6–2. GENERAL INFORMATION FOR REBUILD OF SUBASSEMBLIES
Section 6 REBUILD OF SUBASSEMBLIES
5600, 5800, 5900, 6000, 6600 SERIES TRANSMISSIONS
4. If resistor 41 (in 24V systems) requires re-placement, remove it (Figure 6–2).
5. Remove three screws 47 and lockwashers 48 that retain inhibitor solenoid cover 49 (Figure 6–2).
6. Remove solenoid cover 49 and gasket 50 (Fig-ure 6–3). Remove plunger 52 and washer 53 from the solenoid.
7. Remove the heat-shrink tubing from the sole-noid and wiring harness leads (Figure 6–3).
Disconnect the leads.
8. Remove solenoid coil 54, working the leads through the holes in the shift selector body and solenoid housing (Figure 6–4). Remove seal-ring 55, retainer seal-ring 56, spseal-ring seat 57, and spring 58 from the solenoid housing.
9. Remove two socket head screws 75 and lock-washers 74 that retain the solenoid housing (Figure 6–4). Remove the housing.
10. Remove outer clutch 73 from the solenoid housing (Figure 6–5). Remove sealring 61. Re-move guide pins 59 from the solenoid housing, if new pins are required.
Figure 6–3. Downshift Inhibitor Components
H00918
SOLENOID LEADS
INDICATOR LIGHT LEAD
WIRING HARNESS LEADS ADJUSTING SCREW
COVER
GASKET PLUNGER WASHER SOLENOID
HOUSING SOLENOID
COIL
11. Remove clutch spring 72 (Figure 6–5). Re-move indicator support 71.
12. Remove screw 67 and lockwasher 68 that re-tain cover 69 (Figure 6–5).
Figure 6–4. Shift Selector Assembly With Solenoid Removed
Figure 6–5. Shift Selector Assembly With Solenoid Housing Removed
H00919.01
SOLENOID LEADS SOLENOID
COIL
BODY SCREW (2),
1⁄4-20 x 13⁄4 in.
LOCKWASHER (2) SOLENOID HOUSING RETAINER
RING SPRING SEAT
SEALRING,
15⁄16 in.
H00920.01
INDICATOR SUPPORT CLUTCH SPRING COVER
BODY
INDICATOR
SCREW, 1⁄4-20 x 1 in.
LOCKWASHER
GUIDE PIN (2) SEALRING,
21⁄8 in.
SOLENOID HOUSING
OUTER CLUTCH
REBUILD OF SUBASSEMBLIES
13. Pull cover 69 from the body (Figure 6–6). Re-move the heat-shrink tubing from the power lead terminals. Disconnect the terminals. Dis-connect the fuse lead.
14. Remove fuse holder assembly 63 from the cover, if replacement is necessary (Figure 6–6).
15. Remove three socket head screws 9 and lock-washers 10 that retain body 8 (Figure 6–6). Re-move the body, and its attached parts, from mounting bracket 22.
16. Remove sealring 19 from mounting bracket 22.
Remove 4-pin connector 34 from the body, if replacement is necessary.
17. Remove sealring 3 from inner clutch 2 (Figure 6–6). Remove pin 43 from inner clutch 2. Re-move inner clutch 2 from rotary key 38.
18. Remove nut 12 from pin 37. Remove pin 37 from rotary key 38. Remove handle 15 and knob 16 from rotary key 38. Remove leveler 4 and spring 5. Remove spacer 14, if used.
19. Push rotary key 38 from body 8. Remove seal-ring 13 from rotary key 38.
Figure 6–6. Shift Selector Assembly With Inner Clutch Exposed
H00921.01
INNER CLUTCH KEY
SCREW (3),
5⁄16-18 x 5⁄8 in.
LOCKWASHER (3) LUBRICATION POINTS
MOUNTING BRACKET
POWER LEAD COVER
FUSE HOLDER FUSE LEAD BODY
SEALRING, 11⁄8 in.
20. If bushing 11 requires replacement, press the bushing from body 8.
21. Remove four screws 27 and washers 26 that re-tain switch cover 25 (Figure 6–7). Remove the cover and cover seal 24.
22. Loosen set screw 36 that retains drive adapter 17 on the switch shaft (Figure 6–8). Remove the drive adapter. Remove shim(s) 18 from the switch shaft.
23. Disconnect all of the wiring harness leads from the switch assembly (Figure 6–8). Remove two screws 20 and washers 21 that retain switch as-sembly 23. Remove the switch asas-sembly. The switch assembly is not a serviceable assembly.
24. Remove 4-pin socket 35 if replacement is nec-essary (Figure 6–8).
25. Remove four screws 29 that retain wiring ness 31 (Figure 6–9). Remove the wiring har-ness from the mounting bracket.
26. Remove sealring 28 from the wiring harness connector body.
Figure 6–7. Mounting Bracket, Switch Assembly, and Cover
H00922
SWITCH COVER
COVER SEAL
WIRING HARNESS
SWITCH ASSEMBLY
MOUNTING BRACKET
5600, 5800, 5900, 6000, 6600 SERIES TRANSMISSIONS
Figure 6–8. Mounting Bracket and Shaft-End of Switch
Figure 6–9. Mounting Bracket and Switch Wiring Harness
b. Assembly (Foldout 33)
1. If 4-pin female socket 35 was removed from the mounting bracket, install a new socket. Re-fer to Figure 6–10. Push the socket into the flat side of the mounting bracket until it is flush with the adjacent area. Note the projection on the socket body that indexes with a notch in the mounting bracket.
CAUTION:
Do not use acid or acid-core solder. Use only rosin-core solder.
KEY MOUNTING BRACKET 4-PIN SOCKET
2. Install a 11⁄2 inch (38.1 mm) sealring 28 over the wires and onto the shoulder of main wiring har-ness 31. Insert the wires through the bottom of the mounting bracket (Figure 6–11). Push the 16-pin connector into the mounting bracket, with the index key toward the flat side of the mounting bracket (Figure 6–11). Retain the con-nector with four 6-32 x 3⁄8 inch screws 29.
3. Install the electrical components as shown in Figure 6–10. Note that the wiring diagram shows the front (mating) side of the socket, and the order of installation is counterclockwise.
Locate the lead coming from pin K in the 16-pin connector. Push the free end through the hole nearest the index projection of the 4-pin socket.
Crimp and solder a socket terminal to the lead, and push the lead and terminal into the socket body. Attach the lead from pin M to the 4-pin socket, directly opposite from lead K, in the same manner. Attach the lead from pin L to the 4-pin socket at the hole farthest from the mount-ing bracket base. Attach the separate lead, hav-ing two push-on terminals attached, to the 4-pin socket at the remaining hole.
4. Re-check the connections to make sure they are correct. Looking at the back of the socket (where the wires enter), the light-colored lead from pin K should be nearest the index lug on the socket. Moving clockwise, the separate lead with four connectors is next; then another light-colored lead to pin M; and last, a dark lead to pin L.
5. Install switch assembly 23 onto mounting bracket 22 (Figure 6–11). Position the switch assembly on the mounting bracket so the switch numbers (1 through 8) are not inverted. Retain the assembly with two 6-32 x 3⁄4 inch screws 20 and lockwashers 21. The screw holes in the switch assembly should be approximately mid-way in the elongated holes in the mounting bracket when the screws are tightened.
CAUTION:
Hand tighten all mating connectors. Use of tools will damage the components.
REBUILD OF SUBASSEMBLIES
Figure 6–10. Shift Selector Assembly (Manual-Electric Models)
1 X
RESISTOR (24V SYSTEM) DIRECT
Figure 6–11. Switch Assembly Removed From Mounting Bracket
6. Follow the wiring diagram (Figure 6–10) to connect the wiring harness leads to the switch assembly. Also connect the three jumper leads (from terminal 1 of switch 1, to common ter-minal of switch 4; from terter-minal 1 of switch 6, to common terminal of switch 7; and from common terminal of switch 3, to terminal 2 of switch 5, and to common terminal of switch 6).
H00926
SWITCH ASSEMBLY
MOUNTING BRACKET
Note also that three switch terminals have no leads connected to them.
7. Install one shim 18 (darker side first) onto the switch shaft (Figure 6–8). More shims may be required. This will be determined in Step (10).
8. Install the drive adapter (Figure 6–8). Position the adapter lightly against the mounting bracket, and tighten the set screw against the flat on the switch shaft.
Figure 6–12. Shift Selector Body Section and Switch Section Separated
5600, 5800, 5900, 6000, 6600 SERIES TRANSMISSIONS
9. If bushing 11 was removed from the selector body, press a new bushing into the body until it is flush with the hub of the body. Hone or ream the bushing bore until rotary key 38 fits the bore and can be rotated with finger torque only.
Install the rotary key (without sealring 13). In-stall selector body 8 onto mounting bracket 22, engaging the tongue of drive adapter 17 with the slot in rotary key 38. Retain body 8 with three 5⁄16-18 x 5⁄8 inch socket head screws 9 and lockwashers 10.
10. Using a gauge, determine the end play of ro-tary key 38. If the end play exceeds the thick-ness of one shim 18, remove selector body 8 and drive adapter 17, and install an additional shim 18 (or more, if required). Shims must not hinder rotary actuation of the rotary key and switch.
11. When shim adjustment is completed, remove selector body 8 to complete its assembly.
NOTE:
For assembly of shift selector components use Tex-aco Marfak® No. 2 or equivalent grease.
12. Install 9⁄16 inch sealring 13 into the groove of rotary key 38. Lubricate the rotary key and seal-ring lightly with grease. Put a small quantity of grease into the spring recess of rotary key 38.
Coat spring 5 and leveler 4 lightly with grease, and install them into the rotary key. Install han-dle 15 (and spacer plate 14, if used) into the slot of the rotary key. Push threaded pin 37 through the holes in the rotary key and handle 15 (and spacer plate 14, if used). Secure the pin with nut 12. Tighten the nut only enough to elimi-nate end play of the pin. Do not bind the move-ment of handle 15 in rotary key 38.
13. If either a new rotary key 38 or a new inner clutch 2, or both, are installed, a drilling guide is required. Install inner clutch 2 onto rotary key 38 until the rotary key bottoms in the clutch. Install 11⁄8 inch sealring 3 onto the inner clutch (Figure 6–6).
14. Push inner clutch 2 into the large hole in the drilling guide of Shift Inhibitor Clutch Drilling Fixture, J 24711 (Paragraph 4–8). Position the body dowel pins in the two smaller holes, and the selector handle between the two dowel pins
of the guide. Hold the rotary key and inner clutch firmly against the guide stop screw, and drill a 3⁄32 inch (4.9 mm) hole through the clutch and/or rotary key. Install rotary key pin 43. Re-move the assembly from the drill guide.
15. Install 4-pin connector 34 into the shift selector body (Figure 6–12). Push the connector into the mounting face of the body until it is flush with the adjacent area. Note there is a projection on the connector body that indexes with a notch in the shift selector body for angular alignment of the connector.
16. Install 211⁄16 inch sealring 19 onto mounting bracket 22 (Figure 6–8).
17. Install the assembled body section of the shift selector assembly onto the assembled switch section (Figure 6–6). Install three 5⁄16-18 x 5⁄8
inch socket head screws 9 and lockwashers 10 to retain the two sections.
18. Install fuse holder assembly 63 into body cover 69 (Figure 6–6). Retain it with nut 66. Connect the fuse lead (coming from M in the 16-pin connector, through the 4-pin connector) to the single lead of the fuse holder (Figure 6–10).
Connect the power lead (coming from the lead in the 4-pin socket that connects to the common terminals of switches 3, 5, 6, and 8) to the black lead of the fuse holder. Lightly lubricate the sealring on the inner clutch with grease.
19. Install cover 69 onto the body (Figure 6–5). Re-tain the cover with one 1⁄4-20 x 1 inch screw 67 and lockwasher 68.
20. If necessary, install a new indicator 70 onto in-dicator support 71 (Figure 6–5). Install the indi-cator support onto the body cover. Apply a small quantity of grease to the teeth of the inner clutch. Position clutch spring 72 in the center recess of the inner clutch.
21. If guide pins 59 were removed from the sole-noid housing, install new pins (Figure 6–5).
Press the pins until they are flush with the sur-face of the housing inner hub.
22. Install 21⁄8 inch sealring 61 onto solenoid hous-ing 60 (Figure 6–5). Coat the outer surface of outer clutch 73 lightly with grease. Install the outer clutch, flat end first, into the solenoid housing. The clutch must move freely when en-gaged with the guide pins.
REBUILD OF SUBASSEMBLIES
23. Install the assembled solenoid housing onto the indicator support (Figure 6–5).
24. Install two 1⁄4-20 x 13⁄4 inch screws 75 and lock-washers 74 to retain the solenoid housing (Fig-ure 6–4).
25. Install override spring 58 into the center bore of the solenoid housing.
26. Install spring seat 57 and retainer ring 56 (Fig-ure 6–4). Install 15⁄16 inch sealring 55 into the housing counterbore.
27. Check the angular position of the solenoid housing (Figure 6–13). Push the spring seat downward. While holding the seat downward, push the shift handle in the upshift direction against a gate pin. Then push the handle in the opposite direction. The inhibitor clutch should engage, but should allow the shift handle to move away from the gate pin 0.040–0.060 inch (1.01–1.52 mm) when pull force on the handle knob does not exceed 15 lb (67 N). This 0.060 inch (1.52 mm) maximum movement applies to the gate pin where the least movement is found when all positions are checked. As a result of tolerances in manufacturing, clearance at some gate pins can exceed 0.060 inch (1.52 mm) when the clearance is correctly adjusted at the position where least movement occurs. Check the movement at all gate pins.
Figure 6–13. Checking Solenoid Housing Angular Adjustment
28. To adjust the solenoid housing, loosen two screws 75, rotate the housing, and re-tighten the screws. Too much clearance requires a counterclockwise adjustment of the solenoid housing to reduce the clearance. When clear-ance exceeds the maximum, a clockwise ad-justment may be necessary to engage the inhibitor properly. Too little clearance requires clockwise adjustment of the solenoid housing.
29. Install solenoid coil 54 into the solenoid hous-ing (Figure 6–4). Thread the solenoid leads through two holes in the solenoid housing, in-dicator support 71, and body cover 69 until they can be pulled out of the bottom opening in the body (Figure 6–3).
30. Install solenoid plunger 52 and washer 53 into the solenoid coil (Figure 6–3). Install solenoid housing gasket 50 and cover 49. Retain the cover with three 8-32 x 1⁄2 inch screws 47 and lockwashers 48 (Figure 6–2).
31. With the solenoid and cover installed, check the shift handle for freedom of movement in both upshift and downshift directions. Any ten-dency to catch during downshift movement in-dicates interference between the inner and outer clutch teeth. This may be corrected by re-moving the cover, gasket, solenoid plunger, and washer, and by rotating the adjusting screw (Figure 6–3) clockwise (inward) until there is no interference. Adjust the screw one turn at a time and re-check for clutch interference after each adjustment.
32. At this stage of assembly, there are five uncon-nected leads at the bottom of the shift selector assembly. Four are light color; one is black (Figure 6–3). Attach the two solenoid leads to the proper two wiring harness leads, insulating each connection with a short length of heat-shrink tubing.
33. Replace bulb 44, sealring 45, and resistor 41 in light socket plate assembly 40 (Figure 6–2).
Connect the lead on the plate assembly with the remaining free lead (black) in the shift se-lector assembly, insulating the connection with heat-shrink tubing.
34. Install light socket plate assembly 40, being careful that wires do not touch the light bulb (Figure 6–1). Retain the plate assembly with four 6-32 x 3⁄8 inch screws 46.
5600, 5800, 5900, 6000, 6600 SERIES TRANSMISSIONS
35. Install an SFE 9A fuse 62 into fuse holder 63.
36. Check the circuitry and operation of the shift se-lector assembly as outlined in Paragraph 3–20.
37. Install switch cover 25 and cover seal 24 (Figure 6–7). Retain the cover with four 10-24 x 5⁄8 inch screws 27 and washers 26.