Technical Service Information NTRODUCTION THM 125C This booklet contains the general description, diagnosis and overhaul procedures necessary to repair, overhaul or service the THM - 125C transmission. The THM 125C transmission represents the addition of converter clutch torque converter to the THM 125 transmission that was introduced in 1980. The converter clutch is added to increase the efficiency by eliminating the fluid coupling of the transmission at road load conditions, replacing it with a direct mechanical connection. The torque converter smoothly couples the engine to the planetary gear trains through three multi-disc packs, one roller clutch and band, providing three forward gears and one reverse gear. Changing of the gear ratios and application of the converter clutch is controlled automatically. We thank the General Motors Corporation for the illustrations and information that have made this booklet possible. ROBERT D. CHERRNAY DALE ENGLAND TECHNICAL DIRECTOR FIELD SERVICE CONSULTANT FRANK MIETUS WAYNE COLONNA TECHNICAL CONSULTANT TECHNICAL CONSULTANT WELDON BARNETT ED KRUSE TECHNICAL CONSULTANT LAY OUT AUTOMATIC TRANSMISSION SERVICE GROUP 9200 SOUTH DADELAND BLVD. SUITE 720 MIAMI, FLORIDA 33156 (305) 661-4161 1INDEX MAINTENANCE AND ADJUSTMENTS. ON CAR SERVICE DIAGNOSIS AND REPAIR, DISASSEMBLY VALVE BODY TECHNICAL BULLETINS... Automatic Transmission Service Group 9200 South Dadeland Blvd. Suite 720 Miami, FL 33156 (305) 661-4161 3 35 66 76MAINTENANCE AND ADJUSTMENTS TRANSAXLE OIL PROCEDURES Checking Transaxle Oil Level Approximately 38 liters (4 qts.) of fluid are required to refill {ransaxle after the pan has been drained. The fluid capacity of the 125C transaxle and converter assembly is approximately 85 liters (9 qis.) but correct level is ‘determined by mark on the dipstick rather than by amount added. Use only Dexron») Il automatic transmission Nid fo its equivalent. If the oil changes to a darker color at an early stage, from the usual red color and/or to a strong odor, this is, normal even though itis usually associated with overheated transmission fluid. It is not a positive sign of required imuintenance oF transaxle failure Due to the shape of the filler tube, oil level readings may be misleading. Look carefully for full oil ring on both sides of dipstick. Recheck ifany question of oil level occurs. Check oil level as follows: 1. Place transaxle in "Park" and leave in “Park.” Apply parking brake and block wheels start engine and let idle (carburetor off fast ile step). DO NOT RACE ENGINE. MOVE THE LEVER THROUGH THE RANGES. 2. Vehicle should be on level surface. 3. Check oil level on dipstick The oil level at room temperature of approximately 21°C (7O*F) should be 13mm (1/2*) above the *Full* mark, or between the two dimples on the dipstick, Figure 7A-1 The oil level should be between the “Add” and “Full” marks at normal operating temperature 200°F (90°C). This temperature is obtained after at least 15 miles (24 km) of expressway driving or equivalent city driving. The transaxle oil is stored in the valve body cover. Oil level, will decrease fon the dipstick when warm. Also, at normal operating, temperature, the oil will heat the gage end of the dipstick to.a degree where the average person cannot grasp it firmly with his bare hand without discomfort MAINTAIN OIL LEVEL BETWEEN THE "ADD" AND “FULL” MARKS AT NORMAL OPERATING TEMPERATURE. DO NOT OVERFILL TRANSAXLE, AS THIS MAY CAUSE FOAMING AND LOSS OF OIL THROUGH THE VENT. 4. IF oils low, check for possible causes Drain Intervals ‘The transaxle operating temperature resulting from the {ype of driving conditions under which the car is used is the main consideration in establishing the proper frequency of transaxle uid changes. Change the transaxle fluid and replace strainer every 15,000 miles ifthe car is usually driven under one or more of the following severe transaxle service conditions. 1. In heavy city traffie 2. Where the outside temperature regularly reaches 90F BFC). 3. In very hilly or mountainous areas, OT FL HOY (190-200 F.) On 517K (io zon Voto 165856) (18-29°C) ‘COLD’ READING IS ABOVE ‘FULL’ MARK Figure 7A1 Transaxle Dipstick 4. Frequent trailer pulling. 5. Commercial use, such as taxi, police car, or delivery If you do not use your ear under any of these conditions, change the fluid and replace strainer every 100, (000 miles. NOTICE: DO NOT OVERFILL. It takes only one pint to raise level from "ADD" to “FULL” with a hot + transaxle. Overfilling can cause damage to transaxle. Flui Capacities Pan removal - 3.8 liters (4 qts.) Overhaul - 5.7 liters “6 ts.) Fluid and Filter Change 1. Raise car, 2. With drain pan placed under transaxle oil pan remove oil pan attaching bolts from front and side of pan. 3. Loosen rear pan attaching bolts approximately four (4) turns, 4. Carefully pry transaxle oil pan loose with screwdriver, allowing Mluid to drain, 5. Remove remaining bolts and remove oil pan and gasket, Discard gasket 6. Drain fluid from oil pan. Clean pan with solvent and dry thoroughly with clean compressed air 7. Remove strainer and “O ring seal 8. Install strainer and new “O" ring seal locating strainer against dip stick stop. 9, Install new gasket on oil pan and install oil pan Tighten attaching bolt to 16 Nem (12 fi. Ibs.) 10. Lower car, add approximately 3.8 liters (4 gts.) of Dexron @ I Automatic Transmission Fluid or ils ‘equivalent through filler tube. 11. With selector lever in “park” position, apply parking brake and block wheels, start engine and let idle (carburetor off fast idle step). DO NOT RACE ENGINE MOVE THE LEVER THROUGH THE RANGES. 12, With selector lever in "PARK" range, check for proper fluid levelLy ' ' ' ' ' ' ' t t ' ' t wav A T.C.C. BRAKE ee 3RD GEAR ~~ + NO. SWITCH es Tec. Test (, PINP | LEAD NEAR | FUSE PANEL | 7 ECM i L 4 TRANSMISSION VSS TPS VS f LOCKING TAB ®o a TRANS. CONNECTOR Figure 7A-12 T.G., Wiring Schematic (Computer Command Conta ELECTRICAL CONNECTOR WHITE: PRESSURE~ ~~’ ‘SWITCH Figure 7A11 Auallary Vaive Body - (Computer Command ContraDELAY VALVE VACUUM SWITCH TO THERMAL VACUUM VALVE pe PRESSURE ~~" ‘SWITCH A-BLACK WHITE Figure 74-13 Auxillary Valve Body - (Exc. Computer Command ‘Contra ee NO. T.C.C, TEST 4 [1] U8 NEAR I FUSE PANEL YZ 12 ‘TRANSMISSION TCC, BRAKE SWITCH LOCKING TAB ie CASE LOCATOR’ Cj 7 3 ‘TRANS. CONNECTOR Figure 74-14 T.C.C. Wiring Schematic - (Exc. Computer Command Control} ELECTRICAL CONNECTOR CLIP INS CASE COVER), PRONTRANSMISSION CONVERTER CLUTCH (T.C.C.) ELECTRICAL DIAGNOSIS ‘CARS EQUIPPED WITH COMPUTER COMMAND CONTROL (C.C.C.) MECHANICAL CHECKS SUCH AS LINKAGE, OlL LEVEL, ETC. SHOULD BE PERFORMED PRIOR TO USING THIS CHART. ALSO CHECK FOR A CODE 24, IF PRESENT, SEE SECTION 6€. '* CONNECT TEST LIGHT FROM T.C.C. TEST POINT NEAR FUSE BLOCK TO GROUND. ‘© WITH DRIVE WHEELS OFF FLOOR, TRANSMISSION IN GEAR, INCREASE SPEED TO 25 MPH AND NOTE LIGHT. UGHT ON xr [Est oFF HOLD THROTTLE POSITION. TEST UGHT SHOULD GO OUT AS BRAKE PEDAL IS MOMENTARILY DEPRESSED| ‘STOP ENGINEIGN ON—DISCONNECT HARNESS AT TRANSMISSION. CONNECT TEST LIGHT BETWEEN HARNESS ‘TERMINAL A, AND GROUND. NOTE TEST LIGHT. oo —. — NOT Ox ox] UGHT ON LiGHT OFF I r — I TTIS FAULTY BRAKE | [INCREASE SPEED TO 50.55] [PROBLEM IN Ghinent On ADs | [Morn ANG Nove Licht] | 1A UgSt, comet eMECK WIRES CORRECT AS TO BRAKE SWITCH, ————— S$ NECESSARY. BRAKE SWITCH ADJ. GAT ON (luce or ‘AND FUSE. r x PROBLEM IN G6, CONTROL No TROUBLE REFER TO C.C.C. T.C.C. OK DIAGNOSIS CHARTS TRANSMISSION CONVERTER CLUTCH (T.C.C.) ELECTRICAL DIAGNOSIS CARS NOT EQUIPPED WITH COMPUTER COMMAND CONTROL (C.C.C:) MECHANICAL CHECKS SUCH AS LINKAGE, OIL LEVEL, ETC, SHOULD BE PERFORMED PRIOR TO USING THIS CHART. NOTE LIGHT. LIGHT ON r ‘* CONNECT TEST LIGHT FROM T.C.C. TEST POINT NEAR FUSE BLOCK TO GROUND. START ENGINE AND RUN AT 1500 RPM IN PARK. LIGHT OFF aa HOLD THROTTLE POSITION. TEST. LIGHT SHOULD GO OUT AS BRAKE PEDAL IS MOMENTARILY DEPRESSED. ae NOT OK oK r x PROBLEM IN ITS FAULTY BRAKE TRANSMISSION. SWITCH OR ADJ. | | nepaiR AS NECESSARY ‘CHECK FOR BLOWN FUSE. CHECK OPERATION OF BRAKE SWITCH. CHECK OPERATION OF VACUUM SWITCH ‘SWITCH OPEN—WITH ENGINE OFF. SWITCH CLOSED_AT PART THROTTLE. SWITCH OPEN—AT HEAVY FULL THROTTLE. CHECK FOR OPENS IN HARNESS. CHECK OPERATION OF VRV— ‘CLOSED_AT IDLE AND PART THROTTLE. (OPEN—AT HEAVY FULL THROTTLE. Figure 7A-16 T.G.G, Electrical DiagnosisON-CAR SERVICE ON-CAR SERVICEABLE COMPONENTS The following parts can be serviced with the transaxle in the car. For patt removal and installation procedures not listed in this section, refer to the disassembly and reassembly sections 1. Throttle valve control cable and/or sleeve seal 2. Transaxle filler pipe and/or sleeve seal 3, Transanle governor asembly and speedometer gear assembly, 4. Transaxle intermediate servo assembly and direct clutch accumulator check valve 5. Transaxle valve body assembly, spacer plate, gaskets, throttle lever and bracket assembly, pump shaft, valve body cover and gasket 6. Transaxle converter to flexplate bolts, 7. Transaxle oil pan and/or gasket, strainer assembly and "O" ring, 8. Lo and Reverse pipe, "O ring seal and oil seal 9. Dip-stick stop bracket, parking paw! and return spring. 10. Output shaft, axle joint retaining ring, snap ring (shaft) and axle oil seals. 1. Case cover, cooler fittings, manual valve, electrical connector, 1-2 accumulator piston, spring and seal, thermo- static element assembly, manual detent spring and roller assembly, sprockets, drive link and thrust washers. 12, 3rd clutch pressure switch, governor pressure switch, solenoid, auxiliary valve body, cover and gasket 125C TRANSAXLE ASSEMBLY _ REMOVAL 1. Disconnect negative battery cable from transaxle (see Figure 74-25), 2. Using a 1/4” x 2° long bolt, insert bolt in hole at front RH. motor mount to prevent mount mislocation during transaxle removal, Figure 7A-16, 3. Remove carburetor air cleaner and disconnect TV. cable at carburetor. 4. Remove bolt securing T.V. cable to transaxle, Pull upon cable cover at transaxle until cable is seen. Disconnect, cable from transaxle rod, Figure 7A-17. 5. Remove bolt securing engine wire harness at top front of transaxle. 6. Remove hose from air management valve, allowing the engine wire harness to be pulled up and out of way. 7. Install Engine Support Fixture, J-22825-1 and J- 2825.20. Fixture must be modified and installed as shown in Figure 7A-18, Raise engine enough to take pressure from motor mounts. CAUTION: Engine support must be located in center of cowl and fasteners must be torqued before supporting engine. Fixture is not intended to support entire weight of engine tre Bodily injury could result with improper use of support fixture. 2m (or FTLes) 4x2" BOLT 41Nm (20 FT, 188) FRONT ENGINE MOUNT FRONT ENGINE MOUNT BRACKET a Figure 74-16 Securing Engine Mount TV.CABLE TV.CABLE =) ,-CARBURET INSTALL ROD THRU caste HOLE IN CABLE END Je eRONT oF 0 ean “ACCELERATOR LEVER ACCELERATOR TRANSAXLE © BRACKET Figure 717 TV. Control Cable 8. Remove top transaxle mount and bracket assembly, Figure 7A-19. It may be necessary to raise engine to allow removal. 9. Disconnect shift control linkage from transaxle, Figure 7A-20. 10, Remove top transaxle to engine mounting bolts. Loosen transaxle to engine bolt near starter but do not remove, Figure 7A-19.J-22825-1 HUB ASSEMBLY FRONT OF CAR corTer tw 780m (55 FT. LBs) FRONT OF CAR Lowen conTaoL FRONT OF CAR KNUCKLE AND HUB ASSEMBLY] STABILIZER BAR 6 INSULATOR eS FRONT SUSPENSION SUPPORT ATTACHING BOLT/SCREW SEQUENCE 1. INSTALL LOOSELY, THE CENTER SCREW INTO HOLE). 2. INSTALL LOOSELY, THE TIE BAR SCREW INTO THE SMALL SLOTTED OUTBOARD HOLE. 2, INSTALL AND TORQUE goTH BOLTS IN THE REAR HOLES, 4, INSTALL AND TORQUE 2ND CENTER HOLE(O}BOLTISCREW. 5, TORQUE CENTER HOLE(A)BOLT. 6. INSTALL OTHER TIE BAR BOLT (FRONT HOLE|E)) AND TORQUE 7, TORQUE 2ND BOLT/SCREW IN THE (FRONT HOLE(}} Lower GONTROL FRONT OF CAR ‘aw (65 FT. Les) 88 Hm ne (65 FT. Les) Tae tas) FRONT SUSPENSION SUPPORT Figure 7-21 Control Arm Atachings 2TRANSAXLE \ 7 ‘SHIFT CONTROL FRONT OF CAR TRANSAXLE ‘SPEEDOMETER CABLE 2 SEAL SPEEDOMETER RETAINER CABLE ‘SLEEVE AND RETAINER a / GABLE ROUTING. WO CaUISE CONTROL ‘SPEEDOMETER LOWER, CABLE ‘SpeepOMeTER [UPPER CABLE CABLE ROUTING. Si'cRutse CONTROL Figure 74-22 Speedometer Cable 13 CONVERTER SHIELD 13m (195 1N. Les) vm Lago (8m. LBs.) BON Naam Figure 74-23 Transaxle Converter Sheild| POSITION OF PIPES SHOULD ‘TOUCH TRANSAXLE COVER, PRIOR TO TORQUING OF NUTS. FRONT OFCAR RADIATOR Figure 7A-24 Transaxle Cooler Pipes 4. Remove eleven bolts securing valve body cover to transaxle, Figure 7A-28. Discard cover gasket 5. Reverse procedures for valve body cover installation ‘Add transmission fluid as necessary. VALVE BODY AND OIL PUMP Removal & Installation 1, Disconnect negative battery cable. 2. Raise car on hoist 3. Remove left front wheel/tire assembly. 4. Remove five screws securing lower left air deflector to body and remove deflector, Figure 7A-30. 5, Remove eleven bolts securing valve body cover 10 transaxle, Figure 7A-28, Discard cover gasket, 6. Remove valve body and pump assembly and seperate from the auxillary valve body 7. Reverse procedure for valve body and oil pump installation. Add transmission fluid as necessaryBRACKET LE; Le sranrer CONNECTION NS STARTER moroR TRANSAXLE BRACKET NEGATIVE FRONT OF CAR. BATTERY STARTERWIRING ] CABLE Figure 725 Starter Removal AUXILLARY VALVE BODY 1. Disconnect negative battery cable. 2. Remove carburetor air cleaner and disconnect T.V. cable at carburetor. 3. Remove bolt securing T.V. cable to transaxle, Pull upon cable cover at transaxle until cable is seen. Disconnect, cable from transaxle rod, Figure 7A-17. 4, Raise car on hoist 5. Remove left front wheel/tire assembly. 6. Remove five screws securing lower left air deflector to body and remove deflector, Figure 7A-30. 7. Remove eleven bolts securing valve body cover to transaxle. Discard cover gasket 8. Remove bolt that secures T.C.C. solenoid to auxillary valve body and remove solenoid from valve body, Figure 7A-31 9. Disconnect T.C.C. wires from 3rd gear pressure switch. Remove switch from valve body by unscrewing switch, Figure 7-31. “ 10, Remove bolts securing auxillary valve body cover and remove cover, Figure 7A-31 I, Remove bolt securing T.V. linkage and bracket assembly to valve body and remove T.V. linkage. 12, Remove remaining bolts securing auxillary valve body to transaxle and remove valve body. 13, Reverse procedure for auxillary valve body installation. Add transmission fluid as necessary. TRANSAXLE CASE COVER REMOVAL 1. Disconnect negative battery cable 2. Using a 1/4” x 2 long bolt, insert bolt in hole at front RH. motor mount to prevent mount mislocation during case cover removal, Figure 7A-16, 3. Remove carburetor air cleaner and disconnect T.V. cable at carburetor. 4, Remove balt securing TV. cable to transaxle. Pull upon cable cover at transaxle until cable is seen. Disconnect cable from transaxle rod, Figure 7A-17. 5, Install engine support fixture, J-22825-1 and J. 2825-20. Fixture must be modified and installed as shown in Figure 7A-18, Raise engine enough to take pressure from ‘motor mounts, CAUTION: Engine support must be located in center of cowl and fasteners must be torqued before supporting engine. Fixture is not intended to support entire weight of engine ind transaxle. Bodily injury could result with improper use of support fixture. 6. Remove transaxle engine mount bolts. 17. Raise car on hoist 8. Remove left front wheel/tire assembly. 9. Remove air deflector, Figure 7A-30. 10. Remove eleven bolts securing valve body cover to transaxle, Figure 7A-28, 11. Disconnect electrical connector from transaxle 12. Remove valve body, detent mechanism and five check balls, Figure 7A-31 . 13. Remove oil pump drive shaft, Figure 7A-28. 14, Remove cotter pin and loosen a castelled ball joint ‘nut until ball joint separates from control arm, Figure 7A. 21 15. Loosen bolt securing stabilizer bar to L.H. lower control arm, Figure 7A-21 16, Loosen two bolts at rear of L.H. suspension support and remove the other four bolts, Figure 7-21 17, Disconnect transaxle cooler lines and plug to prevent leakage, Figure 7A-24. 18, Disconnect external transaxle electrical connector, Figure 74-32 19, Disconnect lower transaxle mount from transaxle, Figure 7-19. 20. Remove case attaching bolts and disconnect manual valve, Figure 7A-32. 21. Install two bolts (12 x 1.95 x 14) in dow! pin holes and tighten equally to pull case cover loose.ATSG] Technical Service Information AUTOMATIC TRANSAXLE DIAGNOSIS AND UNIT REPAIR 125C GENERAL DESCRIPTION ‘The 125C automatic transaxle isa fully automatic unit consisting primarily of a 4element hydraulic torque converter, compound planetary get set and dual sproc and drive link assembly. In addition, this. transaxle incorporates a differential and final drive gear set. The 4clement torque converter contains a pump, a turbing, a presure pat splined to the turbine and a stator assembly. The pressure plate, when applied, provides a mechanical direct drive ‘coupling of the engie to the planetary gears. ‘Three multiple-disc clutches, a roller clutch and a band provide the friction elements required to obiain the CHECK BALLS Figure Ao Case Cover - Valve Body Side 22AUTOMATIC TRANSAXLE 125C A. INTAKE B ACCUMULATOR, DIRECT CLUTCH ¢ 2ND D VvoiD E LO- REVERSE F DIRECT CLUTCH G REVERSE H DRIVE 1 LUBE J EXHAUST 404 VENT ASSEMBLY 405 PLUG, PIPE (LINE PRESSURE PICKUP) 405 406 VALVE, MANUAL 412: THERMO-ELEMENT voip DRAINBACK, SEAL LUBE DRIVE REVERSE DIRECT CLUTCH LO- REVERSE 2ND INTAKE GOVERNOR ‘SUPPORT, DRIVE SPROCKET 8888-x._ronmooo> PIPE, LO - REVERSE ‘SUPPORT, DRIVEN SPROCKET ACCUMULATOR, DIRECT CLUTCH EXHAUST, DIRECT CLUTCH ACCUMULATOR, ACCUMULATOR, DIRECT CLUTCH (CUP PLUG) merase Figure An11 Case - Case Gover Side 23125C__ AUTOMATIC TRANSAXLE LO & REVERSE INTAKE 2ND ACCUMULATOR, DIRECT CLUTCH 120 SEAL, REVERSE OIL - CASE TO HOUSING 125 SPRING, ACCUMULATOR EXHAUST 126 VALVE, ACCUMULATOR EXHAUST 138 PIPE, GOVERNOR OIL 138 144. RING, SEAL BACKUP 120 SEAL, “0” - REVERSE PIPE TO CASE voe> Figure A-12 Case - Oil Pan Side A. DRAINBACK, SEAL (SEAL REMOVED) 9 COVER, GOVERNOR 115 SEAL ASSEMBLY, CONVERTER 118 PLUG, CUP (PARKING PAWL SHAFT} 119 PLUG, GOVERNOR PRESSURE PICKUP 704 SHAFT, MANUAL wiasc-oe Figure A-13 Case ~ Right Hand Axle End 24AUTOMATIC TRANSAXLE 125C LUBE FEED, FORWARD CLUTCH SLEEVE, STEEL SHAFT, INPUT 622. RING, OIL SEAL 623 BUSHING, INPUT SHAFT. 624 HOUSING ASSEMBLY, FORWARD CLUTCH 626 SEAL, FORWARD CLUTCH PISTON OUTER, 627 SEAL, FORWARD CLUTCH PISTON INNER 628 INSEAT 629 PISTON, FORWARD CLUTCH 630 GUIDE, RELEASE SPRING 631 RETAINER SPRING ASM., FWD. CL. asst 632 RING, SNAP SPRING RETAINER Vom> Figure A-14 Forward Cluich Assembly - CutAway View DRIVEN SPROCKET SUPPORT DIRECT CLUTCH LUBE DRIVE REVERSE DIRECT CLUTCH DRAIN BACK Figure A-15 Driven Sprocket Support - CutAway View125¢ AUTOMATIC TRANSAXLE wavonsens DETENT REVERSE LINE INTERMEDIATE STV. T.c.c. EXHAUST 10 u 12 13 4 15 16 a 18 DRIVE T.C.C. APPLY RIND S.T.V,EXH. 1:2, ACCUM. LUBE Pr. Lo 2ND 19 20 2 22 23 24 25 LO - 1ST OR REV. SRD CL. (DIRECT) OR REV. BRD CL. (DIRECT) GOVERNOR SRD CL. (DIRECT) ACCUM. SUCTION TO COOLER Figure A-16 Valve Body Spacer Plate - Typical 26AUTOMATIC TRANSAXLE 125¢ A LUBE B FEED, FORWARD CLUTCH c 5 SLEEVE, STEEL, SHAFT, INPUT 622 RING, OIL SEAL 623 BUSHING, INPUT SHAFT 624 HOUSING ASSEMBLY, FORWARD CLUTCH 626 SEAL, FORWARD CLUTCH PISTON OUTER 627 SEAL, FORWARD CLUTCH PISTON INNER 628 INSERT 629 PISTON, FORWARD CLUTCH 630 GUIDE, RELEASE SPRING 631 RETAINER SPRING ASM., FWD. CL. aes 632. RING, SNAP SPRING RETAINER Figure A-14 Forward Clutch Assembly - Gut Away View ORIVEN SPROCKET SUPPORT DIRECT CLUTCH LUBE DRIVE REVERSE DIRECT CLUTCH DRAIN BACK Nousens w2s282. ire A-15 Driven Sprocket Support - CutAway View 25125¢ AUTOMATIC TRANSAXLE RNDI TW. Lo“ ist DETENT REVERSE LINE INTERMEDIATE STV. T.C.C. EXHAUST 10 " 12 13 14 15 16 v7 18 DRIVE T.C.C. APPLY RIND S.T.V, EXH. 1:2 ACCUM. LUBE PAV. Lo 2ND 19 20 21 22 23 24 25 LO - 1ST OR REV. SRD CL. (DIRECT) OR REV. 3RD CL. (DIRECT) GOVERNOR 3RD CL. (DIRECT) ACCUM, SUCTION TO COOLER Hizsc269 Figure A-16 Valve Body Spacer Plate - Typical 26AUTOMATIC TRANSAXLE 125C NO UPSHIFTS, DELAYED UPSHIFTS OR FULL THROTTLE UPSHIFTS | Sane L ieee eeeeeeeeeeees ——— re r ———— eS a T 1 arenes! (Seger co TL T Figure A-17 Upshift Complaint ar125¢__ AUTOMATIC TRANSAXLE 1-2 SHIFT COMPLAINT : I I i" _—— oo 1 AERA Fe I T > {—____ oe (=a es eS Figure A-18 1-2 Shift Complaint 28AUTOMATIC TRANSAXLE 125C 2:3 SHIFT COMPLAINT I I srceincations I L ‘SIGHT DELAY AND HARSH UPGHIFT Muay ALso et cant . ‘nr TEER I oe eee I I se onggygggnne oro — ee Rl 1 I Hi26210 Figure A-18 2-3 Shift Complaint 29125C__ AUTOMATIC TRANSAXLE NO INTERMEDIATE RANGE - NO OVERRUN BRAKING IN LO (L1) ‘2ND GEAR REVERSE OK TRANSMISSION NOISY £ L L SoUEA Ay .on vem | eRe ena | Figure A24 Transmission Noisy 34125C__ AUTOMATIC TRANSAXLE NO 2-3 SHIFT OR DELAYED 2.3, (HAS BOTH FIRST AND SECOND) I T Ld — I Dt eects precnnmibiarsne —) cements “faaeiety MONG LN =T DELAY IN DRIVE AND REVERSE T —— Figure A20 No 23 or De 30126C__ AUTOMATIC TRANSAXLE NO DRIVE IN ANY FORWARD RANGE — REVERSE OK I aS T T I NO REVERSE — ALL FORWARD RANGES OK el kta 2a - L L L L T im T T Figure A-22 No Reverse 32AUTOMATIC TRANSAXLE 125C NO DRIVE IN FORWARD RANGES - No DRIVE IN DRIVE OR INTERMEDIATE RANGE ~ LO AND REVERSE OK REVERSE TIES UP I NO DRIVE FORWARD OR REVERSE — ANY RANGE ee I L i ee I L NNO DRIVE IN DRIVE RANGE. INTERMEDIATE, a ee LOW AND REVERSE OK suena cies I nr canoe Sea eeaaemie i r ar canar or orn = RSA NET mae I se T i Figure A21 No Drive a1126¢ AUTOMATIC TRANSAXLE NO DRIVE IN ANY FORWARD RANGE — REVERSE OK I oc IH —_,{ L NO REVERSE — ALL FORWARD RANGES OK T T i L T I Hazsa13 Figure A22 No Reverse 32AUTOMATIC TRANSAXLE 125C SECOND SPEED START - SHIFTS 3-1 AT HIGH SPEEDS ‘MISSES 1ST AT TIMES FOR PASSING GEAR (DETENT DOWNSHIFTS) T SLIPS - CHATTERS IN 1ST I T I oa I I Tz o NO FULL THROTTLE (DETENT) DOWNSHIFT 3.2 I SHIFTS 1-3 (MISSES 2ND) T Figure A23 Shift Complaint 33DISASSEMBLY [55] Remove or Disconnect 1. 4-21366 Converter holding strap 2. Converter (1) Inatall or Connect (Figure 1) Tools Required: 4.28664 - Transaxle Holding Fixture 43-3289-20 - Fixture Base CAUTION: To reduce the possibility of personal injury or transaxle damage, make sure, when doing the next step, that all the bolts for the support fixture J-28664 are installed as shown and torqued to 11 N-m (8 ft-lbs.). 1, 3.28664 fixture 2. Fixture into J-3289-20 base 3. Drain the transmission fluid. Governor Assembly [2] Remove or Disconnect (Figure 2) Bolt (14 and retainer (13) Speedo sleeve (12) and gear (10) Screws (8) Governor cover (9) and “O” ring (7) Bearing (6) Gear (5) Governor assembly (4) AUTOMATIC TRANSAXLE 125C FixT TRANSMISSION SUPPORT 178664 HIGH PROFILE TRANSMISSION TRANSMISSION CASE| SUPPORT FIXTURE , ELL HOUSING |+3289-20 TRANSMISSION SUPPORT 3 FIXTURE BASE LOCATING PIN 28664 LOW PROFILE TRANSMISSION TRANSMISSION CASE SUPPORT FIXTURE RCNSESSiOn |13289-20 URE BASE niasc-61 RING OIL SEAL GOVERNOR ASSEMBLY GEAR, SPEEDOMETER DRIVE THRUST BEARING ASM. GEAR/COVER SEAL, 'O" RING ‘SCREW, GOVERNOR COVER TO CASE COVER, GOVERNOR ‘SPEEDO DRIVEN GEAR SEAL, ‘O' RING SLEEVE, SPEEDO DRIVEN GEAR RETAINER, SPEEDO GEAR BOLT, SPEEDO GEAR RETAINING + H1a5c-64 Figure 2 Governor AssemblyAUTOMATIC TRANSAXLE 125¢ set H WOLDSTIOO dH 13NOWW N¥d 110 NOISSINSNVULL ‘M3¥OS 10 NOISSINSNWSL ‘NV “WO NOISSIWSNYHLL “A TWASSY U3NIVHAS Wo I1xW ‘A TAWASSY 1V3S dVNS‘ONIY LNdLNO “L3VHS. ANIO? 37X¥ ~ ONINIVL3H “ONT W3A09 AGOB 3AIVA ‘MBHOS ‘AG08 3ATVA ‘Y3AOD 1¥3A09 AGO 3A TVA 'L3xSv9 ‘3Sv9/AG08 3AWA ‘L108 JTULLOWHL 'ATEW3SSV L3NOVUS P Y3ART 318V9 O1 H3AITSTLLOWHL INIT ATEWASSV dNNd 110 8 3A TVA TOBLNOD Wa0VdS AOR 3ATVA “SLY Id 7 9€ Se ee ze Ie of 6 a a 4 sz ¥ ez zz Wz oz Sv Wa0vaS 1SNSVD 3AIH dWNd 110 ‘LaVHS ONILLId 431009 “YOLD3NNOD tviae9) 718 ATaW3SSV'3S¥9 ONINIVL3Y Hv39 003348 1108 ¥v30 003365 ‘Y3NIVI3Y v0 N3AIHG O033dS 3331S ONIY On W3S by30 NEAIHG 003345 WONH3A09 ‘3A09 3SV9 O1 Y3A09 HONYIAOD ‘M3HOS ONT .0,, "TW3S ¥3A00/HV39 'A1W3SSV ONIEV3 LSNUHL BAIN ¥313W0033d8 ‘V39 313 1aWO’ATEW3SS¥ HONY3AOD W38 10 ONY Wd ¥3L43ANO9 ‘NIHSS "AVBWSSY U3LU3ANOO Nowsi¥os3a Figure 3 External Components 36AUTOMATIC TRANSAXLE 125¢ te. No. 101 102 103 104 105 106 107 108 109 110 WW 12 413 4 115, ne 17 18 119 120 121 122 123, 124 125 126 127 128 129 130 131 132 133, 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 DESCRIPTION LINK ASSEMBLY, DRIVE 123—F RING, SNAP 1, | SPROCKET, ORIVE Seay WASHER, CASE COVER TO OR. SKT. THRUST ! RING, OIL SEAL TURBINE SHAFT (GREEN) ee SHAFT, TURBINE 1 SEAL, “0 RING TURBINE SHAFT ise BEARING ASSEMBLY i SUPPORT. DRIVE SPROCKET te BUSHING, RIVE SPROCKET SUPPORT | PIN, DOWEL-CASE COVER TO CASE NY CASE TRANSMISSION Ca SEAL ASSEMBLY, MANUAL SHAFT SCREW, SOCKET BUTTON HEAD @ SEAL ASSEMBLY, (CONVERTER) x as BUSHING, CASE mu Re PLUG, CUP (PARKING PAWL SHAFT) PLUG, (GOVERNOR PRESSURE PICKUP) roy REVERSE OIL SEAL ~ CASE TO HOUSING 4 BEARING ASM., DRIVEN SPROCKET THRUST ‘SPROCKET, DRIVEN WASHER, OR. SKT/SUPPORT THRUST PLUG, CUP (3RD OIL) SPRING, ACCUMULATOR EXHAUST VALVE, ACCUMULATOR EXHAUST PLUG, ORIFICE RING, OIL SEAL INTER. BAND APPLY PIN PIN, INTERMEDIATE BAND APPLY. RETAINER, INTERMEDIATE SERVO SPRING SPRING, INTERMEDIATE SERVO CUSHION RING, OIL SEAL OUTER, INT. SERVO PISTON, INTERMEDIATE SERVO RING, OIL SEAL — INNER INT. SERVO RING, SNAP. GASKET, INTERMEDIATE SERVO COVER COVER, INTERMEDIATE SERVO PIPE, GOVERNOR OIL. PIPE, REVERSE OIL RETAINER, REVERSE OIL PIPE BOLT, INTERMEDIATE SERVO COVER, BOLT. PIPE RETAINER/CASE RETAINER, GOVERNOR & REVERSE OIL PIPE RING ~ SEAL BACKUP SEAL, "O" REVERSE PIPE TO CASE RETAINER, OIL WEIR OIL WEIR, RING, OIL SEAL TURBINE SHAFT (YELLOW) SEAL ASSEMBLY, (AXLE) ro 142 wa8c-19.9 Figure 4 Drive Link Assembly, Servo, Oil Pipes 7125C__ AUTOMATIC TRANSAXLE 142 146. a fas) epee ee WF 145 | S20 197. 32 SEAL .'0" RING 33 STRAINER ASM., TRANSMISSION OIL, 136 34 GASKET, OIL PAN 135: ' 35 PAN, TRANSMISSION OIL aaa 36 SCREW, TRANSMISSION OIL PAN H125¢65.2 Figure 5 Bottom Pan & Oil Strainer = Bottom Pan, Oil Strainer, Oil Pipes TAN [Ey] Remove or Disconnect (Figures 3 and 5) ce 130 1. Bolts (36) 2, Pan (35) — Leave two bolts in place finger tight — tap with a rubber mallet to break the R.T.V. sealant bead or gasket set. 3. Strainer (33) and “O” ring (32) [65] Remove or Disconnect (Figures 4 and 6) T. Bolts (141) and (142) 2. Brackets (140) and retainers (143) 3. Servo cover (137) and gasket (136) 4 Servo assembly (129 - 135) 5. “E™ ring (135) from pin (129) 6. Pin (129) from piston (133) , 125 SPRING, ACCUMULATOR EXHAUST ‘Monsure (Figures 7 and 8) 126 VALVE, ACCUMULATOR EXHAUST ; 127 PLUG, ORIFICE Tool Required: 128 RING, OIL SEAL INTER. BAND APP, PIN. J-28535 Intermediate band apply pin gage 129 PIN, INTERMEDIATE, BAND APPLY 1. Install 28535 on ease (112) and pin (129) into | 190 RETAINER, INTER. SERVO SPRING the gage. 131. SPRING, INTER. SERVO CUSHION sm(looinch | 192. RING, OIL SEAL (OUTER) INTER, SERVO 2 with a rorgue wrench apply 11.2N-m(lO0inch 433 PISTON, INTERMEDIATE SERVO Lae =m) a 134 RING, OIL SEAL (INNER) INT. SERVO 3. If the white line appears in the window the pin 135 RING, SNAP length is correct. 138, GASKET, INTERMEDIATE SERVO COVER = Ifthe white line does not appear, select | 137 COVER, INTERMEDIATE SERVO ‘igure 6) Repeat Pipe, REVERSE OIL RETAINER, REVERSE OIL PIPE 4 BOLT, INTSERVO COVER 142. BOLT: PIPE RET/CASE [Ey tem or Disconnect igre 9 & 10) 133. REtAINER, GOVERNOR AND REV. OIL Pipe 1 Bott (712) 144, RING SEAL BACKUP Mas SEAL, 0” REVERSE PIPE TO CASE 2, Stop bracket (711) 146 RETAINER, OIL WEIR 3. Bracket (710) 147 OIL WEIR 4 Botts (146) wrasces 5. Weir (147) Figure 6 Oil Pipes & Servo Assembly 6. Check valve (126) and spring (125) 7. Pipe (139), backup ring (144) and “0” Ring (145) 38AUTOMATIC TRANSAXLE 125C- Tice a 125. SPRING, 3D ACCUMULATOR EXHAUST. 126 VALVE 3RD ACCUMULATOR EXHAUST. Figure 7 Checking for Proper Apply Pin INTERMEDIATE BAND APPLY PIN Lenora IoewiFicaTion son «260m ation “Gram ton “He Goo Faure 8 hop Fa Char e\ one 705 a ~ aL, s a) Pe OLS [705 [710 Ini ACTUATOR ASSEMBLY BRACKET, PARKING LOCK BRACKET: DIPSTICK STOP [712 BOLT, PARKING LOCK BRACKET/CASE Figure 9 Dip Stick Stop & Brackets LOW AND REVERSE SEAL AND OUTPUT SHAFT [9] Remove or Disconnect (Figure 11 & 12) Tool Required: 4J-28583 - “C” ring remover, output shaft Modified No. 4 screw extractor 1. Lo and reverse seal (120) = Use a modified No. 4 screw extractor Output shaft “C” ring (30) with J-28583, + Push ring with remover - rotate shaft (29) pull the ring with needle nose pliers Output shaft (29) from case 2. 3 39 Figure 10 3rd Accumulator Exhaust Valve & Spring 1 MODIFIED # 4 SCREW EXTHACTOR— 120_CUPPLUG, LO AND REVERSE ~~ {Tizs.ast Figure 11 Lo & Reverse Cup Plug Figure 12 Expanding “C” Ring SIDE COVER AND CONTROL VALVE PUMP ASSEMBLY [69] Remove or Disconnect (Figures 13 and 14) Screws (27) (Leave two screws finger tight - tap the cover (26) with rubber mallet.) Cover (26) Bolts (24) — Do not remove the screw marked (Figure 14) Bracket assembly (23) and T.V. cable link (22) Valve body (21) ~ Do not place the machined side on the bench Number one check ball (16) Pump shaft (18) Spacer plate (20) and gaskets (19) Five check balls (Figure 15) 6. 1 8 9.126C__ AUTOMATIC TRANSAXLE 18 CASE, ASSEMBLY 23. LEVER AND BRACKET ASM., THROTTLE 16 BALL (6.3 DIA) 24 BOLT, VALVE BODY/CASE 18 SHAFT, OIL PUMP DRIVE 25. GASKET, VALVE BODY COVER 19. GASKET, SPACER PLATE 26 COVER, VALVE BODY 20 PLATE, VALVE BODY SPACER 27 SCREW, VALVE BODY COVER 21 CONTROL VALVE & OIL PUMP ASM, 22 LINK, THROTTLE LEVER TO CABLE 21 CONTROL VALVE AND OIL PUMP ASM. ‘A DO NOT REMOVE THIS SCREW wrasese Figure 14 Control Valve/Pump Assembly Input Shaft to Case Cover Selective Snap Ring End Play Check [GG] Monsure (Figures 16, 17 and 18) Tools required: 3-26958-10 Adapter Plug 43-26958 Loading tool 43-26958-11 Bracket J-28544 Input shaft lifter J-25025-7 Dial indicator post ((5-26900-12 or $8001 (M) dial indicator ) 40 Figure 15 Check Ball Locations Install the adapter plug J-26958-10, loading tool 526958 and bracket £20858. * Tighten the loading tool knob until tight. Install the dial indicator set and lifter. Push the lifter down then zero the dial indicator. Pull the lifter up. ‘Reading should be 0.10-0.84 mm (.004"-0.33"), See Figure 18. For choice of selective snap rings for proper end play ranges - record the reading. Remove the dial indicator set and the lifter.AUTOMATIC TRANSAXLE 125C Figure 17 Input Shaft to Case Cover End Play INPUT SHAFT. CE (621) Thickness demttication/Cotor Wit 1.83 -1.93mm (0.071" -0.076"). . 2.03 -2.13mm (0.078" - 0.084") eS os or 7 airs = a —— - ey oom acne on se aoe tut, 413: WASHER, THERMO-ELEMENT Sane fe St. EE, guns fae eee 2a oe ee fh Be iat SE ane Ea ae fee... ae fees See ee Figure 19 Case Cover Case Side at125¢__ AUTOMATIC TRANSAXLE Case Cover ‘® Place the case cover (401) on the bench, 1-2 accumulator side up. [>] Remove or Disconnect (Figures 19,20, 21,and 22) 3. Accumulator spring (419) 4. Piston (421) Tools Required: 3. Gasket (413) ‘Two MI2 bolts 50 mm (2" long) Rod (70) from manual valve (406) All case cover attaching bolts including 2 TORX @ hhead bolts © Install two (2) M12 bolts 50 mm (2") long into dowel pin holes. Bolts wil: self tap, bottom and Separate the case (112) and the cover(401). Alternate tightening of the bolts DO NOT PRY CASE COVER (401). 6 Drive sprocket thrust washer (414) Driven sprocket thrust washer (121) Turbine shaft “O” ring (Figure 21) Link assembly (101), drive and driven sprockets (103) 22) 10. Drive sprocket support thrust washer (104) 11. Driven sprocket support thrust washer (123) 7 8 9. 1 BOLT, M12 x 1.75 x60 401 CASE COVER Hisc22.1| jios SHAFT, TURBINE ho7 SEAL, ‘O" RING og ORIVE SPROCKET SUPPORT (STATOR SHAFT) N15 SEAL, CONVERTER OIL Figure 20 Case Cover Removal Figure 21 Turbine Shaft “O" Ring Seal 101 103, 104 108 108 109 12 LINK ASSEMBLY, DRIVE SPROCKET, DRIVE WASHER, CASE COVER TO DR. SKT. THRUST SHAFT, TURBINE BEARING ASSEMBLY ‘SUPPORT, DRIVE SPROCKET CASE,TRANSMISSION 121 BEARING ASM., DRIVEN SPROCKET THRUST 122 SPROCKET, DRIVEN 123 WASHER, OR. SKT/SUPPORT THRUST 1280-78 Figure 22 Drive 42 ink AssemblyAUTOMATIC TRANSAXLE 125C nu, No. 701 702 703 704 705 708 707 708 709 70 m n2 n3 DESCRIPTION ROD & RETAINER ASSEMBLY PIN, SPRING — DETENT LEVER TO SHAFT LEVER & HUB ASSEMBLY, MANUAL DETENT SHAFT, MANUAL ACTUATOR ASSEMBLY, PARKING LOCK PAWL, PARKING LOCK SPRING, PARKING PAWL RETURN, RETAINER, PARKING PAWL SHAFT SHAFT, PARKING LOCK PAWL BRACKET, PARKING LOCK BRACKET, DIPSTICK STOP BOLT, PARKING LOCK BRACKET/CASE PIN, MANUAL SHAFT/CASE RETAINING 1 RAG 2 PUNCH, 5mm (3/16") 703 LEVER, DETENT 704 SHAFT, MANUAL Figure 24 Retaining Pin Removal INPUT UNIT PARTS [es] Remove or Disconnect (Figures 23, 24, 25, 26, 27, and 28) Pin (702) Pin (713) Detent lever (703) Manual shaft (704) ‘Actuator rod (705) Driven sprocket support (602) Thrust washer (605) (from direct clutch side) © Plug (607) (Figure 27) © Band (606) 602 SUPPORT, DRIVEN SPROCKET 605 WASHER, THRUST — ORIVEN SPROCKET SUPPORT TO DIRECT CLUTCH HOUSING 701 ROD AND LEVER ASSEMBLY 703 LEVER ASSEMBLY, DETENT 704 SHAFT, MANUAL 713 PIN, MANUAL SHAFT/CASE RETAINING 701 703 Figure 23 Manual Linkage 43 Figure 25 Removing Manual Linkage125C__ AUTOMATIC TRANSAXLE *NOT REQUIRED WITH CAST ALUMINUM PISTON Figure 26 Internal Components 44641 643 644 DESCRIPTION BEARING ASSEMBLY SUPPORT ASSEMBLY, ORIVEN SPROCKET BUSHING, DRIVEN SPROCKET SUPPORT RING, OIL SEAL. WASHER, THRUST BAND ASSEMBLY, INTERMEDIATE PLUG, BAND ANCHOR HOLE BUSHING, DIRECT CLUTCH RETAINER & BALL ASM., CHECK VALVE HOUSING & DRUM ASM. ‘DIRECT CLUTCH BUSHING, DIRECT CLUTCH DRUM SEAL, DIRECT CLUTCH PISTON OUTER SEAL, DIRECT CLUTCH CENTER SEAL. DIRECT CLUTCH PISTON INNER PISTON, DIRECT CLUTCH APPLY RING & RELEASE SPRING ASM, RING, SNAP PLATE, DIRECT CLUTCH PLATE, CLUTCH BACKING, OIRECT RING, SNAP SNAP RING, SELECTIVE RING, OIL SEAL BUSHING, INPUT SHAFT HOUSING ASSEMBLY, FORWARD CLUTCH SEAL, FORWARD CLUTCH PISTON OUTER SEAL, FORWARD CLUTCH PISTON INNER INSERT PISTON, FORWARD CLUTCH GUIDE, RELEASE SPRING RETAINER & SPRING ASM., FWD. CL. RING, SNAP SPRING RETAINER. PLATE, FORWARD CLUTCH PLATE, CLUTCH BACKING, FORWARD RING, SNAP WASHER, INPUT SHAFT THRUST GEAR, AND INPUT INTERNAL, BUSHING, INPUT INTERNAL GEAR WASHER, INPUT CARR./IP. INT. GR. THRUST CARRIER ASSEMBLY, INPUT WASHER, INPUT CARR./IP. SUN GR. THRUST GEAR, INPUT SUN DRUM, INPUT RING, SNAP SELECT. INPUT DRUM/SUN GEAR, 646 647 648, 649 650 651 652 653 655, 659 664 665, 686 667 668 669 670 671 672 673 674 675 676 77 678 679 620 631 682 683 684 685, 686, 687 688 AUTOMATIC TRANSAXLE 125C. TON SUN GEAR GEAR, REACTION SUN RING, SNAP, BUSHING, LO & REVERSE CLUTCH HOUSING HOUSING, LO AND REVERSE RING, SNAP. ‘SEAL, LO & REVERSE PISTON OUTER SEAL, LO & REVERSE PISTON INNER PISTON, LO AND REVERSE CLUTCH INSERT, LO & REVERSE CLUTCH PISTON SPRING, LO & REVERSE CLUTCH RELEASE RETAINER, LO & REVERSE CLUTCH SPRING RING, SNAP PLATE, LO & REVERSE CLUTCH PLATE, LO & REVERSE CLUTCH BACKING SPACER, REV. HOUSING/LO RACE SELECTIVE RACE, LO ROLLER CLUTCH ROLLER ASSEMBLY, LO CLUTCH WASHER, REACTION CARR./INT. GR, THRUST BUSHING, REACTION CARRIER CARRIER ASSEMBLY, REACTION WASHER, REACTION CARR./INT. GR. THRUST BEARING, REACTION SUN/INT. GR. THRUST GEAR, REACTION INTERNAL SHAFT, FINAL DRIVE SUN GEAR RING, SNAP SPACER, FINAL DRIVE INTERNAL GEAR BUSHING, FINAL DRIVE INTERNAL GEAR GEAR, FINAL DRIVE INTERNAL BEARING, THRUST SUN GEAR/INT, GEAR GEAR, FINAL DRIVE SUN BEARING, THRUST SUN GEAR/CARRIER RING, SPIRAL RETAINING DIFFERENTIAL, CARRIER GEAR, GOVERNOR DRIVE WASHER, DIFF, CARR_/CASE SEL. THRUST BEARING ASM., DIFF. CARR./CASE THRUST ‘SHAFT, DIFFERENTIAL PINION PIN, DIFF. PINION SHAFT RETAINING WASHER, PINION THRUST. PINION, DIFFERENTIAL WASHER, DIFF. SIDE GEAR THRUST GEAR, DIFFERENTIAL SIDE PLATE, LO & REVERSE CLUTCH WAVED. Leseno, Higsiaoa., “NOT REQUIRED WITH CAST ALUMINUM PISTON Figure 271 Legend 45125¢. 4 5 AUTOMATIC TRANSAXLE ‘© Direct and forward clutch assemblies (610- 624) by lifting input shaft Thrust washer (636) © Internal gear (637) © Carrier (640) thrust washer (641) Input sun gear (642) @ Input drum (643) 1 EXTENSION 2 FEELER GAUGE 4-26900-12 OR UP x ANY 606 BAND ASSEMBLY, INTERMEDIATE ~7 607_PLUG, BAND ANCHOR HOLE wr2scs21 Figure 28 Band Anchor Hole Plug ‘A INPUT SHAFT. A 610 CLUTCH, DIRECT 624 CLUTCH, FORWARD Figure 23 Removing Forward & Direct Clutches 46 REACTION SUN GEAR TO INPUT DRUM SELECTIVE SNAP RING (644) Thickness dentifiation/Color 12.27 -2:37mm (0.089" -0.093". Pink 2.44 -2.54mm (0.096" -0.100") Brown 2.61 -2.71mm (0.103" -0.107") Lt Blue 2.78 -2.88mm (0.108" -0.113") = White 235. 3.5mm (0.118" 0.120")... Yellow 3.12 ONT. ee Us. Green 3.23 0.133" Orange 3.45 0.140") No Color Figure 31 Selective Snap Ring Chart Reaction Sun Gear to Input Drum End Play Measure (Figure 30 & 31) Tools Required: 4J-26958 Loading tool 5-26958-11 Bracket 3-26958-10 Adapter plug 43-28588 Gauge 4-25025-7 Post 4J-26900-12 or J-8001M Dial indicator 1. Install tools as shown. ‘The loading tool should already be in place 2. Position the gage extension between open ends of the snap ring (644). (Reaction sun gear (646) must be properly positioned.) Swing the gage under the extension shoulder. Zero the dial indicator. Position the snap ring (644) under the extension. Remove the gage from under the shoulder ‘Thedial indicator should read 0.33 100.13 mm (0.013" to 0,005"). ~ record the reading For cortect snap ing selection. See Figure 31. Measure washer thickness (new or old) with @ micrometer.7 Roller Clutch Race Selective Spacer End jay Measure (Figures 32 and 33) T. Use tools from “Selective Snap Ring End Play Check” 2. Pry up on internal gear (668) with J-28585 - Do not ry against the spacer (671) 3, The dial indicator reading should be 0.08-1.17 mm (0 003*-0,046"), Record reading For correct washer selection see Figure 33 4. Remove the dial indicator set and J-28588 gage. #138136 Figure 32 Lo Roller Clutch Race Selective Thrust ‘Spacer REACTION UNIT PARTS [ea] Remove or Disconnect (Figures 25, 33, 34, 35 and 36) Tool Required: J-28542 Lo-Reverse Clutch Unit Remover and Installer Sun gear (646) Snap ring (644) ~ ring is 2.36 mm (0.092") thick Lo reverse clutch housing (649) with J-28542 Snap ring (650) Output carrier and roller clutch assemblies and lo reverse clutch plates (658 thru 668) by lifting shaft (669) (Figure 35) a7 AUTOMATIC TRANSAXLE 125C REVERSE CLUTCH HOUSING TO LO RACE SELECTIVE SPACER (660) Thickness IWenttiation 1100 -2.20mm (0.039" -0.083") 1.42. 1.52mm (0.056 - 0.060") 1.84. 1.94mm (0.072"- 0.076") 2.26 236mm (0.089" - 0.093") 2.68 -2.78mm (0.105" -0.109") 3.10 -3.20mm (0.122" -0.126") 1 2 3 4 5 6 Figure 33 Lo Race Selective Spacer Chart > SS a = 649_LO AND REVERSE CLUTCH HOUSING «125226 Figure 34 Removing the Lo & Reverse Clutch Housing 660 SPACER, SELECTIVE @ 665 CARRIER, REACTION 2 668 GEAR, REACTION INTERNAL ~ wasn 669 SHAFT. FINAL DRIVE SUN GEAR Figure 35 Removing Reaction Components125C__ AUTOMATIC TRANSAXLE 649. 650. 659. ‘SNAP RING HOUSING ASM., LO & REVERSE CLUTCH RING, SNAP PLATE, LO & REVERSE CLUTCH PLATE, LO & REVERSE CLUTCH BACKING. SPACER, REV. HOUSING/LO RACE SELECTIVE RACE, LO ROLLER CLUTCH ROLLER ASSEMBLY, LO CLUTCH WASHER, REACTION CARR./INT. GR. THRUST BUSHING, REACTION CARRIER. CARRIER ASSEMBLY, REACTION WASHER, REACTION CARR /INT. GR. THRUST BEARING; REACTION SUN/INT. GR. THRUST GEAR, REACTION INTERNAL SHAFT, FINAL DRIVE SUN GEAR PLATE, LO & REVERSE CLUTCH WAVED 1386.72 sssemble (Figure 26 and 36) Clutch plates (658) & Backing plate (658) ‘© Roller clutch assembly (665) Internal gear (668) © Shaft (669) FINAL DRIVE ASSEMBLY Measure (Figures 37, 38, 39 and 40) Tools Required: J-26958-10 Adapter 43-25025-7 Post 3-26900-12 or J-8001M Dial indiactor 3-28585 Snap ring remover 1, Remove J-26958 and J-26958-11. Leave 3-26958-10 ‘adapter in place. 2. Install the dial indicator set so that stem contacts the adapter. 4:26900-12 ‘OR J-8001-M }).28585 1255+ Figure 37 Final Drive End Play Selective ‘Thrust Washer Measurement (680) FINAL DRIVE TO CASE END PLAY ‘SELECTIVE THRUST WASHER (680) eases IDENTIFICATION NOJCOLOR, 1.40 1.50mm (0.055" - 0.059") OF0range 1.50. 1.60mm (0.059 0.062") = Mhite 1.60 1.70mm (0.062" -0.066") .. 2/8Iue 1.70- 1.80mm (0.066" 0.070")... 3/Piok 1.80-1.90mm (0.070" -0.076") . . 2 Brown 1.90-2.00mm (0.074" -0,078") . = -5/Green 2.00--2.10mm (0,078" - 0.082") + S/Black 2.10- 220mm (0 2... T/Pueple 2.20-2.30mm (0,086' + WPurple & White 2.30- 240mm (0,091" + 9/Purple & Blue wazs.202 Figure 36 Reaction Components Disassembly Figure 38 Final Drive End Play Chet 48Lift up on the governor drive gear (679) with J-28585. Reading on the dial indicator should be 0.12-0.82 mm (0.005"-0.032") ~ Record reading. For correct washer selection see Figure 37 Remove the dial indicator set and the adpater. Ramove or Disconnect (Figures 26, 38, 39 and Tool Required: J-28545 Final Drive Unit Remover and Installer Snap ring (670) ~ Ring is 2.36 mm (0.092") thick. Spacer (671) Final drive assembly (673-688) with J-28545 ‘Thrust bearing (681) Selective washer (680) 671 SPACER, FINAL DRIVE /’ igure 39 Final Drive Spacer & Snap Ring wesc 474 678 DIFFERENTIAL CARRIER, Figure 40 Removing Final Drive Assembly 49 AUTOMATIC TRANSAXLE 125C CASE ASSEMBLY Clean Case (112) thoroughly with solvent and air dry. inspect (Figure 40) Case ~ see Section 7A for Case Repair = Lug damage Snap ring groove damage - Oil passage damage + Servo bore damage = Casting porosity = Stripped threads Case bushing (116) - for scoring Converter seal (115) ~ see drive sprocket support inspection replace ‘Axle seal (117) ~ for damage ASSEMBLY Ss 109 SUPPORT, DRIVE SPROCKET 112 CASE TRANSMISSION 118 SEAL ASSEMBLY, (CONVERTER) 117_ SEAL ASSEMBLY, (AXLE) wi250-70 Figure 41 Axle Seals & Sprocket Bearing Figure 42 Converter Seal and Axle Seal Installation125C__ AUTOMATIC TRANSAXLE Se | Replacement Procedure Romave or Disconnect (Figure 41) © Seal (115) or (117) ~ pry out Install or Connect (Figure 42) Tools Required: 3.26938 or J-29130 Axle Seal Installer 43-28540 Converter Seal Installer © Seal (115) with J-28540 © Seal (117) with J-26938 or J-29130 Inspect (Figure 41) ‘© Drive sprocket support bearing (108) If new bearing is required be sure to inspect drive sprocket (106) race for damage or wear ring Replacement Procedure Remove or Disconnect (Figure 43) Tools Required: J-26941 Bearing puller 3-6125-1 or J-2619-01 Slide hammer 3-6471-8 Adapter Bearing (108) with J tools Install or Connect (Figure 44) Tools Required 128677 Bearing Installer 41-8092 Handle © Bearing (108) identification sie up with 328677 and 38092 Inspect Drive sprocket support (109) for scoring. 108 BEARING ASM. ROLLER 109 SUPPORT, DRIVE SPROCKET 109 SUPPORT , DRIVE SPROCKET Figure 44 Installing Support Replacement Procedure Remove or Disconnect (Figure 45) Tool Required: 43-25359-5 #40 Torx bit or equivalent 1. Converter oil seal (115) Screws (114) with J-25359-5 Support (109) from case Install or Connect (Figure 45) Support (109) into case Screws (114) ~ use thread locking compound J-25259 #40 Torx bit or equivalent © Screws (114) to 24 Nem (18 ft. Ibs.) with 3-25359-5 108 BEARING ASSEMBLY 109 SUPPORT, ORIVE SPROCKET 112 CASE TRANSMISSION 114 SCREW, SOCKET BUTTON HEAD 115. SEAL ASSEMBLY, (CONVERTER) wease-77 Figure 43 Removing Bearing Figure 45 Sprocket Support Replacement[EB] inspect (© Parking paw! (706) for damage Parking Pawl Replacement Procedure Remove or Disconnect (Figure 46) Cup plug with a screw extractor Retainer (708) Shaft (709) Return spring (707) Pawl (706) Install or Connect Return spring (707) Paw! (706) ‘Shaft (709) Retainer (708) (Cup Plug with a 9 mm (3/8") rod 1 2. 5 4 5 1 2. 3 4. 5 [EF] ron ‘© Governor pipe (138) for damage or cracks 706 PAWL, PARKING 707 SPRING, PARKING PAWL 708 RETAINER, PARKING PAWL SHAFT 709 SHAFT, PARKING PAWL. oso et ar St plates engage the clutch hub. ‘© Thrust washer stepped side out (636) - use petrolatum ‘Measure (Figure 72) Ase Rib 3 me (172°) [Fe] stat or Comes igure 73 nd 7 > orard and dit hich ele ice Measure (Figure 74) © Case a hwsing = 2m (11/67 TNPUT SHAFT. CLUTCH, DIRECT. |, FORWARD Figure 71 Direct Clutch Assembly 60 Figure 73 Installing the Clutch AssembliesAUTOMATIC TRANSAXLE 126C 610 HOUSING & DRUM ASM., DIRECT CLUTCH 601 BEARING ASSEMBLY 602_SUPPORT ASSEMBLY, DRIVEN SPROCKET Figure 76 Bearing Replacement 607_PLUG, BAND ANCHOR HOLE Figure 7 Intermediate Band Anchor Hole Plug INTERMEDIATE BAND ASSEMBLY Inspect ‘@ Band (606) for burns, flaking or damage ee] insta or Connect 1. Band (606) ~ must engage the case lug 2. Plug (607) DRIVEN SPROCKET SUPPORT [BF] ems tigre 76 and 28) © Support (602) for cracks, burrs or damage ~ oil passage surface must be flat and smooth ‘© Bushing (603) for damage © Thrust washer (605) for damage © Oil seal rings (604) for nicks, cuts or damage Bes jure 75) ig Replacement Procedure [65] Remove or Disconnect (Figure 76) Tools Required 41-2694) Transmission Case Bearing. Cup Remover 5.6125-1 Slide Hammer © Bearing assembly (601) ~ use J-26941 an ssa Semele OD 4 © Inspet race for damage 6 602. SUPPORT, DRIVEN SPROCKET. 605 WASHER, THRUST — DRIVEN SPROCKET SUPPORT TO DIRECT CLUTCH HOUSING 701 ROD AND LEVER ASSEMBLY 703 LEVER ASSEMBLY, OETENT 704 SHAFT, MANUAL 713. PIN, MANUAL SHAFT/CASE RETAINING 28204 Figure 77 Driven Sprocket Support & Manual Linkage [+4] install or Connect ‘New bearing - manufacturing identification faces up Lie] Assombie (Figure 77 and Figure 26) ‘© Thrust washer (605) ~ retain with petrolarum. ‘© Support assembly (602) into the case. (Do not allow ‘the direct clutch bushing to cut the oil seals.) MANUAL SHAFT Inspect (Figure 77) © Rod and retainer assembly (701) for distortion or damage125C__ AUTOMATIC TRANSAXLE © Detent lever (703) for damage © Manual shaft (704) for damaged threads, raised edges on flats Parking lock actuator »ssembly (705) for damage or broken retainer lugs Assemble Actuator (705) to manual shaft (704) Detent lever (703) into case Slide the manual shaft (704) into the case and engage the detent lever (703) Tap the roll pin (702) into the detent lever with a $ mm GA?) drift 5. Tap nail (703) into place. DRIVE LINK ASSEMBLY 1 2 3 4 inspect (Figure 78) Drive and driven sprockets (103) 122) teeth and splines for nicks, burrs, scoring or wear Shaft (106) for damage, wear Seals (105) for damage Thrust washer (104) for damage or wear Link assembly (101) for damage or loose links 329569.2 105 RING, SOLID SEAL, TURBINE SHAFT (GREEN) 108 SHAFT, TURBINE "148 “RING, SOLID SEAL, TURBINE SHAFT (YELLOW) "REQUIRES USE OF J-29829 Hi2s.a200! Figure 79 Turbine Shaft Seal Replacement @ Thrust bearing (121) for damage or wear @ Driven support thrust washer (123) for damage or wear See drive link inspection in Section 7A. 101 103 104 106 108 109 112 LINK ASSEMBLY, ORIVE SPROCKET, DRIVE WASHER, CASE COVER TO DR. SKT. THRUST SHAFT, TURBINE BEARING ASSEMBLY SUPPORT, DRIVE SPROCKET CASE,TRANSMISSION 121 BEARING ASM., DRIVEN SPROCKET THRUST 122 SPROCKET, DRIVEN 123 WASHER, DR. SKT/SUPPORT THRUST 1386.76 Figure 78 Drive Link AssemblyTurbine Shaft Seal and Drive Sprocket Replacement Procedure Remove or Disconnect (Figure 4 and 7) + Seals (105) fom turbine shat (cut with nife) @ Snap ring (102) from turbine shaft # _ Drive sprocket (103) from turbine shaft Ped] insta or Connect (Figure 73) Tools Required: ‘J-29569 Turbine Shaft Seal Installer J-29829 Turbine Shaft Seal Installer @ Drive sprocket (103) onto turbine shaft @ = Snap ring (102) onto turbine shaft © Slide installer J-29569-1. over the turbine shaft and coat with petrolatum ‘© Guide new seals (105) over tool into seal ring grooves © — Size the seals with sizing tool J-29569-2 © Slide installer J-29829-1 over opposite end of turbine shaft and coat with petrolatum. © Guide new seal (148) over tool into seal ring groove. © Size the seal with sizing tool J-29829-2. AUTOMATIC TRANSAXLE 126C 109 ORIVE SPROCKET SUPPORT (STATOR SHAFT] 115 SEAL, CONVERTER OIL 107 SEAL, 0" RING f at 108 SHAFT, TURBINE a Wier Figure 80 Turbine Shalt “O" Ring Seal Pd Install or Connect (Figures 78 and 80) 1. Thrust washer (123) onto sprocket (122) and retain with petrolatum 2. Thrust washer (104) onto sprocket (103) and retain with petrolatum 3. Drive (103) and driven (122) sprockets into link assembly (101) - colored guide link up Link assembly (101) and sprockets (103) and (122) into case (13) 5. New “O" ring (107) onto the turbine shaft from the converter side of case (Figure 80) 6. Thrust bearing (121) onto sprocket (122) 407 PIN, SPRING (THERMO-ELEMENT} PIN, THERMO-ELEMENT PLATE, THERMOPLASTIC ELEMENT 412 THERMO-ELEMENT. tL, 413 WASHER, THERMO-ELEMENT. No. DESCRIPTION 414 WASHER, THRUST CASE COVER TO DR. SKT. 401 COVER, TRANSMISSION CASE 415 GASKET, CASE TO CASE COVER CENTER 402 NAMEPLATE 416 GASKET, CASE TO CASE COVER 403. SCREW — NAMEPLATE 417 SPRING AND ROLLER ASM., MANUAL OETENT 404 VENT ASSEMBLY. 418 BOLT, MAN. DET. SPRING/CASE COVER 405 PLUG, (LINE PRESSURE PICKUP) PIPE 419 SPRING, 1-2 ACCUMULATOR PISTON 408 VALVE, MANUAL 420 RING, OIL SEAL, 1-2 ACCUMULATOR PISTON 407 SEAL, “0” RING 421 PISTON, 1-2 ACCUMULATOR 408_ ELECTRICAL CONNECTOR 422 PIN, 1-2 ACCUMULATOR 1280-202 Figure 81 Case Cover - Case Side 63125C_ AUTOMATIC TRANSAXLE (CASE COVER ASSEMBLY FB cee igures #1 and 24 ‘Apply gasket remover, then scrape the case cover ‘gasket surface with a plastic scraper Inspect (© Case cover (401) see Section 7A for case cover repair = Casting porosity = Oil passage damage + {-2accumulator bore damage © 1-2 accumulator piston (421), seal (420) and spring (ais) = Cracked or damaged piston + Cut or nicked seal + Distorted spring © Vent assembly (404) for damage Vent Assembly Replacement Procedure [9] Remove or Disconnect Vent assembly with pliers Fee] install or Connect @ Apply thread sealant to the vent (404) vent. © Tap the vent (404) into case cover with a soft salle. [IS] inspect Figure 81 and 84) ‘© Detent spring and roller (617) for damage ~ replace as necessary. © Cooler fittings (17) for thread damage Cooler Fitting Replacement Procedure Dissent Figure 84) ‘© Cooler fittings (17) from case cover [5H Aoene ‘© Apply thread sealer to cooler fittings © Cooler fittings (17) into case cover ~ 38 N-m (23 ft Tbs) Inspect © Electrical connector (408) for damage © Case cover sleeve ~ for feed hole alignment © Manual valve (406) for damage ~ must slide freely in the bore ¥ Thrust washer (418) for damage ‘Thermostatic clement (405-413) for damage Thermostatic Element Replacement Procedure [e5} Disassombie igure 82) Tool Required: 3.29023 © Washers (413) 409 ROLL PIN! 410 ROLL PIN, CAPPEI Figure 82 Setting Genter Roll Pin Height a1). PLATE, THERMOPLASTIC ELEMENT 412. THERMO-ELEMENT 413. WASHER, THERMO-ELEMENT 17 CONNECTOR, COOLER FITTING 31_SEAL ASSEMBLY, AXLE OIL Figure 84 Left Hand Axle Seal & Cooler Fittings © Element (412) @ Element plate (411) FA ‘Assomble (Figure 82 and 83) ‘¢ Set thermo pin height with -29023, ‘¢ Install the element plate (411) (@ Install the element (412) ‘@ Install the washers (413) - use J-29023 to set the washer height. [J] inspect (Figure 24) ¢ Left hand axle seal (31) for damageSeal Replacement Procedure [e+] Remove or Disconnect “e Seal G1) Fr¢] install or Connect (© Seal (31) use J-26938 or J-29130 Assemble (Figure 81) Case cover: ‘Thrust washer (414) - use petrolatum to hold in place. Pin (422), chamfered end first Piston (421) Spring (419) Gasket (415) — use petrolatum to hold in place. Install or Connect Loctite ® 515 or equivalent on both sides of gasket 16) Gasket (416) to case cover Case cover (401) to case Coat bolt (A) with thread sealer (Figure 844), Retainer (701) to manual valve (406) (Figure 85) see e fe eneen Bi Figure 844, = 401 COVER, TRANSMISSION CASE 408. VALVE, MANUAL, 701 ROD & RETAINER ASSEMBLY 70v ° On resc.r54 Figure 85 Manual Valve AUTOMATIC TRANSAXLE 125C was Figure 86 Input Shafi to Case Cover End Play INPUT SHAFT TO CASE COVER SELECTIVE SNAP RING. (621) Thickness eatiication/Color 1.83 1.83mm (0.071" 0.076" 2.03 2.13mm (0.078" -0.084"7. 2.28-2.33mm (0.088" -0.092"). . 2.43- 2.53mm (0.095" 0.099"), 2.63. 2.73mm (0.103"-0.107")..- = White = Blue Figure 87 Selective Snap Ring Chart Input Shaft End Play Measure (Figures 86 and 87) ‘Tools required: J-26958-10 Adapter plug 43-26958 Loading tool and J-26958-11 bracket 3-28544 Input shaft lifter 43-25025-7 Dial indicator post 43-26900-12 or J-8001 Dial indicator Install essential tools Push the lifter down and zero the dial indicator. Pull the lifter up. Dial indicator reading should be 0.10-0.84 mm 004-033") ‘See (Figure 87) for snap ring selection — correct as necessary. 5. Remove tools. CONTROL VALVE AND OIL PUMP ASSEMBLY [2] Disassemble (Figures 88, 89, and SOL) Control Valve Assembly ipriet Valves and springs are not interchangeable. Keep them in the order shown. - Position as shown. = Start at the upper left and remove each valve train, Lay out the valve train as shown 1 2 3 4125¢ AUTOMATIC TRANSAXLE 301 302 303, 308 307 308 309 310 an 312 313 314 ane 36 37 318 319 320 321 22 323, ae ane ane seeain = PIN, COILED SPRING LINE BOOST PLUG 0 PIN; COILED SPRING SLEEVE, SPRING RETAINING VALVE, SHIFT TV. SPRING, SHIFT T.V PLUG, VALVE BORE BALL, PRESSURE RELIEF (9.525 DIA.) SPRING, PRESSURE RELIEF SPRING, 1.2 ACCUMULATOR BUSHING, 1-2 ACCUMULATOR VALVE, 1:2 ACCUMULATOR VALVE, 23 SHIFT VALVE, 2.3 THROTTLE SPRING, 23 THROTTLE VALVE BUSHING, 2:3 THROTTLE VALVE VALVE, 1:2 SHIFT VALVE, 1-2 THROTTLE SPRING, 1.2 THROTTLE VALVE BUSHING, 1.2 THROTTLE VALVE i, 3603p 367_ 388 204 8 eee oS i | 365 364374 363 360_ 361 378 so ame ae eS SO ro mn ase ass 207 a 324 BALL, LO BLOW OFF 325 -SPRING & PLUG ASSEMBLY ~ LO BLOW OF 326 PLUG, LO BLOW OFF VALVE 355 SPRING, 32 VALVE VALVE, 3:2 CONTROL BUSHING, T.V. & REVERSE BOOST VALVE VALVE, T.V. BOOST BUSHING, REVERSE BOOST VALVE VALVE, REVERSE BOOST SPRING, PRESSURE REGULATOR VALVE, PRESSURE REGULATOR BUSHING, T.V. PLUNGER PLUNGER, THROTTLE VALVE SPRING, THROTTLE VALVE VALVE, THROTTLE CHECK BALL #1 PIN, T.V. & REVERSE BOOST BUSHING PLUG, BORE (PRESSURE REGULATOR) RETAINER (PRESSURE REGULATOR) SPRING, PRESSURE REGULATOR ISOLATOR 375 PLUG, VALVE BORE ISOLATOR 376 RING. VALVE RETAINING. 366 367 368 369 370 amt 372 373 374 Figure 68 Control Valve - Roll pins (307) - they are under pressure. Cover the bore when the pin is removed. Pump Assembly All valves, bushings and springs with solvent, air dry - line hole pins must be removed with a #49 Inspect ‘ot (1a mm or O73"), Grind te ta the bit. SS TN Nin poked Valve body (301) and auxiliary valve body (343) il pump and ausiliary valve body assembly + Oil passage damage 1. Screw (327) cass pote 2. Cover 30) and gasker 31) {Machine fae deanags 3. Screw G34, solenoid assembly (33) and "4 ees fing seal 337 4. Switches (335 & 338) - Pump pocket for damage aa <-Aualary valve body sleeve for damage Convener sich repulator valve, pin, bore Sepa plug and spring (006, 40.4104) ee ee 6 CC. Conttl valve (32) and pug (310) So oe 5. Bin Gas) and sige G48) | See 8. Vanes (352) and rotor (353) ‘pang 3. Pimp vane ane G31) ‘© Pump rotor and vanes 2 Rotor damage 353) eae | Vane damage 632) Vane ngs for damage (31) ‘Valve body (301) and auxiliary valve body (340) with + Slide seals (350) solvent = air dry, Lo blow off assembly = 326, 325,326 2 Side “O" ngs seals 046 & 347) must be replaced © Pump shat bearing 054) for damageAUTOMATIC TRANSAXLE 125C- Figure 89 Control Valve & Oll Pump Assembly 67125C__ AUTOMATIC TRANSAXLE 301 BODY, OIL PUMP & CONTROL VALVE 341 SPRING, CONVERTER CLUTCH REGULATOR 302 PLUG, BORE LINE BOOST VALVE 342 VALVE, CONVERTER CLUTCH REGULATOR 303 VALVE, LINE BOOST 343 BODY, AUXILIARY VALVE 304 PIN, VALVE RETAINING SPRING 34% SLEEVE, AUXILIARY VALVE BODY 305 PIN; COILED SPRING LINE BOOST PLUG 345 PIN, SLIDE PIVOT 306 PIN; COILED SPRING 346 RING, OIL SEAL (SLIDE TO COVER) 307 SLEEVE, SPRING RETAINING 347 SEAL, “0” RING (SLIDE) 308 VALVE, SHIFT T.V. 348 SLIDE, PUMP. 308 SPRING, SHIFT TV. 349 SUPPORT, PUMP SLIDE SEAL 310 PLUG, VALVE BORE 350 SEAL, PUMP SLIDE 311 BALL’ PRESSURE RELIEF (9.525 DIA.) 351 RING, PUMP VANE 312 SPRING, PRESSURE RELIEF 352 VANE, PUMP 313 SPRING, 1-2 ACCUMULATOR 353 ROTOR, Olt, PUMP 314 BUSHING, 1-2 ACCUMULATOR 354 BEARING ASSEMBLY, ROLLER PUMP SHAFT 315 VALVE, 1:2 ACCUMULATOR 385 SPRING, 3.2 VALVE 316 VALVE, 2:3 SHIFT 356 VALVE, 3-2 CONTROL 317 VALVE, 2:3 THROTTLE 357 SEAL, PUMP SHAFT 318 SPRING, 2-3 THROTTLE VALVE ‘388. PLUG, SPRING RETAINING 319 BUSHING, 2.3 THROTTLE VALVE ‘359 SPRING, PUMP PRIMING. 320 VALVE, 1:2 SHIFT 360 BUSHING, T.V. & REVERSE BOOST VALVE 321 VALVE, 1.2 THROTTLE 361 VALVE, Tv. BOOST. 322 SPRING, 1-2 THROTTLE VALVE 363 VALVE, REVERSE BOOST 323 BUSHING, 1.2 THROTTLE VALVE 364 SPRING, PRESSURE REGULATOR 324 BALL, LO BLOW OFF 365 VALVE, PRESSURE REGULATOR 325 SPRING & PLUG ASSEMBLY, LO BLOW OFF 366 BUSHING, T.V. PLUNGER ‘326 PLUG, LO BLOW OFF VALVE 367 PLUNGER, THROTTLE VALVE ‘327 BOLT, AUXILIARY V.8./VALVE BODY ‘368 SPRING, THROTTLE VALVE ‘328 RETAINER, VALVE BODY PIPE 369 VALVE, THROTTLE. 329 BOLT. AUXILIARY VALVE BODY TO CASE 371 PIN, TV. & REVERSE BOOST BUSHING 330 COVER, AUXILIARY VALVE BODY 372 PLUG, BORE (PRESSURE REGULATOR} 331 GASKET, AUXILIARY VALVE BODY COVER 373 RETAINER, PRESSURE REGULATOR 332 VALVE, CONVERTER CLUTCH CONTROL 374 SPRING, PRESSURE REGULATOR ISOLATOR 333 SOLENOID ASSEMBLY 375 PLUG, VALVE BORE ISOLATOR 334 BOLT, SOLENOID, 376 RING, VALVE RETAINING 335 SWITCH. PRESSURE 337 SEAL, "0" RING 338 SWITCH, GOVERNOR PRESSURE (DIESEL ONLY) Leceno 339 HARNESS, SOLENOID WIRE Wieser 340 PLUG, VALVE BORE Figure SOL Control Valve and Oil Pump Assy. Legend Oil Pump Rotor and Slide Replacement Measure (Figure $1) Important Measurement of rotor/slide must be made on undamaged Tool Required: surfaces. Select similar size replacements. (Figure 91) Lightly ‘One Inch Micrometer hhone both sides of replacement rotor or slide to remove any © Oil Pump Rotor (353) Thickness nicks or burrs © Oil Pump Siide (348) Thickness TL PUMP ROTOR SELECTION CHAT THICKNESS (mm) | __ THICKNESS (in) arr —} —o7088-07088 1.830. 17.942 0.7060 -0.7064 17943-17955 07085. 0.7068 17986: 17968 07070-0.7074 17.960 17.981 07075 -0.7079 OIL PUMP SLIDE SELECTION CHART THICKNESS (mm) THICKNESS in) i7ss-i7967 | 07070-07078 17968: 17.980 0.7078 0.7078 MS ONL PUMP SLIDE 1798-17963 0.7080 - 0.7084 17.994. 18.006 07085 07089 13.007: 18.020 0.7080: 07004 Figure 91 Oil Pump Rotor and Slide Selection 68Pome S10€ 354 357 ‘CASE COVER SIDE oi 354 BEARING, ROLLER: PUMP SHAFT 357 SEAL, PUMP SHAFT H78059 Figure 92 Pump Be: ing Installation POMP SIDE ‘CASE COVER SIDE 1 PRESS BEARING 1.0mm TO 1.2mm (,040”. .047") ABOVE THIS SURFACE 364 BEARING, ROLLER- PUMP SHAFT Figure 93 Bearing Dimension Hse CASE COVER SIDE \PUMP SIDE 1 PRESS SEAL FLUSH TO 0.5mm (0.020") ABOVE THIS SURFACE 1954 BEARING, ROLLER. PUMP SHAFT [357 SEAL, PUMP SHAFT Figure 94 Bearing Si Hizse55 Dimension Pump Shaft B [Ea] tomar or iscooect Tools Required: 4.28698 Pump Bearing Remover and Installer 43-1079-2 Driver Handle Bearing with J-28698 and J-7079-2 (Drive toward pump pocket) ing Replacement AUTOMATIC TRANSAXLE 126C Install or Connect (Figures 92, 93, and 94) Tools Required: 4328698 Pump Bearing Remover and Installer 43-1079-2 Driver Handle ‘New bearing, use J-28698 and J-7-79-2 — install from pump pocket side ~ bearing cup must be 0.45 - 0.15 mm (0.017°-0.005") below pump pocket Pd] Assemble (Figures 88 and 89) oil pump assembly Pump slide (48) into pump pocket Slide seal support (349) and seal (330 into slide (348) ‘Align side with pivot hole, then install pin (345) ‘Vane ring (351) into pump pocket (1 of 2 rings) Vanes (352) and rotor (353) pocket Vane ring (351) top of rotor 0" ring seal (49) on top of rotor ‘0" ring seal (346) (slide to cover) Auxiliary valve body = Converter clutch regulator valve (342), spring G41), bore plug (340) and roll pin (306) + Control valve (332) and plug (310) + Switches G35 & 338) = Solenoid (333) with oil seal (337) and bolt (334) ~ attach leads ‘Auxiliary valve body to valve body = Position as shown. + Install gasket 031) and cover (330). Tighten ‘Torque the bolts (327) to 11 N-m (8 ft. Ibs.) Fi] Assombie Figures 88, 89, and sol) Control valve assembly Al valves, springs, bushings, bore plugs and roll pins as shown Figure 95 Check Ball Locations125C__ AUTOMATIC TRANSAXLE 15 CASE, ASSEMBLY 23 LEVER AND BRACKET ASM, THROTTLE 16 BALL (6.3 DIA} 24 BOLT, VALVE BODY/CASE 18 SHAFT, OIL PUMP ORIVE 25 GASKET, VALVE BODY COVER 19 GASKET, SPACER PLATE 26 COVER, VALVE BODY 20 PLATE, VALVE BODY SPACER 27 SCREW, VALVE BODY COVER 21 CONTROL VALVE & OIL PUMP ASM. 22 LINK, THROTTLE LEVER 70 CABLI 22 Figure 96 Control Valve Pump Assembly, Oil Pump Shaft CONTROL VALVE AND OIL PUMP ASSEMBLY x 8 c Install or Connect (Figures 95, 96, 97, 98, 99 and . 100) E F 6 4 1 Check balls (16), numbers 2,3, 4 and 5 Gasket (19) Pate (20) Gasket (19) Check ball (16) number one ~ on spacer plate Shaft (18) ~ through case cover 6 mm guide pins Body assembly (21) ~ onto case cover Retainer (328) 10. Bolts (327). Refer to Figure 98 11. Coat bolt “F” Figure 98 with thread sealer. 12) Wiring harness, 13) Link @2) 14. Bracket assembly (23) ~ engage link (22) 15. Remove 6 mm guide pins. 16. Remaining bols (327) EI tien ‘Torque the bolts (327) M6 - 11 Nem (8 ft Ibs.) MB - 24 Nem (18 ft. Ibs). T PINS, 6mm GUIDE rea g SHARE Fume DRIVE SPACER PLATE & GASKETS juon pat eraeenietares Figure 98 Valve Body Bolt Locai 1 PIPE RETAINER ‘TORQUE ALL M6 BOLTS TO 11 Nom (8 FT-LBS) FISABS) 1 2 3 4 5 ‘ 7 8 9, 2 Cover (26) 3. Serews (27) FER] Toren Tone te seve 2) 0 11 Nem (8 Bs) Fog tnt or Cones sr 101) Tia 9) ino cs 2 SStvge G0) pain wi et xe pr Fea] inst o connec 3 Wie Mast phon" ae 6 Figure 87 Spacer Plate & Gaskets 1. Gasket (25) or apply R.TV. silicon sealant 70AUTOMATIC TRANSAXLE 126C MODEL USAGE — BA, BC, BD, BP, CA, CB, CC, CD,CF, CJ, CK, CL, CM, CT, CU, CX, HL, HU, PA, PD, PF,PH, PJ, PK, PN, PR, PW 1 CLIP IN CASE COVER PRONGS 2 RED 3 WHITE 4 BLACK 333 SOLENOID ASSEMBLY 335 SWITCH, 3RD CLUTCH PRESSURE (N.O.) 408 CONNECTOR, ELECTRICAL jas Pe, 301 333 335, 1338 339 343 408 MODEL HS LINE x (BLACK) 335333 BODY, OIL PUMP AND CONTROL VALVE SOLENOID ASSEMBLY SWITCH, SRD CLUTCH PRESSURE (N.O.) SWITCH, GOV. PRESSURE (N.O.) WIRE ASSEMBLY (WHITE) BODY, AUXILIARY VALVE ELECTRICAL CONNECTOR wrascons Figure 89 T.C.c. Wiring Diagram MODELS JD, JM, JN, JS, JW LINE X (BLACK). 335 333 301 BODY, OIL PUMP AND CONTROL VALVE 333 SOLENOID ASSEMBLY 335. SWITCH, 3RD CLUTCH PRESSURE (N.O.) SWITCH, GOV. PRESSURE (N.O.) WIRE ASSEMBLY (WHITE) 338 339 [343 BODY, AUXILIARY VALVE }408_ ELECTRICAL CONNECTOR nr2sc-98-1 Figure 100 T.C.c. Wiring Diagram n Figure 100A T.C.c. Wiring Diagram125C__ AUTOMATIC TRANSAXLE 29. SHAFT, OUTPUT 30. RING, SNAP 125-86 Figure 101 Output Shaft & "C" Ring 0 at. v" 705 l70s. i710 Ini in2 ACTUATOR ASSEMBLY. BRACKET, PARKING LOCK BRACKET. DIPSTICK STOP. BOLT, PARKING LOCK BRACKETICASE,, 154-95 Figure 102 Di ‘Stop & Parking Lock Reverse Pipe and Parking Bracket Ped] install or Connect (Figures 102 and 103) 1. Weir (147) 2. Bracket (143) 3. Retainer (143) 4. Screw (142) 5. Bracket (710) 6 Stop (711) 7. Screw (712) Inspect © Actuator Assembly (705) for proper action Install or Connect (Figure 104) ‘Cup plug (120) - use 9.5 mm (3/8*) drift FB Assamot igure 109 1. Washer (144) onto pipe (139) 2. “O" ring (145) - retain with petrolatum 3. Pipe assembly (139) 4. Bracket (143) 5. Serew (142) 2 141 142 140 143 m4 wl 145, | 142 146. 143 WF 137: 136— 135: ; 134 133 13 131 130. 125 128 127 128 129 130 131 132 133, 134 135 136 137 139 140 vat 142 143 ‘SPRING, ACCUMULATOR EXHAUST VALVE; ACCUMULATOR EXHAUST PLUG, ORIFICE RING, OIL SEAL INTER. BAND APP. PIN PIN, INTERMEDIATE, BAND APPLY RETAINER, INTER. SERVO SPRING SPRING, INTER. SERVO CUSHION RING, OIL SEAL (OUTER) INTER. SERVO PISTON, INTERMEDIATE SERVO RING, OIL SEAL (INNER) INT. SERVO RING, SNAP GASKET, INTERMEDIATE SERVO COVER COVER, INTERMEDIATE SERVO PIPE, REVERSE OIL RETAINER, REVERSE OIL PIPE BOLT, INT. SERVO COVER BOLT, PIPE RET/CASE RETAINER, GOVERNOR AND REV. OIL PIPE RING-SEAL BACKUP SEAL, ‘O" REVERSE PIPE TO CASE RETAINER, OIL WEIR OIL WEIR 144 145 146 147 Wia8c-66 Figure 103 Oil Pipe & ServoTighten "Torque the screws (142, 712, 142) to 24 N-m (18 fi Tes). INTERMEDIATE SERVO Disassemble (Figure 103) ring (135) from pin (129) Piston (133) from pin (129) Spring (131) Retainer (130) Inspect ‘© Pin (129) for damage Seals (134 and 132) for cuts or nicks ~ proper scarf eu ignment. Do not remove seals (132 and 134) unless replacement is necessary, © Spring (131) for damage Retainer (130) for damage © Cover (137) for damage, cracks, porosity ‘© Piston (133) for cracks, seal groove damage [Gi] Messure Figures 105 and 106) Tools Required: J-28535 Intermediate Band apply pin gage 1. Install J-28535 on the case (112) and the pin (129) into the gage. With a torque wrench apply 11.2 N-m (100 inch pounds of torque 1 3 4 + R00.8.5mm S78") ge 120_GUPPLUG’LO AND REVERSE “4 sce? Figure 104 Lo & Reverse Cup Plug AUTOMATIC TRANSAXLE 125¢ INTERMEDIATE BAND ‘APPLY PIN LenoT# IDENTIFICATION Short. . cence cos 2 Grooves Medium ce eeees 1 Groove LON eee ee eect eee eee ees Me Groaves Figure 106 Apply Pin Chart 125. SPRING, 3RD ACCUMULATOR EXHAUST 126 VALVE, 3RD ACCUMULATOR EXHAUST Figure 107 3rd Accumulator Exhaust Valve & Spring 3. If the white line appears in window the pin length is correct. If the white line does not appear, select another length pin ~ Figure 106. Repeat procedure. 4. Remove pin gage. Assomble (Figure 103) 1. Retainer (130) onto pin (129) 2. Spring (131) against spacer (13) 3. Piston (133) onto pin 4. “E ring (135) onto pin fe¢] instatt or Connect (Figures 107 and 103) 1. Spring (125) into bore 2. Check valve (126) into bore 32 SEAL, '0" RING 2 33. STRAINER ASM., TRANSMISSION OIL 34 GASKET, OIL PAN 35. PAN, TRANSMISSION OIL, 36_SCREW, TRANSMISSION OIL PAN sn2sc-s52 Figure 105 Checking for Proper Apply Pin 73 Figure 108 Bottom Pan & Oil Strainer125C_ AUTOMATIC TRANSAXLE Seal Replacement Procedure 2 Remove or Disconnect gee © Seal (3)- cut off a3 eq] tnstat or Connect 3 RING OIL SEAL, 14 4 GOVERNOR ASSEMBLY © Seal 3) ~ use petrolatum 5 GEAR, SPEEDOMETER DRIVE 6 THRUST BEARING ASM, GEAR/COVER [EB] inspect 7 SEAL, ‘0’ RING 8 SCREW, GOVERNOR COVER TO CASE © Gear (5) for wear 8 COVER, GOVERNOR © Bearing (6) for damage 10 SPEEDG DRIVEN GEAR “ © Cover (9) for porosity or cracks 11 SEAL, "0" RING © Gear (10) for wear 12 SLEEVE, SPEEDO DRIVEN GEAR © "Oring (11) for nicks or cuts 13 RETAINER, SPEEDO GEAR 2+ We gout srecooGeAA meTAINING = 37] @ Sleeve (12) for scoring Figure 108 Governor Assambly Servo assembly (133) into servo bore Gasket (136) Cover (137) Bracket (140) Screws (141) EB taht © Torque the screws (141) to 11 N-m (8 ft. Ibs.) OIL PAN AND STRAINER Pq] instal or Connect (Figure 108) “O" ring (32) onto the strainer tube Strainer (33) into the case Gasket (34) or apply R.T.V. silicon sealant. Pan (35) onto the case Bolts (36) al Tighten ‘© Torque the pan bolts (36) to 11 N-m (8 ft. Ibs.) GOVERNOR AND SPEEDOMETER GEAR ASSEMBLY FRR cieen Governor assembly (4) Inspect (Figure 109) Governor + Oil passage blocked + Damaged springs = Missing check balls + Seal (3) damage + Binding weights 74 Install or Connect (Figure 109) Governor (4) assembly into case Gear (5) onto governor Bearing (6) onto gear New “O" ring (7) into cover (9) Cover (9) Make sure shaft (4) is piloted into cover. Screw (8) al Tighten © Torque the screw (8) to 11 N-m (8 ft. Ibs.) Efe] Assembie irigure 109) “O” ring (11) onto sleeve (12) Gear (10) into sleeve (12) Install or Connect, 1. Sleeve (12) into cover (9) 2. Retainer (13) 3. Screw (14) EB tones '@ Torque the screw (14) to 9 N-m (75 inch pounds) Ped tnstat or connect ‘© Transaxle into transmission jack [59] save or inconnact e J-28666 [eq] tnstatt or connect Tool Required: J-21366 Converter Holding Strap Converter (1) 3.21366 Converter retaining strapAUTOMATIC TRANSAXLE 126C 10 u et OO PQAQ9 cs o8 1. Pump Shaft Rolle Bearing Asy. Group 4.226 18, riven Sprocket Thrust Bering Assembly Group 4.131 2. Case Cover To Driven Sprocket Thrust Wosher Group 4.131 18, Bering Assembly Group 4.131 3. Gearing Assembly Group 4.131 20. Selective Snop Ring Group 4.168 4. Case Cover To Give Sprocket Thrust Washer Group 4.131 21: Direct Ciutch Bushing Group 4.169 5. Converter Bushing. Group 4.115 22: Input Shat Thrust Washer Group 4.158 8. Drive Sprocket Suppart Bushing Group 4.226 23. ap ing Group 4.216 7. Direc Gltch Drum Bushing Group 8.169 2 Gear Bushing Group 4.319 8. Input Carir To input Sun Gear Thrust Washer Group 8.15925. To Case Thrust Br AY. Group 4.176 8. Reaction Carer To Lo Race Thrust Washer Group 4.180, 2 ooket Support Thrust Waser Group 8.131 10. fesction Sun To Internal Gear Thrust Bearing Group 4.159 27. Input Shaft Bushing Group 4.158 11. Difleenial Carer To Case Sel. Thrust Washer Group 4.178 28. Thrust Washer Group 4.169 12. Input Internal Gear Bushing Group 4.158 28. Driven Socket Support Busing 13. Input Carrier To Input int. Gear Theut Washer Group 4.159 30, Reaction Sun Gear Bushing Group 14. Lo And Reverse Clutch Mousing Bushing Group 4.159 31. Reverse Housing To Lo Race Selective Washer Group 6.180 15. Reaction Carrier To Int. Guar Thrust Wather Group 4,180 32. Reoction Cater Bushing Group 4.189 16. Sun Gear To Internal Gear Thrust Bearing Group 4.178, 33, Sun Gear To Carrier Thrust Bearing Group 4.189 17._Cate Bushing Group 4.319 Figure 110 Bushing & Thrust Washer Locations 15PAATSG| Technical Service Information Thm 125C Fwd / Direct Clutch Drum Subject: New Forward and Direct Clutch For 1985 Production Model All 1985 THM 125C At the start of production for 1985 all THM 125C transaxles are being built with a new forward and direct clutch assembly (see Figures 1 & 2). ‘The 1985 production forward and direct clutch assemblies are not interchangeable with the 1984 oF prior model year forward and direct clutch assemblies. See Figures 1 & 2 for identification. For 1984 and past model service a new forward and direct clutch housing service assemblies are now available (see Figures 4 & 5). The direct clutch housing service package, Part Number 8653978, will contain the following: Direct clutch housing assembly Direct clutch piston assembly Direct clutch piston inner, outer and center seals Intermediate band assembly ‘The forward clutch housing service package, Part Number 8653977, will contain the following: Forward clutch housing assembly NOTICE: Do not use any component parts from the 1985 production forward clutch assembly or direct clutch assembly to service prior model year clutch assemblies. This includes the 1985 production composition clutch plates for both the forward and direct clutch. Refer to Figures 1 thru 6 for component identification and refer to the appropriate service parts book AUTOMATIC TRANSMISSION SERVICE GROUP 76Technical Service Information 1984 AND PRIOR DIRECT CLUTCH HOUSING SERVICE PACKAGE PART NUMBER 8653978 1984 AND PRIOR SERVICE HOUSING HAS CHAMFER WITH A SLOT ON INSIDE OF DIRECT CLUTCH HOUSING ASSEMBLY ea 612 610 601 BAND ASSEMBLY, INTERMEDIATE 613 SEAL, DIRECT CLUTCH CENTER 610 HOUSING & DRUM ASM. DIRECT CLUTCH 614 SEAL, DIRECT CLUTCH PISTON INNER 612 SEAL, DIRECT CLUTCH PISTON OUTER 615 PISTON, DIRECT CLUTCH FIGURE 5 DIRECT CLUTCH SERVICE PACKAGE FIGURE A FIGURE 8 SERVICE NOTE: THE SNAP RING THAT RETAINS THE APPLY RING AND RELEASE SPRING ASSEMBLY MAY NOT APPEAR TO BE FULLY SEATED IN THE SNAP RING GROOVE WHEN INSTALLED. THIS IS DUE TO THE GROOVE NOT BEING CUT AS DEEP AS PREVIOUS MODEL YEARS (SEE FIGURE 8). WHEN INSTALLING THE SNAP RING USE A DOWNWARD AND OUTWARD PRESSURE TO ENSURE PROPER SEATING (SEE FIGURE A). FIGURE 6 NEW DIRECT CLUTCH SNAP RING POSITION 7TSG Technical Service Information ROUNDED TOOTH EVERY OTHER TOOTH THE 1985 FORWARD AND DIRECT COMPOSITION CLUTCH PLATES ARE APPROXIMATELY 0.254 mm (,010") THINNER THAN PREVIOUS MODEL YEAR COMPOSITION PLATES. THE 1985 COMPOSITION PLATES ARE IDENTIFIED AS SHOWN ABOVE AND THE CLUTCH PACK MAY CONTAIN ONE OR BOTH TYPES. FIGURE 3 1985 COMPOSITION CLUTCH PLATE ASSEMBLY 1984 AND PRIOR FORWARD CLUTCH HOUSING SERVICE ASSEMBLY PART NUMBER 8653977 1984 AND PRIOR SEAVICE HOUSING : HAS CHAMFER Lpey Ra ® is AMEE TL SE INSIDE OF FORWARD CLUTCH HOUSING ASSEMBLY FIGURE 4 FORWARD CLUTCH SERVICE PACKAGE 78ATSG Technical Service Information 1985 PRODUCTION HOUSING = p>] HAS A CHAMFER ON THE ART, INSIDE EDGE OF THE HOUSINGS A Cy 8-633 624 HOUSING ASSEMBLY, FORWARD CLUTCH 631 RETAINER, SPRING ASSEMBLY 626 NSERT ‘4-633 WAVED STEEL PLATE 627 SEAL, FORWARD CLUTCH PISTON INNER 8-633 COMPOSITION FACED PLATE 628 SEAL, FORWARD CLUTCH PISTON OUTER, C-633 STEEL CLUTCH PLATE 629 PISTON, FORWARD CLUTCH 634 PLATE, CLUTCH BACKING, FORWARD 630 CLUTCH RELEASE SPRING GUIDE 635 RING, SNAP FIGURE 1 1985 PRODUCTION FORWARD CLUTCH ASSEMBLY 1985 PRODUCTION HOUSING 1985 BACKING HAS A CHAMFER ON THE PLATE THINNER AND INSIDE EDGE OF THE HOUSING. 85° STAMPED ON PLATE ag 1985 PISTON HAS FOUR 1D. STAMP MARKS ON THIS aac C) @3) ( +? 0 617 616 615 614 612 bis seals orsce ncuron concn Baie concen Ne ae 614 SEAL, DIRECT CLUTCH PISTON INNER 619 PLATE, CLUTCH BACKING, DIRECT pie pevomen cere ten eorenarnne Siemeiirnne caste: ennered 1985 PRODUCTION DIRECT CLUTCH ASSEMBLY 79ATSGI Technical Service Information THM 125C ¢(3THO) REVISED WIRING DIAGRAMS This bulletin covers revised wiring diagram information, and eight 1990 models that were added after the printing of the 1990 service manuals. Refer to this bulletin whenever service to any 1990 wiring assembly is necessary. REFER TO FIGURES 1 THRU 7 FOR WIRING DIAGRAMS “Copyrighted Material Reprinted with Permission from Hydr: er tic Division General Motors Corp." CCONNECTOR-PASS THRU (70 2 12v1 O-RING seat {COLOR TO-BLACK sack: aac, reo ne ware wm tevack| Switen—3Ro CU AB StACK pressure inc.) cee COLOR lowe: PRESSURE INC.) | PRESSURE 2NO CLL {COLOR 10-COPPER! Figure 1 AUTOMATIC TRANSMISSION SERVICE GROUP 80Technical Service Information 1990 MODELS AYE, HAG, HSC. HTC. LKC, LUC Eve, Pb. pc, PN. Pac. PTC, RUC, TAC PAss-THAU. CONNECTOR (COLOR io-NaTURAL Tenwnac € enmamat 0 wai veo'ecm uve a {28ida wo-neoF Tenanat 8 Tennant a Wor Ostet ona so.so1 ano eee SBR ANE a : : une ron Sue woot pa fou alban ewer 1 ° = : TOEGA sol] sno cL Sw wel, ies wwor Ustor so Sergcheare cw. FeesSone aS = (28.Saiowrer unex t2oidaw.asce Figure 2 “Copyrighted Material Reprinted with Permission from Hydra-natic Division General Motors Corp." ass Tang oe CONNECTOR Buc, Bye.sze, cH, CWC! HEE: HPC, HAG, Uae, WG: te, tLe, Pas. Dian (COLOR Io-BLAcKI switcn asm. > Pressure. TenMnan © Tema» (WHE Gino AUrowo HO ee ‘aineoy ' * see \ SOLENOID AND ‘ aw roar aie Be ¥ emMna 8 renmanas A { 1E0.3n o-neo1 ety \ ¢ . INE A BNO GL SW TEE BOE Line @ {eign w.neoy = BS 8eo-eaces ; mon : a UNE D UNE &, , ro ; (2a o.mires | me) | ‘3A Clu, (COLOR 1O-M.ACK) TO MIDOLE TERMINAL on | Presse wc. iol oni corveny Lack ~ t © BLACK ———7>\—— j Y aro cr gw © wHite —3>—_] INCH | Le. —I Figure 3 atATSG Technical Service Information vavioroneo 7988 MODELS Love (ree“soreav oD We. HYG, HzC ao? i wor vstp0>—L far. sw a, ! noearo| HNO. Ot PATH rass-TaRu ehareree . teaawiowATORAD Tepmunat € (worn TERMINAL D inet Oster swnrcn TERMINAL A Boveition Temwnias foe) pressure hor Ueto SoLenain ANd Buu SNe ine as une WESCOR Iowa Woda wore sureh iene ieoss PRESSURE IcoLOR 1o-BLacn) Figure & "Copyrighted Material Reprinted with Permission from fiydra-matic Division General Motors Corp." 1990 MODEL mass THRU ee ceena CONNECTOR 406, me (ar banaruraus TERMINAL € wore TERMINAL O To EeM UNE © CB.8a wownares vemnas TERMINAL A UNE A sure hor User Tota Oe wR Soveewon sressune 9.8010 ano RBuUP AE Gov une a s2v To roRTED TCE SOu_emires MO COLOR 10-REO! Son a a: wot vuseor 7 = > >—ty ‘wine asi stay tamu] TET une o Corse werrer 8k Sor (BEEn owner une x ‘SWITCH ASM. L. Soa aressune wo.TSG Technical Service Information 1990 MODELS KCC, KOC, KC TERMINAL roecK “s f- s012no10 ano remana 6 remanac a — SBSPANE PASS. THRU CONNECTOR (eoLon io-BLAcK) TERMINAL A M10 + 121 SWITCH ASM. PRESSURE (NO CLUTCH Ne B” SwitcH—an0 clu, une D PRESSURE (N.C) Figure 6 “Copyrighted Material Reprinted with Permission from Hydra-matic Division General Motors Corp." 1980 MODELS: xxe ‘TERMINAL ©. TERMINAL B Davack, Baack — waite 9 t PASS-THAU. CONNECTOR (CovoR IO; sLAcK D2. (is : D swircn asm. TERMINAL D @ (WHITE) Pressure, (ro ecm minor fano cuUTcH) wt Bian ane {COLOR 1o.wniTes SOLENOID AND CONDUIT ASM TERMINAL A une ¥ (fos 12 TeOLOR 10-R€0) a {e0L8R 10. a . {COLOR 10-ReD) UNE 8 peels | (COLOR 10-8LAcK? C+ une D i witcH — actu, COLOR 10-BLACKI | PRESSURE INO.) RD cL SW. H wwe) j Figure 7 83PAATSG| Technical Service Information CONVERTER SHUDDER Subject: THM 125-C Torque Converter Clutch Model All THM 125.C ‘Shudder Diagnosis (Summarizes and Supersedes Hydra-matic Bulletins HM 82.25, HM 63-13 and HM 83-14) ‘Some THM 125-C transmissions may exhibit torque converter clutch (T.C.C.) shudder as the TCC applies and/or after it applies when the accelerator pedal is depressed slowly (Crowd Shudder). These types of shudders are best described as a jerking sensation. In some cases the shudder may cause the instrument panel to vibrate. " andlor a “TCC Crowd Shudder’ Listed below are items which may cause a “TCC Apply Shudder CONDITION CAUSE AND CORRECTION TCC Apply TCC Crowd Shudder __ Shudder x x 1. An intermittent incorrect signal from the vehicle speed sensor (V.S.S.). Dirt or grease on the reflective bar in the V.S.S. may be sending an incorrect or erratic signal so that the converter clutch engages early. Remove the V.S.S. and clean it. x x 2. The auxiliary valve body cover attaching bolts may be loose or the bolt threads/holes may be shallow. If the holes are shallow, the bolts will bottom out without torquing the cover down. x 3. Some 1982 models were built with either an exhaust hole or an orifice cup plug in the auxiliary valve body cover. The auxiliary valve body cover was changed to a solid cover (no exhaust hole or orifice cup plug) in 1982. The service auxiliary valve body cover, part number 8643645, should be used on all models to prevent shudder. The service part does not have an orifice cup plug. x 4. There are two types of auxiliary valve bodies in service. One has an orifice cup plug and the other does not (Fig. 1). If the transmission being serviced has the auxiliary valve body with the orificed cup plug, particles of the auxiliary valve body cover gasket may have torn loose. This material may be sticking the torque converter clutch apply valve and/or plugging the converter release orifice in the con- trol valve body spacer plate. If this is found, disassemble the aux- iliary valve body and thoroughly clean. Also, be sure to remove any gasket particles in the valve body spacer plate converter release orifice hole and replace the auxiliary valve body cover gasket, part number 8653947. AUTOMATIC TRANSMISSION SERVICE GROUP 4TSG Torque Converter Clutch Shudder Diagnosis (continued) CONDITION TCC Apply Shudder Tec Crowd ‘Shudder x Technical Service Information 10. n 12 13, ALL THM 125-C. CAUSE AND CORRECTION Check the valves in the auxiliary valve body for freeness. (They must move in and out of their bore without sticking.) . For gas engine/transmissions, the auxiliary valve body converter clutch control regulatcr spring may be weak and require replacement with the new spring, part number 8637888. On February 20, 1984, for US. built and March 5, 1984 (Julian date 065) for Canada built THM 125-C transmissions. (Refer to Chart 1 for U.S. serial number break- points). The new spring part number 8637888, went into production and has a stronger load. For explanations of nameplates, refer to Fig. 2 (U.S.) and Fig. 3 (Canada). Inspect the pump shaft to valve body seal for cuts, damage, distortion. . A new governor pressure switch went into production for diesel models only, in late April, 1982. This change corrects the “Shudder” feel, by raising the converter clutch apply speed. In servicing Diesel model transmissions for this condition, refer to the following chart for proper model usage for 1982 models: Governor Switch eo Part Number (OP, HU, HY, H6, HR (8643369, HW 8637296 HS (8643368 CD, Hi, HC 8643367 Inspect the turbine shaft Teflon seals and “0” ring seal for damage, cuts, distortion (see Figure 4 for these parts). Ifthe teflon seals require replacement, make sure they are installed and sized as shown in Fig. 5. Inspect the turbine shaft seal grooves. A step in the bottom corners of the seal groove will keep the seal from contacting the side wall of the groove and will prevent proper sealing (Fig. 6). If this condition is found, replace the turbine shaft and seals. Check the case cover sleeve converter feed oil hole for being out of alignment with the oil channel in the case cover (Fig. 7). Check the converter end play, using tool J-29830A. The end play specification is .Smm (.020"). Converters with end play more than -5mm (.020") must be replaced. The turbine shaft sleeve may be leaking excessively. If all of the above items are O.K,, replace this shaft. AUTOMATIC TRANSMISSION SERVICE GROUP 85Torque Converter Clutch Shudder Diagnosis (continued) TSG Technical Service Information ALL THM 125-C MODEL | SERIALNO. | MODEL | SERIAL NO. ca | a2a6 EQ 11686 cea | (156657 EW 1007 CE 67281 HC 1748 CF 5938 HM 2235 cT 4574 HP 1154 EB 2639 HS 11705 EF 6579 HX 4397 él 5544 HY 20840 EJ 1006 PD 2080 EK 3843 PE 50353, EL 3594 PF 22983 EM 3062 PG 47268 EN 4984 Py 6007 EP 2085 Pw 67271 CHART 1 U.S. MODELS. TOP OF ORIFICE PLUG MUST BE FLUSH WITH CHANNEL WALL. PAST ORIFICE CUP PLUG AND HOLE OMITTED NEW FIGURE 1 AUXILIARY VALVE BODY (COVER SIDE) AUTOMATIC TRANSMISSION SERVICE GROUPTSG Technical Service Information Torque Converter Clutch Shudder Diagnosis ALL THM 125-C (continued) Page 4 83 PZ 86992 FIGURE 2 THM 125/125-C TRANSMISSION I.D. NAMEPLATE. YPSILANTI, MICHIGAN SS) FIGURE 3 THM 125/125-C TRANSMISSION I.D, NAMEPLATE WINDSOR, CANADA a7Technical Service Information Torque Converter Clutch Shudder Diagnosis ALL THM 125-C (continued) CONVERTER FEED CONVERTER FEED “oO” RING SEAL RINGS SLEEVE FIGURE 4 +J-20569-1 TURBINE SHAFT SEAL INSTALLER eno] ~— J-29569-2 SEAL SIZING TOOL FIGURE 5 TURBINE SHAFT SEAL REPLACEMENT AUTOMATIC TRANSMISSION SERVICE GROUPTechnical Service Information connect iwconnect MACHINING MACHINING PTFE. SEAL CORNER: STEP (i TURBINE SHAFT SEAL GROOVES FIGURES SSS Wie CHECK THIS HOLE FOR ALIGNMENT WITHIN CHANNEL AS SHOWN a = THIS HOLE MUST BE DRILLED THROUGH SLEEVE SLEEVE FIGURE? CASE COVER — VALVE BODY SIDE AUTOMATIC TRANSMISSION SERVICE GROUP 89ATSG] Technical Service Information LUBE SLOT Subject: 1985 Case Cover Oil Slot te A 3985 THM 1 Beginning approximately April 1984, a slot was added to the case cover of the THM 125C Transmission (Figure 1). The slot was added to the “Drive feed” oil circuit to allow transmission fluid to spray onto the rive link (chain) to provide additional lubrication. The slot is a “V" shaped groove cut into the case ‘cover in the area and direction as shown in Figure 1. The slot is intentional and should not be considered as a damaged case cover. FIGURE 1 CASE COVER OIL LUBE SLOT AUTOMATIC TRANSMISSION SERVICE GROUP 90ATSG] Technical Service Information OIL LEAK Subject: Front Converter Seal Oil Leak Model: THM 125-C All Models ‘Some THM 125-C transmissions may experience a front oil leak condition which is due to the front con- verter seal coming out of its seat in the case bore. This condition results from an oil pressure back-up behind the converter seal, which causes the converter seal to lose its seat in the case bore. In servicing any THM 125-C transmission for this condition, it is recommended that an oil drainback hole be drilled into the converter seal bore of the transmission case (Figure 1). Figure 1 Proper location is important in drilling the hole. Refer to the following service procedure: SERVICE PROCEDURE Always refer to the service manual for the proper removal and installation procedures of component parts. AUTOMATIC TRANSMISSION SERVICE GROUPnn 12, 13, 14, 15. 16, 17, 18, 19, 20, Technical Service Information With the converter removed and the transmission in its holding fixture, (Too! No. J-28664), remove ‘the valve body cover and gasket (or R.T.V. sealant] Remove the throttle lever and bracket assembly, Disconnect the wire assembly from the electrical connector. Remove the control valve assembly, spacer plate and gaskets. (Use care not to lose the check balls, which are loose.) Disconnect the manual valve from the rod and retainer assembly. Remove the transmission case cover. Remove the drive link assembly. (Drive sprocket, driven sprocket, chain, thrust washers and bearings.) Remove the converter oil seal Remove the drive sprocket support Drill, from the seal bore side, a 4.76 mm (3/16 in.) minimum diameter hole 2.03 mm (.080 in.) inside the radius of the converter seal bore (Figure 1). The hole must be drilled through so that it exits the other side of the sprocket support mating face, partially outward from the machined surface as shown (Figure 2) USE CARE NOT TO TOUCH THE SEAL BORE DIAMETER WITH THE DRILL BIT. Clean all aluminum chips from the case. The transmission must be thoroughly cleaned and all burrs removed from the drilled hole before reassembly. Install the drive sprocket support and torque the four torx® head bolts to 24 N-m (18 ft-Ibs.). Install a new converter oil seal (Part Number 8637906 for 2 245 mm converter or 8631950 for a 254 mm converter) into the case. Use Tool No. J-28540. Install the drive link assembly. Install the transmission case cover. Torque all bolts to 24 Nem (18 ft-lbs.). Connect the rod and retainer assembly to the manual valve. Install the control valve assembly, spacer plate and gaskets, placing the check balls in their proper locations. Torque all valve body to case cover attaching bolts to 11 N-m (B ft-Ibs.], and all valve body 10 case attaching bolts to 24 N-m (18 ft-Ibs.). Connect the wire assembly to the electrical connector. Install the throttle lever and bracket assembly. Install the valve body cover and gasket (or R.T.V, sealant]. Torque all bolts to 16 N-m (12 ft-lbs.) AS VIEWED FROM OPPOSITE SIDE Figure 2 92C4 ATSG Technical Service Information Model: All THM 125 & BURNED BAND © =«: When diagnosing a burnt band and direct clutch condition, a possible cause might be a third accumulator check valve not seating properly. This allows the intermediate band to drag while the direct clutch is applied causing excessive friction. When servicing THM 125 and 125C transmissions for a burnt band and direct clutch condition, order service package 8643964, which contains a new dual land third accumulator check valve and a conical spring, then refer to the following procedure. Service Procedure 1. Remove the intermediate servo cover and gasket. 2. Remove the third accumulator check valve and spring. 3. Inspect the third accumulator valve bore for presence of the valve seat (Figure 1). Also, inspect for wear or damage to the seat. Plug the feed and exhaust holes in the bore using petrolatum (Figure 1) . Replace the third accumulator check valve with a dual land check valve. Center the valve so as to seat it properly. 6. Leak test the valve seat by pouring solvent into the accumulator check valve bore. Check for a leak on the inside of the case. (A small amount of leakage is acceptable.) 7. If the valve leaks, tap the valve with a brass rod and rubber mallet, to try to re-seat the valve. 8. Re-leak test the valve seat. 9. If the valve continues to leak, it will be necessary to replace the case. 10. If the vaive doesn’t leak, remove the check valve and install the new conical valve spring onto the valve (small end first). Install the valve into the case bore (Figure 2). 11, Install the servo gasket and cover. (Do Not Use Old Gasket.) All THM 125 and 125C transmissions being serviced for a burnt band and direct clutch condition must have the new dual land third accumulator check valve and conical spring installed. For further causes of a burnt band and direct clutch condition, refer to Hydra-matic Service Bulletin +#81-22 as well as the Service Manual, 1D ACCUMULATOR, CHECK VALVE 3RD ACCUMULATOR CHECK VALVE NICAL SPRING FEED HOLE TOP PASSAGE cur PLUG RI RELEASE HOLE ' cabin VALVE SEAT BOTTOM Figure 1 Figure 2ATSG| Technical Service Information BURNED FORWARD CLUTCH Subject: Diagnosing a Burned Forward Clutch (Loss of Drive) Model 1982 THM 125 & 125C When determining the cause of a burned forward clutch in any 1982 THM 125 or 125C transmission, be certain to check the forward clutch housing for cracks as follows: ‘Air check the assembled clutch housing using approximately 30 psi, and watch for leaks at the areas shown in Figure 1. If a leak is found, replace the forward clutch housing. If no eracks are evident, check the following items: 1. Check for missing or damaged seal rings on the input shaft. 2. Check for a missing or damaged input shaft thrust washer. 3. If the forward clutch contains a ball capsule, check it for damage or improper sealing. 4, Check the backing plate for correct instalation. 5, Disassemble the clutch and air check the input shaft feed passage for restrictions or blockage. 6. Check the piston lip seals for cuts or damage. 7. Check all the surfaces which the seals contact for nicks or scratches, for example piston pocket and driven sprocket support sleeve. If no cause is found, refer to Service Manual for further diagnosis. After finding the cause of a burned clutch, reassemble the clutch replacing any worn or damaged parts. Then air check the clutch again and check for leaks. Properly diagnosing the cause of a burned clutch will prevent a later reoccurrence of the same con« AUTOMATIC TRANSMISSION SERVICE GROUP 94Technical Service Information ‘To air check housing without checkball: use an air nozzle to apply 30 PSI air through hole #7, When air nozzle i removed from hole #1 pressure will exhaust. ‘To air check housing with checkball: cover hole #1 with thumb and apply 30 PSI air through checkball #2. CHECK FOR CRACKS IN THESE AREAS Figure 1 AUTOMATIC TRANSMISSION SERVICE GROUP 95@4ATSG Technical Service Information DIESEL WIRING Subject: Wiring Diagram for 1982 THM 125C Diesel Model 1982 THM 125C ‘The wiring diagram for all 1982 THM 125C transmissions used with a diesel engine is shown below. Please use Figure 1 to update your 1982 Service Manual. ELECTRICAL 7ERNOR IRESSURE SWITCH ‘o) Se waite neoqiire BLACK ay Figure 1 AUTOMATIC TRANSMISSION SERVICE GROUP 96