus apply the cluteh. This condition provides low-range operation, A pressure tap, located on the control valve body, provides access to the apply pressure for actuating vehicle signals. (3) Moving the selector valve a sec- ond notch rightward will close off oil to the low-range line and allow it to exhaust. At the same time, oil will charge the forward-2 (high-range) line and thus apply the clutch. This condition provides high-range operation. When the selector valve is in the high-range position, oil to fill the high-range cluteh must pass through both orifice B and the high-range cluteh orifice. ‘The high-range elutch orifice being smaller t han orifice B restricts the volume of oil w hie hean flow through in a given time. As a result, the high-range cluteh fills at @ slower rate and thus provides smoother engagement. (4) Moving t he selector valve one notch leftward of neutral will charge the re- verse line and thus apply the clutch. This condition provides reverse operation. +h. Trimmer Cireuit Q) The trimmer cireuit works in con- junction w i t h orifice B and the high-range orifice. ‘The trimmer regulates clutch apply Copyright 1984 General Motors Corp. 29‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS, pressure during initial stages of clutch en- gagement, and the orifices provide a specific flow at a given pressure. ‘The combination of the trimmer an d orifices provide the final pressure and f10w pattern to engage the clutches in the desired manner. (2) Normally, full main pressure (red) holds the trimmer plug leftward against its spring and a shoulder in the valve body bore. This compresses the main-pressure regulator valve spring which causes main pressure to be regulated at maximum psi. (3) When any shift is made, oil is re~ quired to charge the oncoming eluteh, This ofl must flow through orifice B, direetly be- low the main-pressure regulator valve. The restriction of the oil flow through the orifice causes pressure below the orifice to be re~ duced. ‘This reduction in pressure allows the trimmer plug to move rightward. Force against the main-pressure regulator valve spring is reduced and main pressure is re~ duced. (4) When the cluteh being charged is full, flow through the orifice stops and pres- sure below t he orifice rises until it equals main pressure. ‘This increased pressure acts against t he right end of the trimmer plug, pushing t he trimmer plug leftward. ‘This ‘compresses the main-pressure regulator valve spring and raises main pressure. As main pressure rises, the trimmer plug moves far- ther leftward until, finally, main pressure is restored to maximum, (3) The check valve and orifice in parallel branches of the line connecting the selector valve bore to the trimmer plug bore ensure rapid movement of the trimmer plug toward the right (check valve opens) and slower return of the trimmer plug leftward (cheek valve closes, orifice restricts flow). Main pressure is rapidly reduced but slowly restored, Internal Brake Coolant Lubrication ireult Wig. 2= () Flow in this cireuit is controlled by movement of brake adjusting ring 21 (fold- out 15,B). When the brake is applied, the ad~ justing ring moves forward and uncovers the large port, allowing cooling oil to flood the cavity and cool the brake plates. (2) When the brake is released, the adjusting ring returns to its seat in the rear cover, closing the large port and stopping the flow of cooling oi However, a small orifice in the adjusting ring allows oil to bleed into the cavity to provide sufficient lubrication of the released brake components. 211, HYDRAULIC SYSTEM—-TRT 2221 AND TRT 2421 MODELS (fig. 2-4 through 2-9) a, Oil P um p, Filter Circuit, paragraph 10g b. Main-Pressure Regulator Valve, Con- verden-in Cireuit- Refer to paragraph E103. ¢. Torque Converter. Refer to paragraph 2-10. Refer to d. Converter-out, Cooler, Lubrication Cireuit Refer to paragraph 2-100, & Clutch Cutoff Valve Cireuit (fig. 2-4, 2-6, 2-8). Refer to paragraph 2-10e. f, Inching Control Valve Cireuit (fig. 2-5, 2-1, 2-9), Refer to paragraph 2-10f, Not ali -3 underdrive models (fig. 2-6) use the low- range eluteh for inching. Some use the for- ward or reverse clutch as the slipping clutch. When one of these clutehes is used, the cluteh coolant cireuit directs the coolant to the slipping cluteh. g+ Manual Selector Valve Cireuit (1) Main-pressure oil from orifice B flows into the manual selector valve bore and surrounds the valve in the area of the detent notches. From this area, main oil flows, re~ gardless of valve position, to another area at the right surrounding the valve. He re it is available for high range and forward clutehes and for operation of the trimmer. (2) Four cluteh-apply lines leave the bottom of the selector valve bore. From left Copyright 1984 General Motors Corp.DESCRIPTION AND OPERATION = ee i - | ; —_ | Nae to | corse] cme cri va lf] Fig. 2-4. TRT 2221-1, TRT 2421-1 hydraulic system with eluteh cutoff control to right these are reverse, low range, high range, and forward. In neutral, the low range clutch is applied, and the remaining three are exhausted. Moving t he selector valve one noteh rightward will leave the low-range cluteh applied a n d will charge the forward cluteh, This is forward-1. (3) Moving the selector valve a sec- ond notch rightward will close off oil to the low-range clutch and allow it to exhaust. The forward clutch will remain applied and the high-range clutch will be charged. This is forward-2. Copyright 1984 General Motors Comp. (4) Moving t he selector valve one notch leftward of neutral will charge the re~ verse clutch while allowing t he low-range cluteh to remain charged. This is reverse-1. If the vehicle is equipped w it h a reverse warning signal, clutch apply pressure in the reverse circuit actuates the warning device. (5) Moving the valve a second notch leftward will close off oil to the low-range cluteh and allow it to exhaust. The reverse cluteh will remain applied and the high-range cluteh will be charged. This is reverse-2.TT, TTB, TRT 2001 SERIES TRANSMISSIONS eve oe | ee ne = sme san mesure conan [] convermour ff wanewon J towesnce cure Pig. 2-8. TRT 2221-1, TRT 2421-1 (6) When the selector valve is moved to the high-range position (either F2 or R2), oil to f 111 the high-range clutch must pass through b 0 t h orifice B and the high-range clutch orifice. ‘This is due to the oil passage immediately to the right of the high-range clutch orifice being blocked by the manual selector valve. ‘The high-range clutch orifice is smaller th an orifice B and restricts the flow of oil to the high range clutch. As a re- sult, the high-range eluteh fills at a slower rate than other clutehes and thus provides smoother engagement. ‘Trimmer Circuit, Refer to paragraph bh 2-10h 242 Copyright 1984 G hydraulic system with inching control 2-12, HYDRAULIC SYSTEM—TRT 2211 AND TRT 2411 MODELS (fig. 2-10, 2-1) Refer to a. Oil Pu mp, Filter Circuit. paragraph 10a 2-108 ()- b. Main-Pressure Regulator Valve, Con- verter-in Circuit. Refer to paragraph 6-10b. c. Torque Converter. Refer to paragraph 6-102. ce Lubrication fonverter-out, Cooler, Refer to paragraph 2-10d. jeneral Motors Corp.DESCRIPTION AND OPERATION tai ace) Io ssea at pane sateon oll conor] Fig. 2- . TRT 2221-3, TRT 2421-3 hydraulic system for underdrive model with clutch cutoff & Clutch Cutoff Valve Circuit (fig. 2- Refer to-paragraph 2-10e. Inching Control Valve Circuit (fig. 2- Refer to paragraph 210, g- Manual Selector Valve Cireuit ln. () Refer to paragraph 2-1ig for ex- planation of the manual selector valve cir cuit, but disregarding those explanations on the F2 or R2 driving mode. ‘The TRT 2211-3 and 2411-3 manual selector valve is re stricted to three positions, These are neu- Copyright 1984 General Motors Corp. tral, forward, and reverse. Accordingly, only two cluteh-apply lines lead from the bottom of the selector valve bore. The left-side line goes to the reverse clutch. The right-side line goes to the forward clutch. Movement of the selector valve one notch leftward charges the reverse cluteh, In neutral, both clutches are exhausted. Movement one noteh to the right charges the forward cluteh and exhausts reverse. Two valve stops limit the travel of the manual selector valve to these three positions. h, Trimmer Cireuit. Refer to paragraph 21h.‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS = as eee € } al Ser ca cw chot_ SP amentenmessure “Mercrnorarcoaman tr ——— ~ aac) | (Parana raeeuon | L-Sein ‘REGULATOR ‘TO FORWARO——+| iow a _ on aaa cust tt vay enn t ‘ae | connie Lito on LJ vee Fs scon nie Tit, [b-aceas anne TO REVERSE CLUTCH sow MM wanonessune converters conesneecr Hl woes east 0 sue wwoncaron fl] .owsmce cures] Fig. 2-1, TRT 2221-3, TRT 2421-3 hydraulic system for underdrive ‘model with inching control 2-13, TRANSMISSION TORQUE PATHS 8 Component Functions. The torque converter, driven by the engine, directs torque through the first and/or second tur- bine to the second-turbine driven gear shaft. The shaft, splined to the forward-and-reverse sun gear, drives the range planetaries and the high-range clutch hub. Hydraulic-actuated clutches, when applied, cause reactions with- in the involved range components. The inter- action within the planetaries or application 2-14 of the high-range clutch determines the gear ratio and direction of torque imparted to transfer gears. Thus, the torque path changes for each operating condition. ‘Therefore, a knowledge of how these components direct the power flow through the transmission is necessary for proper diagnosis of transmis- sion trouble, An understanding of the acces- sory gearing and converter-driven PTO is also helpful when the vehicle includes equipment driven by the transmission PTO components. Copyright 1984 General Motors Corp.DESCRIPTION AND OPERATION uo BR Poston tar = owen] cov mee cures] Fig. 2-8 TRT 2221-3, TRT 2421-3 hydraulic system for overdrive model with cluteh eutoff b. Cross-Section Mlustrations (1) Figure 2-12 is a cross-section view of the twin-turbine torque converter. Figures 2-13 through 2-25 illustrate the paths through which the power flows from the en- gine to the transmission outputs. (2) Because the driving turbine is automatically determined by the load and speed requirement imposed by the vehicle, the torque path through the converter is not Copyright 1984 General Motors Corp. necessarily confined to a specific operating range. Thus, both paths are shown—a dotted red line indicates the first-turbine torque path and a broken red line indicates the second-turbine torque path. Engagement of the range clutches is indicated by horizontal red bars across the clutch plates. (3) All individual conditions for each transmission a r e not illustrated. However, the red torque paths and explanations for ifie modes can be applied to otherTT, TTB, TRT 2001 SERIES TRANSMISSIONS oupour on saan Fl q sway ee convees ou Pies Cowvenrcni| “i re | Wel | wg on. coo TW amrentenressune . ae FRE lsmcanoy nutaton SYPASS TU REGULATOR VALE now fe cwutoscoouanr—J ao. oessune om ecinavon ‘ag oroenso uta MER PLUG am ute Tare onic L HECK VALE ai cute x orice a wr aura ; 1 crs conrao. an ossune pane cieon Pot CubtoH on | ncn esuLeTonvauve s-ManUAL seLecToR i F—nevense wannns ubhle StGNAL TAP weuranesir Metis ‘SHH PG Sa TO REVERSE CLE X INDICATES EXIAUST 0 SUMP sun MM] wan eressure J comverreran [] comentencur i} wenicancw J] Low-rance cuurow 7] Fig. 2-9, TRT 2221-3, TRT 2421-3 hydraulic system for overdrive model with inching control nodels. This will be done by referring, in ome instances, to text and illustrations for one model when explaining another model. & Torque Converter, Freewheel Cluteh may oe Q) Power is transmitted from the sngine to torque converter pump assembly 6 vy either a flex disk drive or an input flange. trom the pump, power must be transmitted 16 hydraulically to either first-turbine assembly 3 or second-turbine assembly 4, or to both under certain operating conditions. (2) Speed and load determine wheth- er the torque flows through the first- and second-turbine assemblies 3 and 4, or only through second-turbine assembly 4. At high- load demand and low speed, freewheel clutch 12 is engaged and first-turbine assembly 3 acts as t he driving member. As speed in- Copyright 1984 General Motors Corp.DESCRIPTION AND OPERATION yee [OOD mo ry Ee eH vases ie = a ORIFICE 8 ae rseereeae mer re eet Te anc Lid aoa FTO FORWARD Dae ‘HIGH CLUTCH ORLFLCE XeINDICATES. EXHAUST TO SUMP coe sn ccf cover) cowerencnll socal Fig. 2-10. TRT 2211-3, TRT 2411-3 hydraulic system with clutch cutoff control creases and load demand decreases, free- wheel clutch 12 disengages and second-tur- bine assembly 4 becomes the primary driving member. Thus, first-turbine operation is re~ lated to higher torque, and second-turbine operation to higher speed. ‘The transition from the torque phase to the speed phase is entirely automatic, governed by the load and speed of the vehicle. Copyright 1984 General Motors Corp. 2-14, CONVERTER GEARING TO FORWARD-AND-REVERSE SUN GEAR—TORQUE PATH a, First Turbine (fig. 2-12). Torque from converter pump assembly 6 is transmitted hydraulically to first-turbine assembly 3. ‘The first turbine is splined to first-turbine drive gear 10 which meshes with first-tur- 2-17‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS Fig. 2-11, TRY 2211-3, TRT 2411-3 hydraulic system with inching control bine driven gear 11. The first-turbine driven gear is connected by freewheel clutch 12 to Second-turbine driven gear 14. The second- turbine driven gear is integral with range gear input shaft 13. ‘The forward-and-reverse sun gear is splined onto the shaft end. Thus, all these components rotate when the vehicle is man rressune I | i J cconvesreran| operating in a high-load, low-speed condi- tion. The hydraulic action in the converter and the intereonnection of the turbine-driven gears (first and second) permit the second turbine to assist the first until the freewheel cluteh disengages. Copyright 1984 General Motors Comp.DESCRIPTION AND OPERATION 1+ Input flange 2- First-turbine support bearing 3- First-turbine assembly 4- Second-turbine assembly 5- Stator 6- Converter pump assembly 7- Converter pump bearing 8 Transmission housing 9 Oil pump and engine~ ‘driven PTO 10- First-turbine drive gear 11- Pirst-turbine driven gear 12- Freewheel eluteh 13- Range gear input shaft 14 Second-turbine driven gear 15- Seeond-turbine drive gear 16- Input accessory drive gear 17- Torque converter housing 18- Converter drive cover 19+ Transmission front cover 20- Secon¢-turbine support bearing 21- Converter front support bearing Fig. 2-12. Typical twin-turbine térque converter and converter gearing b, Second Turbine (fig. 2-12). When the output speed of the converter increases, the load is assumed by second-turbine assembly 4, and when it attains sufficient speed, free- wheel clutch 12 will disengage. This allows first-turbine assembly 3 to rotate freely, and no drive is contributed by the first turbine. Second-turbine assembly 4 is splined to the hollow shaft of second-turbine drive gear 15. ‘The drive gear meshes with second-turbine criven gear 14 (integral with range gear input shaft 13) which is splined with the forward- Copyright 1984 General Motors Corp. and-reverse sun gear. Thus, all these com- ponents rotate when the vehicle is operating in @ low-load, high-speed condition. 2-15, TT, TTB 2221-1, 2421-1 TORQUE PATHS a, Neutral and Power Takeoff (fig. 2-13) (1) When the range selector is in neu- tral position, power is transmitted through‘TT, TTB, TRT 200] SERIES TRANSMISSIONS SECOND TURBINE ORIVEN GEAR \ i FIRST-TURBINE DRIVEN EAR ENGINE-DRIVEN PTO REVERSE ‘cure Forwaro (.ow-rance) cuuror 3 HIGH-RANGE - cuuToH SERVICE = BRAKE (one RIVEN PTO LOW-RANGE PLINETARY REVERSE AND LOW-RANGE SUN GEAR REVERSE-RANGE PLANETARY ‘oRQUE Pari vm THROUGH FIRST TURBINE ToROUE PATH em THROUGH SECOND TURBINE —— tor0ue pate Fig. the torque converter to the forward-and- reverse sun gear as described in paragraph 2- 14, No range clutches are engaged. ‘Thus, rotation of the sun gear causes the planetary pinions to rotate freely, and no power flow oceurs in the range gearing. However, on models equipped with a converter-driven PTO, rotation of the sun gear drives the PTO shaft any time the turbines are rotating. (2) Torque from the engine flows through the torque converter pump to the in~ 2-20 1-13. Neutral torque path (TTB 2221-1, TTB 2421-1 with converter-driven PTO) put accessory drive gear. Rotation of the in- put accessory drive gear drives the engine- driven PTO through the accessory driven gear. If the transmission is equipped with an imple ment pump drive, rotation of the input ac- cessory drive gear also drives the accessory drive gear and shaft assembly. The gearing for the implement pump drive is located di- rectly behind (relative to illustration) the engine-driven PTO gearing. Copyright 1984 General Motors Corp.DESCRIPTION AND OPERATION SECoND-TuRBINe? DRIVEN GEAR REVERSE” AND {LOW-RANGE SIN GEAR REVERSE-RANGE PLANETARY FARST-TURB INE DRIVEN GEAR ToRaUE PATH THROUGH FIRST TURBINE uxe TORQUE PATH = THROUGH SECOND TURBINE —— rer cve pa SS mor cute apruieo LOW-RANGE PLANETARY Fig. 2-14, Forward-1 (low-range) torque path (TT 2221-1, TT 2421-1 transmission) Forward-1 (low-range) (fig. 2-14) ()_ In forward-l (low-range) opera- tion, torque is transmitted through the torque converter to the forward-and-reverse sun gear in the same manner as described in paragraph 2-14. When the range selector is moved from neutral to low range (F1), the forward clutch engages and holds the forward ring gear sta~ tionary. (2) The rotating forward-and-re- verse sun gear drives the forward planetary pinions within the stationary ring gear. This causes the forward planetary carrier to ro- tate. The hub of the carrier is splined to the transfer drive gear. ‘The drive gear meshes with the driven gear which is splined to the output shaft. The manual-operated discon ect coupling, when moved forward, will in- terrupt the drive to the front output. Copyright 1984 General Motors Corp. 2-21TT, TTB, TRT 2001 SERIES TRANSMISSIONS ‘SeCOND-TURB NE DRIVEN GEAR REVERSE” AND {OW-RANGE SUN GEAR REVERSE-RANGE” PLANETARY FARST-TuRB NE DRIVEN GEAR ToRQUE PATH THROUGH FIRST TURBINE ToROUE PATH THROUGH SECOND TURBINE ToRQUe PATH RANGE CLUTCH APPLIED ENG NE-DRIVEN P10 FORWARD (LoW-RaNGe) cuurcn IGH-RANGE uur LOW-RANGE PLANETARY Fig. 2-15, Forward-2 (high-range) torque path (TT 2221-1, TT 2421-1 transmission) Forward-2 (high-range) (fig. 2-15) () In forward-2 (high-range) opera- tion, torque is transmitted through the torque converter to the forward-and-reverse sun gear in the same [Link] described in paragraph 2-14. When the range selector is moved from low range (F 1) to high range (F2), the forward (ow-range) clutch releases and the high-range cluteh engages. (2) The rotating forward-and-re~ verse sun gear drives the high-tange clutch hub which is bolted to the high-range clutch friction plates. Engagement of the high range eluteh locks the transfer drive gear to the rotating high-range clutch hub. The transfer drive gear meshes with the driven gear which is splined to the output shaft. The manual-operated disconnect coupling, when moved forward, will interrupt the drive to the front output. 2-22 Copyright 1984 General Motors Corp.DESCRIPTION AND OPERATION SECOND TURBINE DRIVEN GEAR OVERSE- AND LOW-RANGE SUN GEAR REVIRSE-RANGE PLANETARY FARST-TURBINE DRIVEN GEAR ‘oRQUe PATH THROUGH FIRST TURBINE ‘ToRQUE PATH THROUGH SECOND TURBINE ToRaUe PATH RANGE CLUTCH APPLIED FORWARD (voW-RaNce) LOW-RANGE: PLANETARY Pig. 2-16. Reverse-range torque path (TT 2221-1, TT 2421 transmission) Reverse Range (fig. 2-16) (1) _ In reverse-range operation, torque is transmitted through the torque converter to the forward-and-reverse sun gear in the same manner as described in paragraph 2-14, When the range selector is moved to reverse- range position, the forward-range clutehes (F1 and F2) are exhausted and the reverse- Tange clutch engages and holds the reverse- range planetary hub (and carrier) stationary. Copyright 1984 General Motors Corp. (2) The rotating forward-and-re~ verse sun gear drives the pinions which also are in mesh with the reverse-range ring gear. This causes the ring gear to rotate in a diree- tion opposite to t h a t of the sun gear. The ring gear is attached to the forward plane- tary carrier. Th us, the reverse torque is transmitted from the reverse-range ring gear through the forward planetary carrier to the transfer drive gear. The transfer drive gear meshes with the driven gear which in turn 2-23‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS TORQUE PATH CLUTCH APPLIED TORQUE PATH THROUGH FIRST TURBINE TORQUE PATH Ss THROUGH SECOND TURBINE LOW RANGE CLUTCH HIGH RANGE CLUTCH HIGH RANGE “PLANETARY Fig. 2-17. Neutral torque path (TRT 2221-1, TRT 2421-1 transmission) arives the transfer drive gear and output shaft in reverse, ‘The manual-operated dis- zonneet coupling, when moved forward, will interrupt the drive to the front output. 2-16, TRT 2221-1, 2421-1 TORQUE PATHS & Neutral and Power Takeoff (fig. 2-17) (1)_ When the range selector is in Neu tral position, power is transmitted through the torque converter to the forward-and-re~ verse sun gear as described in paragraph 2- 14. ‘The low-range cluteh is engaged but no torque is transmitted because neither the forward nor reverse cluteh is engaged. The reverse carrier and forward ring gear rotate freely. (2) Refer to paragraph 2-158 (2). 2-24 Copyright 1984 General Motors Corp.DESCRIPTION AND OPERATION PF ToRQUE PATH = cutee appiieo TOO" TORQUE PATH THROUGH FIRST TURBINE | THROUGH SECOND TURBINE REVERSE LOW RANGE CLUTCH FORWARD HIGH RANGE CLUTCH HIGH RANGE PLANETARY TORQUE PATH ee Fig. 2-18. Forward-1 torque path (TRT 2221-1, TRT 2421-1 transmission) be Forward (fig. 2-18) (1) When the range selector is in For ward-1 position, power is transmitted through the torque converter to the forward-and-re- verse sun gear as described in paragraph 2-14, (2) The low-range clutch remains en- gaged, which holds the forward planetary ring gear stationary. (3) The forward planetary sun gear rotates the forward planetary pinions within Copyright 1984 General Motors Corp. the stationary ring gear. This causes the for- ward carrier to rotate in the same direction as the sun gear, but at a reduction in speed. The carrier drives a shaft, the rear end of which is splined to the high-range planetary cartier. (4) The high-range planetary sun gear is splined to a sleeve, which is splined to both the low-range eluteh drum and to the trans~ fer drive gear. The high-range ring gear is splined to t he low-range clutch internal- splined plates. ‘The low-range clutch exter- 2-25‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS nal-splined plates engage internal splines in the low-range eluteh drum. (5) Thus, when the forward planetary carrier rotates, the high-range planetary car- rier rotates, This causes both the high-range planetary sun gear and ring gear to rotate in the s a me direction and speed because the low-range clutch is engaged. There is no re~ lative movement of the sun and ring gears. (6) ‘The low-range clutch drum drives the splined sleeve which, in turn, drives the transfer drive geat. ‘The rotation of the transfer drive gear is opposite t ha t of the converter turbine, and at a reduced speed. ‘This results from the combination of the con- verter transfer gearing (which may be under- drive or overdrive), and the reduction ratio of the forward planetary. () The transfer drive gear rotates the driven gear and output shaft, and rotation is converted to that of the engine. The out- put shaft rotates at a speed greater than that of the transfer drive gear. Figure 2-18 illus- trates the one-piece output shaft, b u t some models include a manually operated front output disconnect which interrupts drive to the front output flange. Forward-2 (). Refer to foldout 2 while studying the explanation of Forward-2 operation. Refer to paragraph 2-14 for explanation of power flow from the engine to the transmis- sion gearing. (2). When the manual selector valve is shifted f r 0 m Forward-1 to Forward-2, the low-range clutch releases and the high-range clutch engages. The forward cluteh remains engaged, holding the forward planetary ring gear stationary. (3) ‘The forward planetary sun gear rotates the forward planetary pinions, and drive is transmitted to the high-range plane- tary carries, as deseribed in paragraph 2-16 (4) ‘The engaged high-range cluteh holds the high-range planetary ring gear ste- tionary. The rotation of the high-range car- 2-26 rier pinions within the stationary ring gear overdrives the high-range sun gear. The sun gear, splined to a sleeve which is splined also to the transfer drive gear, rotates the trans- fer drive gear. (3) Refer to paragraph 2-16 (7) for explanation of the remainder of the torque path, @. Revers (1) Refer to foldout 2 while studying the explanation of reverse-1 operation. Ref- er to paragraph 2-14 for explanation of power flow from the engine to the transmission gearing. (2) When the manual selector is shifted from Neutral to Reverse-1, the low- range clutch remains engaged while the re~ verse clutch also engages. ‘The reverse clutch, engaged, holds the reverse planetary carrier stationary. (3) The reverse planetary sun gear rotates the carrier pinions which, in turn, rotate the reverse ring gear in a direction opposite that of the sun gear. The ring gear, being connected by splines to the forward carrier, rotates the forward carrier. ‘The forward carrier drives a shaft, the rear end of which is splined to the high-range plane- tary carrier. (4) From this point, to the transmis sion output flanges, the flow of power is the $m e as deseribed in paragraph 2-16b (4) through (7) except that all rotations are re- versed. & Reverse-2 (fig. 2-19) ()_ Refer to paragraph 2-14 f 0 r ex- planation of power flow from the engine to ‘the transmission gearing. (2) When the manual selector valve is shifted f ro m Reverse-1 to Reverse-2, the low-range clutch releases, the high rang e clutch engages, and the reverse cluteh re~ mains engaged. The engaged high-range eluteh holds t he high-range planetary ring gear stationary. Copyright 1984 General Motors Corp.DESCRIPTION AND OPERATION ‘TORQUE PATit It CLUTCH APPLIED Tame ToRQUE PATH THROUGH FIRST TURBINE o-= ToRQUE PATH THROUGH SECOND TURBINE AGH RANGE PLANETARY Fig. 2-19, Reverse-2 torque path (TRT 2221-1, TRT 2421-1 transmission) (3) The reverse planetary sun gear rotates the carrier pinions in the stationary carrier. They, in turn, rotate the reverse ring gear, driving it in’a direction opposite that of the sun gear. ‘The ring gear, being connected by splines to the forward carrier assembly, rotates it. The forward carrier drives a shaft, the rear end of which is splined to the high-range planetary carrier. (4) The engaged high-range clutch holds t he high-range ring gear stationary. The rotation of the high-range planetary car- rier within t he stationary ring gear causes the carrier pinions to overdrive the sun gear. ‘The sun g ear, splined to a sleeve which is Copyright 1984 General Motors Corp. splined also to the transfer drive gear, rotates the transfer drive gear. (5) Refer to paragraph 2-16b (7) for explanation of the remainder of the torque path. 2-17, TRT 2221-3, 2421-3 (underdrive model) TORQUE PATHS Neutral (1) Refer to foldout 3 while studying the explanation of operation in neutral. Ref- er to paragraph 2-14 for explanation of power 2-27TT, TTB, TRT 2001 SERIES TRANSMISSIONS flow from the engine to the transmission gearing. (2) In neutral, power is not trans~ mitted beyond the forward-and-reverse sun gear. The low-range clutch is engaged but no torque is transmitted because neither the for- ward nor reverse clutch is engaged. ‘The re- verse carrier and forward ring gear rotate freely. (3) Refer to paragraph 2-15a (2) and figure 2-16 f or explanation of t he power takeoff torque path. ‘b. Porward-1 ()_ Refer to foldout 3 while studying t he explanation of operation in forward-1. Refer to paragraph 2-14 f or explanation of power flow from the engine to the transmis- sion gearing. (2) When the manual selector valve is shifted from Neutral to Forwaré-1, the low- range cluteh remains engaged while the for- 2-28 ward elute h also engages. The forward eluteh, engaged, holds the forward planetary ring gear stationary. (3) The forward planetary sun gear rotates the forward planetary pinions within the stationary ring gear. This causes the for- ward carrier to rotate in the same direction as the sun gear, but at a reduetion in speed. ‘The carrier has an integral shaft, splined to the low-range planetary sun gear. (4) The low-range sun gear, rotating with the forward carrier rotates the low- range planetary pinions within the stationary low-range ring gear. This drives the low- range carrier in the same direction as its sun gear but at a reduction in speed. (5) The low-range carrier is splined to the transmission output shaft. The trans- mission output is driven in a direction oppo- site to that of the engine and at a reduction in speed. The speed reduction is the result of t he combination of the converter transfer gear, forward planetary, and low-range plan- etary ratios. Copyright 1984 General Motors Corp.DESCRIPTION AND OPERATION TORQUE PATH CLUTCH APPLIED + TORQUE PATH ‘THROUGH FIRST TURBINE TORQUE PATH ‘THROUGH SECOND TURBINE +5 rie|= oe tae eater Fig. 2-20. Forward-2 torque path (TRT 2221-3, TRT 2421-3 underdrive transmission) Porward-2 (fig. 2-20) (1) Refer to paragraph 2-14 f or ex- planation of power flow from th e engine to the transmission gearing. (2). When the manual selector valve is shifted f ro m Fotward-1 to Forward-2, the Jow-range cluteh releases and the high-range clutch engages. The forward clutch remains engaged. The high-range clutch, engaged, locks the high-range clutch drum to the low- range ring gear. (3) ‘The forward planetary sun gear rotates the forward planetary pinions within the stationary ring gear. This causes the for- ward cartier to rotate in the same direction as the sun gear but at a reduction in speed. ‘The carrier has an integral hollow shaft Copyright 1984 General Motors Corp. which is splined both to the high-range clutch drum and to the low-range planetary sun gear. (4) The high-range clutch drum and low-range planetary sun gear thus rotate to- gether, at the same speed. The high-range cluteh, engaged, drives the low-tange plane- tary ring gear at the same speed as that of the high-range cluteh drum and low-range sun gear. ‘The low-range sun and ring gears drive the low-range carrier and transmission output shaft at an equal speed. (5) Thus, the final transmission ratio in Forward-2 is an underdrive since the com- bined result of the ratios of the converter transfer gears, the forward planetary and a direct drive in the high-range cluteh gives an ‘overall reduction in speed. 2-29TT, TTB, TRT 2001 SERIES TRANSMISSIONS Dy FP ronve Pate CLUTCH APPLIED TORQUE PATH THROUGH FIRST TURBINE TORQUE PATH - THROUGH SECOND TURBINE cen REVERSE HIGH RANGE CLUTCH Co FORWARD Low RANGE CLUTCH SF oy Rance E PLANETARY Fig, 2-21. Reverse-1 torque path (TRT 2221-3, TRT 2421-3 underdrive transmission) Reverse-1 (fig. 2-21) (1) Refer to paragraph 2-14 f or ex- planation of power flow from the engine to the transmission gearing. (2) When the manual selector valve is shifted f r 0 m Forward-2 to Reverse-1, the forward and high-range clutches release, and the reverse and low-range clutehes engage. Engaged, the reverse cluteh holds the re- verse-range planetary carrier stationary, and the low-range cluteh holds the low-range ring gear stationary. (3). The reverse sun gear rotates the reverse planetary pinions in the stationary carrier. ‘The pinions drive the reverse plane tary ring gear in a direction opposite that of the sun gear. The reverse ring gear, splined to the forward carrier, drives the forward carrier in reverse. The forward carrier shaft, in turn, drives the low-range planetary sun gear in reverse, (4) The low-range sun gear rotates the low-range pinions within the stationary low-range ring gear. This causes t h e low- range planetary carrier and transmission out- put shaft to rotate. Th e rotation is in the same direction as that of the engine but at a reduetion in speed. The reduetion is the re- sult of the combination of the ratios of the converter transfer gears. The reverse plan~ etary (underdrive), and the low-range plane- tary (underdrive). @ Reverse-2 () Refer to foldout 3 while studying the power flow during operation in Reverse- 2 Refer to paragraph 2-14 for explanations of power flow from the engine to the trans- mission gearing. 2-30 Copyright 1984 General Motors Corp.DESCRIPTION AND OPERATION (2) When the manual selector valve is shifted f ro m Reverse-1 to Reverse-2, the low-range clutch releases, the high-range clutch engages, and the reverse cluteh re~ mains engaged. Th e high-range clutch, en- gaged, locks the high-tange clutch drum to the low-range planetary ring gear. (8) The reverse sun gear rotates the reverse planetary pinions in the stationary carrier. The pinions drive the reverse plane tary ring gear in a direction opposite that of the sun gear. The reverse ring gear, splined to the forward planetary carrier, drives the forward carrier in reverse. ‘The forward car- rier shaft, in t urn, drives the high-range eluteh drum (and low-range planetary ring gear) in reverse. (4) The high-tange clutch drum and low-range planetary sun gear thus rotate to- gether, at the same speed. The high-range clutch, engaged, drives the low-range plane tary ring gear at the same speed as that of the high-range clutch drum and low-range sun gear. The low-range sun and ring gears drive the low-range carrier and transmission output shaft at an equal speed. (5) Thus, the final transmission ratio in Reverse-2 is an underdrive, resulting from ‘the combined ratios of the converter transfer gears, the reverse planetary (underdrive), and that of the high-range clutch (direct drive). 2-18, TRT 2221-3, 2421-3 (overdrive model) TORQUE PATHS & Neutral (1) Refer to foldout 4 while studying the power flow during operation in neutral. Refer to paragraph 2-14 for explanation of power flow from the engine to the transmis- sion gearing. (2) Refer to paragraph 2-17a (2) and (3) for the remainder of the explanation of power flow in neutral Forward-l (fig. 2-22) (Q)_ Refer to paragraph 2-14 f or ex- planation of power flow from the engine to the transmission gearing. Copyright 1984 General Motors Corp. (2) When the manual selector valve is shifted from Neutral to Forward-1, the for- ward cluteh engages and the low-range cluteh remains engaged. The forward cluteh holds the forward planetary ring gear stationary, and the low-range clutch locks the low-range clutch drum to the low-range cluteh hub, which is splined to the transmission output shaft. (3) The forward planetary sun gear rotates the forward pinions within the sta~ tionary forward ring gear. ‘This causes the forward planetary carrier and its integral hollow shaft to rotate in the same direction as that of the sun gear, but at a reduction in speed. The carrier shaft is splined to the low-range clutch drum and rotates it and the high-range planetary carrier to which the drum is splined, (4) The low-range cluten, engaged, drive's the clutch hub. ‘The hub, in turn, Grives the transmission output shaft, to which it is splined. (5) The overall transmission ratio is an underdrive, resulting from the combined ratios of the converter transfer gears, the forward planetary, and the direct drive, low range clutch. Forward-2 () Refer to foldout 4 while studying power flow during operation in Forward-2. Refer to paragraph 2-14 for explanation of power flow from the engine to the transmis- sion gearing. (2) When the manual selector valve is shifted f ro m Forward-1 to Forward-2, the low-range clutch releases and the high-range clutch engages. The forward cluteh remains engaged. The high-range clutch, engaged, holds the high-range planetary ring gear sta~ tionary. (3) Refer to paragraph 2-18 (3) for explanation of the function of the forward planetary gearing. (4) ‘The high-range planetary carrier, splined to the low-range clutch drum rotates within the stationary high-range ring gear. 2-81‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS sTORQUE PATH IH ‘CLUTCH APPLIED =" TORQUE PATH THROUGH FIRST TURBINE — TORQUE PATH THROUGH SECOND TURBINE REVERSE FORYARD Low RANGE CLUTCH HIGH RANGE CLUTCH ; HUGH RANGE PLANETARY Fig. 2-22. Forward-1 torque path (TRT 2221-3, TRT 2421-3 overdrive transmission) This causes the pinions to rotate and over drive the high-range planetary sun gear, which is splined to the transmission output shaft. (5) The overall transmission g ear ratio in Forward-2 is an overdrive, This re~ sults from the combination of the ratios of the converter transfer gears, the forward planetary and the high-range planetary. a (1) Refer to foldout 4 while studying power flow during operetion in Reverse-l. Refer to paragraph 2-14 for explanation of Power flow from the engine to the transmis- sion gearing. (2) When the manual selector valve is shifted f ro m Neutral to Reverse-1, the re- verse clutch engages, and the low-range cluteh remains engaged. The reverse clutch, engaged, holds the reverse planetary carrier stationary. The low-tange cluteh, engaged, locks the low-range clutch drum to the low- range cluteh hub, and to the transmission output shaft whieh is splined to the hub. (3) The reverse planetary sun gear rotates the pinions in the stationary reverse carrier. The pinions rotate the reverse ring gear in a direction opposite that of the sun gear. The ring gear, being splined to the for- ward carrier, causes it to rotate. (4) ‘The forward carrier has an inte- gral hollow shaft, to which t he low-range elute drum is splined. ‘The low-range clutch drum is splined also to the high-range plane- tary carrier assembly. The low-range clutch, engaged, locks the cluteh drum and low-range elute h hub together. The eluteh hub is splined to the transmission output shaft. 2-32 Copyright 1984 General Motors Corp.DESCRIPTION AND OPERATION TORQUE PATH == cure appuie TORQUE PATH THROUGH FIRST TURBINE mae — TORQUE PATH THROUGH SECOND TURBINE HIGH RANGE PLANETARY Pig. 2-23. Reverse-2 torque path (TRT 2221-3, TRT 2421-3 overdrive transmission) ‘Thus, when the reverse planetary ring gear rotates, it drives, in succession, the forward carrier, low-range cluteh drum, low-range cluteh hub, and the transmission output shaft. (5) The overall transmission ratio is underdrive, resulting from a combination of the ratios of the converter transfer gears, the reverse planetary ratio, and the direct drive, low-range elute. Reverse-2 (fig. 2-23) (1) Refer to paragraph 2-14 f or ex- planation of power flow from the engine to the transmission gearing. (2) When the manual selector valve is shifted f ro m Reverse-1 to Reverse-2, the low-range cluteh releases, the high-range cluteh engages, and the reverse remains en- Copyright 1984 Geheral Motors Corp. gaged. ‘The high-range clutch, engaged, holds the high-range planetary ring gear stationary. (3) Refer to paragraph 2-184 (3) for explanation of the function of the reverse gearing. (4) The forward carrier has an inte- gral holiow shaft which is splined to the low- range cluteh drum. The low-range clutch drum, in turn, is splined to t he high-range planetary carrier. The high-range carrier, thus, rotates within the stationary high-range ring gear. Rotation of the high-tange plane- tary pinions causes t he m to overdrive the high-tange planetary sun gear, and the output shaft. (5) The overall transmission ratio is overdrive, resulting from the combination of the ratios of the converter transfer gears, re- verse planetary, and the overdrive high-range planetary. 2-33TT, TTB, TRT 2001 SERIES TRANSMISSIONS me TORQUE PATH CLUTCH aL = TORQUE PATH ‘THROUGH FIRST TURBINE = ToRQUE PATH ‘THROUGH SECOND TURBINE Fig. 2-24. Forward torque path (TRT 2211-3, TRT 2411-3 transmission) 2-19, TRT 2211-3, 2411-3 TORQUE PATHS Neutral (1) Refer to foldout 5 while studying the explanation of power flow in neutral. Refer to paragraph 2-14 for explanation of power flow from the engine to the transmis- sion gearing. (2) In neutral, no power is transmit ted beyond the forward-and-reverse planetary sun gear. Refer to paragraph 2-15 and figure 2-16 for explanation of t he power takeoff power flow. >, Forward (fig. 2-24) (1) Refer to paragraph 2-14 for expla nation of power flow from the engine to the transmission gearing. 2-34 (2) When the manual selector valve is shifted to Forward, th e forward clutch en- gages. The forward clutch, engaged, holds the forward planetary ring gear stationary. (3) The forward planetary sun gear rotates the forward pinions within the sta~ tionary ring gear. This causes the forward carrier to rotate in the same direction as that of the sun gear, but at a reduction in speed. The transmission output shaft, to which the output flange is splined, is integral with the forward carrier. (4) The transmission output thus ro- tates in @ direction opposite to that of the engine, at reduced speed, The reduction in speed is due to the combination of the ratio of the converter transfer gearing (which may be overdrive or underdrive) and that of the forward planetary. Copyright 1984 Genetal Motors Corp.DESCRIPTION AND OPERATION —e— ‘TORQUE PATH = icuuren aPeciéo ~ "ToRgue paTH ‘THROUGH FIRST TURBINE == Torque pata ‘THROUGH SECOND TURBINE Fig. 2-25. Reverse torque path (TRT 2211-3, TRT 2411-3 transmission) g Reverse (fig. 2-25) () Refer to paragraph 2-14 for ex- planation of power flow from the engine to the transmission gearing. (2) When the manual selector valve is shifted f r 0 m Forward to Reverse, the for- ward clutch releases and the reverse clutch engages. The reverse clutch, engaged, holds the reverse planetary carrier stationary. ight 1984 General Motors Corp. (8) The reverse planetary sun gear rotates the carrier pinions in the stationary carrier. This drives the ring gear in a direc tion opposite that of the sun gear. The ring gear, being splined to the forward carrier as~ sembly, rotates the forward carrier, its inte- gral output shaft and the output flange. (@ Rotation is in the same direction as the engine but at a reduction in speed. ‘The reduction in speed is due to the combina tion of t he ratio of the converter transfer gears and that of the reverse planetary. 2-35/2-36Section 3. PREVENTIVE MAINTENANCE 3-1. SCOPE This section outlines the routine and peri- odie procedures required to maintain the transmission in good operating condition. Included are instructions for care of the oil system, minor adjustments of the transmis~ sion and control linkages, tests to determine condition, instructions for extended storage, and troubleshooting information. 3-2, PERIODIC INSPECTIONS, CLEANING a Inspecting Exterior 1) The exterior of the transmission should be cleaned and inspected at regular intervals. The severity of service and oper- ating environment will determine the fre- queney of such procedures. (2) The transmission should be in- spected for loose or missing bolts, oil leaks, linkage damage, and worn or frayed oil lines. Oil leaks require immediate attention. Refer to paragraph 3-12. (3) Linkage must be clean, adjusted, and well lubricated. b. Cleaning Breather, The prevalence of dust and dirt will determine the frequency at whieh the breather requires cleaning. Clean the area around the breather stem before re- moving the breather. Wash the breather thoroughly by agitating it in mineral spirits or cleaning solvent. Dry it thoroughly with compressed air after cleaning. Always use a wreneh of the proper size to remove or re- place the breather. Pliers or a pipe wrench will rush or damage it and produce metal chips which could enter the transmission. 3-3. OIL CONTAMINATION & Examine at_Oil Change. At each oil change examine the of whieh is rained for evidence of dirt or water. A normal amount of condensation will emulsify in the oil during operation of the transmission, However, if there is evidence of water, check the cooler (heat exchanger) for leakage between the water and oil areas. Oil in the water side of the cooler (or vehicle radiator) is another sign of leakage. ‘This, however, may indicate leakage from the engine oil system. Any accumulation of sludge or soft dirt in the sump should be removed with flushing oil. b, Coolant Leakage. If engine coolant leaks into the transmission oil system, im- mediate action must be taken to prevent malfunetion and possible serious damage. Glycol solution will attack frietion-faced cluteh plates. The transmission must be completely disassembled, inspected, and cleaned. If glycol solution is present, all friction-faced clutch plates must be re- placed. All traces of the coolant and varnish deposits, resulting from coolant contamina- tion, must be removed. The cooler should be thoroughly cleaned or replaced prior to in- stallation of the new or rebuilt transmission. NOTE A Gly-Tek test kit to detect glycol in transmission oil can be obtained from Neleo Company, 1047 MeKnight Road South, St. Paul, Minnesota 55119. (Some transmission fluids may produce a positive reading due to "addi- tives" that are not actually glycol. When test results are Questionable, a test of an un- used sample of the oil type or brand should be made to con- firm test results.) ¢ Metal Particles, Metal particles in the’ oil (except for the minute particles nor- mally trapped in the oil filter) indicate dam- age has occurred in the transmission. When these particles are found in the sump or on the magnetic drain plug, the transmission must be disassembled and closely inspected to find the source. Metal contamination will require complete disassembly of the trans- mission and cleaning or replacement of all internal and external circuits, cooler, filter, Copyright 1984 General Motors Corp. 1TT, TTB, TRT 2001 SERIES TRANSMISSIONS and all other areas where the particles could lodge. @. Auxiliary Filter (1) After a transmission failure that introduces debris into the oil system, a com- plete clean-up of the oil cooler and lines is necessary. (2) Repeated cleaning and flushing may not remove all debris. To prevent a repeated failure, caused by eventual move- ment of trapped debris, installation of an auxiliary filter in the cooler-out line (be- tween cooler and transmission) is reeom- mended. This recommendation applies whether the failed transmission is overhauled or replaced by a new or rebuilt unit. (3) If any doubt exists about the clean-up of the oil cooler, replace the cooler. (4) When an auxiliary filter is placed in the cooler-out line, converter regulator valve spring P/N 6773551 must be replaced with spring P/N 6880795 on S/N's before 92911, (5) Refer to paragraph 6-8 for in- structions for removal and replacement of the converter regulator valve, spring, and pin. (6) The auxiliary filter should be an AC DM 13-5 P/N 5575224 or equivalent 40 micron filter. Pressure drop across the new filter can not exceed 5 psi (34 kPa) and the cooler cireuit pressure differential can not exceed 40 psi (276 kPa) at full throttle stall. (1) Auxiliary filter elements should be inspected for contamination after 500 and 1000 hours operation (depending on applic tion), and changed at regular filter change intervals thereafter. Pressure drop across a dirty filter in excess of 15 psi (103 kPa) will cause the filter bypass valve to open and dirty oil will contaminate the system. 3-4. CHECKING OIL LEVEL & Cold Cheek (using oil level ‘cheek plugs) (1) Two oil level check plugs are lo- cated at the lower-tight front on -1 models (fig. 1-1) and the lower-left rear on -3 models of the transmission housing. Before starting the engine, remove the upper (Full) plug. If oil flows from the plug opening, the hydraulic system has sufficient oil to permit starting the engine. If no oil flow is present, add suf- ficient oil to cause a flow from the opening, and replace the plug. (2) Start the engine and operate at 1000 to 1500 rpm with the transmission in neutral, Operate for approximately 2 min- utes. Then idle the engine and shift through all range positions slowly to charge the hy- draulie system. (3) While the engine is running, add oil as required to establish the oil level at the lower (Add) plug. ‘Then proceed with the hot cheek (para 3-41 NOTE An oil check made at a lower engine rpm may result in low oil level at operating speeds. ‘Thermal expansion will reise oil level when the transmission at tains operating temperature. b. Hot Cheek (using oil level eheck plugs) (1) Start the engine and operate the vehicle until the transmission reaches the op- erating temperature of 180-220°F (82-104°C). ‘Then idle the engine an d shift through all range positions slowly. This will ensure that 11 parts of the system are filled with oil. Shift to neutral and run the engine at approxi- mately 1200-1500 rpm. (2) Remove the upper (Full) oil level check plug. Oil should be at the level of the plug opening. Add or drain oil to bring it to this level. NOTE Foaming or spurting may indi- cate a false oil level. A true level is indicated by a steady trickle of ofl flowing from the check plug hole. ‘The transmis~ sion may be operated safely as long as the oil is ab ove the level of the 1 0 we r (Add) oil check plug. a2 Copyright 1984 General Motors Corp.PREVENTIVE MAINTENANCE & Cold Cheek (using dipstick) () If the transmission is equipped with an oil dipstick, check the oil level be- fore starting the engine. It is safe to start the engine if the oil is near or above the HOT (FULL) mark. If t he oil level is not within thi's range, add oil. (One quart equals ap- proximately 1/2-ineh (12.7 mm) change in oil level.) (2) Start the engine and let engine idle (500-750 rpm) with the transmission in neutral. Idle engine for approximately 2 minutes. Then shift through all range posi- tions slowly to fully charge the hydraulic system. (3) Add oil as required to establish the oil level at the COLD (ADD) mark. (One quart equals approximately 1/2-ineh (12.7 mm) change in oil level.) (4) ‘Then proceed with the hot cheek (para 3-4¢). ¢. Hot Cheek (using dipstick) (1) Start the engine and operate the vehicle until the transmission reaches an operating temperature of 180-220°F (82- 104°C), ‘Idle the engine and shift through all range positions slowly to fully charge the hydraulic system. With the engine at idle speed and transmission in neutral range, the oil level should be within the OPERATING RANGE and not exceed the HOT (PULL) mark. (2) If oil level is below the COLD (ADD) mark, add oil. (One quart equals ap- proximately 1/2-ineh (12.7 mm) change in oil level. 3-5. MAINTENANCE INTERVALS a. Frequency, The severity of service and the environment in which the transmis- sion operates will determine the frequency of some maintenance operations. Under very dusty or dirty operating conditions, the trans- mission oil should be changed more often. Oil should be changed immediately if it has been subjected to overheating. The breather will require more frequent cleaning when dirt and dust conditions are severe. >. Oil and Filter Change. Generally the oil and filter should be changed after each 1200 hours of operation. For severe service, refer to paragraph 3-5a. Refer also to para~ graph 3-3 before changing oil, Do not oper- ate @ transmission which is filled with pre- servative oil except for minimum necessary time and distance. Refer to paragraph 3-Lle. 3-6. CHANGING OIL, FILTER a. Draining Oil, Transmission should be at an operating temperature of 180-220°F (82-104°C) when the oil is changed. Remove the drain plug at the lower-left rear of the transmission housing (fig. 1-3). Remove the oil filter element from the remote-mount filter. Remove and clean the oil strainer assembly. Let the oil drain for 30 minutes if time permits. Replace the oil strainer, gas- ket, and oil drain plug. Install a new oil filter element (PF 151 or equivalent). b. Refilling Oil System. Refer to Tables 3-1 and 3-2 and refill the oil system. Then conduct the hot check as described in pare- graph 3~4b or 4, adding oil as necessary to establish the correct oil level for operation. 3-1. BLEEDING INTERNAL BRAKE (TTB models) a. All air must be bled out of the hy- draulie brake system before the brake will apply properly. Air in the system will cause the brake apply action to feel soft and springy. Also, air in the system may cause the pedal to completely depress without applying the brake. b. To bleed t he system, use a pressure bleeder inserted into either the master valve or plug. When manually bleeding the system, the reservoir must not be permitted to empty, or more air will be introduced. ‘The bleeder valve, or plug 30 or 36 (foldout 15,B) is located directly opposite the point to which the tube from the master cylinder to the transmission is connected (left to right side). Copyright 1984 General Motors Corp. 3-3TT, TTB, TRT 2001 SERIES TRANSMISSIONS Table 3-1. CHOICE OF PROPER C-3 OIL Fluid viscosity Ambient temperature and grade below which PREHEAT 1S REQUIRED SAE 30 32°F (0°C) SAE 15W-40 329F (°C) SAE 10W-30 10°F (-12°C) SAE 10W 10°F (-12°C) SAE 5W-20 10°F (-23°C) ‘Table 3-2. OIL SYSTEM REFILL AMOUNTS Initial fill (ary) Model Amount* 6-1/2 U.S. gal (25 liters) al 8-1/2 U.S. gal (32 liters) Refill (after drain) Model Amount* -3 4-1/2 US. gal (17 liters) a 6-1/2 U.S. gal (25 liters) * less external circuits ¢. Flush fluid through the system with @ pressure bleeder, or pump the brake pedal slowly through complete strokes, until no more air escapes at the bleeder valve or plug. If difficulty is experienced in obtaining a firm, solid feel when the brake is applied after bleeding, loosen one of the nuts at the upper ends of brake manifold 32 or 34 (fold- out 15,B) and continue to purge air from the system. When the brake is bled manually, always close the bleeder valve or plug before the pedal upstroke. 3-8. PRESSURES, TEMPERATURES Figure 3-1 illustrates the points where the transmission temperature and pressure may be measured. The vehicle may be equipped with a temperature gage and a pressure gage. If so, the temperature gage registers the con- FFenenaruné Connecrion (CONVERTER-OUT, FORWARD PRESSURE 0? Fig. 3-1. Pressure and temperature ‘check points verter-out (to cooler) temperature, and the pressure gage registers main (cluteh) pres- sure, Cluteh pressure during normal opera- tion in any range or in neutral is approxi- mately equal to main pressure and may be regarded as main pressure. However, while either the elutch-eutoff control or inching control is being used, clutch pressure may fall to practically zero—this does not indi- cate that main pressure has decreased. Therefore, when checking main pressure, do not actuate either of these controls, 3-9. LINKAGE CHECKS, ADJUSTMENTS a See Vehicle Manual Instructions. The specific design of control linkages for range selection, inching control, output disconnect, and parking brake depends upon the installa tion, Control linkages are provided by the vehicle manufeeturer. Therefore, only gen- eral instructions for linkage adjustments ean be provided in this manual. a4 Copyright 1984 General Motors Corp.PREVENTIVE MAINTENANCE , Selector, Inching Linkage. The selec tor linkage must be adjusted so that the oper- ator's control and selector valve are both within desired range at the same time. Make initial adjustment in neutral. Then shift through all range positions to make sure that the selector vaive is in the full detent posi- tion in each range. Adjust the inching valve control linkage so that the valve has full travel from retracted to extended positions. Linkage must be kept clean, adjusted, and well lubricated. Bent or damaged linkage must be repaired or replaced. ¢ Front Output Disconnect (1) There are two points of adjust- ment for the front output disconnect. The shifter shaft must be adjusted first, and then adjust the linkage. Push the shifter shaft in- ward (toward the rear) to its engaged posi- tion. A spring-loaded detent will indicate positive engagement. Adjust the shifter shaft by rotating it until the center of the elevis pin hole is approximately 3/8 inch (9 mm) ahead of the linkage support bracket mounting pad faces. (2) When the shifter shaft is pulled outward (forward) to its disengaged position, ‘the detent ball should seat when the center of the clevis pin hole is approximately 2-1/8 inch (64 mm) ahead of the bracket mounting pad faces. Adjust the linkage so that the en- gaged and disengaged positions of the oper- ator's control correspond exactly with the detent positions of the shifter shaft. Parking Brake (external, mechanical) (1) Disconnect the brake linkage be- fore adjustment, Adjust the brake shoes for proper drum clearance by inserting a serew- driver or adjusting tool into one of the openings at the rear of the brake drum and turning the starwheel The starwheel should be rotated until 0,010 ineh (0.254 mm) thick- hess gages are held snugly between the ad- justment end of the shoes and the drum (use ‘two gages simultaneously—one at each shoe). (2) Hold the brake assembly actue- ting lever so that all slack is removed (with- out applying the brakes). Adjust the vehicle linkage by releasing the hand lever fully and adjusting the connecting rod so that it can be connected to the brake assembly actuating lever. 3-10. TRANSMISSION STALL TEST NOTE ‘The engine stall speeds for all Detroit Diesel Allison approved eng iney/transmission appli- cations may be obtained from the SCAAN Computerized Ve- hicle Performance program. Access to this program is avail- able at Detroit Diesel Allison distributors and any Detroit Diesel Allison Regional Office. Purpose (Q) A stall test should be conducted when the power package (engine and trans- mismission) is not performing satisfactorily. ‘The purpose of the test is to determine if the transmission is the malfunctioning component. (2) A stall test is condueted with the transmission in F2 range, the engine running at full throttle, and the transmission outputs stalled. The data obtained from t he test must be used in conjunction with engine-con- verter matched performance curves. These performance curves can be obtained from your equipment dealer or distributor. b, Procedure (1) Connect a tachometer of known accuracy to the engine, and bring transmis- sion to the normal operating temperature of 180-220°F (82-104°C). CAUTION Stall condition should never be maintained for more than 30 seconds at any one time be- cause of the rapid rise in oil temperature, (2) Apply the parking brake, block the vehicle securely, and shift the selector control to high range. (The test may also be Copyright 1984 General Motors Corp. 3-5‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS conducted in F1 or reverse, if necessary. However, such tests must be made with ex- treme caution because of the high torque de- livered at the transmission output shaft.) CAUTION Do not apply service brakes if t he transmission is equipped with a cluteh cutoff. (3) Accelerate the engine to wide- open throttle. After reaching a stabilized converter-out temperature of 225°F (107°C) minimum, record the engine speed while the engine is at open throttle. Do not let the converter-out temperature exceed 250°F (a2iec). NOTE Allow approximately 2 minutes of neutral operation between stall tests to prevent overheat ing. During the 2-minute per- iod, engine sp ee d should be maintained (except for the mo- mentary throttle release when shifting to neutral). g. Results. Under stall test conditions, a comparison of actual engine speed with the established normal speed for such conditions will indicate if the engine or the transmission is malfunctioning. NOTE Environmental conditions, such as ambient temperature alti- tude, engine accessory loss var~ iations, ete., affect the power input to the converter. ‘These conditions may cause the stall speed to vary +150 rpm from the established normal value. When deviation can be attri- buted to sueh causes, the act- ual speed can be accepted as normal. 3-11. PRESERVATION, STORAGE & Storage, Ne w Transmissions, Ne w ‘transmissions are tested with preservative oil and drained prior to shipment. The residual oil remaining in t he transmission provides adequate protection to safely store the trans- mission for six weeks without further treat- ment. b. Preservation Methods. When the trans- mission is to be stored or to remain inactive for an extended period (up to one year), spe- cific preservation methods are recommended to prevent damage due to rust, corrosion, and growth of biologicals. Preservation methods are presented for storage with and without oil. Storage, One Year — Without Oil (1) Drain the oil and replace the oil filter element(s) (para 3-6). (2) Seal all openings with moisture proof tape. (3) Coat all exposed, unpainted sur- faces with preservative grease, such as petrolatum (MIL-C-11796), Class 2, (4) If the breather can be easily re- moved, spray one ounce (30 milliliters) of Motorstor® * (or equivalent) into the trans- mission through the breather hole. Also, spray one ounce (30 milliliters) through the fill tube hole. If the breather cannot be removed, spray two ounces (60 milliliters) of Motorstor (or equivalent) into the trans- mission through the fill tube hole. (5) If additional storage time is re~ quired, repeat (3) and (4) at yearly intervals. * Motorstor® ir Motorstor® is the registered trademark for a vapor phase rust preventative manufactured by the Daubert Chemical Company, Chicago, Iinois. Motorstor is covered by Military Specifications MIL-L-46002 (ORD) and MIL-I-23310 (WEP) under the designation of "Nucle Oil. 36 Copyright 1984 General Motors Corp.PREVENTIVE MAINTENANCE gd. Storage, One Year — With Oil (1) Drain the oil and replace the filter element(s) (para 3-6). (2) Fill the transmission to operating level with a mixture of 30 parts Type C-3 oil to one part Motorstor rust preventative (or equivalent). Add 1/4 tsp of Biobor JF® * (or equivalent) for each 3 gallons (0.1 mi/iter) of oil in the system. NOTE When ealeulating the amount of Biobor JF required, use the total volume of the system in- cluding external lines, filters, and cooler; not just the quan- tity required to fill the trans- mission, (3) Shift through all selector posi- tions to thoroughly distribute the oil Then stop the vehicle and stall the transmission output until an oil temperature of 225°F (107°C) is obtained. CAUTION Do not allow the temperature to exceed 225°F (107°C), If the vehicle does not have a temper- ature gage, do not stall the transmission for more than 10 seconds. (4) Stop the engine. As soon as the Unit is cool enough to touch, seal all openings and breather with moisture-proof tape. (5) Cost all exposed, unpainted sur- faces with preservation grease, such as petrolatum (MIL-C-11796), Class 2. (6) If additional storage time is re- quired, just add the prescribed mixture (para 3-11d (2)) of Motorstor and Biobor JF, or equi- * Biobor JF® Borax and Chemical Corporation. valents, and repeat (3) through (5) above, at yearly intervals. It is not necessary to drain the transmission each year. @ Restoring Units to Service (1) Remove the tape from openings and breather. (2) Wash off all the external grease with mineral spirits. (3) If the transmission is new, drain the residual preservative oil Refill the transmission to the proper level (para 3-4) with type C-3 oil. (4) If the transmission was prepared for storage without oil, refill the transmis- sion to the proper level (para 3-6) with type C-3 oil (5) If the transmission was prepared for storage with oil, check for proper oil level (para 3-6). Add or drain transmission oil as required to obtain the proper level. NOTE It is not necessary to drain and refill the transmission with new oil. 3-12, FLANGE RETAINER Oil seepage may occur in some -1 models at the output locations. This seepage can result from a worn lip-type seal within the housing, improper torque at the flange re- tainer nut, or loss of sealing contact between the retainer washer and the flange seat. If inspection reveals that the seepage is due to the loss of contact sealing at the retainer washer, remove and discard the washer. Re- place the flat washer with a stepped washer and seal as shown in figure 3-2. ‘The stepped washer and sealring are available from the dealer or distributor. is the registered trademark for a biological inhibitor manufactured by U.S. Copyright 1984 General Motors Corp. 31TT, TTB, TRT 2001 SERIES TRANSMISSIONS seatRING pf — was NuT (OUTPUT SHAFT ‘OUTPUT FLANGE Fig. 3-2. Output shaft retainer ‘washer and seal 3-13, TROUBLESHOOTING a Importance of ‘Troubleshooting. ‘Trou- bleshooting is the systematic seareh for and location of malfunctions in the engine or transmission that affect transmission perfor mance. A thorough study of the description and operation of components and the hy- draulie system (Section 2) will be helpful in troubleshooting. ‘The engine and transmission must be regarded as a single package during troubleshooting. ‘Troubleshooting Table. Table 3-3 out- Lines the possible: causes of and remedies for transmission troubles. Capital letters indi- cate the symptom; numerals following the symptom indicate several possible causes; numerals in the right column indicate reme- dies for the correspondingly numbered causes in the left column, ‘Table 3-3, TROUBLESHOOTING Cause ‘A. LOW MAIN PRESSURE 1. Low oil level L 2. Clogged oil strainer 2 3. Clogged oil filter 3. 4, Weak or broken main-pressure 4 regulator valve spring 5. Inching control adjustment not 5. fully retracted 6. Oil pump worn 6. 7, Air leak at intake side of oi a pump 8. Internal oil leakage 8 9 External oil leakage % Brake hydraulic (or air) pressure applying clutch cutoff valve B OVERHEATING 1. High oil level lL. 2. Cluteh failed 2 3. Vehicle overloaded 3. 4. Low main pressure 4 5. Engine water overheated 5. 6. Cooler oil or water line kinked 6. or clogged 3-8 Remedy Add oil to correct level (para 3-4) Clean strainer (para 3-6a) Replace filter element (para 3-6a) Replace spring (para 6-3) Cheek, adjust linkage (para 3-9) Rebuild oil pump (para 6-26) Check pump mounting bolts (para 7-130); cheek oil pickup tube nut (para 7-1 0c) Disassemble transmission; rebuild subassemblies as required Tighten bolts or replace gaskets Cheek brake residual pressure (brakes released); check brakes for full release Restore proper oil level (para 3-4) Rebuild transmission Reduce load Refer to A Correct engine overheating Clean or replace line Copyright 1984 General Motors Corp.PREVENTIVE MAINTENANCE Table 3-3. TROUBLESHOOTING (cont) Cause © LOW CLUTCH-APPLY PRESSURE 1. Low main pressure 2 Clutch piston sealrings failed 3. Clutch cutoff control valve sticking 4, Inching control valve sticking 5. Internal oil leakage D_ AERATED (foaming) OIL 1. Incorreet type oil used 2. High oil level 3. Low oil level 4, Air entering suction side of oil pump 5. Air entering at clutch cutoff valve (air actuated) E VEHICLE WILL NOT TRAVEL 1. Low main pressure 2. Low eluteh-apply pressure 3. Selector linkage broken or disconnected 4. Internal mechanical failure Remedy 1. Refer to A. 2 Overhaul transmission 3. Rebuild control valve assembly (para 6-3) 4, Rebuild control valve assembly (para 6-3) 5. Overhaul transmission 1. Change oils use proper type. Refer to Table 3-1 2. Restore proper oil level (para 3-4) 3. Restore proper oil level (para 3-4) 4. Cheek oil pump bolts and gasket (para 7-13b); check oil piekup tube and nut (para 7-10¢) 5. Cheek plug seal and sealring of valve (para 6-3) 1. Refer to A 2, Refer toc 3. Repair of connect linkage (para 3-9) 4. Overhaul transmission E VEHICLE TRAVELS IN NEUTRAL WHEN ENGINE IS ACCELERATED 1, Selector linkage out of adjustment 2. Clutch failed (won't release) 1. Adjust linkage (para 3-3) 2. Overhaul transmission G VEHICLE LACKS POWER AND ACCELERATION AT LOW SPEED 1. Low cluteh-apply pressure 2. Aerated oil 3. High oil viscosity 4. Engine malfunction 5. Turbine freewheel clutch failed H_ STALL SPEED TOO HIGH (see para 3-10) 1. Cluteh slipping 2. Low main pressure 1. Refer to 2. Refer toD 3. Preheat oil, or change to a lighter viscosity. Refer to Table 3-1. 4. Check engine; refer to engine service manual 5. Overhaul transmission 1. Overhaul transmission 2 Refer to A and C Copyright 1984 General Motors Corp. 39‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS Table 3-3, TROUBLESHOOTING (cont) Cause STALL SPEED TOO LOW (see para 3-10) Engine not producing full power 2. Torque converter failed 3. Loss of engine power through accessories attached to engine J SERVICE BRAKE MALFUNCTIONS—TTB |. Brake slips when pedal is fully applied ‘Spongy brake pedal Brake pedal bottoms when brake is applied 2. 3. K CLUTCH CUTOFF VALVE INEFFECTIVE Valve or plug stieking Brake-apply hydraulic pressure not reaching control valve Brake-apply air pressure not reaching air cylinder Plunger sticking in air cylinder Air entering at valve (air actuated) Remedy 1. Tune or repair engine; refer to engine service manual Rebuild converter Disconnect accessories which are absorbing power 3. MODELS Rebuild brake (para 6-16) Bleed hydraulic brake lines (para 3-7) Cheek for leaks in hydraulic brake lines and for broken linkage, Bleed brake hydraulic system (para 3-1) Rebuild control valve body assembly (para 63) Cheek pressure at control valve (min-max limits — 100-2000 psi; 689-13 789 kPa) Cheek at air cylinder for brake-apply pressure (35 lb (136 N) force required to stroke valve) Cheek operation of air cylinder Cheek operation of air cylinder (seals) 3-10 Copyright 1984 General Motors Comp.Section 4. GENERAL OVERHAUL INFORMATION 4-1, SCOPE This section contains preliminary infor- mation required for the overhaul of the trans~ mission. Cleaning instructions, inspection criteria, and recommended rework proce- dures are discussed. Good shop practices, coupled with the recommended procedures described herein, will aid in restoring high- quality performance. 4-2, MODEL CHANGES The release of new assemblies may re~ quire new or different overhaul procedures. Major changes in the transmission will be described in supplementary issues to this manual. Contact your dealer or distributor for the latest information, When requesting service information, be sure to give the model, assembly part number, and serial number as stamped on the transmission nameplate (refer to para 1-3e). 4-3. TOOLS, EQUIPMENT Special Tools. Table 4-1, and figures 4-1"and 4-2 show special tools required for overhaul procedures. b. Mechanic's Tools, S ho p Equipment. ‘The following tools, in addition to common tools, should be available: CAUTION Caustic cleaning — compounds will damage some transmission parts. Use only mineral spirits such as PD 680-2 (or equive- lent). = Container of mineral spirits (for cleaning parts) ~ Hoist (1/2-ton (450 kg) capacity, min) = Press (for removal and installation of press-fit parts) = Supply of wood blocks ‘Table 4-1. SPECIAL TOOLS Tool Not Fig, Item Name Ref. Para. J-23547 44 1 Converter pump assembly puller 5-6a (4) J-23723-6 4-1 2 Converter pump hub bearing driver 6-7b(2) J-33080-1 4-1 3 Bridge 6-28 3-33080-2 4-1 4 Retriever 6-26 J-33080-3 4-1 5 Collet 6-26 5-33080-5 4-1 3 Collar 6-26 J-33080-8 4-1 6 Height gage 6-26 J-33080-13 4-1 3 Washer (two required) 6-26 ” 4-1 7 Flange puller 4-98, * 41 8 — Cam bolt holding fixture 6-90(6) ” 44 9 Suetion tube nut wrench S-Te, 7-1(4) ‘* These tools are manufactured by Kent-Moore Tool Di ion, 29784 Little Mack, Roseville, Michigan 48066, and may be obtained through your local Detroit Diesel Allison dealer or distributor, ** Must be fabricated—not available from Kent-Moore. Copyright 1984 General Motors Corp. 44‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS SoREW PULLER NUT — WASHER nur + waster be erinse J couar 2. CONVERTER PUMP HUB BEARING DRIVER, 3. BRIOGE ASSEMBLY 1. CONVERTER PUMP PULLER Locate sour HOLES TO arcH SCREW MIN LENGTH TYPE FLANGE TO 918 (2286 rm) BE PULLED IK NF THD lo al U Ain on U : 1 1N (254 me) 4 4. RETRIEVER 5. COLLET 6. HEIGHT GAGE SPACER 075 (1805 mm) 17. FLANGE PULLER ; ALTER AS SHOWN STD 12 IN. SQUARE ORIVE T EXTENSION. 10IN, LONG END OF 9/16 (OPEN-END WRENCH 2875-2895 IN 2251N (67 mm) L--- 1 tunfeom sw asenm (836 1m ee a {8 CAM BOLT HOLDING FIXTURE SID 1-374 1N. 1/216 SOUARE DRIVE. OPEN ENO, ‘cRowrooT SUCTION TUBE NUT WRENCH oo Fig. 4-1. Special tools 4-2 Copyright 1984 General Motors Corp.GENERAL OVERHAUL INFORMATION as news (120 cm) STEEL tor 26 NC BOA eiseg Fon tO Paw snp i ers x4 41585 iy onion coo tes) 4-12 NOH (5 ma) DEEP ROUGH H-GAGE SHEET STEEL 2 NCH (5 nn] WIDE - 4-2. Work table e - Clean lint-free shop cloths (do not use - Loctite® ** pipe Sealant with Teflon linty waste) or equivalent (for plugs that are not = Parts receptacles precoated) Loctite Sleeve Retainer 601 or equi- ~ Cleaning equipment (brushes, solvents, ete.) valent (for sleeve-type bearings) ~ Oil-soluble grease (petrolatum) - High temperature grease, MIL-G- = Dry ice (for cooling interference-fit 81322, Mobil Grease No. 28 (Mobil Oil parts) Co.), Aeroshell Grease No. 22 (Shell - Heating equipment or hot plate to Oil Co.) or equivalent (for lip-type oil provide oil at 300°P (150°C) (for seals—do not use inside transmission) heating interference-fit parts) - High-quality molybdenum disulfide Snapring pliers grease, Allison P/N 6769877 or equi- 34eg lifting sling—1 /2 ton (1200 ke) valent (antiseize compound for input capacity--80 degree angle attaching and output shaft threads—do not use plates inside transmission) - Micrometer = 100 ineh-pound (11 N-m) torque wrench CAUTION = 100 foot-pound (136 Nem) torque wrench Use an antiseize compound that - 1000 foot-pound (1356 Nem) torque will not attack the Buna or wreneh Polyaerylate seal material - Nonhardening sealer, Permatex® * Mobile-Grease Special wit h No. 2 or equivalent (for seals that molybdenum disulfide, or equi- are not precoated) valent, is recommended. * Permatex® is a registered trademark of Permatex Co. Inc., West Palm Beach, FL. ** Loctite® is a registered trademark of Loctite Corporation, 705 N. Mountain Re., Newington, CT 06111. Copyright 1984 General Motors Corp. 43TT, TTB, TRT 2001 SERIES TRANSMISSIONS 4-4, REPLACEMENT PARTS & Ordering Information Refer to para~ graph ea forsinformation formation on ordering parts and service kits. b, Parts Normally Replaced. ‘The fol- lowing parts ere normally replaced. curing overhaul: WARNING Do not burn discarded Teflon seals. Toxic gases are produced by burning. - Sealrings =~ Oil seals (if removed) - Gaskets ~ Lockstrips - Washers or snaprings damaged by removal 4-5, CAREFUL HANDLING Parts which have close operating toler- ances must be handled carefully to prevent nicking, seratching, or denting. ‘The slightest damage to these parts can result in erratic operation and possible malfunction of the ‘transmission. These parts should be carefully handled and protected during removal, clean ing, inspection, and installation. 4-6. CLEANING, INSPECTION & Dirt-free Assembly. All parts must be clean to permit effective inspection. During assembly, it is very important that no dirt or foreign matter enters the transmission. Even minute particles can cause the malfunetion of close-fitting parts. ‘b. Cleaning Parts CAUTION Use only mineral spirits for cleaning. ‘Solvents such as trichloroethylene, Benzol, Ace~ tone, and all aromatics are harmful to oil seals using poly acrylate rubber. (1) Use only mineral spirits on frie tion-faced clutch plates and bearings. All other metallic parts of the transmission should be cleaned thoroughly with mineral spirits, or by steam-cleaning. Do not use a caustic soda solution for steam cleaning. (2) Parts (except bearings) should be dried with compressed air. Steam-cleaned parts must be oiled immediately after drying. (3) Clean oil passages by working a piece of soft wire back and forth through the passages and flushing with spirits. Dry the passages with compressed air. (4) After cleaning, examine the parts and especially the oil passages to make cer tain they are entirely clean. Reclean them, if necessary. (5) Removal of minor defects with such items as crocus cloth, sof t honing stones, and scrapers produces debris and residue. Cover adjacent parts, ports, and cavities before removing defects. Thorough- ly reclean the affected areas after rework. & Cleaning Bearings RAENING Never dry bearings by spinning them with compressed air. A spinning bearing can disinte- grate, allowing balls or rollers to become lethal flying projec tiles. Also, spinning a bearing while it is not lubricated ean damage the bearing. (1) Bearings that have been in service should be thoroughly washed in mineral spirits. (2) If the bearings are particularly dirty or filled with hardened grease, soak them in the mineral spirits before trying to clean them. (3) Before inspection, ofl the bearings with type C-3 transmission oil, 44 Copyright 1984 General Motors Corp.GENERAL OVERHAUL INFORMATION @. Inspecting Bearings (1) Inspect bearings for roughness of rotation, Replace a bearing if its rotation is still rough after cleaning and oiling. (2) Inspect bearings for scored, pit- ted, seratched, cracked, or chipped races, and for indication of excessive wear of rollers or balls. If one of these defects is found, replace the bearing. (3) Inspect the defective bearing's housing and shaft for grooved, burred, or galled conditions that indicate the bearing has been turning in its housing or on its shaft. If the damage cannot be repaired with crocus cloth, replace the defective part. CAUTION ‘Any bearing that has been sub jected to metal contamination (para 3-3) must_be closely _in- spected {0 f metal particles Metal particles will cause fail- ure of the bearing. e, Keeping Bearings Clean ‘The presence of dirt or grit in ball bearings is usually res- ponsible for bearing failures. Keep bearings clean during installation and removal. Ob- servance of the following rules will do much to ensure maximum bearing life. (1) Do not remove the wrapper from new bearings until ready to install them, (2) Do not remove the grease in which new bearings are packed. (3) Do not lay bearings on a dirty bench; place them on clean paper. (4) If assembly is not to be completed at once, wrap or cover the exposed bearings with clean paper or cloth to keep out dust. f. Ing Cast Parts, Machined [li eee (1) Inspect bores for seratehes, wear, grooves, and dirt, Remove seratehes and burrs w it h erocus cloth, Remove foreign matter. Replace parts that are deeply grooved or seratched. (2) Inspect all ofl passages for ob- structions. If an obstruetion is found, remove it with compressed air or by working a soft wire back and forth through the passage and flushing it with mineral spirits. (3) Inspect mounting faces for nicks, burrs, seratehes, and foreign matter. Re- move such defects with crocus cloth or a honing stone. If seratehes are deep, replace the defective part. (4) Inspect threaded openings for damaged threads. Chase damaged threads with the correct size used tap (a new tap can cut oversize). (5) Replace housings or other cast parts that are cracked. (6) Inspect all machined surfaces for damage that could cause oil leakage or other malfunction of the part. Rework or replace defective parts. (7), Inspect piston b or es in clutch housings for nicks, burrs, and displaced metal that could interfere with mating parts or damage piston sealrings. Remove these de- feets with crocus eloth or soft honing stone. (8) Inspect sealring grooves in eluteh pistons for nicks, burrs, dents, or displaced metal that could damage sealrings. Remove these defects with crocus cloth or soft honing stone. g: Inspecting Bushings, Thrust Washers (Q) Inspect bushings for scores, round- ness, burrs, sharp edges, and evidence of overheating. Remove scores with crocus cloth. Remove burrs and sharp edges with a seraper or knife blade. If the bushing is out- of-round, deeply scored, or excessively worn, replace it, using the proper size replacer tool Whenever it is necessary to cut out a defective bushing, do_not_damage the bore into whieh the bushing His Copyright 1984 General Motors Corp. 4-5‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS (2) Inspect thrust washers for distor- tion, scores, burrs, and wear. Replace the thrust washer if it is defective or worn. ‘h. Inspecting Oil Seals, Gaskets (1) Inspect piston sealrings for nicks, cuts, tears, splits, and pattern damage. This type damage on old sealrings can indicate de- fects in the piston grooves or in the piston housing bores. Locate and remove the de- fects, Refer to paragraphs 4-6 f, (7) and (8). (2). Inspect metal-encased seals for cuts and hardness. Replace the seal if de- fects are found or if the seal is damaged by removal. Replace all sealrings (exept hook- type) and composition gaskets. (3) Inspect. the hook-type sealrings for wear, broken hooks, and distortion, (4) Install a new hook-type sealring if the ring shows any wear on the outside cir- cumference or if there is excessive side wear. The sides of the sealring should be smooth (0.005 ineh (0.127 mm) maximum side wear). The sides of the shaft groove (or the bore) in which the sealring fits: should be smooth to (50 miero-inches (1.27 gm) and square with the axis of rotation within 0.002 inch (0.05 mm). If the sides of ring grooves have to be reworked (0.020 inch (0.51 mm) maximum side wear), install a new sealring. i, Inspecting Gears (1) Inspect gears for scuffed, nicked, burred, or broken teeth. If the defect cannot be removed with a soft honing stone, replace the gear. (2) Inspect gear teeth for wear that may have destroyed the original tooth shape. If this condition is found, replace the gear. (3) Inspect the thrust faces of gears for scores, scratches, and burrs. Remove such defects with a soft honing stone. 4, Inspecting Splined Parts, Inspect parts f o'r stripped, twisted, chipped, or burred splines. Remove burrs wit h a soft honing stone. Replace the part if other defects are found. Spline wear is not considered detri- mental except where it affects tightness or fit of the splined parts. Inspecting Clutch Plates (1) Inspect the friction-faced plates for burrs, imbedded metal particles, severely pitted faces, excessive wear, cone, cracks, distortion, and damaged spline teeth, Re- move burrs, using a soft honing stone. Re- place plates which have other defects. (2) Inspect steel plates for burrs, scoring, excessive wear, cone, distortions, imbedded metal, galling, cracks, breaks, and damaged tangs. Remove burrs and minor surface irregularities using a soft honing stone. Replace plates which have other defects. (3) The amount of cone is determined by measuring the distance between the inside Giameter of the plate and a level surface (fig. 4-3). Discard plates having excessive cone (refer to wear limits, Section 8). J, Inspecting Threaded P arts. Inspect parts for burred or damaged threads. Remove burrs with a soft honing stone or fine file. Replace damaged parts. m, Inspecting Snaprings. Inspect all snap- rings for nicks, distortion, and excessive wear, Replace the part if any one of these defects is found. ‘The snapring must snap tight in its groove for proper funetioning. A inspecting Springs. Inspect all t he springs for signs of overheating, permanent set, or wear due to rubbing adjacent parts. — EASURE HERE FOR CONE Fig. 4-3. Method for determining cone of eluteh plate 46 Copyright 1984 General Motors Corp.GENERAL OVERHAUL INFORMATION Replace the spring if any one of these de- feets if found. Replace springs which do not meet the load-height specifications in the spring chart in Section 8, ©. Inspecting Seal Contact Surfaces In- spect the surfaces that contact the sealing area or lip of any seal. Roughness, scoring, pitting, or wear that will permit oil leakage or cause damage to the seal must be cor- rected. The affected part must be replaced if defects cannot be corrected. p- Inspecting Swaged, _Interference-fit Parts. ‘Tr there is evidence of looseness due to relative motion, the assembly should be replaced. @ Inspecting Balls in Clutch Pistons. In- |S suucnce ment. Any restriction could prevent the ball from seating during clutch application. Inspecting Pump Gears, Inspect pump goats for evldeise of Heer such os bcorlng oF shiney areas due to rubbing of adjacent parts. Replace gears with any signs of wear. 4-1, ASSEMBLY PROCEDURES & Clutches, Pistons (Q) Soak each frietion face clutch plate (two-minute minimum) in transmission fluid prior to final assembly. (2) Apply a generous amount of trans- mission fluid to the piston cavity prior to final assembly. (3) Assemble cluteh plates so that the cone of each plate faces the same di- rection as the cone of the adjacent plates (fig. 4-3). b. Parts Lubrication. During final assem- bly, lubricate all moving parts with transmis- sion fluid. ‘The lubricant will help protect the friction surfaces and ferrous metals until the unit is in service. External Pipe Plugs, Hydraulic Fittings. New plugs (1) New Precoated Plugs. that are precoated with Teflon need no pre- paration for assembly. (2) Reused_or Uncoated Plugs, Hy- draulic Fittings. Prepare the thi reads wth a small amount of nonhardening sealant, such as Loctite Pipe Sealant with Teflon, or equi- valent. Do not use Teflon tape. CAUTION Inaccurate torque can cause leakage and cracked housings. Tighten all pipe plugs to the torque specified in the assem~ bly step and on the exploded views. d Oil-soluble Grease. Use only oil-sol- uble grease with a low melting point, such as MIL-VV-P-236 or Amojell petrolatum (Amoco Oil Co.) or equivalent to temporarily retain parts, step-joint sealrings, scarf-cut seal- rings, and hook-type sealrings during assem- bly with mating parts. CAUTION Do not use petrolatum to retain cork gaskets. & Sealing Compounds, Nonsoluble Greases. Do not use gasket-type sealing ‘compounds, fibrous greases, or nonsoluble, vegetable-base cooking compounds any place inside the transmission. Do not use them any place where they could be flushed into the transmission hydraulic system. Metal-Encased Oil Seals (1) When replacing metal-encased oil seals, make sure the spring-loaded lip side is toward the oil to be sealed in (toward the in- side of the unit). Coat the inside of the seal with high temperature grease, such as MIL~ G-81322, Mobil Grease No. 28 (Mobil Oil Co.) or Aeroshell Grease No. 22 (Shell Oil Co.) or Copyright 1984 General Motors Corp. 44‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS equivalent to protect the seal during shaft installation and to provide lubrication during initial operation, Do not use high tempera~ ture grease on other internal transmission parts. (2) Precoated Seals. The cireumfer- ence of soime seals is precoated with a dry sealant. The sealant is usually colored for easy identification ‘The precoated seals do not require any additional sealant before installation. (3) Uncoated Seals. Prepare the cit cumferencé of uncoated seals with a nonhar- dening sealant such as Permatex No. 2 or equivalent before installation. g. Interference-fit Parts. Assembly of interference-fit parts may be accomplished by heating and chilling the respective parts. The female part can be heated in an oven or oil bath to 30°F (149°C), and the male part ean be chilled in dry ice. Either one or both parts may require a thermal process. How- ever, if the chill process is used for a ferrous alloy part, coat the components with trans- mission fluid to inhibit rust due to frost and moisture. h, Sleeve-type Bearings. Loctite Sleeve Retainer 601, or equivalent, should be used to retain bushings and sleeve-type bearings that, have press-fit tolerance. 4, Bearings (Ball or Roller) () When installing a bearing on a shaft, heat the bearing to 200°F (93°C) on an electric hot plate or in an oil bath. Coat the mating surfaces with white lead and use the proper size installation sleeve and a press to seat the bearing. NOTE Bearings must be heated long enough for sufficient expan- sion, Heating time is deter- mined by the size of the bear- ing. Forty-five minutes is suf- ficient for the largest bearing in these transmissions. (2) If a bearing must be removed or installed without a sleeve, be careful to drive or press only on the race which is adjacent to the mounting surface. If a press is not avail- able, seat the bearing with a drift and a ham- mer, driving against the supported race. 4-8. REMOVING, INSTALLING TRANSMISSION a, Drain Oil. Drain the oil from the transmission. For better drainage, the trans~ mission should be warm and allowed to drain overnight. Replace the drain plug. b. Check Linkages, Lines. Make sure that all linkages, controls, cooler and filter lines, pressure and temperature lines, drive ine couplings, and mounting bolts are discon- neeted before transmission removal. Care- fully place oil lines clear of the removal path and cover all openings to keep out dirt. Remove, Clean Transmission. Consult t he vehicle service manual for specific in- structions for removal and installation, as ap~ plications will differ. Clean the exterior of the transmission. If steam cleaning is used, the transmission should be disassembled and dried immediately as condensation of the the steam will rust the ferrous parts in the trans~ mission. @, Lifting. Two 3/4-10 tapped openings are provided at the top of the transmission housing. Bolts or eyebolts may be installed into the openings for lifting the transmission. assembly. Reconnect at Installation Q) At installation, reconnect all linkage and lines which were previously re- moved. Refer to the vehicle service manual and to paragraph 3-9 for proper adjustments of control linkage. (2) Use Loctite Pipe Sealant with Teflon, or equivalent, for thread sealing on hydraulic, air, and other threaded fittings. Do not use Teflon tape. Loose slivers of tape can plug orifices, cause valves to stick, or may interfere with check ball operation. 4-8 Copyright 1984 General Motors Corp.GENERAL OVERHAUL INFORMATION (3) On the direct-mount transmis~ sions equipped with torque converter drive cover 12 (foldout 6,B), make sure the coun- terbore in drive ring 8 is packed with high- quality molybdenum disulfide grease. (Refer to para 7-12b.) 4-9, TIGHT-PIT FLANGES & Removal of Flanges (1) If present, flatten the corners of the lockstrip and remove two bolts, lockstrip, retainer washer, and shims (fig. 4-4). (2) Some flanges are retained by a self-locking nut. Before removing the nut, cheek to see how many notehes have been cut into the wrenching flats. If there are five notches, remove the nut and throw it away. (3) If there are less than five notches, or none at all, remove all dirt and any burrs from the exposed shaft threads. ‘Then, only loosen the nut until there is ap- proximately 1/16-ineh (1.59 mm) gap between the nut and flange. (4) Check the running torque while removing the nut. The nut ean be reused only if it meets the following requirements. Fig. 4-4, Removing or installing output flange retaining parts The first time (no notches) the nut is removed, the running torque must be at least 400 Ib in. (45 Nem). - Each additional time (one to four notches) the nut is removed, the run- ning torque must be at least 300 Ib in. ([Link]). (5) Each time the nut is reused, deep- ly seribe @ line onto one of the wrenching flats. ‘This method of marking the nut will indicate how many times the nut has been reused. The nut must not be reused more than five times. CAUTION A puller placed on the outside diameter of the flange may de- form the pilot diameter and mounting face. (6) Install a suitable heavy-duty pul- ler to the face of the flange. A typical pul- ler is illustrated in figure 4-1. A Torgmatic coupling requires a puller that will engage the internal groove machined in the coupling hub. (7) In order to protect the tapped holes in the end of the shaft, install a soft metal spacer between the puller jackscrew point and the end of the shaft. (8) Provide a means for preventing flange rotation, CAUTION Do not use a pry bar or hammer to foree the flange at disassem- bly. (9) Remove the flange by tightening the puller serew against the spacer and shaft. b, Installation of Flanges (1) Coat the shaft splines and the lip of the oil seal with a thin layer of bearing grease. Copyright 1984 General Motors Corp. 49‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS (2) Heat the flange to approximately 30°F (149°C) prior to assembly. Either heat in @ controlled temperature furnace for at least 45 minutes or submerge the flange in a container of oil and heat the oil (If acety- lene toreh is used, heat the container of oil for 15 minutes.) CAUTION Do not let the flange cool prior to installation, If the flange cools and seizes to the shaft prior to its final assembly, it will be necessary to remove the flange and repeat the assembly procedure. Do not attempt to force the flange with a hammer. (3) Immediately after heating, install the flange on the shaft, making sure that the flange is tight against its locating shoulder. ‘The flange should slide freely to its assem- bled position, (4) If an output nut is used, coat the threads of the nut with molybdenum disulfide grease and install the flange retaining washer and nut. (Do not reuse nut with five notches; refer to paragraph 4-98.) Tighten the nut to 450-700 Ib ft (611-949 Nem) (fig. 4-5). (5) If washer and bolts are used, in- stall washer and free running bolts to draw TORQUE WRENCH IMPROVISED HOLDER Fig. 4-5. Tightening rear output flange nut the flange down into final position. (Do not use lock bolts that will be used at final assem- bly.) Remove the bolts and install the lock- strip (and shim(s), if required—see fig. 4-6). Shims are available in thicknesses of 0.005 inch (0.13 mm) and 0.025 inch (0.63 mm). Use shims to allow 0.005-0.009 inch (0.12- 0.22 mm) between surface A (fig. 4-6) and the surface of the shim pack. Install the lock bolts and tighten them to 41-49 Ib ft (56- 66 Nem). (6) After the assembly has cooled, it is good practice to check the nuts or bolts for tightness and, if necessary, retighten them. 4-10. WEAR LIMITS, SPRING DATA 8, Wear Limits Inspection, When parts are being inipotted, these Tisted in Section 8 measured for wear. should be ‘Those parts Vi << SG = an SHIM AS REQUIRED TO 005-0, 00 INCH (0, 12-022 mm) BELOW FACE A OF RANGE. Fig. 4-6. Measurement to determine flange shim thiekness Copyright 1984 General Motors Corp.GENERAL OVERHAUL INFORMATION which have reached or exceeded the specified wear limit should be discarded and replaced. All wear limits data are tabulated in Section 8. The item numbers are keyed to the parts shown in the exploded views at the back of the book. b, Spring Inspection, ‘The data presented in the Spring Chart in Section 8 will aid in Copyright 1984 General Motors Corp. identification and inspection of the springs within the transmission, 4-11, TORQUE SPECIFICATIONS Torque specifications are given with each assembly procedure. Also, the exploded view foldouts state torque specifications for all threaded parts. 411/412,Section 5. DISASSEMBLY OF TRANSMISSION 5-1. SCOPE ‘The procedures of this section deseribe the disassembly of the TT, TTB, TRT 2001 Series transmissions into subassemblies, Dis assembly of the subassemblies is described in Section 6. Refer to the cross sections (fold- outs 1 through 5) for the functional location of parts. Refer to the exploded views (fold- outs 6 through 18) for parts identification. 5-2 PREPARATION FOR DISASSEMBLY General Information. Refer to Sec- tions and 8 Tor general disassembly infor- mation as follows: Paragraph Title 43 Tools, Equipment 44 Replacement Parts 45 Careful Handling 4-6 Cleaning, Inspection 4-9 Tight-fit Flanges 81 Wear Limits Data 82 Spring Data b. Lifting, Handling. All Allison Twin- ‘Turbine transmissions have two 3/4-10 tapped holes in the top of the transmission housing. Eye bolts may be installed into these holes to provide a means of supporting or positioning the transmission housing during disassembly (fig. 5-D. SERVICING OF VEHICLE-MOUNTED TRANSMISSION a Some Servicing Without Removal The 37, 1TB, and TRT Series: twanariilons ore designed so many service operations may be accomplished without removing the transmis- sion from the vehicle. The disassembly pro- cedures in the manual, however, relate to operations with the transmission removed, LIFTING SLING ‘110 EvEBOUT Pig. 5-1. Lifting transmission b, Accessibility. Accessibility of the transmission in the vehicle, the nature of the service required, and other factors will deter- mine the advisability of performing major ‘operations without removing the transmis~ sion. Procedures for disassembly are essen- tially the same, but the position of the trans- mission may cause some inconvenience at times. In general, if the construction of the vehicle provides room, all external subassem- blies and all components which can be re- moved from the rear of the transmission may be serviced. 5-4, REMOVAL OF EXTERIOR COMPONENTS (all models) a, External Thermostat. If present, re~ move external thermostat assembly 31 (fold- out 7, B). If rebuild is necessary, follow the instructions with the new external thermo- stat kit. Copyright 1984 General Motors Corp. 5-1‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS >. Oil Pump Drive Coupling. If the trans- mission is equipped with adapter drive cou- pling 18 (foldout 18,4), remove the coupling. ¢, Qil Strainer Assembly. (1) =1 Models, Remove the oil drain plug. Remove the six bolts and lockwashers tha t retain the oil strainer assembly (fig. 5-2). Remove the oil strainer and gasket. (2) -3 Models. Remove the oil drain plug. Remove two bolts and lockwashers which retain the strainer cover. Remove the cover and sealring (fig. 5-3). Remove the strainer. caster OL STRAINER ASSY CL DRAIN PLUG Fig. 5-2. Removing oil strai (1 models) Fig. 5-3, Removing oil strainer and gasket (-3 models) d. Output Flanges, Parking Brake (1) Depending on the model, the rear output flange may be in a position behind or in front of the parking brake. If the flange is behind the brake, remove the attaching hard- ware and flange. (2) Remove the four (fig. 5-4) or eight (fig. 5-5) self-locking bolts that retain the parking brake drum, Remove the drum. Pig. 5-4. Removing parking brake drum bolts 1 models) WASHER LocesTRIP Bott Bout ‘RAKE DRUM Fig. 5-5. Removing parking brake drum bolts (-3 models) 5-2 Copyright 1984 General Motors Corp.DISASSEMBLY OF TRANSMISSION (3) If the output flange has not yet been removed, remove the attaching hard- ware and flange (fig. 5-6). (4) If the model is equipped with a front output flange, remove the attaching hardware and flange. (5) If present, remove sealrings 3 and 37 (foldout 17,4). (6) Remove brake shoe return springs 5 or 16 (foldout 17,B) and brake shoes and lin- ings 4 or 15, roller 3 or 14, a nd cam lever 6 or 17. Remove four self-locking b ol ts 7 or three bolts 20 and lockwashers 21 and re~ move brake backplate 2, 8, or 13. Refer to figure 5-7. Remove spacer 33 (foldout 17,4), if present, from the output shaft. REAR OUTPUT FLaNGE FRONT OUTPUT Fig. 5-7. Removing parking brake backplate bolts (-1 models) e Control Valve Assembly (1) Remove fifteen 2-1/2 inch bolts and lockwashers and one hidden 1-inch bolt and lockwasher that attach the control valve body to the transmission housing (fig. 5-8). (2)_If present, (foldout 18,B). remove bracket 28 (3) Remove the control valve body and gasket (fig. 5-9). Refer to paragraph 6-3 for the control valve assembly rebuild in- structions, Fig. 5-9, Removing valve body and gasket Copyright 1984 General Motors Corp. 5-3‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS 5-8. REMOVAL OF INPUT COMPONENTS NOTE Position the transmission on its rear surface. Do not allow the transmission to rest on the speedometer drive assembly, if present, or the output shaft. For direct-mount models with flex disk, proceed to paragraph 5-5a, For direet-mount models with drive ring, proceed to paragraph 5-5b. For remote- mount _models, proceed to para~ graph 5-5e. Direct Mount (flex disk) (1) Remove the six self-locking bolts and plate that retain the flex disk assembly (fig. 5-10). (2) Remove the flex disk plate and flex disk assembly consisting of three flex disks a rida disk and washer assembly (fig. 5-10) If present, remove plates 2 and 4 (foldout 6,8). (3) Remove the twenty-four self-lock- ing nuts t hat retain the torque converter drive cover (fig. 5-11). (4) Attach a sling and remove torque converter drive cover (fig. 5-12). Ball bearing isk PLATE ur, D sis24c0 Fig. 5-10. Removing flex disk bolts 1 (foldout 7,A) may remain in the torque converter drive cover; if so, remove the bearing. (5) Proceed to paragraph 5-6. b, Direet Mount (drive ring) () Remove sealring 10 (foldout 6,B) and twenty-four self-locking nuts 11 from torque converter drive cover 12. Remove the torque converter drive cover. Ball bearing 1 (foldout 7,4) may remain in the covers if So, remove the bearing. Fig. 5-11. Removing torque converter drive cover nuts Fig. 5-12, Removing torque converter drive cover 54 Copyright 1984 General Motors Corp.DISASSEMBLY OF TRANSMISSION (2) Converter drive ring 8 (foldout 6,B) and eight twelve-point bolts 9 will re~ main with the engine. Remove the bolts and drive ring only if necessary. (3) Proceed to paragraph 5-6. () Remove the attaching hardware and input flange. If present, remove sealring 3 (foldout 6,A) from the shaft. (2) Remove twelve bolts 12 (foldout 6,A), nuts 22, and lockwashers 21, and re~ move transmission front cover 13 and gasket 14. Refer to paragraph 6-4 for the front cover rebuild instructions. (3). Remove the twenty-four self-lock- ing nuts 19 (foldout 6,A) that retain torque converter drive cover 20 or 24. Remove the torque converter drive cover and attached input s ha f t 18 or 23 and bearing 15, as an assembly. Re f e r to paragraph 6-5 for the torque converter drive cover rebuild in- structions, 5-6. REMOVAL OF TORQUE CONVERTER COMPONENTS AND HOUSING & ‘Torque Converter Components (1). Using two serewdrivers, and lift- ing straight upward, remove the first- and second-turbine assembly (fig. 5-13). Do not disassemble this unit unless necessary. If TOROUE CONVERTER PUMP ASSEMBLY Pig. 5-13. Removing first- and second- turbine assembly necessary, refer to paragraph 6-6 for turbine assembly rebuild instructions. Remove: the sealring, if present, from the torque conver- ter pump assembly. (2) Remove the snapring that retains the converter stator and remove the stator from the converter ground sleeve (fig. 5-14). (3) Remove the stator spacer from the converter ground sleeve (fig. 5-15). ‘onove conventeR PUMP ASSEMBLY ‘ShaPniNG! 9 sy Fig. 5-14. Removing stator snapring STATOR SPACER FIRST-TURBINE DRIVE GEAR ECOND-TURGINE DRIVE GEAR Pig. 5-15. Removing stator spacer Copyright 1984 General Motors Corp. 5-5TT, TEB, TRT 2001 SERIES TRANSMISSIONS TURBINE PULLER 2547 TORQUE CONVERTER PUMP ASSEMBLY Fig. 5-16. Removing torque converter pump assembly (4) Straighten the tabs of the lock- strips at four places equidistant around the pump hub and remove four of the twelve bolts (fig. 5-16). Install puller J-23547, mak- ing sure the puller sleeve rests on the con- verter ground sleeve and extends above the end of the first-turbine drive gear shaft. ‘Tighten the puller serew. (5) When the converter pump bear- ing has be en drawn from its seat on the ground sleeve, remove the puller. (6) Remove the torque converter pump and reinstall the four bolts removed in step (4). If further disassembly is planned, refer to paragraph 6-7 for converter pump rebuild instructions. If disassembly is not necessary, tighten the four 1/4-28 x 1-1/4- ineh bolts to 10-12 Ib ft (14-16 N-m), and bend the lockstrip tabs against the replaced bolts. b, Torque Converter Housing (1) Remove the twenty-four bolts, lockwashers, and plain washers that attach ‘CONVERTER HOUSING ‘ACCESSORY DRIVEN GEAR DRIVE GEAR Fig. 5-17. Removing torque converter housing assembly the converter housing to the transmission main housing (fig. 5-16) (2) Attach a sling to the converter housing flange (fig. 5-17). Apply slight ten- sion on the sling and using a soft hammer, bump the torque converter housing away from the transmission main housing. WARNING Do not allow second-turbine drive gear and freewheel unit to remain with the converter housing. The second-turbine drive gear could fall unexpect- edly and cause damage or in- jury. CAUTION When converter housing has cleared the transmission hous- ing approximately 1-1/2 inches (35 mm), check to ensure that the second-turbine drive gear and freewheel unit remain with the transmission housing. If the freewheel un it is raised with 5-6 Copyright 1984 General Motors Corp.DISASSEMBLY OF TRANSMISSION the torque converter housing, the oil suction t u b e could be damaged. If necessary, use two long screwdrivers to pry the free-wheel front bearing from the converter housing. On units equipped with an internal ther mostat, do not pry against by- pass tube 30 (foldout 7,B). (3) Remove the torque converter housing and attached parts (fig. 5-17). Re- move the gasket. Refer to paragraph 6-8 for converter housing rebuild instructions. 5-7. REMOVAL OF TORQUE CONVERTER TURBINE GEARING AND OIL. SUCTION TUBE a, Turbine Gears and Freewheel Clutch (1) Remove the seconé-turbine drive gear and attached parts (fig. 5-17). Remove the step-joint sealring from the drive gear shaft. ‘Thrust race 25 (foldout 7,B) may re~ main on the hub of the second-turbine drive gear. If so, remove the race. (2) Remove the ball bearing from the seconé-turbine drive gear only if replacement is necessary (fig. 5-17). NOTE On so me models, it may be necessary to remove t he oil suetion tube prior to removal of the freewheel unit, Refer to paragraph 5-Ze. (3) Remove the first-turbine driven gear and the second-turbine driven gear and freewheel unit as an assembly (fig. 5-17). Refer to paragraph 6-9 for freewheel unit rebuild instructions. (4) If the transmission is equipped to provide a standard speed low-gear ratio, re- move the forward-and-reverse sun gear as shown in figure 5-18. If the transmission is equipped with a high speed low-gear ratio, forward-and-reverse sun gear 16 (foldout 9,B) cannot be removed as shown (fig. 5-18) but FARST-TURBINE DRIVE GEAR NEEDLE BEARING AND THRUST RACES FORWARD-AND REVERSE ‘SUM GEAR (STANDARD ‘SPEED MODELS) rir) STP, 3 SEARING [ACCESSORY ORIVE ; SHAFT ASSY Fig. 5-18, Removing forward-and- reverse sun gear (models with standard speed ratio) must be removed from the rear of the trans- mission; however, spacer 8 (foldout 9,B) is accessible and should be removed from the sun gear cavity. (5) Remove the needle roller bear- ing, two thrust races, and step-joint sealring from the first-turbine drive gear (fig. 5-18). Remove the first-turbine drive gear and ball bearing as an assembly. Do not remove the bearing unless replacement is necessary. If necessary, refer to paragraph 6-10 for rebuild instructions. b. Accessory Drive Shaft. Remove the accessory drive shaft (ig. 6-18). Remove bearing 9 (foldout 7,B) from accessory drive shaft 8 only if replacement is necessary. €; Oil Suction Tube. If present, remove three self-locking bolts 30 and bolt '31 (fold- out 9,4) which retain oil baffle plate 29. Re- move t he baffle plate. Using a fabricated wreneh, remove the mele nut that retains the oil suetion tube at the top of the housing (fig. 5-18). If present, remove self-locking bolt 1 (foldout 8,B) at the suction tube support. Re- move the suction tube, and remove the male nut and compression sealring. Copyright 1984 General Motors Corp. STTT, TTB, TRY 2001 SERIES TRANSMISSIONS NOTE Disassembly paragraphs are as follows: Model Para ‘TT 2221-1, 2421-1 5-8, 5-10, 5-12, 5-13, 5-14 ‘TTB 2221-1, 2421-1 5-9, 5-10, 5-12, 6-13, 5-14 TRT-l 5-11, 5-12, 5-13, 5-14 TRI-3 5-11, 5-12, 5-13) 5-8, REMOVAL OF REAR COVER AND HIGH-RANGE CLUTCH PISTON HOUSING (TT 2221-1, 2421-1) NOTE Models without converter- driven PTO, proceed to para~ graph 5-8a, Models with con- verter-driven PTO, proceed to paragraph 5-8. & Rear Cover Assembly (TT 2221-1, 2421-1 without converter-driven PTO) ()_ Position the transmission on wood blocks, front splitline downward. Remove the nineteen bolts and lockwashers that attach the re ar cover to the transmission housing (fig. 5-19). Remove the rear cover Fig. 5-19, Removing transmission rear cover (TT 2221-1, 2421-1 without converter-driven PTO) and gasket. Remove sealring 2 (foldout 16,D) from the rear cover. Remove pipe plug 3 or 33 only if replacement is necessary. (2) If the transmission is equipped with a speedometer drive assembly, remove two bolts 15 and lockwashers 14, Remove speedometer drive sleeve assembly 10, gasket 9, speedometer drive adapter 8, and gasket 7 from rear cover 4, Remove lip-type oil seal 11 and washer 12 from drive sleeve 13 only if replacement is necessary. oH .¢ Clutch Piston Housing tr aaa 2401-1 without converter driven PTO) (1) Straighten the locktabs, and re~ move the six bolts that attach the high-range cluteh piston housing to the transfer drive gear (fig. 5-20). Remove the bolts and lock- tabs. (2) Using two screwdrivers, pry the high-range clutch piston housing and attached parts from the transfer drive gear (fig. 5-21). Refer to paragraph 6-11 for the high-tange eluteh piston housing rebuild instructions. (3) Proceed to paragraph 5-10. g Rear Cover Assembly (TT 2221-1, 2aaI-T with converter-driven PTO) (1). Using a 1-1/4-ineh socket wrench, loosen but do not remove self-locking nut 28 Hlgaenance cuore PISTON HOUSING Pig. 5-20. Removing high-range clutch piston housing bolts (TT 2221, 2421-1 without converter-driven PTO) 58 Copyright 1984 General Motors Corp.DISASSEMBLY OF TRANSMISSION igh nance cuuTon PISTON ROUSING LL BEARING Fig. 5-21. Removing high-range clutch piston housing (TT 2221-1, 2421-1 without converter-driven PTO) (foldout 16,D). Remove nineteen bolts 30 and lockwashers 31. Attach a hoist to PTO out- put flange 27. Remove rear PTO cover as- sembly 22, PTO shaft 17, and attached parts as a unit. Remove gasket 1 and sealring 2. (2) Remove self-locking nut 29, flange retaining washer 28, and PTO output flange 27. Refer to paragraph 6-20 for rear PTO cover assembly rebuild instructions. driven PTO) (1) Remove two step-joint sealrings 38 (foldout 11,B) f ro m high-range piston housing 37. Straighten six locktabs 31, and remove six bolts 30 and the locktabs. (2) Pry high-range cluteh piston hous- ing 37 (and attached parts) f ro m transfer drive gear assembly 2. Refer to paragraph 6-11 for cluteh piston housing rebuild instrue~ tions, (3) Proceed to paragraph 5-10. 5-9, REMOVAL OF REAR COVER, INTERNAL BRAKE, AND HIGH- RANGE CLUTCH PISTON HOUSING (TTB 2221-1, 2421-1 models) NOTE with converter-driven PTO, proceed to paragraph 5 Models without converter- driven PT 0, proceed to para~ graph 5-9b. Ip Rear Cover Assembly (TTB 2221-1, 2421-1, with converter-driven PTO) (Q) Using @ 1-1/4-ineh socket wrench, loosen but do not remove the PTO flange re~ taining nut (fig. 5-22). Remove the eighteen bolts and lockwashers that retain the rear cover assembly. Spring force will push the rear cover upward. (2) Attach a sling to the PTO flange (fig. 5-23). Remove the rear cover assembly, PTO s haf t, and attached parts as a unit. Refer to paragraph 6-21 for rear cover assembly rebuild instructions. (3) Proceed to paragraph 5-9e. Rear Cover Assembly (TTB 2221-1, 2421-1, without converter-driven PTO) () Remove the eighteen bolts and lockwashers that retain the rear cover assem- bly (refer to fig. 5-22). Spring force will push the rear cover upward. (2) Attach a sling to the bolt flange of the rear cover, and remove the rear cover and attached parts. Refer to paragraph 6-21 for rear cover assembly rebuild instructions. LocRTASHER 18) BOLT 382164214 IN 18) Fig. 5-22. Removing power takeoff flange nut (TTB 2221-1, 2421-1 with converter-driven PTO) Copyright 1984 General Motors Corp. 5-9TT, TTB, TRT 2001 SERIES TRANSMISSIONS PTO FLANGE Fig. 5-23. Removing rear cover assembly (TTB 2221-1, 2421-1 with converter-driven PTO) ¢. Internal Brake Components © opm, aD (1) Remove twelve brake return springs a nd twelve guide pins from the re~ cesses"in the diaphragm (fig. 5-24). Remove the eleven brake plates from the brake hub. Remove the ball bearing from the hub of the high-range clutch piston housing. (2) Remove the step-joint sealring from the brake hub (fig. 5-24). Remove the snapring that retains the brake hub, and re- move the brake hub, Remove the sealring from the diaphragm. (3) Remove the three bolts and lock- washers that retain the diaphragm on the transmission housing (fig. 5-24). Remove the diaphragm assembly and gasket. Refer to paragraph 6-16 for diaphragm assembly re- build instructions. High-Range Cluteh Piston Housi te 22a, 2981-1) (1) Straighten the six locktabs and remove the six bolts and locktabs that attach the high-range eluteh piston housing to the transfer drive gear (fig. 5-25). Remove the BAL BEARING HH-Rawce cLuTcH PISTON HQUSING our @1 Fig. 5-24. Removing brake return springs ‘and guide pins (TTB 2221-1, 2421-1) HIGH-RANGE CLUTCH PISTON HOUSING ee B THANSIER oaive ean - . 5-25. Plattening piston housing bolt tabs (TTB 2221-1, 2421-1) two step-joint sealrings and the O-ring seal from the hub of the high-range clutch piston housing. (2) Pry the high-range eluteh piston housing from the transfer drive gear, and re- move it as an assembly. Refer to paragraph 6-11 for eluteh piston housing rebuild instruc- tions. Copyright 1984 General Motors Corp.DISASSEMBLY OF TRANSMISSION 5-10, REMOVAL OF HIGH-RANGE AND FORWARD CLUTCH, GEARING (QT, TTB 2221-1, 2421-1) a High-Range Clutch Assembly and ‘Transfer Drive Gear Q)_ Por models without a converter- driven PTO, remove the high-range clutch and hub assembly from the transfer drive gear (fig. 5-26). For models with a converter- driven PTO, remove, as an assembly, the high~ range clutch and hub 10 (foldout 11,B or 15,4) from the transfer drive gear. Refer to para- graph 6-13 for high-range cluteh and hub as- sembly rebuild instructions, (2) Remove the snapring from the for- ward planetary carrier, and remove the trans- fer drive gear assembly (fig. 5-26). Refer to paragraph 6-17 for the transfer drive gear re- build instructions. b, Forward Clutch and Planetary (1) Replace two of the ten self-lock- ing bolts that retain the forward cluteh piston housing with two 3/8-16 x 2-1/2-inch bolts removed from the control valve assem- bly in 5~3e (fig. 5-27). Install t h e bolts at opposite sides of t he piston housing to re~ strain the spring foree, HiGh-RANGE CLUTCH AND HUB ASSEMBLY Fig. 5-26. Removing high-range cluteh and hub assembly (TT, TTB 2221-1, 2421-1 without converter-driven PTO) Copyright 1984 General Motors Corp. (2) Remove the remaining eight self- locking bolts and plain washers (if present) which retain the forward cluteh piston housing (fig. 5-27). ‘Then loosen the two re- straining bolts evenly and remove them. (3) Remove the forward clutch pis- ton housing and piston as an assembly (fig. 5-28). Remove the forward clutch piston FORWARD PISTON HOUSING (CONFIGURATIONS VARY) ——4 SELF-LOCKING BOLT aa Pig. 5-27. Removing forward clutch piston housing bolts (TT, TTB 2221-1, 2421-1) Fig, 5-28. Removing forward clutch piston housing and piston (TT, TTB 2221-1, 2421-1)TT, TTB, TRT 200] SERIES TRANSMISSIONS from the piston housing. Refer to paragraph 6-12 for eluteh piston assembly rebuild in structions, (4) Do not remove the socket-head plug from the forward cluteh piston housing unless necessary for replacement, or cleaning of the oil passage (fig. 5-28). (8) Remove the forward planetary carrier assembly, ring gear, four cluteh plates, and the attached reverse ring gear as @ unit (fig. 5-29). Remove thrust washer 2 (foldout 10,4) from the carrier, if present. (6) Separate the clutch plates and forward ring gear from the planetary car- rier assembly. Remove the twelve piston return springs and guide pins, and remove the remaining four forward cluteh plates from the eluteh anchor assembly (fig. 5-29). (1) Remove the snapring that retains the reverse ring gear on the forward planetary carrier assembly (fig. 5-30). Refer to para~ graph 6-25 for the planetary carrier assembly Tebuild instructions. 5-11. REMOVAL OF REAR HOUSING, HIGH- AND LOW-RANGE CLUTCHES, PLANETARY, AND ADAPTER (TRT -1, TRT -3) NOTE Disassembly subparagraphs are as follows: Model Para TRY 2221-1, 2421-1 S-Lla TRT 2221-3, 2421-3 with underdrive s-Lb TRI 2221-3, 2421-3 with overdrive S-Lle TRI 2211-3, 2411-3 5-110 a TRT 2221-1, 242) (1) Position the transmission, front downward, and remove seventeen short bolts, three long bolts, and lockwashers (fig. 5-31). FORWARD PLANETARY] ‘CARRIER ASSEMBLY FoRWaaD CLUTCH PLATES (f), ASSEMBLY. FORWARD PLANETARY ‘CARRIER ASSEMBLY REVERSE RING GEAR Fig. 5-30. Removing snapring from reverse ring gear (TT, TTB 2221-1, 2421-1) (2) Remove the rear housing and in- ternal parts in the rear housing, as a unit (fig. 5-32). Remove the gasket. (3) Position rear housing 2 (foldout 16,A) on blocks. Remove snapring 11 which holds oil retainer 10 in the rear housing. Re- move the oil retainer, sealring 9, and internal snapring 8 which retains rear bearing 6 in the housing. Copyright 1984 General Motors Corp.DISASSEMBLY OF TRANSMISSION EAR HOUSING Lone aout Fig. 5-31. Removing rear housing bolts (PRT 2221-1, 2421-1) EAR HOUSING igh RANGE "ING GEAR, Fig. 5-32. Removing transmission rear housing assembly (TRT 2221-1, 2421-1) (4) Using a soft hammer, tap shaft 5 (foldout 16,A) rearward to remove the shaft from th e housing. Remove snapring 7 and rear bearing 6 from the shaft, if replacement is necessary. (8) Remove the internal snapring which retains the high-range clutch anchor assembly (fig. 5-33). (6) Grasp the high-range clutch pack and anchor assembly together and remove Copyright 1984 General Motors Corp. CLUTCH ANCHOR Fig. 5-33. Removing clutch anchor snapring (PRT 2221-1, 2421-1) HGH RANGE ANCHOR ASSEMBLY CLUTCH PLATES REAR HOUSING Fig. 5-34. Removing high-range clutch anchor and plates (TRT 2221-1, 2421-1) the assembly from the rear housing (fig. 5-34). Separate the parts. Refer to paragraph 6-14 for rebuild of the cluteh anchor assembly. Remove t he clutch anchor pin (fig. 5-35). Refer to paragraph 6-11 for rebuild of the housing assembly. (7) Lift the high-range planetary car- rier assembly out of the ring gear (fig. 5-36). Refer to paragraph 6-25 for rebuild of t he planetary carrier assembly. Remove the sun gear and thrust washer assembly. Remove 5-13‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS cue ‘con Pw Fig. 5-35. Rear housing and piston assembly (TRT 2221-1, 2421-1) SKAPAING HGH RANGE ‘SUN GEAR hor-aaNse ING GEAR LOWRANCE luton oR) Fig. 5-36, Removing high-range planetary carrier assembly (TRT 2221-1, 2421-1) the thrust washer only if it is worn or dam- aged. (8) Remove the internal _snapring which retains low-range clutch backplate (fig. 5-36). (9) Lift out the ring gear, bringing with it the backplate, three internal-splined 5-14 ING GEAR BACKPLATE EXTERNAL-SPLNED] PLATE @) INTERNALSPUNED PLATE (2) ‘EXTERNALSSPLINED| PLATE) Fig. 5-37. Removing high-range ring gear and low-range clutch plates (TRT 2221-1, 2421-1) HIGH- RANE SUN Fig. 5-38. Removing high-range sun gear sleeve snapring (TRT 2221-1, 2421-1) plates, and two external-tanged plates (fig. 5-31). Remove the two remaining cluteh plates. (10) Remove the snepring from the splined sleeve (fig. 5-38). (11) Lift the low-range piston housing assembly 0 u t of the adapter assembly (fig. 5-39). Remove the two step-joint Teflon seal- rings from the hub of the housing. Refer to Copyright 1984 General Motors Corp.DISASSEMBLY OF TRANSMISSION paragraph 6-11 for rebuild of the piston hous~ ing assembly. (12) Remove sixteen bolts 10 (foldout 12,A) a nd lockwashers 11 which retain the rear housing adapter assembly 7. (13) Remove the rear housing adapter assembly. Remove sealring 6 and gasket 5 from the adapter. Refer to paragraph 6-15 for rebuild of the rear housing adapter assem- bly. (14) Remove the transfer drive gear and sun gear sleeve assembly (fig. 5-40). Re- move the sleeve from the gear and the snap- ring from the sleeve, Refer to paragraph 6-19 for rebuild of the sleeve assembly, and to paragraph 6-18 for rebuild of the output transfer drive gear. Fig. 5-39. Removing low-range cluteh drum assembly (TRT 2221-1, 2421-1) IGHRARGE SUN GEAR SLEEVE TRANSFER ‘RVE GEAR Fig, 5-40. Removing transfer drive gear and sun gear sleeve Copyright 1984 General Motors Corp. (15) The forward carrier thrust washer may remain either with the transfer drive gear or with the forward planetary car- rier, Remove the thrust washer. (16) Proceed to paragraph 5-12. b, TRT 2221-3, 2421-3, Models With Underdrive (1) Position the transmission, front downward, and remove fifteen bolts and lock- washers which retain the rear housing to the adapter (fig. 5-41). (2) Lift the output shaft, rear housing, and attached parts f ro m the adapter (fig. 5-42). Remove the gasket. a se 0050 — V Hy EY Tansmsion o ws Pe iS 01 Fig. 5-41. Removing rear housing bolts (TRT 2221-3, 2421-3 with underdrive) TRANSMSS 0. ‘OUTPUT SHAFT HIGH-RANGE CLUTKy DRL Fig. 5-42. Removing rear housing (TRT 2221-3, 2421-8 with underdrive) S15‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS REAR HOUSING ANCHOR ASSY LoW-RANGE ‘LUTCH PLATES Fig. 5-43. Rear housing and low-range cluteh (TRT 2221-3, 2421-3 with underdrive) (8) Position the r e ar housing, rear downward, and remove t he large snapring that retains the clutch anchor assembly (fig. 5-43). (4) Remove the cluteh anchor assem- bly, five external-tanged clutch plates, an d five internal-splined clutch plates as an as- sembly (fig. 5-43). Separate the plates from the anchor assembly. Refer to paragraph 6-14 for rebuild of the clutch anchor assem- bly. (3) Remove t he clutch anchor pin (tig. 5-44). Do no t remove the welch plug from the anchor pin hole in the housing. (6) Refer to paragraph 6-11 for re~ build of the housing assembly. (2) Remove the internal snapring which retains the high-range cluteh backplate (tig. 5-43). (8) Remove the low-range ring gear, backplate, two internal-splined clutch plates, and one external-tanged clutch plate as a unit (fig. 546). Remove the low-range plan- etary carrier assembly. Refer to paragraph 6-25 for rebuild of the planetary carrier as- sembly. Remove the two remaining clutch plates. TRANSMISSION Pig. 5-44. Removing eluteh anchor pin (TRT 2221-3, 2421-3 with underdrive) LOW-RANGE PLANETARY CARRIER ASSEMBLY Fig. 5-45. Removing high-range clutch backplate snapring (TRT 2221-3, 2421-3 with underdrive) (9) Remove the low-range planetary sun g ear (fig. 5-47). Remove the snapring from the hub of the forward planetary carrier. (10) Remove the high-range piston housing assembly (fig. 5-48). Remove the Copyright 1984 General Motors Corp.DISASSEMBLY OF TRANSMISSION ING GEAR EXTERNAL-SPUNED CLUTCH PLATE INTERNAL SPLNED ‘CLUTCH PLATE Fig. 5-46. Removing low-range planetary ring gear (TRT 2221-3, 2421-3 with underdrive) SUN GEAR ForWwaRD PLANETARY Cd HIGH RANGE CLUTCH ORUM Pig, 5-47. Removing low-range planetary sun gear (TRT 2221-3, 2421-3 with underdrive) two step-joint Teflon sealrings from the hub of the drum. Refer to paragraph 6-11 for re~ build of the housing assembly. (11) ‘The adapter assembly (fig. 5~48) compresses the piston return springs. Loosen the two recessed bolts (12-point heads) even- ly while holding the adapter against spring fore. Copyright 1984 General Motors Corp. FORWARD PLANETARY CARRIER, eur Locking Fig. 5-48. Removing high-range clutch drum assembly (TRT 2221-3, 2421-3 with underdrive) aoaoren ASSEMBLY FORWARD PLANETARY AEIENSE RS SEAN CARRIER ASSEMBLY FORWARD CLUTCH PLATES THRUST WASHER Pm ‘SPRING Asner Fig. 5-49. Removing adapter assembly and attached parts (TRT 2221-3, 2421-3 with underdrive) (12) Remove the adapter assembly, forward planetary carrier assembly, and other attached parts as a unit (fig. 5-49). S-lT‘TT, TTB, TRT 200] SERIES TRANSMISSIONS: (13) Remove six self-locking bolts 28 (foldout 10,8). Remove adapter assembly 24. Refer to paragraph 6-15 for rebuild of the rear housing adapter assembly. (14) Remove forward cluteh piston 17 with sealrings 18, 19, and 20, Refer to pare~ graph 6-12 for rebuild of the clutch piston as- sembly. (15) Remove bearing 22 by using @ puller bolted to retainer 21. (16) Remove ring gear 14 and two cluteh plates 15 and 16. Remove snapring 11 and separate ring gear 1 from carrier assem- bly 3. Refer to paragraph 6-25 for rebuild of the planetary carrier assembly. (17) Remove the piston return springs and pins, four eluteh plates, the forward-and- reverse Sun gear and thrust washer, and the adapter gasket (fig. 5-49). (18) Proceed to paragraph 5-12. TRT 2221-3, 2421-3, Models With Overdrive (1) Remove fifteen bolts a nd lock- washers which retain t h e rear housing (fig. 5-50). (2) Attach @ lifting sling to the out- put shaft and remove the rear housing, high- range clutch, and output shaft as a unit (fig. 5-51). uTPUT SHAFT EAR HOUSING Fig. 5-50. Removing rear housing bolts (TRT 2221-3, 2421-3 with overdrive) 5-18 (3) Remove the rear housing gasket. Remove the lifting sling. (4) Position t he rear housing, rear downward, a nd remove internal snapring 2 (foldout 14,B) which retains t h e high-range cluteh anchor assembly. Remove anchor as- sembly 3. Refer to paragraph 6-14 f or re~ build of the eluteh anchor assembly. (3) Remove the high-range planetary ring gear and the three cluteh plates which come with it (fig. 5-52). Remove the three clutch plates remaining in the housing. (6) Remove ¢1ut ¢ h anchor pin 12 (foldout 16,B). Do not remove the weleh plug in t he anehor pin hole at the outside of the housing. (1) Refer to paragraph 6-11 f or re~ build of the housing. REAR HOUSING ourPuT SHAFT HIGH-RANGE PLANETARY (CARRIER ASSEMBLY Gasket cumewonu Fig. 5-61. Removing rear housing and attached parts (TRT 2221-3, 2421-3 with overdrive) Copyright 1984 General Motors Corp.DISASSEMBLY OF TRANSMISSION (8) Remove the high-range planetary sun gear (fig. 5-53). Remove the internal snapring which retains the high-ange plane- tary carrier assembly. Ag) enWAL-OxTeRNAL-TANGED H 'seunco ATE PLATE ING GEAR, AAR HOUSING Fig. 5-52. Removing high-range planetary ring gear and three clutch plates (PRT 2221-3, 2421-3 with overdrive) SUN GEAR GH Rance PLANETARY CARRIER ASSEMBLY LOW-RANGE ‘LUTCH ‘RUM Pig. 5-53, Removing high-range planetary sun gear (TRT 2221-3, 2421-3 with overdrive) (9) Remove the high-range planetary carrier assembly (fig. 5-53). Refer to para~ graph 6-25 for rebuild of the planetary car- rier assembly. (10) Remove low-renge clutch hub 15 (foldout 14,4). Remove the roller bearing assembly consisting of two races and a bear- ing assembly (items 12, 13, and 14). (11) Remove five internal-splined cluteh plates 16 and f 0 ur external-splined eluteh plates 17. Remove the snapring which retains the low-range piston housing. (12) Remove the low-range piston housing and its attached parts (fig. 5-54). Remove two step-joint ‘Teflon sealrings from the hub of the cluteh drum. Refer to para graph 6-11 for rebuild of the piston housing assembly. (13) The adapter assembly (fig. 5-54) compresses the piston return springs. Loosen the two recessed bolts (12-point heads) even- ly while holding the adapter against spring force. (14) Remove t he adapter assembly [Link] its attached parts (fig. 5-55). Remove the adapter gasket and sun gear thrust acs Pig. 5-54, Removing low-range cluteh drum (TRT 2221-3, 2421-3 with overdrive) Copyright 1984 General Motors Corp. S19‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS nabTeR aur FORWARD PLANETARY ‘CARRIER ASSEMBLY FORWARO CLUTCH PLATE THRUST WASHER Pig. 5-55. Removing adapter assembly and attached parts (TRT 2221-3, 2421-3 with overdrive) washer (if it remained in the forward plane~ tary carrier). (15) Remove the forward-and-reverse planetary sun gear and thrust washer (fig. 5-65). Remove twelve piston return springs and pins, (16) Remove four forward clutch Plates remaining to t fie transmission (fig. 5-55). (17) Remove six self-locking bolts 28 (foldout 10,8). Remove adapter assembly 24. Refer to paragraph 6-15 f or rebuild of the rear housing adapter assembly. (18) Remove forward cluteh piston 17 (foldout 10,B) with sealrings 18, 19, and 20. Refer to paragraph 6-12 f 0 r rebuild of the eluteh piston, (19) Re move bearing 22 (foldout 10,B) by using a puller bolted to retainer 21. 5-20 (20) Remove ring gear 14 and two cluteh plates 15 and 16. Remove snapring 11 and separate ring gear 1 from carrier assem- bly 31. Refer to paragraph 6-25 for rebuild of the planetary carrier assembly. (21) Proceed to paragraph 5-12. |. TRT 2211-3, 2411-3 (). Position t he transmission, front downward, and remove eighteen bolts 4 (fold- out 16,C) and lockwashers 3 that retain rear housing 9 to the transmission housing. (2) Remove rear housing assembly 5, tapping the output shaft with a soft hammer, if necessary, to keep it from coming out with ‘the housing. (3) Remove gasket 1 (foldout 16,C). (4 Remove the forward clutch pis- ton with sealrings, items 18 through 21 (fold- out 11,4), from the housing. Remove spacers 12a nd 24 from the housing. Refer to para- graph 6-24 for rebuild of the rear housing as~ sembly. (5) Remove twelve piston return springs 22 (foldout 9,B) and pins 23. (6) Remove forward planetary ring gear 15 (foldout 11,4) and clutch plates 16 and 17, as a unit. Separate the plates from the ring gear. Remove th e remaining two internal-splined cluteh plates 13 and two external-tanged clutch plates 14. (7) Remove forward planetary carrier assembly 3 and reverse planetary ring gear 1 as a unit. Remove snapring 10 and separate the ring gear from the carrier. Refer to para graph 6-25 for rebuild of the planetary car- ier assembly. (8) Remove thrust washer 2 (foldout 11,A) from the bore of forward planetary car- rier assembly 3 or from sun gear 16 (foldout 9,8). (9) Remove forward-and-reverse sun gear 16. Copyright 1984 General Motors Corp.DISASSEMBLY OF TRANSMISSION FORWARDANDTEVERSE z cin anc ase irae Fig. 5-56. Removing forward-and-reverse ‘eluteh anehor assembly 5-12, REMOVAL OF REVERSE CLUTCH AND PLANETARY (All Models) a. Remove the forward-and-reverse clutch anchor assembly (fig. 5-86). Do not remove six eluteh anchor pins 21 (foldout 9,B) from anchor 20. Remove the anchor pin from the valve body mounting pad (fig. 5-56). b, Remove the reverse planetary carrier assembly and one internal-splined clutch plate as a unit (fig. 5-57). Separate the clutch Plate from the carrier assembly. Refer to paragraph 6-25 for the reverse planetary car rier assembly rebuild instructions. Remove the remaining nine reverse cluteh plates from the transmission housing. ¢, Remove the reverse clutch piston from its bore in the transmission housing (fig. 5-58). Refer to paragraph 6-12 f or cluteh piston rebuild instruetions. 5-13. REMOVAL OF OIL PUMP & Remove the bolts and lockwashers thatattach the oil pump to the transmission housing (fig. 5-59). Pig. 5-57. Reverse planetary carrier assembly and clutch plates i SS coer Fig. 5-68. Removing reverse clutch piston b, Remove the ofl pump and gasket, pump cover, and cover gasket as an assembly. Do not separate the oil pump components un- less inspection or parts replacement is necessary. Refer to paragraph 6-26 for oil pump rebuild instruetions. NOTE This concludes the disassembly of -3 models in t o subassem- Copyright 1984 General Motors Corp. 5-21TT, TTB, TRT 2001 SERIES TRANSMISSIONS: Fig. 5-59. Removing oil pump assembly blies. F or rebuild of the -3 transmission housing, refer to paragraph 6-28. For 1 models, proceed with paragraph 5-14. 5-14, REMOVAL OF OUTPUT COMPONENTS AND TRANSFER DRIVEN GEAR (TT, TTB, TRT 2221-1, 2421-1) NOTE Models with front and rear out- puts without output disconnect, proceed to paragraph 5-14a. Models with front and rear ou puts with output disconnect, proceed to paragraph 5-14b. Models with rear output only, proceed to paragraph 5-14c. & One-piece Output Shaft (outputs at Tront and Fear (1) Using a puller, remove the oil seal from the front of the transmission housing (fig. 5-60). 5-22 SHIFTER SHAFT Vi HOLE PLUG Fig. 5-60. Removing output shaft front oil seal (-1 models with ‘one-piece output shaft) SHIFTER SHAFT MOLE PLUG Fig. 5-61. Removing output shaft front bearing snapring (-1 models with one-piece output shaft) (2) Remove the snapring that retains the front output shaft bearing in the housing bore (fig. 5-61). Do not remove the shifter shaft hole plug unless replacement is neces- sary. (3) Using a soft hammer, drive the output shaft forward until the front bearing is free from the housing bore (fig. 5-62). (4) Remove the output shaft and front bearing as an assembly (fig. 5-63). Re- move the front bearing from the output shaft. (5) Removal of the output shaft will free transfer driven gear 23 and spacer 27 (foldout 17,A). Remove the transfer driven gear (fig. 5-64) and remove the spacer from Copyright 1984 General Motors Corp.DISASSEMBLY OF TRANSMISSION TRANSHSSION HOUSING: REAR Fig. 5-62. Loosening output shaft front bearing (-1 models with one-piece output shaft) Fig. 5-63. Removing output shaft (C1 models with one-piece output shaft) the sump area. Remove lip-type oil seal 30 (foldout 17,4) from the rear of the housing. Remove the output shaft rear bearing from its bore (fig. 5-64). (6) Remove remaining parts from the transmission housing only if part replacement or additional servicing is required. Refer to paragraph 6-27 for the transmission housing rebuild instructions. Copyright 1984 General Motors Corp. Fig. 5-64, Removing transfer driven gear C1 models with one-piece output shaft) b, Two-piece Output Shaft (with output eee CAUTION If only the output shaft seal needs to be replaced, do not _re- move the output disconnect Shifter shaft. Removal of the output disconnect shifter shaft allows the shifter fork to drop into the sump area, and partial disassembly of the transmission is requited to reinstall the out- put disconnect shifter compo- nents. Remove and discard the failed output shaft seal. Install anew seal. Press it lightly against the shoulder in the bore. (1) Rotate shifter fork shaft counter- clockwise to remove it from the front of the transmission housing (fig. 5-65). Removal of the shifter fork shaft will allow the shifter fork to fall into the sump area. Remove the shifter fork, Remove the shifter shaft oil seal 5-23‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS rad RIF PIN SHIFTER FORK SHAFT Fig. 5-65. Removing disconnect shifter shaft (-1 models with output disconnect) Fig. 5-66. Removing rear output shaft oil seal (-1 models with output diseonnect or with no front output) (2) Using a puller, remove the oil seal from the rear of the transmission housing (fig. 5-68). (3) Remove the snapring that retains the rear bearing in the housing bore (fig. 5-61). (4) Using a soft hammer, drive the front output shaft rearward until the bearing ‘on the rear output shaft is free from the housing bore (fig. 5-68). Remove the rear output shaft and the attached bearing and spacer as an assembly (fig. 5-69). Remove the bearing only if replacement of the bearing or spacer is necessary. Do not remove bushing 22 (foldout 17,4) from rear output shaft 23 unless replacement is necessary. 5-24 bearing snapring (-1 models with output disconnect or with no front output) FRONT OUTPUT SHAFT EAR OUTPUT SHAFT TRANSMISSION HOUSING: FRONT Pig. 5-68. Driving output shaft rearward (C1 models with output disconnect) Fig. 5-69. Removing rear output shaft assembly (-1 models with output disconnect) (5) Removal of the rear output shaft from the transmission housing will free trans- fer driven gear 23 and allow spacer 22 to fall Copyright 1984 General Motors Corp.DISASSEMBLY OF TRANSMISSION Fig. 5-70. Removing transfer driven gear C1 models with output disconnect or with no front output) into the sump area. Remove the transfer driven gear (fig. 5-70), and remove the fallen spacer from the sump. (6) Remove the center bearing from its bore in the housing web (fig. 5-71). (1) Remove the front output shaft and disconnect coupling as an assembly (fig. 5-12). NOTE A. spring and two detent balls will be released when the dis- connect coupling is removed from the front output shaft Drape a shop towel over the as sembly to prevent possible loss of the balls. (8) Remove the disconnect coupling from the front output shaft, and place the two detent balls and spring in a parts re~ ceptacle. (9) Using a puller, remove the oil seal from the front of the transmission housing. (10) Remove the snapring and output shaft bearing (refer to fig. 5-61) only if re- placement is necessary. If necessary, remove the snapring and, using @ puller which will ap- Copyright 1984 General Motors Corp. Fig. 5-71. Disconnect coupling, front ‘output shaft, and center bearing 1 models with output disconnect) TRANSMISSION aon EN, orscbmgcr coUPLING foearton Fig. 5-72, Removing front output shaft and diseonnect coupling (-1 models with output disconnect) ply its foree to the rear surface of the outer race, draw the bearing from its bore. If such a puller is not available, use a drift and tap evenly around the outer race to drive the bearing forward. (11) Remove remaining parts from the transmission housing only if part re placement ot additional servicing is re~ quired. Refer to paragraph 6-27 for the transmission housing rebuild instructions. 5-25TT, TTB, TRT 2001 SERIES TRANSMISSIONS Rear Output Shaft (no front output) (1) Using @ puller, remove the oil seal from the rear of the transmission housing (fig. 5-66). (2) Remove the snapring that retains the rear bearing in the housing bore (fig. 5-67). (3) Remove plug 8 (foldout 17,A) from the front output shaft orifice in the housing. If necessary, remove plug 16 from the front of the housing. Using a drift, drive rear output shaft 26 rearward until bearing 28 is free in its bore. Remove rear output shaft 26, spacer 27, and bearing 28 es an assembly. Remove the bearing only if re- 5-26 placement of the bearing or spacer is neces- sary. (4) Removal of the rear output shaft from the transmission housing will free trans~ fer driven gear 23 and allow spacer 22 to fall into the sump area. Remove the transfer driven gear (fig. 5-70), and remove the fallen spacer from the sump. (5) Remove bearing 21 (foldout 17,4) from its bore in the housing web. (6) Remove the remaining parts from the transmission housing only if part re~ placement or additional servicing is required. Refer to paragraph 6-27 for the transmission housing rebuild instructions. Copyright 1984 General Motors Corp.Section 6. REBUILD OF SUBASSEMBLIES 6-1. SCOPE This seetion contains the rebuild proce- dures for the subassemblies which were re~ moved in Section 5. The rebuild procedures refer to photographs and to exploded-view foldouts in the back of this manual. 6-2. GENERAL INFORMATION FOR SUBASSEMBLY REBUILD Refer to Sections 4 and 8 for general overhaul information as follows: Paragraph Title 4-3 ‘Tools, Equipment 44 Replacement Parts 45 Careful Handhing 46 Cleaning, Inspection 41 Assembly Procedures 41 ‘Torque Specifications 8-1 Wear Limits Data 2 Spring Data 6-3. CONTROL VALVE BODY ASSEMBLY 8 Disassembly (foldout 18,B) (1) Remove plug 6 and gasket 7 that retain main-pressure regulator valve 8 and remove the valve. (2) Remove plug 18 and gasket 17 that retain trimmer plug 16. Remove trim- mer plug 16, main-pressure regulator spring 14, spring retainer 13, and trimmer spring 15. (3) Remove main-pressure check plug 36. Remove cluteh signal pressure plug 54. Remove gasket 53 from plug 54. Remove se lector valve plug 35 and gasket 34. NOTE Por models with air-actuated cluteh cutoff, proceed to step (4), For models with hydraulic actuated clutch cutoff, proceed tos tep (5). For models with Copyright 1984 General Motors Corp. inching control, proceed to steps (6) through (12). (4) Models with air-actuated_eluteh cutoff. Remove retainer plug 50 and gasket 23. Remove cutoff valve plug 49 from re~ tainer plug 50. Remove sealring 22 from cut- off plug 49, Remove clutch cutoff valve 20 and valve spring 19 from contéol valve body 9. Proceed to step (13). (3) Models with hydraulie-actuated cluteh cutoff. Remove retainer plug 25 and gasket 23. Remove cutoff valve plug 21 from retainer plug 25. Remove sealring 22 and cup 24 from cutoff valve plug 21. Remove elutch cutoff valve 20 and valve spring 19 from con- trol valve body 9, Proceed to step (13). (6) Models with inching control. Re- move valve 5 to p 37. Clean the paint and dirt away from the valve body in the area of oil seal 46. (7) If present, remove snapring 47 or retainer ring 48. (8) Clean the outer stem of valve 42 to permit seal 46 and plug 45 to be easily re~ moved. Insert a bolt through the linkage pin hole in inching control valve 42, and pull the valve from its bore in valve body 9. If seal 45 prevents removal of inching valve 42, break the sealant bond between the seal OD and the valve bore by driving a wood drift against the seal case. (8) Remove seal 46, plug 45, sealring 44, and spring 43. (10) Remove spring 41 from control valve body 9. (11) Insert a small serewdriver from the inner (mounting) side of the valve body assembly and push inching regulator valve 39 forward to release valve stop 40. Remove valve stop 40. (12) Remove inching regulator valve 39 and spring 38.TT, TTB, TRT 2001 SERIES TRANSMISSIONS (13) All models. Remove plug 31 and gasket 32, and remove one spring 33 and ball 30. NOTE Before removing s t 0 p(s) 12, take note of the location of the stop(s). This will assist reas~ sembly. Refer to figure 6-1 (14) At the inner (mounting) side of control valve body 9, remove valve stop(s) 12 from range selector valve 29 or 52. (15) If present, remove snapring 27. (16) Insert @ bolt through the linkage pin hole in selector valve 29 or 52. Being careful not to loose detent balls 30, pull the selector valve and seal 26 from the bore and remove them from control valve body 9 If seal 26 prevents removal of selector valve 29 or 52, break the sealant bond between seal OD and the valve bore by driving a wood drift against the seal case. Remove the seal from the selector valve. Remove the remaining detent b a1 30 and spring 33, which were freed during removal of the selector valve. (17) Do not remove retainer plug 11 and ball 10 from control valve body 9 unless parts replacement is necessary. rexccagoen feucton ie ior Seteronmte toes Pig. 6-1. Control valve body ‘assembly~mounting side (18) Remove plugs 51 and 55 if necessary. b Assembly (foldout 18,B) NOTE Before beginning assembly, re- fer to step (9) f 0 r possible re- work of valve body 9. NOTE At assembly, all spool valves, when dry, must move freely, by their own weight, within their bores. (1)_ If the retainer plug and ball were removed from the control valve body, install a new ball and retainer (fig. 6-1). Place the retainer plug, open end upward, over the ball. Press the retainer plug to a depth of 0.000 0.010 ineh (0.25 mm) below the surface of the three supporting bosses. (2) Install one spring 33 (foldout 18,B) and detent ball 30 into control valve body 9. Depress the ball against the spring, and i stall selector valve 29 or 52, linkage end last, through the seal bore of the control valve body. (3)_ Install the remaining detent ball 30 and spring 33} install gasket 32 and plug 31 to retain t he ball and spring. Tighten the plug to 60-70 Ib ft (82-94 N-m). (4) Position the selector valve in the middle detent position (neutral). Refer to figure 6-1 and install the selector valve stop(s) as follows: No. of Models Stops ‘TT, TTB 1 A TRT 2211, 2411 2) B ‘TRI 2221, 2421 1 ic (5) For models without a groove in valve body 9 for snapring 27, apply Loctite Retaining Compound No. 75 (or equivalent) onto the outer circumference of the new se- lector valve oil seal. Install the seal, manu- 6-2 Copyright 1984 General Motors Corp.REBUILD OF SUBASSEMBLIES facturer's identification numbers outward, over the linkage end of the selector valve into its bore (fig. 6-1), Press the seal into the bore to a location *0.010 inch (0.25 mm) from the bottom of the chamfer. (6) For models with a groove in valve body 9 for snapring 27, apply a light coat of Loetite Retaining Compound No. 75 (or equiv- alent) onto the outer circumference of new selector valve oil seal 26. Being careful not to load up the snapring groove with retaining compound, install seal 26, with the manufac~ turer's identification numbers outward, to a depth that clears the snapring groove. ‘Clean out the snapring groove and install snapring 27. (7) Install _main-pressure regulator valve 8 (foldout 18,B), and install gasket 7 and plug 6. Tighten plug 6 to 80-90 Ib ft (109-122 Nem), Install gasket 53 and plug 54. Tighten plug 54 to 30-40 Ib ft (41-54 Nem). (8)_ Install plugs 36, 51, and 55. Tight- en the plugs to 10-12 Ib ft (14-16 Nem). Install gasket 34 onto plug 35 and install the plug. Tighten plug 35 to 80-90 tb ft (109-122 Nem). (9) Refer to figure 6-2. If main pres sure regulator valve 8 (foldout 18,B) is of the earlier design, spring retainer 13 mus t be used. If valve 8 is of the later design, no spring retainer is used. If a later design re- placement valve is to be used in an earlier valve body, rework is required (fig. 6-2). (Qo) If required, instal spring retainer 13, concave side first, onto the stem end of main-pressure regulator valve 8. In- stall main-pressure regulator spring 14, trim- mer spring 15, and trimmer plug 16 into the valve bor e. Install gasket 17 and plug 18. Tighten plug 18 to 90-100 Ib ft (123-135 Nem). NOTE For models with inching con- trol, proceed to steps (11) through (16). For models with hydraulie-actuated clutch cut- off control, proceed to ste p (1). For models with air-actu- ated eluteh cutoff, proceed to step (18). FEARLER DESIGN LATER DESIGN RETAINER REWORK TO 0740-0760 IN (1880-1830 mm) TO ACCEPT NeW VALVE 0740-0760 1m (1880-1930 rm Fig. 6-2. Control valve body rework area (earlier models with new valve) (11) Models _with_inehing control. In- stall spring 38 and valve Ising a small screwdriver, push valve 39 forward and in- stall valve stop 40 to retain valve 39 against spring 38, (12) Install spring 41, valve 42, and spring 43. (13) Install sealring 44 onto plug 45. (14) Install plug 45, larger bore first, over the stem of valve 42, Push plug 45 in until it seats, hold it against spring 43, and install stop 37 to retain plug 45. (15) For models without a groove in valve body 9 for snapring 47, apply Loctite Copyright 1984 General Motors Corp. 6-3TT, TTB, TR 2001 SERIES TRANSMISSIONS Retaining Compound No. 75 (or equivalent) onto the outer cireumference of new oil seal 46, Install the new seal, manufacturer's identification numbers outward, over the stem of valve 42, Press the seal to a location 0.010 inch (0.25 mm) from the bottom of the chamfer. Install push-on retaining ring 48, (18) For models with @ groove in valve body 9 for snapring 47, apply a light coat of Loctite Retaining Compound No. 75 (or equiv- alent) onto the outer circumference of new oil seal 46. Being careful not to load up the snapring groove with retaining compound, in- stall seal 46, manufacturer's identification numbers outward, to a depth that clears the snapring groove. Install snapring 47. (17) Models _with_hydraulie-actuated gluteh cutoff. Assemble valve spring 19 onto clutch cutoff valve 20 and install the assem- bly, spring first, into valve body 9. Install sealring 22 onto cutoff valve plug 21. Install cup 24, small diameter first, onto the stemmed end of the cutoff valve plug. Lu- bricate and install the assembled cutoff valve plug, cup first, into the smooth bore end of retainer plug 25. Install retainer plug 25 and gasket 23, ‘Tighten plug 25 to 60-70 Ib ft (82-84 Nem). Cover the exposed orifice in the retainer plug until the hydraulic brake line is to be attached. (18) Models with _air-actuated_cluteh cutoff, Assemble valve spring 19 onto clutch cutoff valve 20 and install them, spring first, into valve body 9. Install sealring 22 onto cutoff valve plug 49. Lubricate a nd install the assembled cutoff valve plu g, sealring first, into the smooth b o re end of retainer plug 50. Install retainer plug 50 and gasket 23, Tighten plu g 50 to 60-70 Ib ft (82-94 Nem). Cover the exposed orifice in the re- tainer plug until the air-actuated cylinder assembly is to be connected. 6-4. TRANSMISSION FRONT COVER a, Disassembly (foldout 6,4). If replace- ment of off seal 1] is necessary, drive the seal out of the front of front cover 13. b. Assembly (foldout 6,4) (Q)_ Install seal 11, spring-loaded lip first, straight into the bore in front cover 13. (2) If the transmission is equipped with input shaft 18, press ofl seal 11 into cover 13 until it bottoms lightly against the bore shoulder. If the transmission is equipped with input shaft 23, press oil seal 11 into cover 13 to a depth of 0.230-0.290 inch (5.9- 7.3 mm) below the lead chamfer in the bore. 6-5. TORQUE CONVERTER DRIVE COVER Disassembly (foldout 6,A) (1). Using a puller, remove bearing 15 from input shaft 18 or 23 (2) Straighten the ears of lockstrips 11, and remove six bolts 16. Remove input shaft 18 from torque converter drive cover 20, or input shaft 23 from torque converter drive cover 24, >, Assembly (foldout 6,4) (1) Install input shaft 23 onto torque converter drive cover 24, or input shaft 18 ‘onto torque converter drive cover 20. Install three new lockstrips 17 and six 1/2-13 x 1-1/8-ineh bolts 16. Tighten the bolts to 67- 80 Ib ft (1-108 Nm). Bend corners of lockstrips 17 against the heads of bolts 16. (2) Install shielded bearing 15, shield 8 ide upward, onto input shaft 18 or install plain bearing 15, manufacturer's identifica~ tion upward, onto input shaft 23. Press the bearing firmly to a seat against the shoulder of the input shaft. 6-6. FIRST- AND SECOND-TURBINE ASSEMBLY 4, Disassembly (foldout 7,4) () Locate the index marks (V-groove) in the outer rims of the first- turbine support and the first turbine (fig. 6-3). Make sure these marks are well de- 6-4 Copyright 1984 General Motors Corp.REBUILD OF SUBASSEMBLIES SECOND ROLL FN runne "0 Frnt TURBINE fARSTTUREINE ‘SUPPORT Dex MARKS. (FOR ALIGNMENT) Fig. 6-3. Pirst- and seeoné-turbine assembly fined in both parts. If the marks are not prominent, deepen them to 0.040 inch (1_ mm) (maximum) before continuing with disas- sembly. (2) Drive (but do not remove) the six (or nine) roll pins inward toward the hub until they clear the holes in the first-turbine sup- port (fig. 6-3). Remove the roll pins only if replacement is necessary. (3)_ Remove the first turbine from its support (fig. 6-4). Remove the second tur- bine and its bearing from the first-turbine support. (4) If replacement is necessary, re~ move bearing 8 (foldout 7,A) from second tur- bine 6 by pressing lengths of drill rod through the three removal holes in the hub of second turbine 6. Remove snapring 7 from second turbine 6 only if replacement is necessary. (5) If replacement is necessary, re- move bearing 1 from first-turbine support 3 by pressing lengths of drill rod through the removal holes in the hub of first-turbine sup- port 3. FIRST TURBINE secono TURBINE out pin seAkine / REMOVAL FIRST-TURBINE INDEX Hou SUPPORT MARKS. Fig. 6-4. Removing (or installing) first turbine b. Assembly (foldout 7,4) (1) If removed, install bearing 1. Position the bearing, manufacturer's identi- fication outward, and press it firmly to a seat against the hub of support 3. (2) If removed, install bearing & Position the bearing, manufacturer's identi- fication outward, and press the bearing firmly to a seat against the hub of second turbine 6. If snapring 7 was removed, install its replacement. (3) Install the second-turbine (and Bearing) Into the frst-turbine support (Cig. 6-4). (4) Install the first turbine into the first-turbine support and align the V-groove index marks (fig. 6-4). (5) Drive the six (or nine) roll pins outward to a depth of 0.000-0.030 ineh (0.76 mm) below the outer surface of the first- turbine support (fig. 6-3). Copyright 1984 General Motors Corp. 6-5TT, TTB, TRT 2001 SERIES TRANSMISSIONS 6-1, TORQUE CONVERTER PUMP a. Disassembly (fig. 6-5) () Straighten the ears of the six lockstrips. Remove the twelve bolts that attach the pump retainer and input accessory drive gear to the torque converter pump. Remove the six lockstrips, pump retainer, input accessory drive gear, and bearing. Remove gasket 17 (foldout 7,A) or O-ring 21, if present. (2) Inspect the twenty-four special bolts around the eireumference of the pump. Remove any defective bolts by pressing them from the pump flange. b, Assembly (fig. 6-5) (1) If any of the special bolts were re~ moved from the pump, install their replace- ments, Align the flat’ side of the bolt head next to the pump and press the new bolt into place. (2) Using drive tool J-23723-6, install double-row ball bearing 18 (foldout 7,A), load ing notch upward, into accessory drive gear 19, (3) Place gasket 17 or sealring 21 on- to input accessory drive gear 19. Install con- SPECIAL . BEARING “BOLTS (24) AEIANER 4201-11448 sourt2) ‘oADMG TOROUE CONVERTER -AGCESSORY ORIVE GEAR PUN? Pig. 6-5. Torque converter pump assembly verter pump 15 onto drive gear 19, bearing 18, and gasket 17 or O-ring 21, aligning the bolt holes in the pump with those in the gear and gasket, if used. (4) Install pump retainer 14, and in- stall six lockstrips 13 and twelve 1/4-28 x 1-1/4-inch bolts 12. Tighten the bolts to 10- 12 Ib ft (14-16 Nem). Bend the lockstrip ears against the bolt heads (fig. 6-5). 6-8. TORQUE CONVERTER HOUSING a. Disassembly (foldout 7,B) NOTE If the transmission does not in- clude the diaphragm shown in figure 6-6, begin disassembly at step (5). Q). "Dry" converter housings. If the transmission has @ “dry” converter housing, it will have a pressed steel diaphragm and oil seal (fig. 6-6). These must be removed be- fore the accessory gearing can be removed. Removal of the diaphragm destroys the dia- phragm and seal. (2) To remove the diaphragm, cut a slit through the diaphragm, as shown in figure 6-6. Insert a hooked tool into the slit and pry the metal above the slit outward. ‘This will push t he metal below the slit inward. De- forming the diaphragm in this manner will Feduce its outside diameter and allow the diaphragm to be lifted from the converter housing. (3) Clean the bore from which the diaphragm was removed. A smooth, clean bore will prevent leakage after the new Giaphragm has been installed, (4) Remove t he cup plug from the converter housing only if replacement is necessary (fig. 6-6). If necessary, drive the plug from its bore, and clean the bore from which the plug was removed. (5) 411 models, Remove step-joint searing 50 (foldout 7,B) from converter hous- ing sleeve 40. If replacement is necessary, 6-6 Copyright 1984 General Motors Corp.REBUILD OF SUBASSEMBLIES [CONVERTER HOUSING DIAPHRAGM ‘Rects$ony DRIVE CAR Fig. 6-6. Torque converter housing— front view (models with "dry" converter housing) remove sleeve 40 from the front of converter housing 38. (6) At the rear of the converter housing, remove the snapring that retains the outer race of the accessory-driven gear bear ing (fig. 6-7). Tap the accessory-driven gear forward and remove it and the attached parts from the housing. (7) Remove the outer race and rollers of bearing 12 (foldout 7,B). Press the inner race of bearing 12 f ro m accessory-driven gear 2, Remove snapring 11 and bearing 10 or separable bearing 45. (8) On transmissions equipped with an accessory drive g e ar, remove the snapring from the accessory gear bearing (fig. 6-7). Tap the accessory drive gear forward and re- move it and the attached parts from the housing. (9) Remove snapring 7 (foldout 7,B) and bearing 6 from accessory drive gear 1. (10) Use care during this operation to prevent damage to the protruding converter pressure regulator valve 23 or lubrication by- AccessoRy ‘DAVEN GEAR ower. IN accessony DRIVE GEAR ‘GROUND mi SLEEVE | S COMERTER dua REGULATOR VALVE i De Wancation Rleccutsronn ve Maes Fig. 6-7. Torque converter housing— rear view pass tube 30, if present. If replacement of the ground sleeve is necessary, remove the four attaching bolts and press the sleeve from the converter housing (fig. 6-7). (1D If converter pressure regulator valve spring 22 (foldout 7,B) is no t colored light blue or if other replacement is neces- sary, drive pin 21 rearward with @ pin drift and remove spring 22 and valve 23. (12) If the lubrication regulator valve components 18, 19, and 20 require replace- ment, remove them by twisting pin 18 from the converter housing. (13) If the transmission is equipped with an internal thermostat, remove. lubri- cation bypass tube 30 and thermostat assem- bly 31. Remove sealring 33 from thermostat assembly 32. Copyright 1984 General Motors Corp. 6-1TT, TTB, TRT 2001 SERIES TRANSMISSIONS (14) Do not remove plugs 37 or 39 un- less necessary for cleaning or replacement. Do not remove dowel pins 41 unless necessary for replacement. ‘b. Assembly (foldout 7,B) (1) If plug 37 was removed, replace it. Tighten it to 33-37 Ib ft (45-50 Nem). If plug 39 was removed, replace it. Tighten it to 23-27 Ib ft (32-36 Nem). If dowel pins 41 were removed, install new dowel pins. Press the pins to a height of 0.430-0.450 inch (10,92-11.43 mm) above the housing splitline. (2) If the transmission is equipped with an internal thermostat assembly, install lubrication bypass tube 30 into the rear face of converter housing 38 Install sealring 33 onto the thermostat and install thermostat assembly 32 into the converter housing, as shown in figure 6-8. (3) If lubrication regulator valve 20 (foldout 7,B) was removed, install spring 19 and valve 20 onto guide pin 18. Install the assembled parts, pressing pin 18 into housing 38 to a depth of 0.000-0.010 inch (0.25 mm) below the housing splitline, Refer to the Note below step (4). (4) If converter pressure regulator valve 23 was removed, install spring 22 (spring 22 must_be light blue) and valve 23 onto guide pin 21. Install the assembled parts, pressing pin 21 to a height of 1.16-1.18 inches (29.4-29.9 mm) above the top of the valve. ‘ean fine Dinter oF Cowentek our on Kon Fig. 6-8, Installation of thermostat assembly NOTE If the press fit of pins 18 or 21 is not satisfactory, clean the bore and pin of all oil residue and apply Loctite Grade B (Loctite Corp. Newington, Conn.) or equivalent to the bore and mating surface of the pin. Install the pin as described. Al- low the sealant to cure for two hours at room temperature. (5) If ground sleeve 13 was removed, chill the replacement sleeve in dry ice for at least 1 hour. Align the bolt holes in ground sleeve 13 with those in housing 38, and press the sleeve to a firm seat against the rear of the housing. Install four 5/16-18 x 3/4-inch, self-locking bolts 14, and tighten them to 17-20 Ib ft (24-27 Nm). (6) If the transmission is equipped with accessory drive gear 1, install bearing 6, with snapring groove away from the gear. Install snapring 7 to retain bearing 6. (2) Install accessory drive gear 1 and bearing (outer race snapring removed) into the front of housing 38. Install the snapring onto the outer race of the bearing. (8) install bearing 10 or the outer race and rollers of bearing 45, with its snapring groove away from the gear, onto accessory- driven gear 2. If bearing 45 is used, install the bearing inner race, flanged side away from the gear. Install snapring 11 to retain the bearing. Press bearing 12 inner race, flange first, against the rearward seat on aceessory-driven gear 2. Install the outer race and rollers of bearing 12. (9) Install accessory-driven gear 2 and assembled bearings (outer race snapring removed) into the front of housing 38 Install the snapring onto the outer race of bearing 10 or 45. (10) If converter housing sleeve 40 was removed from housing 38, install a new sleeve. Heat the sleeve for ease of replace- ment. Press converter housing sleeve 40, 6-8 Copyright 1984 General Motors Comp.REBUILD OF SUBASSEMBLIES sealring groove last, onto the hub of housing 38, Seat the sleeve firmly against the shoul- der on the hub. Install stepjoint sealring 50 into the groove in the converter housing sleeve, Retain the sealring with oil-soluble grease. NOTE ‘This completes procedures for “wet™ torque converter hous- ings. For "dry" torque conver- ter housings, proceed to step an. (11) "Dry" _converter_housings. Coat the outer diameter of a new diaphragm and seal assembly with nonhardening sealer and start it, convex side first and arrow pointing toward bottom of transmission, into the front of the converter housing (fig. 6-6). Using two soft hammers (one driving against the other or a block of wood contoured to the cireum- ference of t he diaphragm), drive the dia~ phragm assembly onto its seat in the housing bore. Move t he driver evenly around the cireumference, driving only slightly at each position. (12) If plug 49 (foldout 7B) was re- moved, coat the outer diameter of the new plug with nonhardening sealer. Drive plug 49, flat side first, into the converter housing, and seat it against the shoulder in the bore. 6-8. TURBINE-DRIVEN GEARS AND FREEWHEEL CLUTCH 8, Disassembly (foldout 8,4) (Q) Press the second-turbine driven &e ar out of the assembled unit (fig. 6-9). ‘This will free spacers 29 and 31 (foldout 8,8) and bearing 32 which may be removed. Re- move fifteen rollers 9 or 23, also freed. (2) Remove bearing 30 from gear 28. Remove twelve nuts 2 or 16 from bolts 14 or at (3) Using a serewdriver, pry eam as- sembly 10 or 24 away from gear 3 or 17. Re- move spring plate 5 or 19 and roller cage 8 or FIRST-TURBINE DRIVEN EAR F secon TURBINE DRIVEN GEAR Pig. 6-9. Pressing second-turbine ‘driven gear assembly from freewheel clutch assembly 22, Remove three spring pins 6 or 20 and springs 7 or 21 from the roller cage. Remove bolts 14 or 27 and retainer plate 13 (if pres- ent). Remove roll pin 11 or 25 from eam 12 or 26 if replacement is necessary. (4) If replacement is necessary, re~ move bearings 1 or 15 and 4 or 18 from gear 3or lt. b. Assembly (foldout 8,) () If bearings 1 or 15 and 4 or 18 were removed from gear 3 or 17, install the bearings by pressing them against the shoulders on the gear. (2) Install the roll pin into the cam and press it to the bottom of the bore (fig. 6-10). (3) Insert the rolier cage into the freewheel cam, and align the index marks on the cam and cage as shown in figure 6-10. Install the spring retainer plate onto the cam, indexing the small hole with the roll pin. (4) Install the three springs and spring pins into the bored ears of the roller cage (fig. 6-11). Copyright 1984 General Motors Corp. 6-9‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS Rou PIN FREEWHEEL, ROLLER CAGE FREEWHEEL cat Fig. 6-10. Freewheel roller cage installed in freewheel cam SPRING FREEWHEEL PATE ROUER CAGE Sprig SPRING PING) Fig. 6-11. Installing spring and ‘Spring pin into roller cage (5) If applicable to the model, place retainer plate 13 (foldout 8A), flat side first, against the rear face of the assembled cam and cage. Insert twelve bolts 14 or 27. In- stall the assembled cam onto the assembled seeond-turbine driven gear (fig. 6-12). (6) Secure the assembled parts with twelve self-locking nuts (fig. 6-13). To pre- vent rotation of the bolt heads, use a fabri- cated wrench or an open-end’ wrench, and tighten the nuts to 41-49 Ib ft (56-66 Nem). RETAINER PLATE ow 12) can SECOND-TURBINE ‘DRIVEN GEAR Fig. 6-12, Installing assembled cam ‘onto assembled second-turbine driven gear SECOND-TURBINE DRIVEN GEAR RENEE, SELE-ADCKING Nur Fig. 6-13. Installing self-locking nut onto freewheel eam bolt (7) Install fifteen rollers into the cam pockets; use oil-soluble grease to retain the rollers in the cage (fig. 6-14). (8) install the first-turbine driven gear by placing the lead chamfer on the gear hub against rollers, and while pressing down- ward, rotate the first-turbine driven gear ina counterclockwise direction (fig. 6-15). 6-10 Copyright 1984 General Motors Corp.REBUILD OF SUBASSEMBLIES FREEWHEEL ROLLER CAGE sécovo-YuRBint DRIVEN GEAR Fig. 6-14. Installing roller into roller cage FIRST-TURBINE DRIVEN GEAR Fig. 6-15. Installing first-turbine driven gear (9)_ Install the bearing spacer onto the an of the second-turbine driven gear (fig. 6-16). (10) Install the remaining bearings and spacer, as shown in figure 6-17, onto the shaft of the second-turbine driven gear. Ac- curately center the spacer to prevent it from getting caught on the shaft shoulder. Press SECOND-TURA NE ‘ion 7 DRIVEN GEAR Tere SPACER Figst-tuReine DRIVEN GEAR | Fig. 6-16. Installing bearing spacer onto second-turbine driven gear BEARING. FRST-TURBINC a7 DRIVEN GEAR SPACER Fig. 6-17. Installing bearings and spacer onto second-turbine driven gear the bearings and spacer firmly into place while supporting the second-turbine driven gear. 6-10. FIRST-TURBINE DRIVE GEAR AND BEARING ASSEMBLY ‘a. Disassembly (foldout 7,B) (1)_ If bearing 29 can be easily pressed from first-turbine drive gear 28, remove the Copyright 1984 General Motors Corp. el‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS bearing. If unusual resistance is encountered, heat the inner race of bearing 29 to 450°F (232°C) and press first-turbine drive gear 28 from the bearing. (2) If the bearing did not easily press from the drive gear, discard bearing 29 and clean the journal of gear 28. . Assembly (foldout 7,B) (1) Apply Loctite Retaining Com- pound, or equivalent, to the ID of new bearing 29 and its journal on first-turbine drive gear 28. (2) _ Press bearing 29 firmly against its seat on first-turbine drive gear 28, Allow assembled parts to cure for two hours at room temperature. 6-11. CLUTCH PISTON HOUSING NOTE ‘These procedures will rebuild any of the assemblies listed in Table 6-1. ‘Table 6-1, PISTON HOUSING ASSEMBLIES 4 s @ ]|o 8 s ek Ju EX |O E N o jo |p |a P Jk al}s Ja Te |e eee ees lee dp {js |s |r n]{TR]RYIR Oe te |e ve oe ee te ee Oe Ne ee ieee he Nee ee |G 1S High-Range Cluteh Piston Housing 1 uB| 24] 19 | 20@0, | 18 |i7 | 16 34, 39 36, 37 TTB 15,4] 22,] 19 | 20@0, | is |i7 | 16 35 38 TRT-1 12,Bs 23 | 21 (20) gor |e 16,4] 2 TRT -3 w/underdrive wal 4] 8] 66) 1 9 | 10 TRI -3 w/overdrive 14,85 in | 154) we [13 | i 16,B] 2 Low-Range Cluteh Piston Housing TRT 12,4] 15 | 19 | 1706) ey | ‘TRY -3 w/underdrive 13,By 23 | 2120) 2 fis | 18 16,B| 2 TRT -3 w/overdrive wal 4 [a] 6) 1 s | 10 6-12 Copyright 1984 General Motors Corp.REBUILD OF SUBASSEMBLIES Disassembly NOTE For high-range clutch piston housing, if the transmission is equipped with a speedometer drive assembly, proceed to step (). Otherwise, proceed to step QQ. (Q) Speedometer _drive_models, hi range. Remove Seainings 77 and. 95 Golde ings 27 and 29 (foldout T1,B), and drive pin 25 from the hub of high- range clutch piston housing 24. Remove speedometer drive shaft 26 and bearing 28 from the high-range eluteh piston housing. (2) If present, remove the bearing from the housing. (3) Position the piston and housing, piston side up, in a press. Use care to pre~ vent damage to the assembly. Depress the belleville spring and remove the snapring (fig. 6-18). (4) Remove the piston and sealring (and expander, if present) from the piston housing. Refer to paragraph 6-12 for clutch piston rebuild instructions. (5) Remove the hook-type sealring from the inner hub of the housing. (6) Remove the bushing and sleeve from the piston housing only if replacement is necessary. b, Assembly (1) If a bushing was removed from the housing, install a new bushing. Press the new bushing to a depth of 0.040-0.080 inch (1.01-2.03 mm) below the face of the hub. If a sleeve was removed, install a new sleeve. Press the new sleeve against the shaft shoul- der. (2) Install the hook-type sealring onto the inner hub of the housing. Install the pis~ ton, with sealring (and expander) in place (es assembled in para 6-12), into the housing. (3) Install the belleville spring, con- vex side up, onto the piston. Place the as- Copyright 1984 General Motors Corp. PRESS Ra PRESS TOOL PrSTON ASSEMBLY couse aun BELLEVILLE ‘SPRING SHAPRING Fig. 6-18. Removing (or installing) piston return spring (typical configuration) sembled parts, piston side upward, in press. Depress the spring and install the snapring (fig. 6-18). (4) If a bearing was removed from the rear hub of the housing, install the bear- ing. (5) If the transmission is equipped with a speedometer drive assembly, install sealrings 27 and 29 (foldout 11,B) onto the hub of high-range piston housing 24. Install speedometer drive shaft 26 into the rear hub of piston housing 24. Install pin 25 through the hub of the piston housing and drive shaft. Press the pin to a depth of 0.020-0.040 inch (0.51-1.01 mm) below the surface of the piston housing hub. (6) For TRT 2221-1, 2421-1 models, refer to paragraph 6-22 for rebuild of the rear housing; for TRT 2221-3, 2421-3, para~ graph 6-23. 6-12, CLUTCH PISTON ASSEMBLIES NOTE Warming Teflon sealrings in oil at 150°F (65°C) will make them easier to remove and install. Disassembly. (1) Do not use sharp-edged or pointed tools to remove Teflon sealrings. Rather, 6-13TT, TTB, TRT 2001 SERIES TRANSMISSIONS: slip a very thin, flat blade into piston groove between the sealring and side of the groove and work the seal out of the groove until it can be grasped with the fingers. Remove and discard the sealring. (2). Remove the expander, if present, from the groove in the piston. (3) Check for the presence of three holes in the piston. One hole should be clear. ‘The other two holes have ball check valves. ‘The ball should be clean and seat properly. (4) If the balls need to be replaced, pry the retainer plugs from the piston and remove the balls. Discard the retainer plugs and balls. b. Assembly (1) If the retainer plugs and balls were removed, replace them in accordance with the instructions contained in the parts Kit. (See Parts Catalog SA 1248.) (2) For pistons that use an expander with the sealring, install the expander into the groove in the piston. Make sure the free ends of the expander turn away from the seal ring (fig. 6-19). ‘The ends of some expanders may require additional bending to ensure they turn toward the bottom of the groove. ENDS MUST BE AS SHOWN WHEN EXPANDER IS COILED FOLLOWING THE NATURAL CURVATURE OF THE STRIP. BEND ENDS IF NECESSARY (0.25 1N.[6 mm] R MIN) SO THAT SHARP ENDS WILL NOT GOUGE SEAL: TYPICAL FOR EXTERNAL TYPE SEAL EXPANDER VIEW A TYPICAL FOR INTERNAL TYPE SEAL EXPANDER VIEW B Fig. 6-19, Typical expanders for teflon sealrings (3) Oil the installed expander and sealring. Start the sealring into the piston groove at a point directly opposite the gap in the expander. (4) Carefully work the sealring into the groove, compressing the expander while moving both directions from the starting point to the expander gap location. Do not stretch or distort the sealring more than absolutely necessary. (5) For sealrings that do not require expanders, install the lip-type sealring into the groove of the piston. Make sure that the lip of the sealring is toward the oil-pressure side of the piston. Refer to the exploded- view foldout for illustrations of lip directions. CAUTION Clutch application or leakage will occur if sealrings are im- properly installed (lip in wrong direction). (6) After installation, adjust the seal- ring in the groove to center it radially in the piston, 6-13, HIGH-RANGE CLUTCH AND HUB (v7, TTB) 8. Disassembly (foldout 11,B for TT; or foldout 15,A for TTB) (Q) Position the assembly so that nuts 6 and lockstrips 7 are upward. If the trans- mission is not equipped with a power takeoff, remove snapring 11 from hub 12. (2) Platten the corners of six lock- strips 7 and remove twelve nuts 6, Remove twelve bolts 15 and washers 14. (3) Separate hub 10 or 12 from clutch plates 8 9, and 13. »b. Assembly (foldout 11,B for TT; or foldout 15,4 for TTB) (1) Assemble twelve flat washers 14 onto twelve 5/16-24 x 7/8-ineh, self-locking bolts 15. Install bolts 15 into clutch plate 13. Copyright 1984 General Motors Corp.REBUILD OF SUBASSEMBLIES (2) Install clutch hub 10 or 12 onto the bolt and clutch plate assembly. Note that the long end of hub 10 or the unsplined end of hub 12 should be at the same side of clutch plate 13 as washers 14. (3) Install external-tanged plate 9 on- to the front side of clutch plate 13. Install clutch plate 8 onto the front side of external- tanged plate 9, engaging bolts 15. (4) Install six lockstrips 7 and twelve 5/16-24 nuts 6. Tighten the nuts to 14-18 Ib ft (19-24 Nem), and bend the lockstrip cor- ners against the bolt heads. () On models using hub 12, install snapring 11 into its groove on the splined shaft. 6-14, CLUTCH ANCHOR (TRT 2221-1, 2421-1, 2221-3, 2421-3) NOTE These procedures are for anchor assembly 12 (foldout 12,B), anchor assembly 12 (fold~ out 13,B), or anchor assembly 3 {foldout 14,B). Callouts are for foldout 12,B unless otherwise noted. & Disassembly (1) Disassemble anehor assembly 12 only if parts replacement is necessary. (2) Position the assembly, pins down- ward, in a press. Press pins 14 and 15 out of anehor 13, Assembly: NOTE Chill pins 14 and 15 in dry ice for at least 1 hour before in- stalling them into anchor 13. CAUTION For anchor 13 (foldout 12,B or 13,B), the flat side of the Copyright 1984 General Motors Corp. anchor f ac e's the rear of the transmission, For anchor 4 (foldout 14,8), the flat side of the anchor faces the front of the transmission, (1) Position the anchor front side downward, in @ press. Install two (longer) pins 15 at e ac h side of the large cutout in the outer perimeter of anchor 13. Press the pins toa height of 1.55-1.57 inches (39.4-39.8 mm) above the rear face of the anchor. NOTE Longer pins 15 project slightly at the front side of anchor 13. They prevent snapring 11 from rotating. (2) Press four (shorter) pins 14 into the remaining holes to a height of 1.55-1.57 inches (39.4-39.8 mm) above the rear face of anchor 13. 6-15. ADAPTER ASSEMBLY (TRT) Disassembly (1) Remove sleeve 27 (foldout 10,B) from adapter 26 or sleeve 9 (foldout 12,4) from adapter 8 only if replacement is neces- sary. (2) -3 models. Remove two plugs 25 (foldout 10,B) from adapter 26. b. Assembly ()_ If removed, position sleeve 27 (foldout 10,8) or sleeve 9 (foldout 12,A), internal chamfer first, into the front (ball bearing bore side) of the adapter. (2) Press the sleeve (rearward) until its forward (unchamfered) end is to a depth of 0.000-0.010 inch (0.25 mm) be 10 w the shoulder against which the ball bearing as~ sembly seats, (3) -3_models. Install two plugs 25 (foldout 10;B) into adapter 26. Tighten the plugs to 8-10 Ib ft (11-13 Nem).TT, TTB, TRT 2001 SERIES TRANSMISSIONS 6-16, INTERNAL BRAKE DIAPHRAGM (rr) a, Disassembly (foldout 15,B) (1) Remove plug 3 from diaphragm 4. (2) Position diaphragm assembly 2, pins upward, in a press. Support the area of ‘the hub surrounding sleeve 5 and press the sleeve from the hub of the diaphragm. Do not remove pins 6. b, Assembly (foldout 15,B) (1) Position diaphragm 4, rear side downward, in a press. (Rear side of dia- phragm has the recess for two bolts.) Sup- port the hub area around the center bore on a sleeve having a slightly larger inside diameter than the bore of the diaphragm. (2) Install sleeve 5, chamfered inside diameter end last, into the hub bore of dia~ phragm 4. Press the sleeve until the cham= fered inside diameter end is to a depth of 0.075-0.085 inch (1.90-2.15 mm) below the front mounting surface (outer bolt circle) of the diaphragm. (3) Install plug 3 into diaphragm as- sembly 2, Tighten the plug 14-16 lb ft (19-21 Nem). 6-17, TRANSFER DRIVE GEAR (TT, TTB) & Disassembly (foldout 11,B for TT; foldout 15,A for TTB) (1) If bearing replacement is neces- sary, pull bearing 1 from transfer drive gear assembly 2. (2) If the drive pins require replace- ment, press pins 4 from transfer drive gear 3. b. Assembly (foldout 11,B for TTs > foldout 15,4 for TTB) (1) If pins 4 were removed, place transfer drive gear 3, hub downward, in a press and install new pins. Press the pins to a height of 0.74-0.76 inch (18,8-19.3 mm). 6-16 (2) If bearing 1 was removed from transfer drive gear assembly 2, install a new bearing, outer snapring first, onto the gear hub. Seat the bearing firmly against the shoulder on the gear hub. 6-18, TRANSFER DRIVE GEAR (TRT -1) a, Disassembly (foldout 12,A) (Q)_ Remove the bearings from gear 3 only if parts replacement is necessary. (2) Remove the snapring from bear ing assembly 1. Using a bearing puller, re- move bearings 1 and 4 from gear 3. Assembly (foldout 12,4) (1) Press bearing 4, manufacturer's number outward, onto the splined hub of gear 3. Seat it firmly against the hub shoulder. (2) Press bearing 1, outer snapring groove toward gear, onto ‘the smooth-bore hub of gear 3. Seat it firmly against the hub shoulder. (3) Install the external snapring into t he groove in the outer race of bearing as- sembly 1. 6-19. TRANSFER DRIVE GEAR SLEEVE ASSEMBLY (TRT -1) a. Disassembly (foldout 12,4). If neces- sary for replacement, remove bushing 23 from sleeve 24. If the bushing must be cut out, do not damage the sleeve bore. ‘b. Assembly (foldout 12,4). Install. bush ing 23 into the 1 ar ger bore of sleeve 24. Press it in until the front (outer) end of the bushing is at a depth of 0.29-0.31 inch (7.4- 7.8 mm) below the end (front) of sleeve 24. (The bushing is prebored to give the proper inside diameter when installed.) 6-20. REAR PTO COVER ASSEMBLY (TT) Disassembly (foldout 16,D) () Tap PTO shaft assembly 17 for- ward from rear PTO cover assembly 22. Re- Copyright 1984 General Motors Corp.REBUILD OF SUBASSEMBLIES move snapring 16 from the shaft assembly. Do not remove pin 18 from shaft 19 unless replacement is necessary. (2) Remove snapring 20 from rear PTO cover 24 and remove bearing 21. Re- move sleeve 23 only if replacement is necessary. (3) Remove dust shield 26 and lip- type sealring 25 from rear of cover 24, and remove plug 32. b Assembly (foldout 16,D) (1) Install the PTO oil seal and dust shield as shown in figure 6-20. Install plug 32 (foldout 16,D). If the plug is 1/8-in. NPTR, tighten the plug to 10-12 Ib ft (14-16 N-m). If the plug is 3/8-in. NPTP, tighten the plug to 18-22 Ib ft (25-29 Nem). r INE REAR CovER 1M sueve up-tyeE ‘ . Olt Seat \ oust sno 0, 70-0.78N, 09,31-19.81 mon) 4 Fig. 6-20. Oil and dust shield installation (TT with converter-driven PTO) Copyright 1984 General Motors Corp. (2) If sleeve 23 was removed, install a new sleeve, beveled OD first, into PTO cover 24. Press the sleeve to the dimension shown in figure 6-20. Install bearing 21 (fold~ out 16,D) and snapring 20 into PTO cover 24. (3) If pin 18 was removed from shaft 19, install @ new pin, straight outer diameter first, into the shaft. Press the pin to a height of 0.810-0.830 inch (20.58-21.08 mm) from the front end surface of the shaft. (4) Install snapring 16 onto shaft as- sembly 17 and install the shaft, threaded end first, through bearing 21 and into PTO cover assembly 22, Seat the shoulder of the shaft against the bearing. 6-21, REAR COVER ASSEMBLY (TTB) a, Disassembly (foldout 15,B) NOTE For models with converter~ driven PTO, proceed to step (1). For models without converter- driven PTO, proceed to step (3). (1) Position the rear cover assembly on its side on a bench and remove flange re- taining self-locking nut 43, flange retaining washer 42, and output flange 41. (2) Tap the PTO shaft forward and remove it from the rear cover assembly (fig. 6-21). Remove the snapring from the shaft. Remove the pin only if replacement is neces- sary. (3) Position the rear cover so that the mounting flange is upward and remove the snapring t hat retains the brake-apply plate assembly (fig. 6-22). Remove the brake- apply plate assembly. Do not disassemble the apply plate assembly unless it does not meet the minimum press force of 400 pounds (1780 N) during the readjustment procedure described in step (4). (4) The brake apply plate assembly (fig. 6-23) must be readjusted to the setting established when the transmission was new, so that the automatic adjustment for brake 6-17‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS EAR COVER SAPRING Fig. 6-21. Removing PTO shaft from rear cover (TTB) ADJUSTING RING ‘APPLY PLATE ASSEMBLY SNAPRING REAR COVER. PANG PN 6) Fig. 6-22, Removing (or installing) brake-apply plate snapring (TTB) wear and proper release clearance are pro- vided. This adjustment is made by position ing the apply plate assembly, front down- ward, in a press on a smooth, flat plate (fig. 6-23), (5) Press brake adjusting ring 21 (fold- out 15,B) downward until its front surface is flush with the front surface of brake-apply Plate 23. If the adjusting ring moves with the application of less than 400 pounds (1780 N) force of the press, heat breakdown of spring pins 22 is indicated, and the pins must be replaced, PRESS RAM PRESS TOOL {ow ADIUSTING ING) OnAKE aprLy PLATE ASSEMBLY Fig. 6-23. Pressing brake adjusting ring flush with apply-plate surface (TTB) swapaING ean coven BALL BEARING BRAKE STON @) SERLAING RAKE FLUID LINES. Fig. 6-24, Removing snapring from rear bearing bore (TTB) (6) If replacement of spring pins 22 is necessary, press adjusting ring 21 from brake- apply plate 23, Remove si x spring pins 22 from adjusting ring 21. (7) If present, remove the snapring that retains the ball bearing and remove the bearing from the rear cover (fig. 6-24). Re- move the Teflon sealring from the inner hub. Note the location of the three brake pistons. Copyright 1984 General Motors Corp.REBUILD OF SUBASSEMBLIES DUST SHIELD BRAKE FLUIO LINES Fig. 6-25. Removing dust shield from rear cover (TTB) (8) Position the rear cover so that it rests on the mounting flange and remove the dust shield and oil seal (fig. 6-25). Or remove plug 44 (foldout 15,B), if necessary. Remove the brake fluid lines and fittings. (9) Using forced air at e a ¢ h brake fluid port, remove the brake pistons and re- lated parts from their bores (fig. 6-26). Each piston bore contains a piston 26 (foldout 15,8), sealring 25, piston cup 27, and expander as~ sembly 28. Remove sealrings 25 from pistons 26. b. Assembly (foldout 15,B) (1) Pack the inside diameter groove of oil seal 39 with high temperature grease, MIL-G-3545A or equivalent. Install oil seal 39 and dust shield 40 into rear cover 38 in the positions shown in figure 6-27. Or, apply a nonhardening sealer and install plug 44 (fold- out 15,B). (2) Lubricate the brake piston com- ponents with hydraulic brake fluid prior to installation into their bores. Install the three expander assemblies, brake piston cups (flat side upward), and brake pistons (flat side first), with sealrings assembled, into the three bores in the rear cover (fig. 6-28). (3) Install a new Teflon sealring, outer lip upward, into the groove in the inner hub of the rear cover (fig. 6-28). Install the bearing and snapring into the rear cover. BRAKE FLUIO PORT Fig. 6-26, Removing brake pistons from rear cover (TTB) 0.300 0.50 IN on. 20,2 wn) (142 mm) REAR. SHIELO ‘cover cose Fig, 6-27. Oil and dust shield installation (TTB with converter-driven PTO) Fig. 6-28, Installing brake piston components in rear cover (TTB) Copyright 1984 General Motors Corp. 6-19‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS (4) If removal of six spring pins 22 (foldout 15,B) was not necessary, proceed to step (6). CAUTION It is-essential that ring 21 be parallel to plate 23 and that pins 22 not be distorted or damaged during installation. (8)_If removal of six spring pins 22 (foldout 15,B) was necessary, install six new pins into apply plate 23. Press the pins to a seat against the bottom of their bores. Press adjusting ring 21 onto pins 22 until the front surface of ring 21 is at a height of 0.000- 0.010 inch (0.25 mm) above the front surface of apply plate 23. (6) Install brake-apply plate assembly 20 into rear cover 38. Align the small noteh in the plate with the cast lug located at the bottom of the cover bore (fig. 6-22). Install ‘the snapring to retain the brake-apply plate in the rear cover. ()_ Install the brake fluid lines and fittings (fig. 6-25). Tighten the fittings to 275-325 Ib ft (373-440 Nem). NOTE ‘This completes procedures for repair of this subassembly for models without — converter- Griven PTO. For models with converter-driven PTO, proceed with step (8). (8) If pin 29 (foldout 15,4) was re- moved from PTO shaft 30, install a new pin, straight outer diameter first, to a height of 0,810-0.830 inch (20.57-21.08 mm) from the front end surface of the shaft. Install snap- ring 27 onto PTO shaft assembly 28. (9) Install PTO shaft assembly 28, threaded end first, into the assembled rear cover and seat the shaft in bearing 32 within the assembled rear cover. (10) Install output flange 41 (foldout 15,B) and flange retaining washer 42 onto output shaft assembly 28 (foldout 15,4). Ap- 6-20 ply molybdenum disulfide grease (Molykote Type G or equivalent) onto the threads of flange retaining nut 43 (foldout 15,B) and in- stall the nut. Do not tighten the nut at this time. 6-22, TRANSMISSION REAR HOUSING ASSEMBLY (TRT 2221-1, 2421-1) 8, Disassembly (foldout 16,A). If re- placement is necessary, remove welch plug 13 and pipe plug 14. To remove plug 13, in~ sert a punch from the inside of housing 2, through the cluteh anchor pin hole, and drive out plug 13. Clean the bore from which it was removed. Assembly (foldout 16,4) () If welen plug 13 was removed, coat the new plug with nonhardening sealer. Press or drive the plug, closed end first, into housing 2 until its outer end is even with the inner end of the chamfer in the bore. (2) If plug 14 was removed, install it into the threaded opening in the housing. ‘Tighten plug 14 to 8-10 Ib ft (11-13 Nm). 6-23, TRANSMISSION REAR HOUSING ASSEMBLY (TRT 2221-3, 2421-3) a, Disassembly (foldout 16,B) (1) Remove oil seal 11 and internal snapring 9 (2) Using a soft hammer, drive output shaft 5 or 7 rearward and out of housing 2. (3) If present, remove snapring 6. (4) Remove bearing 8 from shaft § or 1, if replacement is necessary. (5) If replacement is necessary, re- move plug 13 by inserting a punch through the eluteh anchor pin bore inside housing 2 and driving the plug out. (6) Remove pipe plug 14, and plug 15 (if used). Copyright 1984 General Motors Corp.REBUILD OF SUBASSEMBLIES 'b. Assembly (foldout 16,B) ()_ Install 1/4-ineh pipe plug 14. ‘Tighten plug 14 to 8-10 lb ft (11-13 Nem). If used, install 3/8-inch plug 15. Tighten plug 15 to 12-16 Ib ft (17-21 Nem). (2) If plug 13 was removed, coat the new plug with nonhardening sealer. Install it, closed end first, into the clutch anchor pin bore in housing 2. Press or drive the plug in until its outer end is even with the inner end of the chamfer in the bore. (3). Install bearing 8 onto shaft 5 or 7 and seat it firmly against the shaft shoulder. (4) If removed, install snapring 6 onto shaft 7. (5) Install the assembled output shaft and bearing, unsplined end first, into the rear ‘of housing 2. Tap on the outer race of bear- ing 8 to seat it against the housing shoulder. Install snapring 9. (6) Install oil seal 11, spring-loaded lip first, into the rear bore of housing 2. Seat it lightly against the shoulder in the housing bore. 6-24. TRANSMISSION REAR HOUSING ASSEMBLY (TRT 2211-3, 2411-3) a, Disassembly (foldout 16,C) (1) If present, remove baffle 6. (2) Remove oil seal 7. (3) If present, remove tube 8 only if replacement is necessary. (4) Re move snapring 22 (foldout 11,A) and bearing 23. (5) Remove plug 2 (foldout 16,C). 'b. Assembly (foldout 16,0) (1) Install plug 2 into housing 9 ‘Tighten plug 2 to 4-5 Ib ft (5.5-6.7 Nem). (2) Install bearing 23 (foldout 11,4) and snapring 22 into the housing. (3) If tube 8 (foldout 16,C) was re~ moved, coat the larger end of the tube with nonhardening sealer and install it, smaller end first, through the rear bore of housing 9. Press the tube into its bore until the upper end of the tube is even with the lower edge of the countersink in the bore (tube not used in some models). (4) Press a new seal 7, spring-loaded lip first, into the rear of housing 9. Seat it lightly against the shoulder in the housing bore. (5) Coat baffle 6 (not used in some models) with nonhardening sealer. Install the baffle, convex side first, into the housing. Press it into the housing bore to a depth of 0.060-0.090 inch (1.52-2.28 mm) below the rear surface of housing 9. 6-25. PLANETARY CARRIER ASSEMBLY NOTE Planetary pinions are a matched set. If one pinion re- quires replacement, the re- maining pinions must also be replaced. Also, new needle bearings, thrust washers, and spindles should be installed any time a planetary carrier assem- bly is being rebuilt. a. Disassembly (Table 6-2) (1) Use Table 6-2 to determine the data for the specific planetary assembly which is to be disassembled. CAUTION Do no t drill into the carrier. The diameter of spindles is slightly more than the diameter of the drill (Table 6-2, K). Cen- tering the drill accurately will prevent drilling into the carrier. Copyright 1984 General Motors Corp. 6-21‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS Table 6-2. PLANETARY ASSEMBLIES 7 1 i Tales seein | see ses | ols ae ae toe” | sa tuntny| Mose soma | tae | SS tna | sm) [Twewie [own ]eete | tats five | AB mo |e | ne + Tae |= | To | Be ae eso | Fas 38 | | Bsa tems | rea fie] ae fn | ag | mw | gum | — | x wey) —- fo [a fags | mm ff | ww | ee | aw | gam | — | x awn | — | ror | tar fase | ar | eo | mw | seem | asa | ar | x wre | — fa |e 1 \ | | vee fe Jw a | ose | gy | aw | gua | — | x wen] — fs [a | | wer | ora fue} s | ow | ce | rm | eee | — | x som | — fs |e vm | mr fins} s | sm | o@ | rm | sen | — | x won | — ‘ 2 Es, 28 ae oh esteiae L ! I (2) Use the size drill indicated in Table 6-2, K. Drill into the ends of the pin- ion spindles (Table 6-2, 5), to weaken the swage. (3) Refer to figure 6-29, Place the carrier assembly (Table 6-2, D) in a press and press out a spindle. (4) Remove two thrust washers (Table 6-2, F and G), the pinion (Table 6-2, 4H), and the pinion rollers (Table 6-2, D. (5) Repeat steps (3) and (4), for re~ moval of the remaining pinion assemblies. (6) If present, and replacement is necessary, remove the bushing (‘Table 6-2, J). b, Assembly (Table 6-2) ()_If removed, install the bushing (Table 6-2, J) to the depth shown in figure 6-29, View 4. 6-22 Copyright 1984 Gener: (2) Chill the new spindles (Table 6-2, E) in dry ice for one hour, or heat the carrier (Table 6-2, D) in an oil bath or oven to 300-350°F (150-176°C). NOTE An aligning tool can be made by grinding a used spindle to 0.005-inch (0.13 mm) under- size. (3) Install a thrust wesher (Table 6-2, P) ona spindle aligning tool. (4) Coat the bore of the pinion (Table 6-2, H) with oil-soluble grease and install the pinion onto the aligning tool. (5) Install the pinion rollers (Table 6-2, 1) into the space between the aligning tool and the pinion bore. Install the second thrust washer (Table 6-2, G) onto the pinion. al Motors Corp.REBUILD OF SUBASSEMBLIES NOTE: SEE TABLE 62, COLUMN (0240 1 (355 FoR SELECTION OF VEW BEFORE STAKING 0180 1 4.57 mm ‘BEFORE STAKING __t ness. PaEss In| ris = A ewe ge Press o"n view 0082 WN (233 mm) ‘BEFORE STAKING a 1082 m,(233 BEFORE STARING ress n> 0281 (71 mm) 83218 ta) ase view 3 view 4 (0092 8 (239 nm ‘BEFORE STAKING 085 1.241 wey BEFORE STAKING r maess ress na tt TEs: view 6 00 Fig. 6-29. Planetary assembly spindle installation (6) Remove the aligning tool and in- (7) Refer to figure 6-29. Place the stall the assembled pinion parts into the carrier assembly into a press, remove the Planetary carrier (Table 6-2, D). Insert the aligning tool, and start a spindle (Table 6-2, aligning tool to center the assembled pinion —_ £) into the pinion bore. parts with the bore in the carrier. Copyright 1984 General Motors Corp. 6-23TT, TTB, TRT 2001 SERIES TRANSMISSIONS NOTE: SEE TABLE 6-2, COLUMN FOR SELECTION OF VEW APPEARANCE OF SWAGING ACH END OF SPINDLES I CARB, ML CHROME, NTRIDE, ROCK °C" 62-63 os75m 53164 Ny 2222 mm) — (21.03 mm owe LENGTH OPTIONAL BREAK ‘5 PLACES 0010 (025 mn) 71821N {58 mn) ‘OCTAGON view (0062 N (157 ma BLEND TANGENT TO FLATS is DS e 0625 (0588 nj O% ew 2 Fig. 6-30. Swaging tools (8) Press the spindle into the bore to the indicated dimension. Refer to Table 6-2, Land M, and to figure 6-29, (9) Refer to Table 6-2, N and to fig ure 6-30. Support the spindle and swage it securely at both ends with an octagon punch. ‘The pinion must rotate freely after assembly. (10) Install the remaining _ pinion assemblies in the same manner as described in steps (3) through (9). (11) If chilled spindles were installed, apply a coating of oil around the spindles to inhibit rust. 6-26. OIL PUMP Disassembly (1) Remove the pump cover and gas- ket (fig. 6-31). (2) Remove the drive gear and driven gear assembly. (3) If necessary, remove the needle bearings from the driven gear. 6-24 Pune covER (GEAR SHAFT NEEDLE BEARING riven GEAR ASSEMBLY DOWEL Pk OUSEAL GASKET Fig. 6-81. Oil pump assembly (4) If necessary for replacement, re~ move the dowel pin by clamping it in a vise and twisting the pump body. Copyright 1984 General Motors Corp.REBUILD OF SUBASSEMBLIES hK PULLER soneW PULLER NUT 3080-13 WASHER —~f {COLLAR LOCK NUT. 3 35080-15 WASHE 4330008 CouAR cour 30603 u TWPICAL SHAFT REMOVAL ne] HH LL nee coe Pb o/s DRIVEN GEAR HAST 330604 BRIDGE be = TT [mee TYPICAL SHAET INSTALLATION eTRIEVER REMOVING SHAFT FROM ‘COLLET Fig. 6-32. Removal and installation of pump driven gear shaft (5) If present, remove the oil seal by driving or pressing it toward the rear (acces- sory mounting face) of the pump. (©) If replacement of the driven gear shaft is necessary, remover assembly J-33080 may be used. (2) Assemble the puller over the shaft as shown in figure 6-32 with collet J-33080-3, (8) Tighten the collar locknut until the collar is secured against the collet and onto the shaft that is to be removed (fig. 6-33). (9) Retain the puller screw (fig. 6-82) with @ wrench while tightening the puller nut to remove the shaft. If the collet does not pull the shaft, repeat steps (8) and (9) and ap~ ply additional torque to the collet loeknut. (10) To remove the shaft from the collet, back off the collar locknut and puller nut, position the collar over retriever 4J-33080-2 (fig. 6-34), and tap the top of the puller screw with a hammer (fig. 6-32). Copyright 1984 General Motors Corp. 3080 CHARGING PUMP. DORWEN GEAR SHAFT REMOVER couLAR oceNuT 3000-43 ‘WASHER saa0a0s ‘COLLAR ‘yPIcaL TT BoDY ASSEMBLY OIL PUMP Fig. 6-33, J-33080 shaft remover in place (1D) If the pump body, drive gear, or driven gear requires replacement, a new pump assembly must be used. 6-25‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS 33060 CHARGING PUMP DRWEN GEAR SHAFT REMOVER PULLER NUT COLLAR LocKwr ccouaR b SHAET RETRIEVER — “#23080-2 Fig. 6-34. Removing shaft from collet Assembly (1) If the driven gear shaft was re- moved, support the charging pump housing in a press (fig. 6-32). (2) Position height gage J-33080-8 over the driven gear shaft bore in the pump housing and place the new shaft into the gage; chamfer on the shaft will engage into the housing bore. (3) Press the shaft until it is flush with the height gage (fig. 6-35). (4) Install a new seal, spring-loaded lip first, into the rear of the pump body. Press the seal until it seats lightly on the shoulder in the body bore (fig. 6-31). (5) If the dowel pin was removed, press a new pin to a height of 0.41-0.43 inch (1.04-1.09 mm) above the front surface of the pump body. 6-26 ergur Gace 530808 TYPICALTT Boo |ASSEMBLY OL PUMP Fig. 6-35. Height gage J-33080-8 in place (6) If the needle bearings were re- moved from the driven gear, install new bearings so that the replacer tool rests against the part number end of the bearing race. Press each bearing to a depth of 0.000- 0.020 inch (0.50 mm) below t h e end surface of the driven gear. (7) Install the driven gear assembly over the gear shaft and into the pump body. Install the drive gear into the pump body. When properly installed, the e nd faces of both gears will project 0.002-0.003 inch (0.05- 0.07 mm) above the front surface of the pump body (measured before gasket is installed). If the end faces of the gears are below the flush line of the pump body, the pump will not per- form satisfactorily and should be replaced. (8) Apply a liberal amount of oil onto the pump gears and install the cover gasket and cover. Position the pump assembly front upward, until ready for installation onto the transmission housing. 6-27. TRANSMISSION HOUSING (rT, TTB, TRY -1) a, Disassembly (foldout 8,B) (1) Remove six bolts 13 and lock- washers 14, and remove core hole cover 15 and gasket 16, Copyright 1984 General Motors Corp.REBUILD OF SUBASSEMBLIES (2) Remove plug 7, but do not remove filter plug 6 unless replacement is necessary. If necessary, measure and record the depth of installed plug 6 prior to removal of the plug. (3) Remove breather 9. (@ If the transmission is equipped with an accessory drive gear, remove lip-type oil seal 11. If the transmission is not equipped with an accessory drive gear, re- move cup plugs 10 and 12 only if replacement is necessary. (5) If present, remove plugs 17 and 25, and plug 30 and washer 29. (6) Remove oil level plugs 26 and 27 from the front face of housing 8. (1) If present, remove cup plug 28, (8) Do not remove nameplate 18 and drive screws 19 unless a new nameplate with the correct data stamped on it is available for replacement. b. Assembly (foldout 8,B) () If nameplate 18 was removed, install the new nameplate (with the correct information stamped on it). Secure the name plate with four No. 4 x 1/4-inch drive serews 19, (2) If off level plugs 26 and 27 were removed, replace them. Tighten the plugs to 14-16 Ib ft (19-21 N-m). (3) If cup plugs 10, 12, or 28 were removed, install new plugs, closed end first, into housing 8 Press each plug against the shoulder in its bore. If lip-type oil seal 11 was removed, install a new seal, spring- loaded lip first, into the rear face of housing 8. Press the seal to a depth of 0.2575-0.2825 inch (6.541-7.175 mm) below the surface ad- jacent to the bore. (4) Install breather 9 and tighten it sufficiently to prevent leakage. (5) Install washer 29 and plug 30. Install drain plug 17. Tighten both plugs 17 Copyright 1984 General Motors Corp. and 30 to 33-37 Ib ft (45-50 Nem). Install oil filler plug 25. ‘Tighten plug 25 sufficiently to prevent leakage. (6) If plug 6 was removed, apply non- hardening sealant onto the outside diameter of the new plug. Install the new plug, closed end first, into the passage. Press the plug to the exact depth recorded prior to removal in paragraph 6-27a(2). Install plug 7 and tighten it to 33-37 Ib ft (45-50 Nem). (7) Install core hole cover gasket 16 and cover 15, Retain them with six 3/8-16 x 7/8-inch bolts 13 and lockwashers 14. Tight- en the bolts to 26-32 Ib ft (36-43 N-m). 6-28. TRANSMISSION HOUSING (TRT -3) a Disassembly (foldout 9,4) () Remove plug 7. If plug 6 must be removed, accurately measure and record the depth at which it is installed. Remove plug 6 only if replacement is necessary. (2) Remove breather 8. (3) If the transmission is equipped with an accessory drive gear, remove oil seal 13. If the transmission is not equipped with an aceessory drive gear, remove cup plugs 9 and 12 if replacement is necessary. (4) Remove oil check plugs 19 and 20, and oil level tubes 21 and 22. (5) Remove plugs 23 and 24. If plugs 28 are used, remove them only if necessary. (©) Do not remove nameplate 10 and drive screws 11 unless a new nameplate with the correct data stamped on it is available for replacment. Assembly (foldout 9,A) () If nameplate 10 was removed, in~ stall the new nameplate (with the correct in- formation stamped on it). Secure the name- plate with four No. 4 x 1/4-inch drive screws te 6-27‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS (2) Install two plugs 28, plug 23, and plug 24 into the transmission housing. Tight- en the plugs sufficiently to prevent leakage. (3) Install oil level tubes 21 and 22. (4) Install oil cheek plugs 19 and 20 into the transmission housing. Tighten the plugs sufficiently to prevent leakage. (5) Install a new oil seal 13, spring- loaded lip first, into the rear of housing 26. Press the seal to a depth of 0,255-0.285 inch (6.48-1.23 mm) below the surface adjacent to the bore. 6-28 (6) If the transmission is not equipped with an accessory drive gear, install new cup plugs 9 and 12, (7) Install breather 8 and tighten it sufficiently to prevent leakage. (8) If plug 6 was removed, coat the outer diameter of a new plug with nonharden- ing sealer and install, closed end first, into the top of housing 26. Press the plug to the exact depth recorded when it was removed in paragraph 6-28a (1). Install plug 7 and tight- en it to 33-37 Ib ft (45-50 Nem). Copyright 1984 General Motors Corp.Section 7. ASSEMBLY OF TRANSMISSION Tl. SCOPE a, The assembly procedures in this see- tion describe the assembly of the transmis~ sion from subassemblies. Refer to the eross- sections of the transmissions (foldouts 1 through 5) for funetional location of parts. Refer to par t s exploded views (foldouts 6 through 18) for parts identification. Mlustrations may not, in some areas, show the specific model being serviced. However, the procedure represented will be correct. ¢, Assembly techniques for vehicle- mounted transmissions are presented in paragraph 7-14, NOTE Assembly paragraphs are as follows: Model Paragraphs TT 221-1, 2421-1 -3, T-4, 1-5, THT, rough 114 | TTB 2221-1, 2421-1 -3, 7-4, 1-5, hough 7-14 ‘TRY 2221-1, 2421-1 1-3, 1-4, 7-8, 7-10 ugh 7-14 TRT-3 7-8, 1-10 through 7-2, GENERAL INFORMATION FOR ASSEMBLY OF TRANSMISSION Refer to Section 4 for general assembly information as follows: Paragraph Title 43 Tools, Equipment 44 Replacement Parts 45 Careful Handling 4-1 Assembly Procedures 4-9 Tight-fit Flanges 411 ‘Torque Specifications &1 Wear Limits Data 82 Spring Data 7-8 INSTALLATION OF OUTPUT COMPONENTS, TRANSFER-DRIVEN GEAR (-1 models) NOTE For -1 models with front and rear outputs without output dis- conneet, proceed to paragraph 7-2, For -1 models with front and rear output with output dis- connect, proceed to paragraph 1-b. For -1 models with rear output only, proceed t o para~ graph 7-3e, a One-Piece Output Shaft (Q) Install the transfer-driven gear into the rear of the housing (fig. 7-1). (2) If shifter shaft hole plug was re- moved, install a new plug (fig. 7-2). Apply nonhardening sealant onto the outside diam- eter of the new plug. Install the plug, closed Fig. 7-1. Installing transfer-driven gear (1 models) Copyright 1984 General Motors Corp. TrTT, TTB, TRT 2001 SERIES TRANSMISSIONS “TRANSFER DRIVEN (EAR HUB, ‘ourPuT SHAFT Fig. 7-2. Installing output shaft (-1 models with one-piece shaft, with outputs at front and rear) end first, and seal it against the shoulder in ‘the housing bore. (3) Install the output shaft, double- splined end first, through the front of the housing and the splined hub of the transfer- driven gear (fig. 7-2). (4) Start bearing 11 (foldout 17,4), the shield side last, into the front bore of the housing. (5) Install the spacer onto the rear end of the output shaft (fig. 7-3). Start the rear bearing, loading groove first, into its bore in the housing, pushing the spacer toward the transfer gear hub. (6) Supporting the shaft at the front end surface, drive the rear bearing and spacer forward until they are firmly seated against the transfer gear hub. (2) At the front of the transmission housing, drive the bearing rearward and seat it firmly against the shoulder in the bore. In- Stall the snapring to retain the bearing (fig. 4). (8) Reseat the rear bearing, if neces- sary. (9) Install lip-type oil seal 9 (foldout 17,A), spring-loaded lip first, into the front output bore. Press or drive the seal squarely and lightly against the counterbore in the housing. Fig. 1-3, Installing output shaft rear bearing and spacer (-1 models) SHIFTER SHAFT OLE PLUG Fig. 7-4. Installing output shaft front bearing snapring (1 models) (10) Install lip-type oil seal 30, spring- loaded lip first, into the rear output bore. Press or drive the seal squarely and lightly against the counterbore in the housing. (11) Proceed to paragraph 7-4. b. Two-piece Output Shaft (1) If the front output shaft bearing was removed, replace the bearing, shield side ast, into the housing bore (fig. 7-5). Seat the front bearing firmly against the shoulder in the bore, and install the snapring against the bearing outer race. (2) Install a new output shaft oil seal, spring-loaded lip first, and press it squarely into the bore until it is lightly seated against the counterbore shoulder (fig. 7-5). 1-2 Copyright 1984 General Motors Corp.ASSEMBLY OF TRANSMISSION a (@ vrcsster ND orgy &, ® iT SHAFT © ve GALL BEARING Fig. 7-5. Output shaft front bearing and sealring (-1 models) (3) Install new shifter shaft oil seal, spring-loaded lip first, and press it squarely into the bore at the front of the housing, un- til it is lightly seated against the counterbore shoulder. (4) Install one ball 14 (foldout 17,4), spring 15, and another ball 14 into front out put shaft 13. While holding these balls against the spring pressure, slide disconnect coupling 20, grooved end first, onto shaft 13 until the re ar end of the coupling is flush with the shaft rear splines (disengaged posi- tion) (fig. 7-6). (5) Install the front output shaft and assembled disconnect coupling, threaded end first, into the rear output shaft bearing bore (fig. 7-6). Support the inner race of the front output bearing (fig. 7-5), and seat the shoul- der of the front output sh af t against the bearing. (6) Install the output shaft center bearing, shield side first, into the web of the transmission housing (fig. 7-1). Press or tap on the bearing outer race to seat it against the shoulder in the housing web bore. (7) Install the transfer-driven gear (tig. 7-8). (8) If bushing 25 (foldout 17,A) was removed from rear output shaft 26, install a new bushing. Press the bushing into the front bore of the shaft to a depth of 0.160-0.200 inch (4.06: TRANSMISSION — HOUSING Front ourPut a SHAFT en FRONT ROR RNC Location DiscoNnecr ‘COUPLING. Fig. 7-6. Installing front output, shaft and disconnect coupling (1 models with two-piece output shaft) TRANSMISSION HOUSING Fig. 7-1. Installing output shaft center bearing (-1 models with two-piece output shaft) (9) If bearing 28 or spacer 27 were removed from rear output shaft assembly 24, replace them, Install spacer 27 and bearing 28, shield side last, onto the shaft. Seat the bearing firmly against the spacer. (10) Place the spacer at the front side of the transfer-driven gear hub (fig. 7-9). Install the assembled rear output shaft, splined end first, through the splined hub, of Copyright 1984 General Motors Corp. 1-3TT, TTB, TRT 2001 SERIES TRANSMISSIONS. TRANSFER even AR Fig. 7-8. Installing transfer-driven gear (-1 models) a TRANSFER DANE Fig. 7-9. Installing rear output shaft assembly (-1 models with two-piece or rear output shaft) the gear, the spacer, and the center support bearing. (11) Support the transfer-driven gear and drive the rear output shaft assembly and TRANSFER DRIVEN GEAR Pig. 7-10. Seating rear output shaft in housing (-1 models with two-piece or rear output shaft) Pig. 7-11. Installing rear output shaft snapring (-1 models with two-piece or rear output shaft) bearing forward (fig. 7-10). If necessary, re- seat the rear bearing by driving on its inner race until the outer race clears the snapring groove in the bore. (12) Install the snapring and tap pro- gressively around its circumference until it aatos] ino) [olace tacsinat ats Beare ie) 7-1). (13) Install the new rear output lip- type oil seal, spring-loaded lip first, and press it squarely i'n to the bore until it is lightly seated against the counterbore shoulder (fig. 7-12). 1-4 Copyright 1984 General Motors Corp.ASSEMBLY OP TRANSMISSION Fig. 7-12. Installing disconnect shifter fork and shaft (-1 models with two-piece output shaft) (14) Position the disconnect shifter fork in the groove of the disconnect coupling (fig. 7-12). While holding the fork in position, stall the shifter fork shaft, threaded end first, through the oil seal in the front of the housing and fully engage the threads in the shifter fork, Refer to paragraph 3-9¢ for final adjustment of the shifter fork shaft. (15) Proceed to paragraph 7-4. Rear Output Shaft (no front output) (1) Install bearing 21 (foldout 17,A), shield side first, into the web of the transmis~ sion housing (refer to fig. 7-7). Press or tap on the bearing outer race to seat it against shoulder in the housing web bore. (2) Install the transfer-driven gear (fig. 7-8). (3) If bearing 28 (foldout 17,A) or spacer 27 w ere removed from rear output shaft 26, replace them. Install spacer 27 and bearing 28, shield side last, onto the shaft. Seat the bearing firmly against the spacer. (4) Place the spacer at the front side of the transfer-driven gear hub (fig. 7-9). In- stall the assembled rear output shaft, splined end first, through the splined hub of the gear, the spacer, and the bearing installed in the housing web. (5) Support the transfer-driven gear, and drive the assembled rear output shaft forward (fig. 7-10). If necessary, reseat the rear bearing by driving on its inner race until the outer race clears the snapring groove in the bore. (6) Install the snapring and tap pro- gressively around its circumference until it snaps into place aguinst the bearing (fi 71). (7) Install the new rear output lip type oil seal, spring-loaded lip first, and press it squarely i'n t o the bore until it is lightly seated against counterbore shoulder (refer to fig. 7-12). (8) Apply nonhardening sealant onto the smaller outside diameter of plug 8 (fold- out 17,A) and install the plug into the front output orifice. Press the plug into the bore until its flange is firmly seated against the front surface of the housing. (8) If shifter shaft hole plug 16 was removed, apply nonhardening sealant onto the outside diameter of the plug. Install the plug, closed end first, and seat it against the shoulder in the housing bore. 7-4, INSTALLATION OF REVERSE AND FORWARD CLUTCHES, GEARING (All -1 Models) a. Reverse Clutch, Planetary (Q) Position the transmission housing on blocks on its front splitline (fig. 7-13). In- stall the reverse cluteh piston with sealrings (as assembled in para 6-12) into the transmis- sion housing. NOTE For vehicle-mounted transmis- sions, refer to paragraph 7-14. Copyright 1984 General Motors Corp. 1‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS TRANSMISSION PISTON HOUSING INTERNAL-SPLINED PLATES 1) Fig. 7-14. Installing reverse planetary carrier assembly (2) Beginning with an external-tanged clutch plate, alternately install four external- tanged clutch plates and four internal-splined clutch plates o nt o the reverse piston (fig. 7-14), Install the reverse planetary carrier assembly, long splines first, into the reverse plates. (3) Install one external-tanged plate and one internal-splined plate onto the re- verse planetary carrier assembly (fig. 7-15). (4)_If transmission is equipped with a high-speed, forward ratio, install sun gear 16 (foldout 9,B), small end first, into the re~ verse planetary carrier assembly. ANCHOR PIN on ae INTERNAL SPLINED Pure REVERSE PLANET CARGIER ASSEMBLY | a Fig. 7-15. Installing forward-and- reverse clutch anchor assembly (5) Align t he slots of the five re~ verse, external-tanged clutch plates to re~ ceive the pins in the clutch anchor assembly (fig. 7-15). Install the clutch anchor pin into the control valve mounting pad on the left side of the transmission housing. Aligning the anchor pin slot with the clutch anchor pin hole within the transmission housing, install the forward-and-reverse eluteh anchor assem bly, longer ends of pins downward, and engage the slots of the five external-tanged cluteh plates. Be sure that the six notches of the five external-tanged plates are engaged by the six anchor pins in the anchor assembly. (Listen for a sound of the assembly seating when the plates are aligned.) (6) Push the cluteh anchor pin into the slot in the forward-and-reverse clutch anchor assembly (fig. 7-15). Temporarily in stall a 3/8-16 x 1-inch bolt and a flat washer to retain the anchor pin during subsequent assembly operations. (Refer to fig. 7-17.) b. Forward Clutch and Planetary (1) Assemble t h e forward planetary carrier assembly onto the reverse ring gear (fig. 7-16). 14 Copyright 1984 General Motors Corp.ASSEMBLY OF TRANSMISSION FORWARO PLANETARY CARRIER ASSEMBLY Fig. 7-16. Installing snapring into reverse ring gear (2) If the transmission is equipped with a high-speed, forward ratio, install thrust washer 2 {foldout 10,A) into the inner hub of six-pinion, forward carrier 3. Apply oil-soluble grease to retain the washer during installation of the carrier. (3) Install the assembled reverse ring gear and forward planetary carrier, en- gaging the reverse ring gear teeth with the planetary pinion teeth (fig. 7-17). (@ Place an external-tanged plate between two internal-splined plates and in- stall them as a unit onto the flat side of the forward ring gear (fig. 7-18). Install the as~ sembled clutch plates and ring gear, flat side first, onto the forward planetary carrier as~ sembly, and engage the slots of the external- tanged plate onto the six eluteh anehor pins. (5) Starting with an external-tanged clutch plate, alternately install three exter- nal-tanged clutch plates and two internal- splined eluteh plates onto the forward ring gear (fig. 7-19). (6) Install t he twelve piston return springs and spring guide pins into the holes in the clutch anchor assembly (fig. 7-19). (2) If plug 39 (foldout 10,8) was re~ moved from forward clutch piston housing 37, replace it. Apply nonhardening sealant onto the plug threads and install the plug into the FORWARD PLANETARY CARRIER ASSEMBLY Fig. 7-17, Installing forward planetary carrier assembly and reverse ring gear Fp FORWARD A, rnc cea INTERNAL:SPLINED PLATE 2) Pig. 7-18. Installing forward ring ‘gear and three cluteh plates housing. Tighten the plug to 14-16 Ib ft (19- 21 Nem). (8) Install the forward clutch piston with sealrings (as assembled in para 6-12), Copyright 1984 General Motors Corp. 14TT, TTB, TRT 2001 SERIES TRANSMISSIONS CLUTCH ANCHOR ASSY SPRING PIN Pe FEXTERNAL-TANGED: PLATE Pig. 7-19. Installing piston return springs and guide pins ‘erton SEALRINGS 9) STON HOUSING FORWARD. (AUTEN PISTON Fig. 7-20. Installing forward eluteh piston into piston housing flat side first, into the forward cluteh piston housing (fig. 7-20). (9) Install the forward clutch piston housing and piston assembly. For earlier models, install flat washers and eight of ten 3/8-16 x 1-1/2-ineh self-locking bolts (fig. 7-21). For later models, install eight of ten 3/8-16 x 1-3/4-ineh self-locking bolts. Use ‘two of the longer valve body mounting bolts FORWARD PISTON HOUSING (CONFIGURATIONS VARY) SELF-LOKING BOLT ‘RESTRAINING COLT al Fig. 7-21. Installing forward clutch piston housing bolts (3/8-16 x 2-1/2-ineh) to draw the piston hous- ing down sufficiently to engage the piston housing bolts. Remove the two draw bolts and install the two remaining flat washers (earlier models) and self-locking bolts. ‘Tight- en the bolts to 36-43 Ib ft (49-58 N-m). (10) For TRT-1 models, proceed to paragraph 7-8. 7-5. INSTALLATION OF TRANSFER DRIVE GEAR, HIGH-RANGE CLUTCH (TT, TTB) 8. ‘Transfer Drive Gear (1) Install the transfer drive gear (as assembled in para 6-17), bearing first, onto the splined hub of the forward planetary car- rier (fig. 7-22). (2) Using a suitable hook-type tool, raise the forward planetary carrier suffi- ciently to expose the snapring groove in the splined hub, and install the snapring (fig. 1-23). b High-Range Cluteh and Hub Assembly (Q) If the model is equipped with a power takeoff, install the high-range cluteh 1-8 Copyright 1984 General Motors Corp.ASSEMBLY OF TRANSMISSION FoRwano ASTON HOUSING = FonwARO PLANETARY CARRER Pr aE : aa Fig. 7-22. Installing transfer drive gear assembly (TT, TTB) TRANSFER DRIVE GEAR f — Es N55 econ eee Fig. 7-23. Installing transfer drive gear snapring (TT, TTB) hub assembly (as assembled in para 6-13) onto the transfer drive g e a r (fig. 7-24). (2) If the model is not equipped with a power takeoff, install the high-range clutch and hub assembly (as assembled in para 6-13), splined end of shaft first, into the hub of the transfer drive gear (fig. 7-25). (3) For TT models, proceed to para- graph 7~ PLATE ANO HUB ASSY: Fig. 7-24. Installing high-range cluteh plate and hub assembly (TT, TTB models with power takeoff) ob-Ranse cuuroH AND HUB ASSEMBLY JO Fig. 7-25. Installing high-range cluteh and hub assembly (TT, TTB models without power takeoff) 7-6, INSTALLATION OF HIGH-RANGE CLUTCH PISTON HOUSING, INTER- NAL BRAKE, REAR COVER — TTB a, High-range Clutch Piston Housing (1) A Lig n the bolt holes in piston housing 22 or 35 (foldout 15,A) with those in transfer drive gear 3, and install the high- range eluteh piston housing (as assembled in para 6-11) onto the transfer drive gear. Using a soft hammer, seat the piston housing in the counterbore of the gear. Copyright 1984 General Motors Corp. 1-8TT, TTB, TRT 2001 SERIES TRANSMISSIONS (2) Install six 1/2-20 x 2-3/4-inch bolts 24 or 37 and locktabs 23 or 36 to retain piston housing 22 or 35. Tighten the bolts to 83-100 Ib ft (113-135 Nem). Bend the lock- tabs against the bolt heads. Install the step- joint sealrings 25 and one O-ring 26 onto the hub of the piston housing. b, Internal Brake Components (1) Install the gasket onto the dia~ phragm (as assembled in para 6-16) and in- stall the diaphragm onto the transmission housing (fig. 7-26). Install two 3/8-16 x 1-1/8-ineh bolts, one 3/8-16 x 2-inch bolt, and three lockwashers to retain the dia~ phragm. ‘Tighten the bolts to 26-32 Ib ft (85-43 Nem). (2) Install the sealring onto the dia phragm (fig. 7-27), Install the brake hub onto the splined hub of the high-range cluteh pis- ton housing. Retain the brake hub with a snapring. (3) Beginning with an external-tanged brake plate, alternately install six external- tanged plates and five internal-splined plates ‘onto the diaphragm and brake hub (fig. 7-28). Be sure that the slots of the external-tanged HIGH Rance CLUTCH ASTON HOUSING Fig. 7-26. Installing diaphragm bolts (TTB) plates engage the six anchor pins in the dia~ phragm. (4) Install the ball bearing onto the hub of the high-range clutch piston housing (fig. 7-29). (5) Install t he twelve brake return springs, flared end first, into the recesses in the diaphragm. Twist ‘the springs counter- clockwise to seat them in the recesses and Grop the twelve guide pins into the springs. HIGH-RANGE CLUTCH ae PISTON HOUSING puna Pig. 7-27. Installing brake hub snapring (TTB) Pig. 7-28, Installing brake plates (TTB) Copyright 1984 General Motors Corp.ASSEMBLY OF TRANSMISSION OH-RANGe cuUTCH PISTON HOUSING ALL BEARING culoe PIN 02) BRAKE RETURN SPRING (2) DIAPHRAGAL 7-29, Installing brake return spring guide pins (TTB) Rear Cover (TTB without converter- “driven PTO) NOTE For TTB models with converter- driven PTO, proceed to para- graph 7-6. (2) Attach a sling to the bolt circle flange of the rear cover assembly (as assem- bled in para 6-21). Hoist the assembly into position over the transmission in a manner similar to that shown in figure 7-30. (2) Cheek to ensure that all of the brake return springs are straight and aligned, and that the sealring is in place on the dia~ phragm (fig. 7-30). (3) Lower the assembly to within approximately 1-1/4 inches (32 mm) of the diaphragm and check "by feel" to ensure that each brake return spring will enter its recess in the brake-apply plate. (4) Continue lowering the assembly until it stops its downward travel and its weight is supported by the brake return springs. Remove the sling. Using two 3/8-16 x 3-ineh bolts, draw the rear cover assembly down sufficiently to allow the engagement of the proper bolts. Install sixteen 3/8-16 x Fig. 7-30. Installing rear cover assembly (TTB) 2-3/4-inch bolts 45 (foldout 15,B) and lock- washers 46. Remove the two draw bolts, and install the remaining two 3/8-16 x 2-3/4~inch bolts 45 and lockwashers 46, Tighten the eighteen bolts to 26-32 Ib ft (35-43 N-m). (5) Proceed to paragraph 7-7. d. Rear Cover (TTB with converter- driven PTO) () Attach a sling to the PTO flange of the rear cover assembly (as assembled in para 6-21). Hoist the assembly into position over the transmission, as shown in figure 7-30. (2) Cheek to ensure that all of the brake return springs are straight and aligned, and that the sealring is in place on the diaphragm (fig. 7-30). (3) As the rear cover assembly is lowered, rotate the PTO flange, so that the shaft splines will engage the high-range cluteh hub and the forward-and-reverse sun gear. (4) Lower the assembly to within ap- proximately 1-1/4 inches (32 mm) of the dia~ phragm and check "by feel" to ensure that each brake return spring will enter its recess in the brake-apply plate. Attach the rear Copyright 1984 General Motors Corp. TH‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS over assembly as described in paragraph (5) Proceed to paragraph 7-10, 7-1, INSTALLATION OF HIGH-RANGE CLUTCH PISTON HOUSING, REAR COVER — TT High-range Clutch Piston Hou: a NOTE 'p For TT models without conver ter-driven PTO, proceed to Paragraph 7-7c. ()_ Install high-range cluteh piston housing 37 (foldout 11,B) and attached parts {as assembled in para 6-11) onto transfer drive gear assembly 2. Align the drive pin holes in the piston with the drive pins in the transfer drive gear. Using a soft hammer, seat the piston housing in the counterbore of the transfer drive gear. (2) Attach the piston housing to the transfer drive gear with six 1/2-20 x 2-3/4- inch bolts 30 and locktabs 31. Tighten the bolts to 83-100 Ib ft (113-135 Nem). Bend the locktabs against the bolt heads. (3) Install two step-joint sealrings 38 into the grooves in the hub of piston housing 7. b, Rear Cover Assembly (TT with ‘converter-driven PTO) (1) Lubricate sealring 2 (foldout 16,D) and install it into its groove in rear PTO cover assembly 22 (and attached parts as assembled in para 6-20). Apply oil-soluble grease onto gasket 1 and install the gasket onto the mounting flange of the rear PTO cover assembly. (2) Install PTO output flange 27 and flange retaining washer 28 onto the threaded end of PTO shaft assembly 17. Apply molyb- denum disulfide grease (Molykote Type G or equivalent) onto the threads of 7/8+14 self- locking nut 29 and install the nut onto PTO shaft assembly 17. Do not bring the nut to full torque at this time. (3) Attach a sling to PTO output flange 27 and hoist the rear PTO cover as- sembly and attached parts into position over ‘the transmission, While lowering the cover assembly into the transmission, rotate the PTO output flange so that the PTO shaft splines will engage the high-range cluteh hub and forward-and-reverse sun gear. (5) Retain the rear PTO cover assem- bly with nineteen 3/8-16 x 1-1/8-ineh bolts 30 and lockwashers 31. Tighten the bolts to 26- 32 Ib ft (35-43 Nem). Proceed to paragraph 4 ¢ High-range Cluteh Piston Housi TT without converter-ariven PTO) (1) Install the high-range cluteh pis- ton housing and attached parts (as assembled in para 6-11) onto the transfer drive gear (fig. 7-31). During installation, align and engage the recesses in the piston with the drive pins in the transfer drive gear. (2) Using a soft hammer, seat the piston housing in the eounterbore of the drive gear, and install the six locktabs and six 1/2- PISTON HOUSING ASSY Fig. 7-31. Installing high-range eluteh piston housing assembly (TT) Copyright 1984 General Motors Corp.‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS (2) Install six 1/2-20 x 2-8/4-ineh bolts 24 or 37 and locktabs 23 or 36 to retain piston housing 22 or 35. Tighten the bolts to 83-100 Ib ft (113-135 Nem), Bend the lock- tabs against the bolt heads. Install the step- joint sealrings 25 and one O-ring 26 onto the hub of the piston housing. b. Internal Brake Components () Install the gasket onto the dia phragm (as assembled in para 6-16) and in- stall the diaphragm onto the transmission housing (fig. 7-26). Install two 3/8-16 x 1-1/8-inch bolts, one 3/8-16 x 2-ineh bolt, and three lockwashers to retain the dia~ phragm. Tighten the bolts to 26-32 lb ft (35-43 Nm). (2). Install the sealring onto the dia~ phragm (fig. 7-27). Install the brake hub onto the splined hub of the high-range cluteh pis ton housing. Retain the brake hub with a snapring. (3) Beginning with an external-tanged brake plate, alternately install six external- tanged plates and five internal-splined plates onto the diaphragm and brake hub (fig. 7-28). Be sure that the slots of the external-tanged High-nave cure STON HOUSING | Fig. 7-26. Installing diaphragm bolts (TTB) plates engage the six anchor pins in the dia~ phragm. (4) Install the ball bearing onto the hub of the high-range clutch piston housing (fig. 7-29). (5) Install t he twelve brake return springs, flared end first, into the recesses in the diaphragm. Twist the springs counter- clockwise to seat them in the recesses and drop the twelve guide pins into the springs. Higu-Rance cuuTcH sruxcwe — [ PSTON HOUSING DuaPHRAGML Fig. 7-27. Installing brake hub snapring (TTB) Gh BgAKe PLATE Pig. 7-28, Installing brake plates (TTB) Copyright 1984 General Motors Corp.ASSEMBLY OF TRANSMISSION oh-Ranoe cut PISTON HOUSING. BALL BEARING GUIDE PIN 02) RAKE RETURN serine aS DIAPHRAGNL 7-29, Installing brake return spring guide pins (TTB) Rear Cover (TTB without converter- riven PTO) NOTE For TTB models with converter~ driven PTO, proceed to para- graph 7- () Attach a sling to the bolt circle flange of the rear cover assembly (as assem= bled in para 6-21). Hoist the assembly into position over the transmission in a manner similar to that shown in figure 7-30. (2) Check to ensure that all of the brake return springs are straight and aligned, and that the sealring is in place on the dia~ phragm (fig. 7-30). (3) Lower the assembly to within approximately 1-1/4 inehes (32 mm) of the diaphragm and check "by feel" to ensure that each brake return spring will enter its recess in the brake-apply plate. (4 Continue lowering the assembly until it stops its downward travel and its weight is supported by the br ak e return springs. Remove the sling. Using two 3/8-16 x 3-inch bolts, draw the rear cover assembly down sufficiently to allow the engagement of the proper bolts. Install sixteen 3/8-16 x PTO Face ‘SPRING M2) DIAPHRAGM Fig. 7-30. Installing rear cover assembly (TTB) 2-3/4-ineh bolts 45 (foldout 15,B) and lock- washers 46. Remove the two draw bolts, and install the remaining two 3/8-16 x 2~3/4-inch bolts 45 and lockwashers 46. Tighten the eighteen bolts to 26-32 Ib ft (35-43 N-m). (5) Proceed to paragraph 7-7. d. Rear Cover (TTB with converter- driven PTO) () Attach a sling to the PTO flange of the rear cover assembly (as assembled in para 6-21). Hoist the assembly into position over the transmission, as shown in figure 7-30. (2) Check to ensure that all of the brake return springs are straight and aligned, and that the sealring is in place on the diaphragm (fig. 7-30). (3) As the rear cover assembly is lowered, rotate the PTO flange, so that the shaft splines will engage the high-range clutch hub and the forward-and-reverse sun gear. (4) Lower the assembly to within ap- proximately 1-1/4 inches (32 mm) of the dia~ phragm and check "by feel" to ensure that each brake return spring will enter its recess in the brake-apply plate. Attach the re ar Copyright 1984 General Motors Corp. Trl‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS ver assembly as described in paragraph 7-6e(4), (5) Proceed to paragraph 7-10. 7-1. INSTALLATION OF HIGH-RANGE CLUTCH PISTON HOUSING, REAR COVER — TT a High-range Cluteh Piston Housi Ut with sonverterdriven PTO) NOTE For TT models without conver- ter-driven PTO, proceed to paragraph 7~ ()_ Install high-range cluteh piston housing 37 (foldout 11,B) and attached parts (as assembled in para 6-11) onto transfer drive gear assembly 2. Align the drive pin holes in the piston with the drive pins in the transfer drive gear. Using a soft hammer, seat the piston housing in the counterbore of the transfer drive gear. (2) Attach the piston housing to the transfer drive gear with six 1/2-20 x 2-3/4- ineh bolts 30 and locktabs 31. Tighten the bolts to 83-100 Ib ft (113-135 Nem). Bend the locktabs against the bolt heads, (3) Install two step-joint sealrings 38 into the grooves in the hub of piston housing 31. Rear Cover Assembly (TT with converter-driven PTO) (1) Lubricate sealring 2 (foldout 16,D) and install it into its groove in rear PTO cover assembly 22 (and attached parts as assembled in para 6-20). Apply oil-soluble grease onto gasket 1 and install the gasket onto the mounting flange of the rear PTO cover assembly. (2) Install PTO output flange 27 and flange retaining washer 28 onto the threaded end of PTO shaft assembly 17. Apply molyb- denum disulfide grease (Molykote Type G or equivalent) onto the threads of 7/8-14 self- locking nut 29 and install the nut onto PTO shaft assembly 17. Do not bring the nut to full torque at this time. (3) Attach a sling to PTO output flange 27 and hoist the rear PTO cover as- sembly and attached parts into position over the transmission, While lowering the cover assembly into the transmission, rotate the PTO output flange so that the PTO shaft splines will engage the high-range clutch hub and forward-and-reverse sun gear. (5) Retain the rear PTO cover assem- bly with nineteen 3/8-16 x 1-1/8-ineh bolts 30 and lockwashers 31. Tighten the bolts to 26- 32 1b ft (35-43 Nem). Proceed to paragraph 11. & High-range Clutch Piston Housi @1P witheut converter-ariven PTO) (J) Install the high-range cluteh pis ton housing and attached parts (as assembled in para 6-11) onto the transfer drive gear (fig. 7-31). During installation, align and engage the recesses in the piston with the drive pins in the transfer drive gear. (2) Using a soft hammer, seat the piston housing in the counterbore of the drive gear, and install the six locktabs and six 1/2 PISTON HOUSING ASSY Pig, 7-31. Installing high-range eluteh piston housing assembly (TT) Copyright 1984 General Motors Corp.ASSEMBLY OF TRANSMISSION 20 x 2-3/4-ineh bolts (fig. 7-32). Tighten the bolts to 83-100 Ib ft (113-135 Nem). Bend the locktabs against the bolts heads. @. Rear Cover (TT without converter- ‘driven PTO) (1) If the transmission is equipped with a speedometer drive assembly, install washer 12 (foldout 16,D) into drive sleeve 13. Install lip-type oil seal 11, metal side first, into drive sleeve 13. Press the seal to a depth of 0.035-0.065 inch (0.88-1.65 mm) below the front surface of the drive sleeve. (2) Install gasket 7, speedom- eter drive adapter 8, gasket 9, and sleeve as~ sembly 10 onto rear cover 4. Retain the speedometer components with two 5/16-18 x 2-1/4-inch bolts 15 and lockwashers 14. ‘Tighten the bolts to 13-16 Ib ft (18-21 N-m), (3) If the pipe plug was removed from the rear cover, install the plug (fig. 7-32). If the plug is 1/8-in, NPTF, tighten the plug to 10-12 Ib ft (14-16 Nem). If the plug is 3/8-in, NPTP, tighten the plug to 18-22 Ib ft (25-29 Nem), CAUTION Rear covers having two ribs on the inside of the cover (used ean covERASSENEDY EARLIER MODELS) asker one a8 KT etl a PPSTON HOUSING ASSEMBLY our 220 vi Sc VANES) Pig. 1-32. Installing transmission Tear cover (TT) Copyright 1984 General Motors Corp. with later models) must not be used with piston housings having sixty vanes (used with earlier models) (fig. 7-32). (4) Lubricate the seairing and install it in to the groove in the rear cover pilot diameter (fig. 7-32). Apply oil-soluble grease onto the gasket and install the gasket onto the rear cover pilot diameter. Install the rear cover onto the transmission housing and re~ tain it with nineteen 3/8-16 x 1-1/8-inch bolts and loekwashers. Tighten the bolts to 26-32 Wb ft (35-43 Nem). (5) Proceed to paragraph 7-10. 7-8. INSTALLATION OF TRANSFER DRIVE GEAR, HOUSING ADAPTER, LOW-RANGE CLUTCH, HIGH- RANGE CLUTCH (TRT“1) ‘Transfer Drive Gear, Housing Adapter (Q) Install the snapring into the groove nearer the end of the high-range sun gear splined sleeve. Install the sleeve into the transfer drive gear assembly at the side which has a smooth bore in the hub (fig. 7-33). SNAPRING Fig. 7-33. Installing high-range sun gear sleeve into transfer drive gear (TRT-1)‘TT, TTB, TRT 200] SERIES TRANSMISSIONS (2) install the transfer drive gear and splined sleeve, bearing w it h snapring first, onto the forward planetary carrier (fig. 7-34). (3) Install the gasket and sealring on- to the rear housing adapter assembly. Install the adapter assembly (fig. 7-35). (4) Install the sixteen 3/8-16 x 1-1/8- inch bolts, w i t h lockwashers, to retain the adapter (fig. 7-36). Tighten the bolts to 26- 32 Ib ft (36-43 N-m). ‘b. Low-Range Cluteh, High-Renge Planetary NOTE Ne w Teflon sealrings may re~ quire forming by hand to help RIE GEAR 3 ae STO 3 ae | Re Fig. 7-34. Installing transfer drive gear assembly (TRT-1) ADAPTER Pig. 7-35. Installing rear housing adapter (TRT-1) 714 retain their proper circular shape. Wrap them in a circle around an object about two- thirds the diameter of the groove they fit. (1) Install two Teflon step-joint seal- rings 12 (foldout 12,4) into the grooves in the front hub of low-range clutch drum 15. Use oil-soluble grease to retain them, (2) Install low-range eluteh drum as- sembly 13 onto the high-range sun gear sleeve (fig. 7-37). (3) Install snapring 25 (foldout 12,4) into the groove in the high-range sun gear sleeve. (4) Install o ne low-range, internal splined clutch plate into the low-tange clutch drum (fig. 7-38). Install the high-range ring Fig. 7-36. Installing rear housing adapter bolts (TRT-1) ;DRUM ASSEMBLY GH RANGE SUN GEAR SLEEVE oF Pig. 7-37. Installing low-range cluteh drum assembly (TRT-1) Copyright 1984 General Motors Corp.ASSEMBLY OF TRANSMISSION gear, positioning ring first, into the cluteh plate splines. (5) Beginning with an external splined plate, alternately install three exter- nal- and three internal-splined, low-range eluteh plates (fig. 7-39). (6) Install the low-range clutch back- plate, flat side first, into the low-range cluteh drum (fig. 7-39). (7) Install the internal snapring which retains the clutch backplate (fig. 7-40). (8) Install the high-range planetary sun gear, thrust washer upward, onto the splines of the sun gear sleeve (fig. 7-40). (8) Install high-range planetary car- tier essembly Into high-range Hing geer (fig. 7-41). High-Range Cluteh, Rear Housing (1) Install the eluteh anchor pin into the rear housing (as rebuilt in paragraph 6-11). Leave the flat-milled end of the pin extend- ing at the inside of the housing (fig. 7-42). INTERNAL-SPLNEO {CLUTCH PLATE) LOWRANCE CLUTCH DAUM Pig. 7-38, Installing high-range ring gear (TRT=1) Copyright 1984 General Motors Corp. (2) Position the high-range cluteh anchor assembly 12 (foldout 12,B), pins up- HIGH. RANGE: ING GEAR LOE RANGE CLUTEM PLATES g LOWRANCE cuUTcH DRUM Pig. 1-39. Installing low-range cluteh backplate (TRT-1) Pig. 7-40. Installing high-range sun gear (TRT‘TT, TTB,'TRT 2001 SERIES TRANSMISSIONS, SNAPRING oH mane ‘SUN GEAR High aN RING GEAR. LoW-RANGE ‘CLUTCH BACKELATE yt Fig. 7-41. Installing high-range planetary carrier assembly (TRT-1) cute ANCHOR PN Fig. 7-42. Rear housing and piston assembly (TRT-1) ward on a flat surface. Beginning with an internal-splined clutch plate, alternately install five internal-splined and five exter- nal-tanged, high-range cluteh plates. Engage the external tangs with the cluteh anchor pins. (3) Grasp the entire anchor and plate assembly to hold the parts together. Install HIGH-RANGE ANCHOR ASSEMBLY CLUTCH PLATES ANCHOR PN suar REAR WOUSING Fig. 7-43. Installing high-range clutch anchor and plates (TRT-1) ‘LUT anchoR SNAPRING Rea Pig. 7-44, Installing clutch anchor snapring (TRT-1) the anchor and plates into the rear housing, aligning the anchor pin slot with the clutch anchor pin (fig. 7-43). (4) Install the heavy internal snapring which retains the cluteh anchor (fig. 7-44). Note the position of the ends of the snapring in relation to the two slightly extended pins in the anchor. (5) If bearing 6 (foldout 16,4) was re~ moved from shaft 5, install the bearing and T-16 Copyright 1984 General Motors Corp.ASSEMBLY OF snapring 7. Press the assembled shaft and bearing, splined end first, into the rear of housing 2. Seat the bearing against the shoulder in the housing. (6) Install the internal snapring whieh retains the shaft rear bearing (fig. 7-45) (D Install the sealring into the groove in the rear bore of the rear housing (fig. 7-45). Install the retainer, chamfered side first. (8) Install the snapring which holds the oil retainer in the rear of the rear housing (fig. 7-46). (9) Install the rear housing gasket on- to the rear housing, using oil-soluble grease to retain it. Install the rear housing onto the transmission (fig. 7-47). NOTE Rotate the transmission output shaft slowly to engage the splines of the high-range clutch plates with t h e splines of the high-range ring gear. (10) Install three 3/8-16 x 1-1/2-ineh bolts and lockwashers, and seventeen 3/8-16 x I-1/8-ineh bolts and lockwashers to retain Fig. 7-45. Installing oil retainer (TRT-1) Copyright 1984 General Motors Corp. ‘TRANSMISSION the rear housing on the adapter (fig. 7-48). Tighten the bolts to 26-32 Ib ft (35-43 N-m). (11) Proceed to paragraph 7-10. SHARRING Fig. 7-46. Installing oil retainer snapring (TRT-1) EAR HOUSING High-RANSE "ING GEAR Fig. 7-47. Installing transmission rear housing assembly (TRT-1)TT, TTB, TRT 2001 SERIES TRANSMISSIONS REAR HOUSING ee Fig. 7-48, Installing rear housing bolts (TRT-1) 7-8, ASSEMBLY OF TRT-3 MODELS & Reverse Cluteh and Planeta: ORT modes} () Position the transmission housing on blocks on its front splitline (refer to fig. 7-13). Install the reverse clutch piston with sealrings (as assembled in para 6-12) into the transmission housing. NOTE For vehicle-mounted transmis- sions, refer to paragraph 7-14. (2) Beginning with an external-tanged cluteh plate, alternately install four external- tanged cluteh plates and four internal-splined clutch plates onto the reverse piston (refer to fig. 7-14). Install the reverse planetary car rier assembly, long splines first, into the re- verse plates. (3) Install one external-tanged plate and one internal-splined plate onto the re verse planetary carrier assembly (refer to fig. 7-15). (4) Align the slots of the five reverse, external-tanged cluteh plates to receive the pins in the cluteh anchor assembly (fig. 7-49). Install the eluteh anchor pin into the control valve mounting p ad on the left side of the transmission housing. Aligning the anchor pin slot with the cluteh anchor pin hole within the transmission housing, install the forward- 1-18 and-reverse clutch anchor assembly, longer ends of t h e pins downward, and engage the slots of the five external-tanged clutch plates. Be sure that the six notehes of the five external-tanged plates are engaged by the six anchor pins in the anchor assembly. (Listen for a sound of the assembly seating when the plates are aligned.) (8) Push the clutch anchor pin into the slot in the forward-and-reverse clutch anchor assembly (fig. 7-49). Temporarily in~ stall a 3/8-16 x 1-inch bolt and a flat washer to retain the anchor pin during subsequent as- sembly operations (refer to fig. 7-17). (6) For TRT 2221-3, 2421-3 with over- drive, proceed to paragraph 7-9b. For TRT 2221-3, 2421-3 with underdrive, proceed to paragraph 7-9e. For TRT 2211-3, 2411-3 models, proceed to paragraph 7-9h. b. Forward Cluteh, Planetary and Adapter Assembly (TRT 2221-3, 2421-3 overdrive models) () Beginning with an internal-splined eluteh plate, alternately install two internal- ae | Eg 4 (= / ANCHOR ASSEMBLY REVERSE CARRIER ASSEMBLY Fig. 7-49, Installing forward-and-reverse clutch anchor assembly (TRT-3) Copyright 1984 General Motors Corp.ASSEMBLY OF TRANSMISSION FoRWano PLANETARY CRRRIER ASSEMBLY re ING GEAR REVERSE ING GEAR Tenn spun CLUTCH PLATE) REVERSE PLANETARY (CARBIER ASSEMBLY )3 2... Moise ince GLUTEN PLATE FORWARD AND ETS, ‘SUN GEAR Pig. 7-50. Installing forward planetary carrier assembly and attached parts (TRT-3) splined plates and two external-tanged plates (fig. 7-50). (2) Install the forward-and-reverse sun gear into the reverse planetary carrier assembly (fig. 7-50). (3) Install ring gear 1 (foldout 10,8) onto carrier assembly 30. Retain it with snapring 11. Install ring gear 14, longer ends of external splines first, onto carrier assem- bly 30, (4) Install retainer 21, flat side first, conto the rear of carrier assembly 30. Install bearing assembly 22 against the shoulder at rear of carrier assembly 30. (6) Install the thrust washer into the forward carrier assembly, using oil-soluble grease to retain it (fig. 7-50). (6) Install the forward carrier assem- bly, as assembled ins t e p s (3), (4), and (5), meshing its teeth with those of the reverse cartier pinions and the forward sun gear (fig. 7-50). Also, mesh the external splines of the forward ring gear with the installed internal splined clutch plates Copyright 1984 General Motors Corp. Fg foamren assemaur 2 FoRwano clUTeH PISTON ASSEMBLY CARRIER ASSEMBLY aiscvo: FEXTERNAL-TANGED GLUTCH PLATE INTERNAUSPLINED FORMARD sm SUUTCH PLATE AE TAINEE ig Gene Fig. 7-51. Installing rear housing adapter assembly (TRT-3 overdrive) (7) Install another internal-splined clutch plate and another external-tanged plate above the positioning ring on the for- ward ring gear (fig. 7-51). (8) Install twelve cluteh piston return springs and twelve pins (fig. 7-51). (9) Install t he adapter gasket onto the transmission housing (fig. 7-51). Install headless guide bolts at the f o ur positions shown in figure 7-51. (10) Install forward eluteh piston, with sealrings, flat side first, into the rear housing adapter assembly (fig. 7-51). (1D Install the adapter assembly, aligning oil ports in the adapter and retainer (fig. 7-51). (12) Install two 3/8-16 x 2-3/4-inch bolts temporarily to pull the adapter assem- bly down against the piston return springs (fig. 7-52).TT, TTB, TRT 2001 SERIES TRANSMISSIONS: Fig. 7-62. Installing adapter assembly bolts (TRT-3 overdrive) (13) Install two 3/8-16 x 1-3/4-ineh, 12-point-head bolts into the recessed holes at each edge of the adapter assembly (fig. 7-52). Remove the t wo outer guide bolts and the ‘temporary pull-down bolts. Tighten the 12- point-head bolts to 36-43 Ib ft (49-58 N-m). (14) Install six 3/8-24 x_1-1/4-ineh, self-locking bolts into the inner cirele of bolt holes. Remove the two inner guide bolts to install the last two bolts. Tighten the bolts to 41-49 Ib ft (56-66 Nem). Installation of Low-Range Clute! High-Range Planetary (TRT 2221-3, TARE overdrive models) NOTE New Teflon sealings may re- quire forming by hand to help retain their proper circular shape. Wrap them in a circle around an object about two- thirds the diameter of the groove they fit. (1) Install two step-joint sealrings 1 (foldout 14,A) into the grooves in the hub of low-range eluteh drum assembly 2. Use oil- soluble grease to retain them, 1-20 (2) Install the low-range eluteh drum assembly. (3) Install the snapring which retains the cluteh drum assembly on the forward car- rier (fig. 7-53). Install two bearing races and bearing assembly (fig. 7-53). The thinner, lipped race is installed, flat side first, against the forward carrier hub. (4) Beginning with an internal-splined clutch plate, alternately install five internal- splined and four external-splined cluteh plates (fig. 7-54). ‘THRUST BEARING ASSEMBLY BEARING RACE BS Fig. 7-53. Installing needle roller thrust bearing assembly (TRT-3 overdrive) LoWe-RANGE CLUTCH HUB, Low RANGE (CLUTCH PLATES () Low-RANGE cuuTeH ORUM BEARING Fc asseualy i. (TRT-3 overdrive) Copyright 1984 General Motors Corp.ASSEMBLY OF TRANSMISSION (5) Install the low-range clutch hub, engaging its splines with those of the inter~ nal-splined cluteh plates (fig. 7-54). Rotate the hub until it is engaged with all five in- ternal-splined plates. (6) Install the high-range planetary carrier assembly and retain it with an inter~ nal snapring (fig. 7-55). (7) Install high-range planetary sun gear 1 (foldout 14,B), meshing its teeth with the high-range planetary pinions. (1) Install the eluteh anchor pin into the rear housing (as rebuilt in paragraph 6-1 1). Leave the flat-milled end of the pin extend- ing at the inside of the housing (fig. 7-56). (2) Position the high-range clutch an- chor assembly, pins upward, on a level sur- face. Beginning w it h an internal-splined clutch plate, install alternately two internal- pplined and two external-tanged plates (tig. 7-57). (3) Install the high-range planetary ring gear, longer e nds of external splines first, into the internal-splined clutch plates (fig. 7-57). LOWRANCE High RANGE CLUTCH DRUM ASSEMBLY CARRIER ASSEMBLY Fig. 7-55 Installing snapring retaining high-tange planetary carrier assembly (TRT-3 overdrive) Copyright 1984 General Motors Corp. ANCHOR PIN Fig. 7-56. Installing clutch anchor pin (TRT-3 overdrive) INTERNAL-SPLINED PLATE 2 TeRTAL-TaNGeD PLATE (2) avcHOR ASSY PostTiowiNe RING Fig. 7-51. Assembling high-tange cluteh ‘and anchor (TRT-3 overdrive) (4) Install another _internal-splined and another external-tanged clutch plate on- to the assembly made in steps (2) and (3). (5) Grasp the entire cluteh assembly, invert it, and install it into the rear housing (fig. 7-58). Engage the slot in the anchor with the anchor pin in the housing. (6) Install the heavy internal snapring to retain the high-range cluteh anchor assem~ bly (fig. 7-59). Note the relation of the ends 1-21TT, TTB, TRT 2001 SERIES TRANSMISSIONS REAR vie Aance CLUTCH PLATES| ANGHOR Pm ‘LOCATION Pig. 7-58. Installing assembled high-range eluteh (TRT-3 overdrive) High-RANGE CLUTCH "ANCHOR ASSEMBLY SNAPRING ‘vgHon Ps Pig. 7-59. Installing cluteh anehor snapring (TRT-3 overdrive) of the snapring to the two long pins extending through the anchor. (@)_ Suspend the assembled rear hous~ ing on a hoist. Install the gasket, using oil- soluble grease to retain it (fig. 7-60). 1-22 EAR HOUSING output suart HIGH-RANGE PLANETARY CARRIER ASSEMBLY GASKET Be Lov-sance sure on Fig. 7-60. Installing rear housing and attached parts (TRT-3) (8) Install the rear housing assembly, rotating the output shaft to align the splines and gear teeth, Install fifteen 3/8-16 x 2-3/4- ineh bolts 4 (foldout 16,B) with lockwashers 3 to retain the housing and adapter. Tighten the bolts to 26-32 Ib ft (36-43 Nm). (9) Proceed to paragraph 7-10. Forward Cluteh, Planetary, and Adapter Assembly (TRT 2221-3, 2421-3 underdrive models) 'p (1) Beginning with an internal-splined clutch plate, alternately install two internal- splined plates and two external-tanged plates (fig. 7-61). (2) Install the _forward-and-reverse sun gear into the reverse planetary carrier assembly (fig. 7-61). Copyright 1984 General Motors Corp.ASSEMBLY OF TRANSMISSION REVERSE FORWARD CARRIER Assy FORWARD RING GEAR ms 2 = EXTERNAL-TANGED CLUTCH PLATE pe os INTERNAL-SPLINED CH PLATE) = Fig. 7-61. Installing forward planetary carrier assembly and attached parts (TRT-3 overdrive) (3). Install ring gear 1 (foldout 10,8) onto carrier assembly 3. Retain it with snap- ring 11. Install ring gear 14, longer ends of external splines first, onto carrier assembly 3. (4) Install retainer 21, flat side first, onto the rear of carrier assembly 3. Install bearing assembly 22 against the shoulder at the rear of carrier assembly 3. (5) Install the thrust washer into the forward planetary carrier assembly, using oil-soluble grease to retain it (fig. 7-61). (6) Install the forward carrier assem- bly and attached parts (fig. 7-61). Rotate the carrier and ring gears until all gear teeth and clutch plate splines are engaged. (2) Install another internal-splined, and another external-tanged clutch plate on- to the forward ring gear, above the position- ing ring (fig. 7-62). __ (8) _ Install twelve cluteh piston return springs and pins (fig. 7-62). Install the adapt- er gasket. Copyright 1984 General Motors Corp. Fig. 7-62. Installing rear housing adapter assembly (TRT-3 underdrive) (9) Install headless guide bolts into the retainer and transmission housing as shown in figure 7-62. (10) install the forward clutch piston, with sealrings, flat side first, into the adapter assembly (fig. 7-62). (11) Install the adapter assembly, aligning the oil p or t's in the retainer and adapter (fig. 7-62). (12) Install two 3/8-16 x 2-3/4-inch bolts at opposite sides of the adapter assem- bly to pull the adapter down against the clutch piston return springs. Install the two 3/8-16 x 1-3/4-inch, 12-point-head bolts (fig. 7-63). Tighten the bolts to 36-43 Ib ft (49-58 Nem). (13) Remove the two outer guide bolts and 3/8-16 x 2-3/4-ineh pulldown bolts which were temporarily installed in step (12). Install the six 3/8-24 x 1-1/4-ineh, self-locking bolts 28 (foldout 10,B) into the inner bolt cirele. (Remove the inner guide bolts to install the last two self-locking bolts.) Tighten the bolts to 41-49 Ib ft (56-66 Nm). 1-23‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS FoRwano PLANETARY CARRIER, seur- Locking BOLTS BOLT, 12-PONT HEAD (2) Fig. 7-63. Installing high-tange clutch drum assembly (TRT-3 underdrive) ae C Ride ores High-Range Cluteh, Low-Range ~ Planetary (TRT 2221-3, 242 underdrive models) NOTE New Teflon sealrings may re- quire forming by hand to help retain their proper circular shape. Wrap them in a circle around an object about two- thirds the diameter of the groove they fit. () Install two step-joint sealrings 1 (foldout 13,A) into the grooves in the hub of the high-range clutch dr u m assembly (fig. 7-63). Use oil-soluble grease to retain the sealrings. (2) Install the high-range cluteh drum assembly onto the forward planetary carrier (tig. 7-63), (3) Install the snapring which retains the high-range cluteh drum on the forward Planetary carrier. (4) Install low-range planetary sun gear assembly 1 (foldout 13,B), thrust washer 3 upward, onto the forward planetary carrier. 1-24 (5) Install one internal-splined clutch plate (fig. 7-84). Install the low-range plane- tary carrier assembly. (6) Install the low-range ring gear, ositioning ring first, into the cluteh plate installed in step (5) (fig. 7-65). (7) Install two external-splined and two internal-splined, low-range clutch plates, stacked alternately as shown in figure 7-65. INTERNAL-SPLNED ‘CUTOM PLATE (i) Fig. 7-64, Installing low-range planetary carrier assembly (TRT-3 underdrive) Low ance ING GEAR EXTERAL-SPLINED Jewrcn pia Pig. 7-65, Installing high-range clutch plates (TRT-3 underdrive) Copyright 1984 General Motors Corp.ASSEMBLY OF TRANSMISSION (8) Install high-range cluteh _back- plate 17 (foldout 13,4), flat side first. Retain it with large internal snapring 18. g- Low-Range Clutch, Rear Housin, ‘Assembly (TRT 2241-3, T41-3 = underdrive models) (Q)_ Install the cluteh anchor pin into the rear housing (as rebuilt in paragraph 6-11). Leave the flat-milled end of the pin extend- ing at the inside of the housing (fig. 7-66). (2) Beginning with an external-tanged cluteh plate, alternately stack five external- tanged and five internal-splined plates on the face of t he low-range clutch piston in the housing (fig. 7-66). (3) Install the low-range eluteh anchor assembly, engaging the anchor pins with the slots in the external-tanged clutch plates, and the slot in the anchor with the anchor pin in the rear housing (fig. 7-66). (4) Install the heavy internal snapring which retains the low-range clutch anchor as- sembly. Note the relation of the ends of the snapring to the two anchor pins which extend FEXTERNALTANGEO CLUTCH PLATE) INTERNAL-SPLINED ae CLUTCH PLATES) EAR HOUSING Pus ANCHOR PN LOCATION) Fig, 7-66. Installing low-range clutch anchor assembly (TRT-3 underdrive) Copyright 1984 General Motors Corp. slightly above the anchor surface (refer to fig. 7-59). (5) Suspend the assembled housing on a hoist and install the rear housing gasket. Use oil-soluble grease to retain the gasket (tig. 7-67). (6) Install the rear housing assembly onto the adapter assembly (fig. 7-67). To align gear teeth and clutch plate splines, ro- tate the output shaft while lowering the as~ sembly. (2) Install fifteen 3/8-16 x 2-3/4-inch bolts 4 (foldout 16,B) and lockwashers 3 to re~ tain the rear housing and adapter. Tighten the bolts to 26-32 Ib ft (36-43 Nem). (8) Proceed to paragraph 7-10. h (Q)_ Beginning with an internal-splined forward clutch plate, alternately install two internal-splined plates and two external- tanged plates onto the forward-and-reverse cluteh anchor assembly (fig. 7-68). ‘UFTING SUNG urPur sHaer EAR ousing ASSEMBLY [Link] ING GEAR GASKET ADAPTER ASSEMBLY Fig. 7-67. Installing rear housing assembly (TRT-3 underdrive) 1-25‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS EXTERNAL-TANGED CLUTCH PLATE 2) InrenASPONED {CLUTCH PATE (2) Fig. 7-68. Installing forward-and-reverse sun gear (TRT 2211-3, 2411-3) (2) Install the forward-and-reverse sun gear into the reverse planetary carrier assembly (fig. 7-68). (3) Install reverse ring gear 1 (foldout 11,A) onto carrier assembly 3. Retain it with snapring 10. (4) Install bearing 11 onto the rear of carrier assembly 3, pressing it to seat on the shoulder of the carrier. (5) Install bearing spacer 12 against bearing 11. (6) Install thrust washer 2 into the front of carrier assembly 3, retaining it with oil-soluble grease, Install forward ring gear 15, longer splines first, onto the carrier as~ sembly. (7) instal the carrier assembly, as assembled in steps (3) through (6) into the transmission. Rotate the carrier shaft and forward ring gear to mesh gears and clutch plate splines. (8) Install one internal-splined cluteh plate 16 and then one external-tanged eluteh plate 17 onto those previously installed. (9) Install twelve piston return springs 22 (foldout 9,B) and twelve pins 23 into the circle of holes in the forward-and- reverse clutch anchor assembly. 1-26 (10) Install forward clutch piston 18 (foldout 11,A), with sealrings 19, 20, and 21, into housing 9 (foldout 16,C). (11) Install gasket 1 onto the front flange of housing 9. (12) Install housing assembly 5 onto the transmission and retain it with eighteen 3/8-16 x 1-3/4-ineh bolts 4 and lockwashers 3. Tighten the bolts to 26-32 lb ft (36-43 Nem). 7-10, INSTALLATION OF TURBINE GEARING, OIL SUCTION TUBE, AND STRAINER ‘a, Accessory Drive Shaft Assembly (1) If removed, install bearing 9 (fold- out 7,B) onto drive shaft 8 and seat the bear- ing firmly against the shaft shoulder. Apply Molykote Type G or equivalent into the drive splines of the shaft. (2) Install the accessory drive shaft and bearing into the transmission housing (fig. 7-69). b, Turbine Gears, Freewheel Cluteh () If the transmission is equipped with a standard-speed, low-gear ratio, pro- ceed to step (2) If the transmissions is equipped with a high-speed, forward-gear ratio, proceed to step (3). (2) Install the forward-and-reverse sun gear, as shown in figure 7-69. Proceed to step (5). (3) Install the spacer into the sun gear cavity in the housing wall, as shown in figure 7-70. (4) After installation, the end of the spacer (fig. 7-70) should be flush with the bearing bore seat (shoulder) in the transmis- sion housing. If the spacer is above the shoul- der, this indicates the forward-and-reverse sun gear thrust washer is not seated properly. To reseat t he thrust washer, remove the spacer and use a suitable probe through the forward-and-reverse sun gear to relocate Copyright 1984 General Motors Corp.ASSEMBLY OF TRANSMISSION Accessory ORIVE SHAFT ASSY su oraR << Pig. 7-69. Installing forward-and-reverse sun gear (-1 models) & FIRST TURBINE ORWE GEAR SPACER accessony ORIVE SHAFT thames Fig. 7-70. Installing forward-and-reverse sun gear spacer (-1 models) (center) t he thrust washer. spacer. Reinstall the (5) Install the first-turbine drive gear and bearing (as assembled in para 6-10) (fig. 7-11). Install the step-joint sealring into the groove in the drive gear hub. Use oil-soluble grease to retain the sealring in its groove. Install the rear thrust bearing race (flat) and the needle roller bearing onto the drive gear. (6) Install the turbine-driven gears and freewheel clutch assembly (as assembled in para 6-8) (fig. 7-72). Rotate the assembly to engage t he second-turbine driven gear splines with those of the forward-and-reverse sun gear (fig. 7-71). Copyright 1984 General Motors Corp. FIRST-TURBINE DRIVE GEAR el Ba FORWARD-AND-REVERSE 'SUNGEAR occeomamaaa Fig. 7-71. Installing first-turbine drive gear components 131614 MALE NUT COMPRESSION SEALRING lt suction Tuee FIRST-TURBINE DRIVEN GEAR ont pune INTAKE Fig. 7-72. Installing oil suetion tube ¢ Oil Suction Tube, Oil Strainer (1) Generously lubricate the oil sue- tion tube compression sealring with transmis~ sion fluid (fig. 7-72). Using’ the fabricated wrench, install the 1-3/4-14 male nut and compression sealring onto the pump end of the oil suction tube. Insert the suction end of the tube into the sump area, and the pump end into the threaded hole at the pump in- 1-27TT, TTB, TRT 2001 SERIES TRANSMISSIONS take. Make sure the sealring is squarely seated in the intake boss. Install the nut into the boss but do not tighten at this time, NOTE For -1 models, proceed to step (2). For -3 models, proceed to step (3). (2) -1 Models. Install one 3/8-16 x 5/8-ineh self-locking bolt to secure the sue~ tion tube to the housing but do not tighten at this time (fig. 7-73). Install the oil strainer and gasket (fig. 7-74). Secure the oil strainer with six 3/8-16 x 7/8-inch bolts 20 (foldout SECOND-TURBINE. DRIVE GEAR BEARING. STEP-0INT SEARING SUMP AREA 0 Fig. 7-73. Installing second-turbine drive gear “OIL DRAIN PLUG Fig. 7-74, Installing oil strainer and gasket (-1 models) 1-28 8,B) and lockwashers 21. ‘Tighten the bolts to 26-32 lb ft (36-43 N-m). Install the oil drain plug (fig. 7-74) and tighten it to 33-37 Ib ft (45-50 Nem). ‘Then, while holding the suction tube flush with the ofl pump mounting sur face and using a fabricated wrench, tighten the male nut to 120-150 Ib ft (163-204 N-m). Tighten the self-locking bolt, which holds the oil suction tube, to 36-43 Ib ft (49-58 Nem). Proceed to step (4). (3) -3 Models, Install one 5/16-18 x 5/8-inch self-locking bolt to secure the sue- tion tube to the housing but do not tighten at this time (refer to fig. 7-73). Install the oil strainer (fig. 7-75). Install the O-ring gasket onto the strainer cover and install the cover. Secure the cover with two 3/8-16 x 3/4-inch bolts and lockwashers. Tighten the bolts to 26-32 Ib ft (36-43 N-m). Install the oil drain plug and tighten it to 33-37 Ib ft (45-50 N-m). Then, while holding the suction tube flush with the oi pump mounting surface and using a fabricated wrench, tighten the male nut to 120-150 lb ft (163-204 N-m). Tighten the self- locking bolt, which holds the oil suction tube, ‘to 17-20 Ib ft (23-27 Nem). Install baffle plate 29 (foldout 9,A) and retain it with three 5/16- 18 x 5/8-inch, self-locking bolts 30. Leave bolt hole for the suction tube bracket. Tight- en bolts 30 to 17-20 lb ft (23-27 N-m). (4) If the ball bearing was removed from the seconé-turbine drive gear, install a Fig. 7-15, Installing oil strainer and O-ting gasket (-3 models) Copyright 1984 General Motors Corp.ASSEMBLY OF TRANSMISSION new bearing (fig. 7-73). Install the step-joint sealring into its groove near the bearing. In- stall the front race of the thrust bearing, flange first, onto the bottom (rear) of the drive gear. Use oil-soluble grease to retain the bearing race on the drive gear. Install the second-turbine drive gear and assembled paris onto the firsi-turine drive gear (fig. 7-13). 7-11. INSTALLATION OF CONVERTER HOUSING, CONVERTER, COMPONENTS a Converter Housing ()_ If roller bearing 45 (foldout 7,B) is used with the accessory-driven gear, install the outer race, lip toward the rear, into the main housing bore. It may be necessary to temporarily install the charging pump to maintain bearing race alignment. Install the gasket onto the converter housing splitline (fig, 7-76). Use cil-soluble grease to retain the gasket during installation of the housing. Attach a sling to the converter housing front flange and, while lowering the converter housing (as assembled in para 6-8) onto the transmission housing, guide the accessory- driven gear past the second-turbine drive gear. Seat the converter housing and remove the sling. (2) To attach the converter housing, install one 7/16-14 x 2-3/4-inch bolt, twenty- cconverrer HOUSING ASS TRANSMISSION iG Pst HOUSING Se ‘cater aay ee oe Fig. 7-76. Installing torque converter housing assembly Copyright 1984 General Motors Corp. three 7/16-14 x 1-3/8-ineh bolts, twenty-four 7/16-inch flat washers, and twenty-four 7/16- inch lockweshers (fig. 7-77). Tighten the bolts to 42-50 lb ft (67-67 N-m). b. Converter Components () Cheek to ensure that the step- joint sealring (installed in para 6-8) is firmly seated in the converter housing sleeve (fig. 7-17). For models with a dry converter hou- sing, check to be sure the diaphragm oil seal is packed with high-temperature grease. (2) Install the torque converter pump (as assembled in para 6~7) onto the converter Bround sleeve (fig. 7-78). Install the splined OL SEAL DIAPHRAGHE ‘odes wiTH ADRY HOUSING) Fig. 7-77. Installing torque converter housing bolts Comvenren STATOR es ISEALRING WODELS | WITH DRY HOUSING) SPLINED rae _— Fig. 7-78, Installing torque converter stator 1-29‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS spacer, Install the stator, hub projection first, onto t h e ground sleeve. (3) For models with a dry converter housing, install the sealring into the groove in the converter pump splitline. Th e sealring used on models witha dry housing has a ree- tangular cross-section--0.113-0.123 x 0.133 0.143 in, (2,88-3.12 x 3.38-3.63 mm), and will fit int o the groove in the converter pump either way. The sealring must be installed with the 0.133-0.143 inch (3.38-3.63 mm) di- mension in the clamp direction (fig. 7-79) in order to provide adequate seal, (The 0.D. of the sealring may be marked with white paint.) Fill in t he remaining sealring groove area with petrolatum. (4) Install the snapring onto the con- verter ground sleeve to retain the stator (fi 7-80). Install the first- and second-turbine assembly (as assembled in para 6-6) onto the turbine drive-gear shafts 7-12. INSTALLATION OF INPUT COMPONENTS NOTE Direct-mount models with flex disks, proceed to paragraph 7-12a, ' Direct-mount models with @ drive ring, proceed to paragraph 7-12). Re mote- mount models, proceed to pare- graph 7-12e, a, Direct Mount (flex disk) (1) Install the torque converter drive cover (fig. 7-81). come Pun: F213 -0.18 in, 5.38 -3.65 mm) SEALRING (NoDALS—] FL008E FIT-FUL Wits DRY HOUSING WITH PETROLATUM 0,103 = 0.113 In, 2-287 mn Fig. 7-19, Assembly of converter pump sealring 1-30 (2) Install twenty-four 5/16-24, self- locking nuts to retain the cover (fig. 7-82). Tighten the nuts to 14-18 Ib ft (19-24 Nem). (3) Install the flex disk and washer assembly, washer side first, into the hub of Fast. ano secon TURBINE ASSEMBLY ‘SECOND-TURBINE DRE GEAR Fig. 7-80. Installing first-and-second turbine assembly Fig. 7-81. Installing torque converter drive cover—direet mount Copyright 1984 General Motors Corp.ASSEMBLY OF TRANSMISSION sour 12BXIIN. isk PLATE =n pre ssen6ty MMO Oo Ra bens. Fig. 7-82. Installing flex disk ‘assembly (direct mount) the converter cover (fig. 7-82). Install flex disk plate 4 (foldout 6,B), if applicable. As~ semble the three flex disks so the cone of each will be parallel to the flex disk and washer assembly and install the three disks as an assembly (fig. 7-82). Install the disk plate and align all the disk holes with the tapped holes in the converter drive cover. Install six 1/2-13 x 7/8-ineh, self-locking bolts and tight- ten them to 81-97 Ib ft (110-131 Nem). (4 If the transmission is equipped with a wet converter housing, gasket 13 (fold- out 6,B) must be used when the transmission is attached to the engine housing. Proceed to paragraph 7-13, b “ect Mount (drive ring) () install torque converter drive cover 12 (foldout 6,B). Install twenty-four 5/16-24, self-locking nuts 11 to retain torque converter cover 12. Tighten the nuts to 14- 18 Ib ft (19-24 Nem). (2) Lubricate sealring 10 with a high quality molybdenum disulfide grease, and in- stall it into the groove behind the splines on converter drive cover 12. (3) Apply sealer (Permatex No. 3 or equivalent) to drive ring 8 and to the drive ring mounting face on t he engine flywheel or drive disk (also to gasket 13, if used). In- stall converter drive ring 8 and attach it with Copyright 1984 General Motors Corp. eight 3/8-16 x 1-1/4-inch, 12-point bolts 9. Tighten the bolts to 36-43 Ib ft (49-58 N-m). Pack the spaces between the internal teeth of drive ring 8 with molybdenum disulfide grease. Fill the spaces between the teeth completely, bu t do not use an excessive amount of grease. Proceed to paragraph 7-13. ¢, Remote Mount (foldout 6,4) (1) Install torque converter drive cover 20 or 24 and attached parts (as assem- bled in para 6-5) on to the converter pump. Install twenty-four 5/16-24 self-locking nuts 19 to retain the cover. Tighten the nuts to 14-18 lb ft (19-24 Nm). (2) Install gasket 14 onto the con- verter housing front splitline. Install trans- mission front cover 13 with oil seal 11 (as assembled in para 6-4) and secure it with twelve 3/8-24 x 2-ineh bolts 12, lockwashers 21, and 3/8-24 nuts 22. Tighten the nuts to 33-40 lb ft (45-54 Nem). (3) Install spacer 3, if required. In- stall coupling assembly 8 ot input flange 9 or 10 onto input shaft 18 or 23. Refer to para graph 4-9 for instructions for installation, shim pack selection, and torque requirements. 7-13. INSTALLATION OF EXTERIOR COMPONENTS a, External Thermostat. If required, in- stall external thermostat kit 33 (foldout 7,8). b Oil Pump (1) Install the gasket and oil pump assembly onte the pump mounting ped tig. 7-83). (2) Retain the pump with two 3/8-16 x 3-inch bolts, seven 3/8-16 x 2-inch bolts, and nine lockwashers (fig. 7-84). Tighten the bolts to 26-32 Ib ft (36-43 N-m). NOTE If the p um p assembly has a two-bolt, SAE C mounting pad, install six 3/8-16 x 2-inch bolts, three 3/8-16 x 3-ineh bolts, and 1-31‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS soo Sor a Fig. 7-83. Installing ofl pump assembly Fig. 7-84. Installing ofl pump assembly nine lockwashers. Tighten these bolts to 26-32 Ib ft (36-43 Nem). ¢. Oil Pump Drive Coupling. If the trans- mission is equipped with adapter drive cou- pling 18 (foldout 18,4), replace the coupling. Apply molybdenum disulfide grease (Molykote Type G or equivalent) ont o the coupling splines and the mating splines of the pump. Install the drive coupling into the pump and retain it temporarily with a strip of tape. 1-32 Fig. 7-85. Installing control valve body assembly Fig. 7-86. Installing valve body bolts ¢. Control Valve Body (Q) Remove the temporarily installed bolt and washer from the valve body mount- ing pad (refer to fig. 7-17). Install the valve body gasket and retain it with oil-soluble grease (fig. 7-85). Install the control valve body assembly. (2) Install fifteen 3/8-16 x 2-1/2-ineh bolts with lockwashers and one hidden 3/8-16 x l-ineh bolt and lockwasher (fig. 7-86). Pro- gressing from the center of the valve body Copyright 1984 General Motors Corp.ASSEMBLY OF TRANSMISSION outward, tighten the bolts evenly to 26-32 1b ft (36-43 Nem). e. Parking Brake, Qutput Flanges (1). Install the brake backplate onto its mounting pad (fig. 7-87). Install and tight- en the bolts. Refer to foldout 17,B. Back- Torque Model. plate Bolts Ib ft (N-m) TT, TRT-1 2 -7(4) 81-97 (110-131) ‘TTB 8 = 7 (4) 81-97 (110-131) TRI-3 13 20(3) 117-140 (159-189) with lock- washers (2) Install the spacer roller onto the backplate lever, and install the cam lever (fig. 7-88). (3) Install two brake shoes (fig. 7-89). Install the two springs into the brake shoe holes away from the backplate. Install spacer 33 (foldout 17,4), if used, onto the output shaft. If flange 31, 32, or 34 is used, install the rear output flange. Install shaft sealring 37, making sure that it is well seated in the cavity between the shaft and flange. (Seal- ring not used in some models.) Refer to para- graph 4-9b for instructions for flange instal- lation and torque requirements. BACKPLATE MOUNTING SURFACE Pig. 7-87. Installing parking brake backplate Copyright 1984 General Motors Corp. CaM Leven 'SELFLOCKING BOLT (4) P sbacen GicPLAte ROWER LEVER Fig. 7-88. Installing brake apply arm ourpur FLANGE Rake SHOE 2) LEVER Fig. 7-89. Installing rear output flange (4) For transmission equipped with output flanges 35 or 36 (foldout 17,4), install the flange into brake drum 9 or 18 (foldout 17,B) and retain it with 3/8-24 self-locking bolts. Tighten the bolts to 41-49 Ib ft (56-66 N-m) and install the assembly onto the output shaft. Refer to paragraph 4-9b for instruc~ tions for installation and torque require ments. (5) _If flange 31 or 32 (foldout 17,A) is used, install the brake drum onto the output flange (fig. 7-90); then rotate the drum 90° For -1 models, attach the brake drum with four 3/8-24 x 5/8-inch, self-locking bolts (fig. 1-33TT, TTB, TRT 2001 SERIES TRANSMISSIONS: drum’ Pig. 7-91. Installing park drum (some -1 model: brake 7-91). For -3 models, install eight 3/8-24 x 3/4-ineh self-locking bolts (fig. 7-92). Tight- en the bolts to 41-49 Ib ft (56-66 N-m). (6) For -1 models, install spacer 5 {foldout 17,A), if used, onto the output shaft and install the front output flange (fig. 7-93). Install shaft sealring 3 (foldout 17,A), making sure that it is well seated in the cavity be- tween the shaft and flange. (Sealring is not used in some models.) Refer to paragraph 4-9 for instruetions for flange installation and torque requirements. (7) Tighten PTO flange retaining nut 29 {foldout 16,D) to 275-325 Ib ft (373-440 Nem). 1-34 ‘RAKE ORUN Fig, 7-92. Installing parking brake drum (-3 models) FRONT OUTPUT FRONT OUTPUT Rice e a Fig. 7-93. Installing front output flange 7-14, ASSEMBLY TECHNIQUES FOR VEHICLE-MOUNTED TRANSMISSIONS 8. Similar Procedures. Components are installed into the transmission in the vehicle by methods similar to those usd when the transmission is removed. The methods and Copyright 1984 General Motors Corp.ASSEMBLY OF TRANSMISSION sequence outlined in the manual are a general guide but may require some variation because of positioning and space limitations, Cluteh Installation (1) Special care is required to install clutch assemblies into @ transmission mounted in the vehicle. Make sure that all cluteh plates are properly engaged with their mating components and that all eluteh springs are properly positioned. (2) The reverse cluteh requires that the cluteh components be installed as an as- sembled unit. The assembly of the reverse eluteh components results in a clutch and planetary unit similar to that shown in figure 1-94, (3) Using two wires or cords, tie the eluteh plates to the cluteh anchor assembly by passing the wires or cords over the oppo- site tangs of the cluteh plates, around the inner side of the anchor pins, and through the adjacent holes in the anchor (fig. 7-94). Secure the wire or cord ends at the under (rear) side of the clutch anchor. Copyright 1984 General Motors Corp. REVERSE PLANETARY ‘ASSEMBLY FORWARD-AND-REVERSE CLUTCH ANCHOR ASSEMBLY wine 0 CORD wine 98 coRD ANCHOR PIN Fig. 7-94. Reverse clutch plates and planetary wired in position on forward-and-reverse cluteh anchor (4)_ Install the entire assembly, cluteh plates first, into the rear of the transmission, ‘engaging the anchor pin slot with the anchor in the transmission housing. Remove the wires or cords and continue with the assem- bly procedures as applicable. 1-35/1-36Section 8. WEAR LIMITS AND SPRING DATA 1, WEAR LIMITS DATA 2, Maximum Variations, The wear limits information in this section shows the maxi- mum wear at which components are expected to funetion satisfactorily. Table 8-1 lists the wear limits data and is referenced to the ex- ploded view (foldouts 6 through 18) in the back of the manual. >, Cleaning, Inspection, Parts must be clean to permit affective Tispection for wear or damage. Refer to paragraph 4-6. Bearings, Bearing Journals, Bore ‘The application of bearings to any product is based on the recommendations of the bearing manufacturer and, therefore, no diametral dimensional deviation should be permitted in the bearing or mated parts. Bearings should be carefully checked for signs of distress before reinstalling. g, Gears, Gears should be inspected for load pattern and signs of distress. Any dis tress indicates a possible future failure, and the reuse of such gears should be the decision of the individual customer, based on experi~ ence. Backlash cannot be used to establish critical wear of a gear. A gear usually pits, scuffs, scores, or galls long before the gear wear becomes critical. & Splines. Unless severe, spline wear is not considered detrimental except where it affects tightness of an assembly such as driveline flanges. Backlash cannot be used to establish critieal wear because both mating parts must be concentrically located to ob- tain accurate measurement of backlash. Hook-type Sealrings. Sides of the seal- ring’ should be smooth neximam wear” 0.005 ineh (0.12 mm). The sides of the groove into which the sealrings fit should be smooth--50 microinch (1.25 micrometers) equivalent, and square with the axis of rotation within 0.002 inch (0.05 mm). A new sealring should be in- stalled if the groove is reworked or if there is wear on the sealring outside the diameter. 82. SPRING DATA a, Springs must be clean to permit ef- feefive inspection. Springs should be re- placed if there are signs of overheating, wear due to rubbing adjacent parts, or permanent set. Discard springs which do not meet the load-height specifications in Spring Data Table 8-2. Inspection criteria (load versus height) and identification characteristics of the springs are presented in Table 8-2, ‘The spring data are keyed to the exploded views (foldouts 6 through 18) in the b ae k of the menual. NOTE When more than one spring part member is listed for the same location, refer to parts catalog SA 1248 to determine which spring is used for your specific assembly number. Copyright 1984 General Motors Corp. e1TT, TTB, TRT 2001 SERIES TRANSMISSIONS ‘Table 8-1. WEAR LIMITS Wear Limit lustration Description in (mm) Foldout 7,8 TORQUE CONVERTER HOUSING AND TURBINE DRIVE GEARS 25 ‘Thrust bearing front race, min thiekness 0.028 0.71 20 ‘Thrust bearing rear race, min thiekness 0.120 3.04 Foldout 8,4 TURBINE DRIVEN GEARS AND FREEWHEEL CLUTCH 9, 23 * Freewheel roller, min diameter 0.4980 12.65 12, 26 + Freewheel cam, max surface wear 0,003 0.07 28 * First-turbine driven gear hub, min OD 3.0327 77.02 Foldout 9B REVERSE CLUTCH AND PLANETARY 5,17 Cluteh plate: min thickness 0.097 2.46 max cone 0.030 0.76 6, 18 Cluteh plate: min thickness 0130 3.30 max cone oo2 0:30 ** Cluteh pack, min thiekness 1.185 30.09 e n Pinion, max end play in carrier 15 0.055 1.39 20 Cluteh anchor, max face wear reverse face 0.020 0.50 forward face 0.020 0.80 Foldout 10,4 FORWARD CLUTCH AND PLANETARY (-1 MODELS) 2 ‘Thrust washer, min thickness 0.125 3.17 7, 14, 21 Pinion, max end play in carrier 0.055 1.39 24 ‘Thrust washer, min thickness 0.088 2.26 26 Cluteh plate: min thickness 0.130 3.30 max cone 0.012 0.30 27 Clutch plate: min thickness 0.097 2.46 max cone 0.030 0.76 ** Clutch pack, min thickness 6-plate pack 0.681 17.29 &-plate pack 0.908 23.06 * Total wear of freewheel parts (2 x roller wear + sum of cam surface wear at two opposing points + gear hub wear) must not exceed 0.010 inch (0.25 mm). (Determine cam surface wear by measuring depth of groove caused by roller contact in the cam pocket.) e ‘** Total of individual plate thicknesses. Replace plates having the most wear with new plates to increase pack thickness. 82 Copyright 1984 General Motors Corp.WEAR LIMITS AND SPRING DATA Table 8-1. WEAR LIMITS (cont) Wear Limit Dlustration Deseription in mm) Foldout 10,8 FORWARD CLUTCH AND PLANETARY (TRT 2221-3, 2421-3) 2 Thrust washer, min thickness 0.087 2.20 4, 31 Bushing, min ID 1.885 47.87 9, 36 Pinion, max end play in carrier 0.055 1.39 12, 18 Cluteh plate: min thiekness 0.130 3.30 max cone 0.012 0.30 13, 16 Cluteh plate: min thickenss 0.097 2.46 max cone 0.030 0.76 27 Adapter sleeve no scoring permissible * Cluteh pack, min thickness 0.691 17.55 Foldout 11,4 FORWARD CLUTCH AND PLANETARY (TRT 2211-3, 2411-3) 2 ‘Thrust washer, min thickness 0.125 3.17 8 Pinion, max end play in carrier 4 0.055 1.39 13, 16 Cluteh plate: min thickness 0.130 3.30 max cone 0.012 0.30 14,17 Cluteh plate: min thiekness 0.097 2.46 max cone 0.030 0.76 * Cluteh pack, min thickness 0.691 17.55 Foldout 11,3 HIGH-RANGE CLUTCH AND PISTON HOUSING (TT MODELS) 3 ‘Transfer drive gear, max face wear 0.020 0.50 8,13 Cluteh plate: min thickness 0.130 3.30 max cone 0.012 0.30 9 Cluteh plate: min thickness 0.097 2.46 max cone 0.030 (0.76 * Clutch pack, min thickness 0.357 9.06, Max diametral clearance between: 10, 12 high-range clutch hub and 23, 33 bushing in piston housing 24, 34, 36, of 37 0.005 O12 18 Sealring, min thickness 0.0880 2.23 19 Piston, max face wear 0.020 0.50 27, 29 Sealring, min thiekness 0.0875 2.22 * Total of individual plate thicknesses. Replace plates having the most wear with new plates to inerease pack thickness. Copyright 1984 General Motors Corp. 83‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS: Table 8-1. WEAR LIMITS (cont) lustration Foldout 12,4 9 19 23 26, 29 21, 30 31 Foldout 12,B 1 7 13, 16 Ww Foldout 13,4 8 12, 15 13, 16 17 Foldout 13,B * Total of individual plate thicknesses. Replace plates having the most wear with new plates to Wear Limit Deseription in (mm) LOW-RANGE CLUTCH AND TRANSFER DRIVE GEAR (TRT-1 MODELS) Adapter sleeve no scoring permissible Cluteh piston, max face wear 0.010 0.25 Sleeve bushing, max ID 2.008 51.00 Cluteh plate: min thickness 0.130 3.30, max cone 0.012 0.30 Cluteh plate: min thiekness 0.097 2.46 max cone 0.030 0.76 Backplate, max face wear 0.010 0.25 * Cluteh pack, min thickness 0.841 21.36 HIGH-RANGE CLUTCH AND PLANETARY (TRT-1 MODELS) High-range sun gear assembly, L718 min thickness Pinion, max end play in carrier 5 0.055 Anchor, max face wear (rear) 0.020 Cluteh plate: min thickness 0.130 max cone 0.012 Cluteh plate: min thickness 0.097 max cone 0.030, * Cluteh pack, min thickness 1.135 HIGH-RANGE CLUTCH, LOW-RANGE RING GEAR, (PRT 2211-3, 2421-3 UNDERDRIVE) Clutch piston, max face wear Cluteh plate: min thiekness 0.130 max cone 0.012 Cuuten plate: min thickness 0.097 max cone 0.030 Backplate, max face wear 0.010 * Cluteh pack, min thickness 0.595, LOW-RANGE CLUTCH AND PLANETARY (PRT 2221-3, 2421-3 UNDERDRIVE) Low-range sun gear assembly, Ls min thickness inerease pack thickness. 84 Copyright 1984 General Motors Corp. 2.46 0.76 28.82 0.25 2.46 0.76 0.25 15.11 43.63WEAR LIMITS AND SPRING DATA ‘Table 8-1. WEAR LIMITS (cont) Wear Limit Mlustration Deseription in (om Foldout 13,B LOW-RANGE CLUTCH AND PLANETARY (cont) (TRY 2221-3, 2421-3 UNDERDRIVE) (cont) 7 Pinion, max end play in carrier 5 0.055 1.39 13 Clutch anchor, max face wear (rear) 0.020 0.50 16 Cluteh plate: min thickness 0.130 3.30 max cone 0.012 0.30 17 Cluteh plate: min thickness 0.097 2.46 max cone 0.030 0.76 * Clutch pack, min thickness 1.185 29,09 Foldout 14,4 LOW-RANGE CLUTCH, HIGH-RANGE PLANETARY 8 Cluteh piston, max face wear 0.010 0.25 12 ‘Thrust bearing race, min thickness 0.028 0.71 14 Thrust bearing race, min thickness 0.182 4.62 16 Cluteh plate: min thickness 0.130 max cone 0.012 i Clutch plate: min thickness 0.097 2.48 max cone 0.030 (0.76 19 Carrier, max face wear (front) 0.010 0.25 23 Pinion, max end play in carrier 19 0.055 1.39 * Clutch pack, min thickness 1.108 28.14 Foldout 14,8 HIGH-RANGE CLUTCH, PLANETARY SUN AND RING GEARS 4 Clutch anchor, max face wear (rear) 0.020 0.50 7,10 Cluteh plate: min thickness 0.130 3.30 max cone o.012 0.30 811 Cluteh plate: min thiekness 0.097 2.46 max cone 0.030 0.76 * Cluteh pack, min thickness 0.721 18.31 Foldout 15,4 HIGH-RANGE CLUTCH AND PISTON HOUSING (TTB MODELS) 3 ‘Transfer drive gear, max face wear 0.020 0.50 8, 13 Cluteh plate: min thickness 0.130 3.30 max cone 0.012 0.30 * Total of individual plate thicknesses. Replace plates having the most wear with new plates to increase pack thiekness. Copyright 1984 General Motors Corp. 8-5TT, TTB, TRT 2001 SERIES TRANSMISSIONS ‘Table 8-1, WEAR LIMITS (cont) Wear Limit Dlustration Deseription ih (mm) Foldout 15,A HIGH-RANGE CLUTCH AND PISTON HOUSING (TTB MODELS) (cont) (cont) 8 Cluten plate: min thickness 0.097 2.46 max cone 0.030 0.76 * Clutch pack, min thickness 0.357 9.06 18 Sealring, min thiekness 0.880 2.23 19 Piston, max face wear 0.020 0.50, Max diametral clearance between: 12 high-tange cluteh hub and 34 bushing in piston housing 35 0.005 0.12 Foldout 15,B INTERNAL BRAKE AND REAR COVER (TTB MODELS) “4 Brake plate: min thickness 0.097 2.46 0.030 0.76 15 min thickness 0.130 3.30 max cone 0.012 0.30, * Brake pack, min thickness 1.232 31.29 38 Rear cover, brake cylinder bores, max ID 1.6290 41.37 @ Foldout 17,4 OUTPUT SHAFTS AND DISCONNECT ASSEMBLY Max diametral clearance betwee! 13 front output shaft and 25 bushing in output shaft 26 0.010 Foldout 18,A OIL PUMP ASSEMBLIES 3 Cover no scoring permissible 12 Driven gear shaft, min OD 0.749 19.02 Foldout 18,8 | CONTROL VALVE ASSEMBLIES 8 Valve, max clearance in body 9 0,004 0.10 16 Plug, max clearance in body 9 0.0035 0.09 20 Valve, max clearance in body 9 0.004 0.10 21 Valve plug, max clearance in plug 25 0.004 0.10 29, 39, 42 Valve, max clearance in body 9 0.003 (0.07 45 Valve plug, max clearance in body 9 0.004 0.10 49 Valve plug, max clearance in plug 50 0.004 0.10 52 Valve, max clearance in body 9 0.003 0.07 Total of individual plate thicknesses. Replace plates having the most wear with new plates to inerease pack thickness. 86 Copyright 1984 General Motors Corp.sdiog siojoW TEED FRET WSIIdoD 8 ‘SPRING DATA Fold- 7.8 7.8 8A 9,8 Ref. 2 72 2 Sering Lubrication pressure regulator valve Convertor pressure regulator valve Freewhee! clutch Reverse, low-range clutch piston return ‘ange clutch return Lowerange clutch Piston return High-range clutch piston return High-range clutch piston return Lowcrango clutch piston return Lowcrange, clutch piston return ange clutch piston return High-range clutch piston return Pact Nos 6773689 6773551 6880795 774681 6833973 6835343 6772068, 6775437 6756134 6759491 6759491 6759491 6759891 6777032 6777032 6736134 No color Green stripe No color No color No color No color No color No color No color 13.5 0.088 ay 10 0.080 2208) 120.067 30) 19 0.08 00) % 0.038 18) 270.038 0:88) 370.105 een 35 Bol lovitto ‘pring Bot levi ‘spring Bot evi te ‘spring Bol evil lo soring Bot lovitto spring Bot tovitte coring Bol tovitte spring Bal levi te spring 0.403 16.24) 0.468 i.89 0.834 «ion 0.251 (6.38) 0.175 casaay 0.185 4.70) 0,625 6.70 6.70 70.2) 5.14 «0.0 5.51 io. 6.13 5.7) 0.28 amy 0.27 « 0.27 69 0.27 6.9) 0.27 6.9 0.27 6.9) 0.27 6.9) 0.28 a Length Under Load ins (om) 1,00 8) 1,00 5.4) 1,02 3.9 1.00 (35.4) bra (23.0) Lis (23.0) 4.18 (106.2) 4,80 21.9 tb. WD, 5.6-6.8 5230) 23.4-28.6 05-127) 31A-34.6 ao-155) 553-63 a2) 651-72 28-30) 61-72 28-3) 45,8-49.6 (200-220) 45.1-49.9 (261-222) VLVG ONIYdS CNV SLINIT UVEMa8 *diog siojowy TeI0UED HEEL WBIIKdoD Table 8-2. SPRING DATA (cont) Spring Free A Color No. Wire dia "00 Length Length Under Load Fn Part No. Code, Gols ins (mm) ine (om) ins Gem) Ine (om) Ib. CAD '5,B 11 Hydraulic brake 6758503 No color 2 0.092 0,625 3.20 238 27,9-34.1 roturn (TTB models) 23) 05.88) BI.) (60.5) 195-151), 6765710 No color 18.5 0.080 0.625 3.04 2,08 18.9-23.1 (2:03) (15.88) (77.2) (52.8) (85-102) 6831441 No color 2» 0.080 0.622 3.86 2.94 16,7-20.3 (2:03) (15.80) 80) (74.7)—— 75-90 17,4 15 Disconnect detent 6773464 No color “ 0.353132 Hed 11.9214. B97 33.5). 5-68) 17,8 5 Parking brake 9027076 Solid black 12 0,500 . 2.62 20.08 shoo-to-shoe® 12.70) . 5) 83) 17,B 16 Parking brake 6758260 Solid black 18 0,812 4.62, 60,0-75.0" shoo-fo-shoe™ (20.62) iz.) 267-335) 18,8 14 Mein-pressure reguistor valve: T35°170 psi 6835211 Green stripe 18.5 0.772 2,50 90,0-102.0 (831-1172 kPa) 03.6 (63.5) (401-853) 6834941 No color 7 0.768 2,50 90.0-102.0 3.5) (63.5) (401-853), 6835377 Blue stripe 17 0.754 2,50 90.0-90.0 19.15) (63.5) (356-400) 160-195 psi 6835705. No color 16 9.765 2.50 100.0-110.0 (1104-1344 KPa Gi) (19.43) (63.5) (445-489) 6885165 Solid white 17.6 0.128027 2.50 100.0-110.0 6.25) 19.78) (63.5) (485-489) 18,8 15 Trimmer 6773593 No color 10 O.13t 120 2.38 25.6-31.2 G33 8.45) 6.5) 4138) 6830365 No color a 0.128 1.12.58 1.43 72,2-82.2 25) B19) 655) 6.35 22-365) Tension spring SNOISSINSNV UL SAIWAS 1002 LUL ‘ELL ‘LLsdiog siorow TBIAUED FEET IUSLkdog 01-8/6-8 Toble 8-2. SPRING DATA (cont) Spring Free Fold Color ‘00 Length Length Under Load out Ref. Spring Part No. Code ine (om) ine Gm) nee (am) 1b. 18,B 19 Clutch cutoff valve: 130 psi 6765710 No color 18.5 3,08 2,08 18,9-23.1 (896 KPa) 62.8) (85-102) 6831441 No color 20 2,98 — 167-20.3 a 5-90) 250 psi 6758503 Wo color 20 2.38 27,9-34.1 C724" kPa) 5) 135-151) 23017350 Solid yellow, 20 2.03 39.6-48.4 green on Gio 077-215) 400 psi 6830366 Solid white 16.5 71.0-86.6 (2758 kPa) (316-385) 18,8 33. Selector valve 6769251 No color 10 13.6-14.0 detent 6i-62) 6710253 White stripe 11 7,6-8.4 6037 6833934 Solid white, 10 0.054 1, 9-15.1 orange stripe an (33-58) 1B,B 38 Inching regulator 6770298 No color, 14.6 0.041 3938.07 front «04 75-18.) 6772046 No color 15.5 0.085 25.2-27.8, a6 i315) 18,8 41 Inching regulator 6774595. No color 21.5 0.072 25.2-27.8 reer «83 ist5 6838473 Wo color 26.4 0.090 0,620 4.29 2.50 41.9-51.1 (229) 15.75) (169.0) (63.5) (187-227) 18,8 43 Inching valve return 6774594 Wo color 7 0.120 © 1.105575 4.04 28.5-51.5 3.05) (28.07) (146.0) (102.6) (137-140), VLVC ONRIdS CNV SLINIT UVEMSection 9. OWNER ASSISTANCE AND SERVICE LITERATURE $1. OWNER ASSISTANCE The satisfaction and goodwill of the owners of Allison transmissions are of pri- mary concern to Detroit Diesel Allison, its distributors, and their dealers. As an owner of an Allison transmission, you have service locations throughout the U.S. and Canada, plus many outlets world- wide that are prepared and eager to meet your parts and service needs with: ‘© Expert service by trained personnel ¢ Emergency service 24 hours a day in many areas ‘© Complete parts support Sales teams to help determine your power requirements © Produet information and literature We recognize, however, that despite the best intentions of everyone concerned, mis- understandings may occur. Normally, any sueh situation that arises in connection with the sale, operation, or service of your trans mission will be handled by the distributor or cealer in your area (check the Yellow Pages for the Detroit Diesel Allison service outlet nearest you). To further assure your complete satis- faction, we have developed the following three-step procedure to be followed in the event you have a problem that has not been handled satisfactorily. Step One~Discuss_your problem _with_a member_of management from the distrib- Worship or -deelership, — Frequently, com plaints are the result of a breakdown in communication and can quickly be resolved by a member of management. If you have already discussed the problem with the Sales or Service Manager, contact the General Manager. If your problems originate with a dealer, explain the matter to a management member of the distributorship with whom the dealer has his service agreement. Step Two—When it appears that your problem cannot readily be resolved at the distributor level without additional _assis- tanee, contaet_the Detroit Diesel Allison Regional Office nearest you listed below: EASTERN REGION 9 Sylvan Way P.O. Box 3001 Parsippany, New Jersey 07054 USA Phone: (201) 993-4047 TWX: 710-998-0563 SOUTHEASTERN REGION 5730 Glenridge Drive, NE Atlanta, Georgia 30328 USA Phone: (404) 257-3640 TWX: 810-751-8141 GREAT LAKES REGION Suite 365 New Center One Building 3031 W. Grand Blvd. P.O. Box 33122 (N65) Detroit, Michigan 48232 USA Phone: (313) 556-5400 TWX: 810-221-6283 MIDWESTERN REGION 475 Alexis R. Shuman Blvd. Naperville, Illinois 60566 USA Phone: (312) 961-6750 TWX: 910-651-3032 SOUTHWESTERN REGION General Motors Building 130 E. Carpenter Freeway Irving, Texas 75062 USA Phone: (214) 659-5070 ‘TWX: 910-860-5063 WESTERN REGION Suite 2700 39465 Paseo Padre Parkway Fremont, California 94538 USA Phone: (415) 498-5200 TWX: 910-381-6105 Copyright 1984 General Motors Corp. oe‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS. CANADA Diesel Division - GM of Canada Ltd, P. O, Box 5990 600 Clarke Road London, Onterio NGA 416, Canada Phone: (519) 452-5000 Telex: 064-5850 ‘TWX: 610-352-0269 LATIN AMERICAN REGION Detroit Diesel Allison Gables Center, suite 321 95 Merrick Way Coral Gables, Florida 33144 USA Phone: (305) 446-4900 Telex: 810-848-7061 EUROPEAN REGION Detroit Diesel Allison - Europe Div. of GM Continental, S.A. Nederland Parmentierplein 1, 3088 GN Rotterdam Mail: P.O. Box 5061 3008 AB Rotterdam, Netherlands Phone: 010-290-000 Telex: 28355 GMCNL ASIA REGION Detroit Diesel Allison Div. of GM Oversea Corp. 15 Benoi Sector Jurong Town, Singapore 2262 (65) 265-4697 or (65) 261-0801 RS 21608 A/B GM SING MIDDLE EAST/AFRICA REGION Detroit Diesel Allison Athens Towers, "A" Bldg., 6th Floor Messoghion 2/4 Athens 610, Greece Phone: (30) 1770-6669 (30) 1-78-5344 0) 1-778-7281 Telex: 215759 DDA PACIPIC REGION Detroit Diesel Allison - Australia Div. of GM Overseas Corp. Princes Highway, P. O. Box 163 Dandenong, Vietoria 3175 Australia Phone: (61) 3-797-7911 Telex: AA30792 Step Three—If you are still not satisfied, resent the entire matter in writing of bj Phone to the product headquarters Allison Transmission Operations: Man- ageF OFF Highway "NansmissTors Service, Detroit Diesel Allison, P. ©. Box 894 Indianapolis, Indiana 46206. Phone: (3173 242-3549, The inclusion of all pertinent information will assist the Home Office in expediting the matter. If an additional review by the Home Office of all the facts involved indicates that some further action can be taken, the Regional Office will be so instructed. If at this point your problem is still not resolved to your satisfaction, call or writ Manager Transmission Service, Indianapolis Operations (317) 242-3547 of Director Trans- mission Sales, Indianapolis Operations, (317) 242-3584. When contacting the Regional or Home Office, please keep in mind that ultimately your problem will likely be resolved at the Gistributorship or dealership utilizing their facilities, equipment, and personnel. There- fore, it is suggested that you follow the above steps in sequence when experiencing a problem. Your purchase of a Detroit Diesel Allison product is greatly appreciated, and it is our sincere desire to assure complete satisfaction. 9-2. SERVICE LITERATURE Additional service literature is available for the owner who takes pride in his equip- ment. ‘These books provide fully illustrated instructions for the maintenance, service, overhaul, and parts support of your trans- mission. To ensure that you get maximum performance and service life from your unit, see your dealer or distributor for the fol- lowing publications. Check the Yellow Pages under Transmissions — Truck or Engines — Diesel for your nearest authorized service outlet. 92 Copyright 1984 General Motors Corp.OWNER ASSISTANCE AND SERVICE LITERATURE ‘TT, TTB, TRT 2001 ‘Transmission Publications 1200, 1400, 2000 Series Parts Catalog SA 1248 TT, TTB, TRT 2001, 3000, 4000 Operators Manual SA 1278 9-3, FACTORY SERVICE "INFO" Detroit Diesel Allison maintains factory serv- ice "INFO" telephone lines to respond to cus- tomer needs on a timely basis when the nor- mal channels of communications are not available. "INFO" lines, created as part of Detroit Diesel Allison's customer response effort, are open between 8:00 a.m. and 4:30 p.m. (local time). Copyright 1984 General Motors Corp. Por Allison Transmission number information, the (317) 242-INFO. For off hours and times when all "INFO" lines are busy, telephone answering equipment will provide the opportunity for the caller to leave a name and phone number for a prompt re- turn eall or eall back on the next business day. As a reminder, the service "INFO" lines are not intended to bypass the normal channels of communication, but rather to provide direct factory assistance when normal contacts are not available. ‘Therefore, you are urged to use the three-step procedure outlined under "Owner Assistance" prior to using the service "INFO" telephone line(s). 9-3/9-4Flex disk drive assembly ‘Torque converter cover Second turbine First turbine ‘Torque converter stator Torque converter pump Input flange ‘Transmission front cover - Torque converter drive cover Accessory-driven gear ‘Transmission housing Oil suetion tube Oil pump: Accessory pump mounting pad Pirst-turbine drive gear Reverse clutch piston Reverse clutch Reverse planetary pinion Forward (low-range) clutch Forward (low-tange) piston Forward (low-range) planetary pinion ‘Transfer drive gear ‘Transmission rear cover High-tange clutch High-range clutch hub Forward-and-reverse sun gear High-range piston Forward (low-range) planetary carrier assembly Rear output flange - Rear output shaft Parking brake ‘Transfer-driven gear Forward-and-reverse clutch anchor Disconnect coupling Disconnect shifter fork Front output shaft Front output flange Forward (low-range) ring gear Disconnect shifter shaft Reverse ring gear Reverse planetary carrier assembly First-turbine driven gear Freewheel clutch Second-turbine driven gear Second-turbine drive gear ‘Torque converter housing Accessory drive gear Converter-driven PTO output flange Converter-driven PTO shaft Internal brake = Brake-apply plate Brake piston Rear cover plug Diaphragm Output-driven PTO output shaft One-piece output shaft Shifter shaft hole plug Converter diaphragm Plug Oil sealFOLDOUT 1 ‘TT, TTB, TRT 200] SERIES TRANSMISSIONS Foldout 1. ‘TT 2001 and TTB 2001 Series transmissior ns Copyright 1984 General Motors Corp.Plex disk drive ‘Torque converter cover ‘Torque converter housing Second turbine First turbine Converter ground sleeve Accessory driven gear Oil suction tube ‘Transmission housing Oil pump drive gear Accessory mounting pad Accessory drive splines First-turbine drive gear Second-turbine drive gear Reverse planetary carrier Forward eluteh piston ‘Transfer drive gear Forward planetary carrier Adapter Low-range cluteh piston Low-range clutch High-range clutch anchor High-range clutch Rear housing High-range cluteh piston Output shaft High-range sun gear High-range planetary carrier High-range ring gear Rear output flange ‘Transmission output shaft Parking brake ~ Forward-and-reverse sun gear ‘Transfer driven gear Forward ring gear Forward-and-reverse cluteh anchor Front output flange Forward cluteh = Reverse cluteh ~ Reverse ring gear Reverse clutch piston Reverse cluteh hub First-turbine driven gear Second-turbine driven gear - Freewheel cluteh = Accessory drive gear Converter pump Converter statorFOLDOUT 2 TT, TTB, TRT 2001 SERIES TRANSMISSIONS ' j 7 4 | pee 0 2, lL a yf \ SL wf = f —# S fy ” " ie a ? & LS» a8 Pe > Foldout 2. TRT 2421-1 Transmission Copyright 1984 General Motors Corp.Flex disk drive Torque converter cover ‘Torque converter housing Second turbine First turbine = Accessory driven gear = Oil suetion tube ‘Transmission housing Oil pump drive gear ~ Accessory drive coupling Accessory mounting pad First-turbine drive gear Second-turbine drive gear Reverse planetary carrier Rear output housing adapter Forward eluteh piston High-range cluteh drum High-range cluteh ‘Low-range clutch anchor Low-range clutch Low-range cluteh piston ‘Transmission output shaft Parking brake 24 25 26 27 28 29 31 32 - 33 34 35 36 - 37 38 39 40 4 43 44 - ~ Torque converter stator Output flange Rear housing Low-range planetary carrier Low-range ring gear Low-range sun gear Forward planetary carrier High-range eluteh piston Forward-and-reverse sun gear Forward ring gear Forward elute! Forward-and-reverse clutch anchor Reverse ring gear Reverse clutch Reverse eluteh hub Reverse cluteh piston First-turbine driven gear Second-turbine driven gear Freewheel cluteh Accessory drive gear Diaphragm Torque converter pumpFOLDOUT 3 ‘TTB, TRT 2001 SERIES TRANSMISSIONS 4 15 18 1718 19 20 oat m ‘ 8 2 020 28 27 26 25 a de ba 30.98 sy 36 35 3 Poldout 3. TRT 2221-3 Transmission (with underdrive) Copyright 1984 General Motors Corp.Plex disk drive Torque converter cover ‘Torque converter housing Second turbine First turbine Diaphragm ‘Accessory driven gear Oil suetion tube ‘Transmission housing Oil pump drive gear Adapter coupling Accessory mounting pad First-turbine drive gear Second-turbine drive gear Reverse planetary carrier ~ Adapter Forward clutch piston Low-range eluteh drum Low-range cluteh High-range cluteh anchor High-range cluteh High-tange clutch piston Output shaft Parking brake Output flange = Rear housing ~ High-range sun gear High-range ring gear ~ High-range planetary carrier Low-range cluteh hub Low-range cluteh piston - Forward planetary carrier ~ Forward-and-reverse sun gear Forward cluteh Forward ring gear Forward-and-reverse clutch anchor Reverse eluteh = Reverse eluteh hud = Reverse cluteh piston First-turbine driven gear ‘Second-turbine driven gear Freewheel cluten Accessory drive gear ~ Torque converter pump ~ Torque converter statorFOLDOUT 4 ‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS 42 43 16 J 38 y9 0 21 22 Bo os ous eeu is 2 H » & % bbe Copyright 1984 General Motors Corp.Flex disk drive ‘Torque converter cover Torque converter housing Second turbine First turbine = Accessory driven gear = Oil suction tube ‘Transmission housing Oil pump drive gear = Accessory drive coupling Accessory mounting pad First-turbine drive gear ~ Second-turbine drive gear Reverse ring gear Forward clutch piston Forward ring gear Reverse planetary carrier Parking brake Output flange Rear housing Forward-and-reverse sun gear Forward planetery carrier Forward clutch Forward-and-reverse clutch anchor Reverse elutch Reverse eluteh hub Reverse clutch piston First-turbine driven gear Second-turbine driven gear Freewheel cluteh Accessory drive gear Diaphragm Torque converter pump Torque converter statorFOLDOUT 5 ‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS1 ~ Flange retaining nut, 1-1/4-12 (nylon insert) A 2 ~ Flange washer 3 - Plange spacer 4 ~ Self-locking bolt, 3/8-24 x 1-1/8 in. (2) B 5 - Lockstrip 6 - Plange retaining washer 7 ~ Shim (as required) 0.025-in. (0.63-mm) thick 0.005-in, (0.13-mm) thick 8 - Torqmatie coupling assembly 9 ~ Flange (Mechanics 5C) 10 - Flange (Mechanics 6C) 11 - Oil seal 12 - Bolt, 3/8-24 x 2 in. (12) 13 - ‘Transmission front cover 14 - Front cover gasket, Self-locking bolt, 1/213 x 7/8 in. (6) A ~ Flex disk plate ~ Plex disk (3) ~ Flex disk plate Plex disk and washer assembly Self-locking nut, 5/16-24 (24) B ‘Torque converter drive cover Converter drive ring Twelve-point bolt, 3/8 x 1-1/4 in. (8) C 15 ~ Ball bearing 16 - Bolt, 1/2-13 x 1-1/8 in. (6) C 17 ~ Loekstrip (3) 18 ~ Input shaft 19 - Self-locking nut, 5/16-24 (24) D 20 - Torque converter drive cover 21 - Lockwasher, 3/8 in. (12) 22 - Nut, 3/8-24 (12) E 23 - Input shaft 24 ~ Torque converter drive cover Torque ft Nm A 450-700 611-949 B 4149 56-66 Cc 67-80 91-108 D 14-18 19-24 Ez 33-40 45-54 10 ~ Sealring 11 ~ Self-locking nut, 5/16-24 (24) B 12 ~ Torque converter drive cover 13 - Gasket Torque ft Nem A 81-97 110-131 B 14-18 19-24 Cc 36-43 49-58FOLDOUT 6 ‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS.meee 10 12 13 Ball bearing First turbine and support assembly ~ First-turbine support = First turbine Pirst-turbine roll pin ‘TT, TTB, TRT 2211, 2221 (6) TT, TTB, TRT 2411, 2421 (9) Second turbine Internal snapring Ball bearing External snapring ‘Torque converter stator Spacer Bolt, 1/4-28 x 1-1/4 in. (12) A Lockstrip (6) Accessory drive gear Accessory-driven gear Bolt, 7/16-14 x 1-3/8 in. (23) A ‘Lockwasher (23) ~ Flat washer (23) Ball bearing External snapring Accessory drive shaft Ball bearing Ball bearing (standard duty) External snapring: Ball bearing Converter ground sleeve Self-locking bolt, 5/16-18 x 3/4 in. (4) B Step-joint sealring ~ Ball bearing = Second-turbine drive gear Lubrication regulator valve guide pin = Lubrication regulator valve spring Lubrication regulator valve ~ Converter pressure regulator valve guide pin Converter pressure regulator valve spring Converter pressure regulator valve Step-joint sealring Thrust race Thrust roller bearing ‘Thrust race First-turbine drive gear Ball bearing 14 ~ Torque converter pump retainer 15 - Torque converter pump assembly 16 ~ Special bolt, 5/16-24 x 1.30 in, (24) 17 - Torque converter pump gasket 18 - Double-row ball bearing 19 - Input accessory drive gear 20 ~ Sealring* 21 - Sealring *Not used with "wet" housings ‘Torque Ib ft N-m A 10-12 14-16 30 - Lubrication bypass tube 31 - External thermostat kit 32 - Thermostat assembly 33 - Sealring 34 - Connector 35 - Adapter 36 - Converter housing assembly 37 ~ Pipe plug, 3/4 in, NPTF C 38 - Converter housing 39 - Plug, 1/2-14 PTF D. 40 - Converter housing sleeve 41 - Dowel pin (2) 42 ~ Plat washer, 7/16 in. 43 - Lockwasher, 7/16 in. 44 ~ Bolt, 7/16-14 x 2-3/4 in. A 45 - Roller bearing (heavy duiy) 46 - Diaphragm assembly* 47 ~ Oil seal* 48 - Diaphragm* 49 - Cup plug* 50 - Step-joint sealring Used with "dry" housings Torque ft Nem A 42-50 57-67 B 17-20 24-27 c 33-37 45-50 D 23-27 32-36FOLDOUT 7 ISSIONSBall bearing Self-locking nut, 3/8-24 (12) A Second-turbine driven gear Ball bearing Spring retainer plate Spring pin (3) Spring (3) Freehweel roller cage Freewheel roller (15) Freewheel cam assembly Roll pin Freewheel eam Retainer plate Square-head bolt (12) Ball bearing Self-locking nut, 3/8-24 (12) A Second-turbine driven gear Ball bearing ~ Self-locking bolt, 3/8-16 x 5/8 in. A = Suetion tube Male nut, 1 3/4-14 B Suetion tube compression sealring Transmission housing gasket ~ Remote filter plug = Plug, 3/4-14 NPTE C - Transmission housing Breather Cup plug Oil seal Accessory drive cup plug Bolt, 3/8-16 x 7/8 in, (6) D Lockwasher, 3/8 in, (6) Core hole cover Gasket Drain plug, 3/4-14 NPTF C Nameplate Drive serew, no. 4 x 1/4 in. (4) Spring retainer plate 20 - Spring pin (3) 21 ~ Spring (3) 22 ~ Freewheel roller cage 23 - Freewheel roller (15) 24 - Freewheel cam assembly , 25 ~ Roll pin f 26 - Freewheel cam i 27 ~ Square-head bolt (12) ff 28 - First-turbine driven gear { 29 - Bearing spacer 30 - Ball bearing 31 - Bearing spacer 32 - Ball bearing Torque Ib ft Nem A 41-49 56-66 20 ~ Bolt, 3/8-16 x 7/8 in. (6) D 21 ~ Lockwasher, 3/8 in. (6) 22 ~ Oil strainer assembly 23 - Gasket 24 - Anehor pin 25 ~ Oil filler plug 26 - Add-level oil plug, 1/4-18 NPTF E 27 - Fullevel oil plug, 1/4-18 NPTF E 28 - Cup plug 29 ~ Flat washer 30 - Plug C Torque Ib ft Nm A 36-43 49-58 B 120-150 163-204 ct 33-37 45-50 D 26-32 36-43 E 14-16 19-21FOLDOUT 810 ul 12 13. 15 Oil suction tube Sealring Male nut, 1-3/4-14 A Sealring ‘Transmission housing gasket Remote filter plug Plug, 3/4-14 NPTF B Breather Cup plug Nameplate Drive serew, No. 4 x 1/4 in. (4) Accessory drive cup plug Oil seal Oil strainer Sealring Oil strainer cover Lockwasher, 3/8 in. (2) Bolt, 3/8-16 x 3/4 in. (2) C Oil level ADD plug D Oil level FULL plug D Piston sealring Piston sealring Piston sealring Reverse clutch piston External-tanged, reverse cluteh plate (4) = Internal-splined, reverse cluteh plate (4) Forward-and-reverse sun gear (standard-speed low gear) Spacer Reverse planetary carrier assembly ‘Thrust washer (4) Planetary pinion (matched set of 4) Pinion roller (88) ‘Thrust washer (4) Spindle (4) Reverse planetary carrier Oil level tube 22 - Oil level tube 23 - Oil drain plug, 3/4 in. NPTF B 24 - Oil filler plug D_ 25 - Anchor pin 26 - Transmission housing assembly 27 - Transmission housing 28 - Plug (2) D 29 - Baffle plate 30 ~ Self-locking bolt, 5/16-18 x 5/8 in, (3) E 31 - Self-locking bolt, 5/16-18 x 5/8 in. E Torque ft Nem A 120-150 163-204 B 33-87 45-50 c 26-32 36-43 DB Tighten sufficiently to prevent leakage E 17-20 23-27 16 - Porward-and-reverse sun gear (high speed, low gear) 17 ~ External-tanged reverse cluteh plate 18 - Internal-splined reverse clutch plate 19 - Forward-and-reverse clutch anchor assembly 20 - Forward-and-reverse cluteh anchor 21 ~ Anchor pin (6) 22 - Piston return spring (12) 23 - Return spring guide pin (12) 24 - Cheek ball, white (2) 25 - Retainer (2)FOLDOUT 9 ‘TT, TYB, TRT 2001 SERIES TRANSMISSIONSReverse ring gear = Thrust washer = Potward planetary carrier assembly = spinate (0 = Thrust washer (4) Pinion roller (88) inion (matehed set of 4) ‘Thrust washer (4) Forward planetary carrier Forward planetary carrier assembly Spindle (6) ‘Thrust washer (3) Pinion roller (120) Pinion (matened set of 6) ‘Thrust washer (8) Forward planetary carrier Porward planetary carrier assembly Reverse planetary ‘Thrust washer Forward planetary carrier assembly Bushing Forward planetary carrier Spinaie (6) Thrust washer (8) Roller (120) Pinion (matched set of 6) ‘Thrust washer (6) Internal snapring Internal-splined clutch plate (2) External-tanged cluteh plate (2) Forward planetary ring gear Internal-splined cluten plate Extemnal-tanged eluteh plate gear 16 19 20 2 22 B 24 25 26 n 29 Fa 3 2 ww 18 19 20 a1 2 2 2 % 26 2 2 29 A Spinate (6) ‘Thrust washer (6) Pinion roller (120) Pinion (matehed set of 6) ‘Thrust washer (6) Porward planetary cartier ‘Thrust washer Internal snapring Internalsplined low-range clutch plate (d) Extemal-tanged low-range clutch plate () Forward ring gesr Forward eluteh piston assembly ‘Cheek ball and retainer kit Cheek bal, white ( Retainer (2) Forward clutch piston Piston sealring Piston sealring Piston sealring, Bearing retainer ‘Ball bearing, ‘Acepter gosket ‘Aaapter assembly Plug, 1/410. (2) A Acapter Sleeve Self-looking bolt, 8/8-24x 1-1/4 in. (6) B Twelverpoint bolt, 8/816 1-8/4 in. (2) 33 ~ Porward eluten piston 34 = Piston sealrng 35 = Piston sealing 36 = Piston sealring 31 = Forward eluteh piston housing 56 = Stocking bot (10) A S/8-16 ¢1-1/2n. (eater models)* 3/8-16 x 1-3/4-n. (ater models) 39 ~ Plug, 1-18 PTF B ‘Deed with fat washers Torue ft Na A 3439-58 8 iis isa 20 ~ Forward planetary carrer assembly 531 Bushing 32 ~ Forward planetary earcier 35 ~ Spindle (© Sa Thrust wesher (6) 38 Roller (120) 36 = Pinion (matched set of 6) 37 ~ Thrust washer (@) Torque wit A e10 143 5 to 3648 ct 36-43 1958FOLDOUT 10 s~ Reverse planetary ring gear ‘Thrust washer Forward planetary carrier assembly Forward planetary carrier Spindle (6) - Thrust washer (6) Roller (120) = Pinion (matched set of 6) u- 12 - ‘Thrust washer (6) Internal snapring Ball bearing Spacer Ball bearing ‘Transfer drive gear assembly ‘Transfer drive gear Pin (6) External snapring Nut, 5/16-24 (12) A Lockstrip (6) High-range cluteh plate High-range, external-tanged cluteh plate High-range cluteh hub (PTO) External snapring High-tange cluteh hub High-range clutch plate = Plat washer (12) Self-locking bolt, 5/16-24 x 1/8 in, (12) External snapring High-range clutch piston return spring Hook-type sealring High-range clutch piston Sealring Sealring expander High-range cluteh piston housing assembly (speedometer drive) 13 ~ Internal-splined eluteh plate (2) 14 - External-tanged cluteh plate (2) 15 - Forward planetary ring gear 16 - Internal-splined clutch plate 17 ~ External-tanged cluteh plate 18 - Forward eluteh piston 19 - Piston sealring 20 - Piston sealring 21 ~ Piston sealrit 22 - Internal snapring 23 - Ball bearing 24 - Spacer 23 - Bushing 24 - High-range cluteh piston housing 25 - Pin 26 - Speedometer drive shaft 21 ~ Hook-type sealring 28 - Ball bearing 29 - Hook-type sealring 30 - Bolt, 1/2-20 x 2-3/4 in. (6) B 31 - Lock tab (6) 32 - High-tange clutch piston housing assembly (earlier models) 33 ~ Bushing 34 ~ High-range cluteh piston housing 35 - Sleeve 36 - High-range cluteh piston housing assembly (later models) 37 - High-range cluteh piston housing (PTO without brake) 38 - Step-joint sealring (2) 39 - Sealring Torque oft Nem A 14-18 19-24 B 83-100 113-135FOLDOUT 11Ball bearing External snapring Transfer drive gear Ball bearing Adapter gasket = Adapter sealring = Acapter assembly Adapter Sleeve Bolt, 3/8-16 x 1-1/8 in, (16) A Lockwasher, 3/8 in, (16) Sealring (2) Low-range cluteh drum assembly Pin (4) Cluteh drum Sealring expander Cluteh piston outer sealring Cluteh piston inner sealring High-range planetary sun gear assembly ‘Sun gear ‘Thrust washer High-range planetary carrier assembly High-range planetary carrier ‘Thrust washer (6) Pinion (matehed set of 6) Roller (96) Spindle (6) ‘Thrust washer (6) Internal snapring High-tange clutch anchor assembly Low-range clutch piston Cluteh piston return spring = External snapring Sleeve assembly Bushing Sleeve External snapring Internal-splined clutch plate External-splined cluteh plate High-range ring gear Internal-splined eluteh plate (3) External-splined clutch plate (2) Low-range clutch backplate 32 - Internal snapring Torque ft Nem A 26-32 36-43 13 - Anchor 14 = Pin (short) (4) 15 ~ Pin (ong) (2) 16 - Internal-splined clutch plate (5) 17 - External-tanged clutch plate (5) 18 - External snapring 19 - Cluteh piston return spring 20 Sealring expander 21 - Cluteh piston outer sealring 22 = Cluteh piston inner sealring 23 - High-range clutch pistonFOLDOUT 12 NSMISSIONS 3 Se,‘Sealring (2) High-range clutch drum assembly Pin (4) luteh drum Sealring expander ~ Clutch piston outer sealring Cluteh piston inner sealring High-range clutch piston Cluteh piston return spring ~ Low-range planetary sun gear assembly Sun gear ‘Thrust washer ‘Low-range planetary carrier assembly Low-range planetary carrier ‘Thrust washer (6) Pinion (matehed set of 6) Roller (96) Spindle (6) ‘Thrust wasehr (6) Internal snapring Low-range clutch anchor assembly 10 - ul 12 13. 14 15 - q- External snapring External snapring Internal-splined clutch plate External-splined eluteh plate Low-range ring gear Internal-splined clutch plate (2) External-splined eluteh plate High-range clutch backplate Internal snapring Anchor Pin (long) (2) Pin (short) (4) Internal-splined cluteh plate (5) External-tanged eluteh plate (5) - External snapring Clutch piston return spring Sealring expander Cluteh piston outer sealring Clutch piston inner sealring Low-range clutch piston FolFOLDOUT 13 lout 15,4. High-range eluteh, low-range ring gear (TRT 2221-2, 2421-3 with underdrive)ul 12 Sealring (2) Low-range cluteh drum assembly Pin (4) Cluteh drum Sealring expander Cluteh piston outer sealring Cluteh piston inner sealring Low-range clutch piston Cluteh piston return spring External snapring External snapring Bearing race Roller bearing High-range planetary sun gear Internal snapring High-range cluteh anchor assembly Anchor ~ Pin (long) (2) Pin (short) (4) Internal-splined cluteh plate (2) External-tanged clutch plate (2) High-tange ring gear Bearing race Low-range cluteh hub Internal-splined eluteh plate (5) External-splined cluteh plate (4) High-tange planetary carrier assembly High-range planetary carrier Spindle (6) Thrust washer (6) Roller (120) Pinion (matched set of 6) ‘Thrust washer (6) Internal snapring Internal-splined cluteh plate External-tanged clutch plate External snapring Cluteh piston return spring Sealring expander Cluteh piston outer sealring Cluteh piston inner sealring High-range cluteh pistonFOLDOUT 14S cwroanene Ball bearing ~ Transfer drive gear assembly ‘Transfer drive gear Pin (6) External snaprit = Nut, 5/16-24 (12) A = Lockstrip (6) rorad High-range clutch plate High-range, external-tanged clutch plate High-range cluteh hub (models with converter-driven PTO) External snapring High-range eluteh hub High-range cluteh plate Flat washer (12) Self-locking bolt, 5/16-24 x 7/8 in. (12) External snapring Piston return spring Hook-type sealring High-range clutch piston Sealring Sealring expander Gasket Diaphragm assembly Pipe plug, 1/4 in, NPTF A Diaphragm - Sleeve Pin (6) Lockwasher, 3/8 in. Bolt, 3/8-16 x 2 in. B Lockwasher, 3/8 in. (2) Bolt, 3/8-16 x 1-1/8 in. (2) B Brake return spring (12) Spring guide pin (12) Brake hub External-tanged brake plate (6) Internal-splined brake plate (5) Step-joint sealring External snapring Ball bearing External snapring Brake-apply plate assembly Brake adjusting ring = Spring pin (6) Brake-apply plate ~ Sealring Sealring (3) Brake piston (3) 22 ~ High-range clutch piston housing (PTO) 23 ~ Lock tab (6) 24 - Bolt, 1/2-20 x 2-3/4 in, (6) B 25 - Step-joint sealring (2) 26 - O-ring seal 27 ~ External snapring 28 - PTO shaft assembly 29 - Pin 30 - PTO shaft 31 ~ Internal snapring 32 - Ball bearing 33 - High-tange clutch piston housing assembly 34 - Bushing 35 - High-range clutch piston housing 36 - Lock tab (6) 37 - Bolt, 1/2-20 x 2-3/4 in. (6) B 38 - Sealring Torque ft Nm A 14-18 19-24 B 83-100 113-135 27 ~ Brake piston cup (3) 28 - Expander assembly (3) 29 ~ Sealring 30 - Plug, 7/16-20 C 31 - Brake manifold fitting © 32 - Brake manifold 33 - Brake manifold fitting © 34 - Brake manifold 35 ~ Brake manifold fitting C 36 - Plug, 7/16-20 C 37 - Rear cover assembly (PTO) 38 - Rear cover 39 - Lip-type oil seal 40 - Dust shield 41 ~ PTO output flange 42 ~ Plange retaining washer 43 ~ Self-locking nut, 7/8-14 C 44 - Plug 45 - Bolt, 3/8-16 x 2-3/4 in, (18) B 48 - Lockwasher, 3/8 in. (18) Torque dbft Nem A 14-16 19-21 B 26-32 35-43 c 275-325 373-440FOLDOUT 151 ~ Rear housing gasket 12 ~ Cluteh anchor pin 2 > Rear housing 15 = Welen plug 3 = Lockwasher, 3/8 in. (17) 14 — Plug, 1/4 tn. B 42 batt e-lex 1/8 in (1) A 15 — Bolt 3/6-16 1-1/2 in (9) 5 = High+ ane low-range input shaft 16 = Lockwasher, 3/8 in. 6 ~ Rear bearing = External snapring 8 = Internal snapring Torque ft em 9 = Sealring 10 Oilretsiner A 2323649 11 = Internal spring g a0 nas B 1 = Rear housing gasket 12 = Cluteh anchor pin 2.7 Reer housing 15 = Weleh pt 4 = Loctewashery 3/8 in. (15) 14 = Plug, 1/4 in. B 4 = Bott, 376-18 x 2-5/4 in. (15) A 15 > Plug, 378 ine 5 = Output shaft (uncererive models) 6 = External snoring 7 = Output shaft (overdrive models) Torque = bit 8 = Rear bearing 9-— internal snapring A west a4 10 ~ Spacer 8 e-10 nas 11> Oitseal & Testa c 1 ~ Rear housing gasket 8 - Oiterain tube 27 Plug, 1/8 im A 8 = Rear housing 3 = Lockwasher, 3/8 in. (18) 4 = Bott, 3/818 x 1-3/4 in 18) B Tore ft xm § = Reat housing assembly & = Battie A +3 35 7 Ollseal 8 tear Seas D Gasket 17 ~ PTO shaft assembly 38 ~ Pipe plug A Sentring 18 Pin 34 = Rearcover Pipe plug A 19 ~ PTO shaft 35 ~ Lookwasher, 3/8 in (19) Rear cover (ith speedometer drive) 20 ~ Internal snapring 38 ~ Bolt, 3/616 1-1/8 in. (19) B Lockwasher, 3/8 in. (19) 21 - Ball bearing 7 Bott, 3/6-16 x 1-1/8 in (19) B 22 ~ Rear PTO cover assembly Torque ft 2 Gasket 23 - Sleeve a a Speedometer crive adapter 24 Rear cover A lowe ase Gasket 25 ~ Lip-type oll seal Tere 25.2004 Speedometer drive sleeve assembly 25 ~ Dust shield B wea isa Lip-type oll seal = PTO output flange & iis eal Wasner (cor) ~ Flange retaining washer D Bo328 T3440 Speedometer drive sieeve Self-locking nut, 7/8-14 D Lockwasher, 5/16 in. (2) Bolt, 5/16-18 x 2-1/4 in, (2) © al - External snapring 32 Bolt, 3/8-16 x 171/8 in. (19) B Lockwasher, 3/8 in, (18) Pipe plug A * For 1/8 in. NPTP plugs = Por 3/8 in. NPTF plugsFOLDOUT 16Flange retaining nut, 1-1/4-12 A (nylon insert) ~ Flange washer ~ Sealring (use after S/N 23290) Flange (Mechanics 5C) Flange spacer Flange (Type 5N) Flange ($1480) Front output shaft orifice plug Lip-type oil seal Internal snapring Ball bearing Output shaft Front output shaft Detent ball (2) Detent spring Shifter fork shaft orifice plug Lip-type oil seal Shifter fork shaft Shifter fork ~ Disconneet coupling Ball bearing ~ Spacer Parking brake assembly* - Brake backplate* = Roller* Brake shoe and lining (2)* = Brake shoe return spring (2)* - Cam lever Self-locking bolt, 1/2-13 x 7/8 in. (4) A¥ Brake backplate (TTB) Brake drum* ~ Self-locking bolt, 3/8-24 x 5/8 in. (4) Bt Self-locking bolt, 3/8-24 x 5/8 in. (4) BY ~ Parking brake assembly** Brake backplate** ~ Roller** = Brake shoe and lining (2)** 23 - Transfer-driven gear 24 - Rear output shaft assembly 25 - Bushing 26 - Rear output shaft 27 ~ Spacer 28 - Ball bearing 29 - Internal snapring 30 - Lip-type oil seal 31 ~ Flange (Type 5N) 32 - Plange (Mechanics 5C) 33 - Spacer 34 ~ Flange (Mechanics 5C) 35 ~ Plange ($1480) 36 - Flange (Mechanies 5C) 37 - Sealring (use after S/N 23290) 38 - Flange washer 39 ~ Flange retaining nut, 1-1/4-12 A. (nylon insert) Torque Ibft Nem A 450-700 611-949 16 - Brake shoe return spring (2)** 17 - Cam lever** 18 ~ Brake drum** 19 ~ Self-locking bolt, 3/8-24 x 3/4 in, (8) B** 20 - Bolt, 5/8-11 x 1-1/4 in, (3) C** 21 ~ Lockwasher, 5/8 in. (3)** ‘Torque ib ft Na A 81-97 110-131 EB 4149 56-66 c 117-140 159-189 * =1 models ** -3 models,FOLDOUT 17 ‘TT, TTB, TRY 200] SERIES TRANSMISSIONS Op Pag i Paldout 17,4. Output shafts and disconnect assembly (-1 models) i Copy 1984 Cnet Motors Com.A Gasket 15 - Bolt, 3/8-16x 2 in. A Oil pump assembly 4-bolt C pad (7) = Oil pump cover 2-bolt B pad (7) Oil pump cover gasket 2-balt C pad (6) Drive gear 16 - Lockwasher, 3/8 in. (2) Driven gear assembly 17 ~ Bolt, 3/8-16 x 3 in. (2) A Driven gear 18 - Adapter drive coupling Needle bearing (2) 19 ~ Bolt, 3/8-16 x 3 in. A Oil pump body assembly 20 - Lockwasher, 3/8 Oil pump body Dowel pin Driven gear shaft Torque Ibft Nem Lip-type oil seal Loekwasher, 3/8 (7) A 26-32 36-43 B Control valve body gasket 32 - Gasket - Lockwasher, 3/8 (16) 33 - Detent spring (2) = Bolt, 3/8-16x 1 in, A 34 - Gasket Bolt, 3/8-16 x 2-1/2 in, (15) A 35 - Plug B Control valve body assembly 36 - Plug, 1/8 in. E Plug B 37 ~ Inching valve stop Gasket 38 - Spring Main-pressure regulator valve 39 ~ Inching regulator valve Control valve body 40 - Regulator valve stop Ball 41 ~ Inching regulator valve spring Ball retainer plug 42 ~ Inching control valve Valve stop 43 - Valve return spring TRY 2211-3 (1) 44 - Sealring ‘TRT 2411-3 (2) 45 - Plug Spring retainer (earlier models) 46 - Oil seal = Main-pressure regulator spring 47 - Internal snapring ‘Trimmer spring 48 - Push-on retaining ring ‘Trimmer plug 49 - Cutoff valve plug (air actuated) Gasket 50 - Retainer plug (air actuated) D Plug © 51 ~ Plug E Cluteh cutoff valve spring 52 - Manual range selector valve (models Cluteh cutoff valve with neutral start switch) Cutoff valve plug (hydraulic actuated) 53 - Gasket Sealring 54 - Plug (neutral switeh hole) F. Gasket 55 - Plug, 1/8 in. E Cup (hydraulic actuated) Retainer plug (hydraulic actuated) D ‘Torque Ib ft Nem Oil seal Internal snapring A 26-32 36-43 Bracket B 80-90 109-122 ‘Manual range selector valve (models Cc 90-100 123-135 without neutral start switeh) BD 60-70 82-94 Detent ball (2) E 10-12 14-16 Plug D. F 30-40 41-54FOLDOUT 18 ‘TT, TTB, TRT 2001 SERIES TRANSMISSIONS e Poldout 18,A. Oil pump assemblies i