light CHEVROLET CAMARO 1967 1.G Chassis Manual Online

CLUTCH AND TRANSMISSIONS 7-14

SPEED HEAVY DUTY TRANSMISSION

(WARNER MODEL T 16)

INDEX

General Description ......

Maintenance and Adjustments

Shift Linkage Adjustment

Side Cover ........

Removal .........

Disassembly
7-14

7-14

7-14

7-14

7-14

7-14
Assembly 7-14

Installation • 7-15

Other Maintenance
&
Adjustment

Operations See 3-Speed Saginaw Section

Transmission Replacement . . . See 3-Speed Saginaw Section

GENERAL DESCRIPTION

The Borg-Warner heavy duty three speed fully syn-

chronized (all forward gears) transmission incorporates

helical gears throughout specially designed to provide

high torque capacity, and gear teeth proportion to operate

at high speeds with neither excessive heat generation nor

excessive frictional losses. Shafts, bearings, high ca-

pacity clutches and other precision parts are held to

close limits providing proper clearances necessary for

durability during extended heavy usage.

The main drive gear is supported by a heavy duty ball

bearing at the front end of the transmission case and is

piloted at its front end in an oil impregnated bushing

mounted in the engine crankshaft. The front end of the

mainshaft is piloted in a row of roller bearings set into

the hollow end of the main drive gear and the rear end

is carried by a heavy duty ball bearing mounted in the

front of the extension housing.

The countergear is carried on a double row of rollers

at both ends while thrust is taken on thrust washers lo-

cated between the ends of the gear and the thrust bosses

in the case. An anti-rattle plate assembly at the front
of the countergear provides a constant spring tension be-

tween the counter and clutch gears to reduce torsional

vibrations. The reverse idler gear is carried on 25

roller bearings while thrust is taken on thrust washers

located between the ends of the gear and the thrust bosses

of the case.

Gear shifting is manual through shift control rods from

the shifter tube in the mast jacket to the rearward shift

lever of the side cover assembly for first and reverse

gear; and through a cross shaft assembly attached to the

forward side cover lever for second and third gear. All

three forward gears are fully synchronized. The syn-

chronizer assemblies consist of a clutch hub, clutch

sleeve, two clutch key springs and three energizer clutch

keys and are retained as an assembly on the main shaft

by a snap ring. The transmission may be used as an aid

in deceleration by downshifting in sequence without

double-clutching or any gear clashing. Reverse is not

synchronized, however, it is a helical gear to insure

quiet operation.

MAINTENANCE AND ADJUSTMENTS

Refer to similar procedures under the 3-speed Saginaw

Transmission Section for—Column Mounted Shift Linkage

Adjustment, Speedometer Driven Gear and Oil Seal Re-

placement, Extension Oil Seal Replacement and Trans-

mission Replacement. ~~

Camaro and Corvette Floor Shift Linkage Adjustment

(Fig.
lc)

1.
Set Lever (L), (K) in neutral position.

2.
Move Lever Assembly (A) and Levers (C), (D) to

neutral position and insert Locating Gauge (B) into

control Lever Bracket Assembly.

3.,
Install Rod (H) with Retainer (M) on Lever (L).

4.
With two Jam Nuts (G), (E) and Swivel (F) loose on

Rod (H) insert and attach Swivel with Retainer (N)

to Lever (D).

5.
Repeat steps 3 and 4 for Rod (J) and Levers (C
&
K).

6. Remove' Locating Gauge and check shift to insure

proper operation.

SIDE COVER ASSEMBLY

Removal

1.
Drain transmission and disconnect control rod and

cross shaft from side cover levers. *

2.
Remove nine cap screws securing the transmission

side cover assembly to transmission, case and re-

move cover assembly, shifting forks, and gasket.
Disassembly (Fig. 2C) '

1.
Remove shifting forks from shift lever assemblies.

2.
Remove nut and lock washer from each shift lever

shaft.

3.
Remove outer shift levers and lightly tap shift lever

shafts from assembly.

4.
Remove two steel balls, poppet spring, interlock pin

and interlock sleeve from cover.

5.
Remove "O" ring seals from shift lever shafts.

Assembly (Fig. 2C)

1.
Install new "O" ring seals to shift lever shafts.

2.
Install low and reverse shifter shaft and plate as-

sembly to cover.

3.
Place shifter shaft and plate assembly in neutral po-

sition, middle detent, and install interlock sleeve,

ball, poppet spring and interlock pin.

4.
Install remaining poppet ball and then install second

and third shifter shaft and plate assembly.

NOTE: Installation is easiest if shifter shaft

and plate assembly passes over ball in its neu-

tral position.

5.
Check clearance between end of interlock sleeve and

shifter shaft and plate cams when one plate is in

neutral and the other is shifted into gear position.

CHEVROLET CHASSIS SERVICE MANUAL

CLUTCH AND TRANSMISSIONS 7-24

is at the full mark on the dip stick, it is just slightly be-

low the planetary gear unit. If additional oil is added,

bringing the oil level above the full mark, the planetary

unit will run in the oil, foaming and aerating the oil. This

aerated oil carried through the various oil pressure pas-

sages (low servo, reverse servo, clutch apply, converter,

etc.) may cause malfunction of the transmission assem-

bly, resulting in cavitation noise in the converter and

improper band or clutch application. Overheating may

also occur.

If the transmission is found consistently low on oil, a

thorough inspection should be made to find and correct

all external oil leaks.

PERIODIC OIL CHANGE

The transmission oil should be changed periodically as

recommended in Section 0, and whenever transmission is

to be removed from the vehicle for repairs.

1.
Run engine for one minute in neutral prior to chang-

ing.

2.
Be sure vehicle is level or raise from the rear only.

3.
Remove the oil pan drain plug and allow oil to drain

thoroughly into a pan or can.

Replace drain plug and refill with approximately two

quarts of oil specified in Section 0.

NOTE: To refill the transmission, remove dip

stick from oil filler tube and refill transmission

with oil specified in Section 0 using filler tube

and funnel J-4264. Then, after shifting into all

ranges at idle speed to fill all oil passages, the

engine should be run at 800-1000 rpm with the

transmission in Neutral until the oil warms up,

then add oil as required to raise the fluid level

to the full mark on the dip stick. Refill capacity

is approximately 2 qts.
4.

Fig.
1PG - Adjusting Low Band Using J-21848
PERIODIC LOW BAND ADJUSTMENT (Fig. 1PG)

Low band adjustment should be periodically performed

at 12,000 mile intervals, or sooner, as necessary if op-

erating performance indicates low band slippage.

1.
Raise vehicle and place selector lever in neutral.

2.
Remove protective cap from transmission adjusting

screw.

3.
a. On Corvette Models: Drop left exhaust pipe for

clearance.

b.
On Chevelle Models: To gain clearance between

underbody and transmission, it may be necessary

to remove rear mount bolts from crossmember,

and move transmission slightly toward passenger

side of vehicle. .

4.
Loosen adjusting screw lock nut 1/4 turn and hold in

this position with wrench.

5.
Using Special Tool J-21848 adjust band to 70 in. lbs.

and back off four (4) complete turns for a band which

has been in operation for 6,000 miles or more,.or

three (3) turns for one in use less than 6,000 miles.

CAUTION: Be sure to hold the adjusting screw

lock nut at 1/4 turn loose with a wrench during"

the.adjusting procedure.

6. Tighten the adjusting screw lock nut to specified

torque.

CAUTION: The amount of back-off is not an

approximate figure, it must be exact.

MANUAL SHIFT LINKAGE CHECK & ADJUST

(Column Type)

1.
The shift tube and lever assembly must be free in the

mast jacket. See Section 9 for alignment of steering

column assembly if necessary.

2.
To check for proper shift linkage adjustment, lift

the transmission selector lever towards the steering

wheel. Allow the selector lever to be positioned in

drive (D) by the transmission detent.

NOTE: Do not use the indicator pointer as a

reference to position the selected lever. When

performing linkage adjustment, pointer is ad-

justed last.

3.
Release the selector lever. The lever should be in-

hibited from engaging low range unless the lever is

lifted.

4.
Lift the selector lever towards the steering wheel,

and allow the lever to be positioned in neutral (N) by

the transmission detent.

5.
Release the selector lever. The lever should now

be inhibited from engaging reverse range unless the

lever is lifted.

6. A properly adjusted linkage will prevent the selector

lever from moving beyond both the neutral detent, and

the drive detent unless the lever is lifted to pass

over the mechanical stop in the steering column.

7.
In the event that an adjustment is required, place

the selector lever in drive (D) position as determined

by the transmission detent. See Steps 2 and 3.

8. Loosen the adjustment swivel at the cross-shaft,

and rotate the transmission lever so that it contacts

the drive stop in the steering column.

9. Tighten the swivel and recheck the adjustment. See

2 and 6.

CHEVROLET CHASSIS SERVICE MANUAL

CLUTCH AND TRANSMISSIONS
7*30

V-8 Models-With Uni-Directional Linkage

1.
Remove air cleaner.

2.
Disconnect accelerator linkage at carburetor.

3.
Disconnect accelerator return and TV rod return

springs.

4.
With right hand, pull TV upper rod forward until

transmission is through detent. With left hand, open

carburetor to wide open throttle position. Carbure-

tor must reach wide open throttle position at the

same time the ball stud contacts end of slot in upper

TV rod.

5. Adjust swivel on end of upper TV rod to obtain set-

ting described in Step 4. Allowable tolerance is

approximately 1/32".

6. Connect and adjust accelerator linkage as described

in Section 6.

7. Check for throttle linkage freedom.

Neutral Safety Switch Adjustment

The adjustment at the neutral safety switch is de-

scribed in the Electrical Section 12.

Throttle Return Check Valve (Dashpot) Adjustment

The adjustment of the throttle return check valve is

described in Section 6M for each carburetor installation.
Fig.
12PG - Floor Mounted Control Lever and

Bracket Assembly (Chevrolet Shown)

COMPONENT PARTS REPLACEMENT

TRANSMISSION REPLACEMENT (EXC. CORVETTE)

Removal

1.
Raise car on hoist (preferably) or on stand jack and

remove oil pan drain plug to drain oil.

NOTE:
If desired, the oil may be drained after

transmission removal.

2.
Disconnect the oil cooler lines (external cooled

models), vacuum modulator line and the speedometer

drive cable fitting at the transmission. Tie lines

out of the way.

3.
Disconnect manual and TV control lever rods from

transmission.

4.
Disconnect propeller shaft from transmission.

5. Install suitable transmission lift equipment to jack

or other lifting device and attach on transmission.

6. Disconnect engine rear mount on transmission ex-

tension, then disconnect the transmission support

crossmember and slide rearward.

7. Remove converter underpan, scribe flywheel-con-

verter relationship for assembly, then remove the

flywheel-to-converter attaching bolts.

NOTE:
The "light" side of the converter is

denoted by a "blue" stripe painted across the

ends of the converter cover and housing. This

marking should be aligned as closely as possible

with the "white" stripe painted on the. engine

side of the flywheel outer rim (heavy side of

engine) to maintain balance.

8. Support engine at the oil pan rail with a jack or other

suitable brace capable of supporting the engine

weight when the transmission is removed.
9. Lower the rear of the transmission slightly so that

the upper transmission housing-to-engine attaching

bolts can be reached using a universal socket and a

long extension. Remove upper bolts.

CAUTION: Oh V-8 engines, care must be taken

not to lower rear of transmission too far as the

distributor housing may be forced against the

dash causing damage to the distributor. It is

best to have an assistant observe clearance of

all upper engine components while the trans-

mission rear end is being lowered.

10.
Remove remainder of transmission housing-to-

engine attaching bolts.

11.
Remove the transmission by moving it slightly to the

rear and downward, then remove from beneath the

car and transfer to a work bench.

NOTE:
Observe converter when moving the

transmission rearward. If it does not move

with the transmission, pry it free of flywheel

before proceeding.

CAUTION: Keep front of transmission upward

to prevent the converter from falling out. Install

converter Tool J-9549 (or a similar tool con-

structed as shown in Figure 13PG, or, in an

emergency, a length of strong wire may be used)

immediately after removal from the engine.

Installation

NOTE:
The "light" side, of the converter is

denoted by a "blue" stripe painted across the

ends of the converter cover and housing. This

marking should be aligned as closely as possible

CHEVROLET CHASSIS SERVICE MANUAL

CLUTCH AND TRANSMISSIONS 7-32

21.
Remove transmission output shaft slip yoke and in-

sert a plastic shipping plug in end of extension to

prevent spillage of transmission fluid.

NOTE:
The yoke is removed to avoid tearing

the heat reflecting pad on the underbbdy, when

the transmission is being removed.

22.
Remove bright metal ignition shielding from dis-

tributor area.

23.
Remove the transmission dip stick and tube

assembly.

24.
Disconnect transmission vacuum modulator line at

distributor advance line tee.

25.
Position transmission hoist under transmission and

attach safety chain to transmission.

26.
Remove transmission converter housing-to-engine

attaching foolts and slide transmission rearward.
NOTE:
Observe converter when moving trans-

mission rearward. If converter does not move

with the transmission, pry it free of flywheel

before proceeding.

27.
Install converter retaining strap.

28.
Lower and remove transmission from vehicle by

tilting the front down and to the right while inter-

mittently lowering the transmission to facilitate its

• removal.

29.
Reinstall transmission assembly by performing the

above steps in reverse order.

Bolt Torques

Transmission Case to Flywheel

Housing Bolts 35 ft. lbs.

Converter to Flywheel Bolts. . , . . 35 ft. lbs.

OTHER SERVICE OPERATIONS

Although certain operations, such as oil pan or gasket

replacement, valve body, governor, filler pipe "O" ring,

speedometer drive gear, case extension "0" ring and

rear oil seal, vacuum modulator, and servo cover or

gasket service may be performed from underneath the
vehicle without removing the Powerglide; their service

procedure is covered in the Passenger Overhaul Manual

and is not repeated here. Refer to the- Powerglide Sec-

tion of the Passenger Overhaul Manual for all other

service operations not covered here.

DIAGNOSIS

Proper operation of the Powerglide transmission may

be affected by a number of factors, all of which must be

considered when trouble in the unit is diagnosed.

Proper trouble diagnosis can only be accomplished

when performed in a thorough step by step procedure.

The following procedure has been devised and tested and

is recommended for all trouble diagnosis complaints and

if the service man will follow this checking procedure,

accurate and dependable diagnosis may be accomplished.

This will result in a savings of time, not only to the

service man, but to the customer as well.

WARMING UP TRANSMISSION

Before attempting to check and/or correct any com-

plaints on the Powerglide transmission it is absolutely

essential that the oil level be checked and corrected if

necessary. An oil level which is either too high or too

low can be the cause of a number of abnormal conditions

from excessive noise to slippage in all ranges.

It must be remembered that cold oil will slow up the

action of the hydraulic controls in the transmission. For

this reason a trouble or oil leak diagnosis should not be

attempted until the transmission has been warmed up by

either of the following procedures:

Shop Warm Up

1.
Connect tachometer to engine.

2.
Set parking brake tight and start engine.

3.
Place selector light in
"D"
(drive) range.

4.
Adjust carburetor idle speed adjusting screw to run

engine at approximately 750 rpm and operate in this

manner for two minutes. At the end of two minutes

of operation, the transmission will be sufficiently

warmed up for diagnosis purposes.
NOTE:
At this point, readjust the engine idle

speed to 450-475 rpm in
"D"
range.

Road Warm Up

Drive the car approximately 5 miles with frequent

starts and stops.

NOTE:
At this point, make sure the engine idle

speed is set to 450-475 rpm in
"D"
range.

CHECKING FLUID LEVEL AND CONDITION

After transmission has been warmed up, check the

fluid level with the engine idling, parking brake set and

control lever in "N" (neutral). If the fluid level is low,

add fluid to bring level up to the full mark on gauge rod,

CAUTION: If fluid level is too high, fluid may

be aerated by the planet carrier. Aerated fluid

will cause turbulence in the converter which will

result in lost power, lower stall speed and lower

pressures in control circuits. Lower fluid level

to full mark, then shut off engine to allow air

bubbles to work out of fluid.

When checking oil level, aburned smell and discolora-

tion indicate burned clutches or bands and the transmis-

sion will have to be removed.

MANUAL LINKAGE

Manual linkage adjustment and the associated neutral

safety switch are important from a safety standpoint.

The neutral safety switch should be adjusted so that the

engine will start in the Park and Neutral positions only.

With the selector lever in the Park position, the park-

ing pawl should freely engage and prevent the vehicle

CHEVROLET CHASSIS SERVICE MANUAL

CLUTCH AND TRANSMISSIONS 7-33

from rolling. The pointer on the indicator quadrant

should line up properly with the range indicators in all

ranges.

OIL LEAKS

Before attempting to correct an oil leak, the actual

source of the leak must be determined. In many cases

the source of the leak can be deceiving due to "wind flow1 f

around the engine and transmission.

The suspected area should be wiped clean of all oil

before inspecting for the source of the leak. Red dye is

used in the transmission oil at the assembly plant and

will indicate if the oil leak is from the transmission.

The use of a "black light"* to identify the oil at the

source of leak is also helpful. Comparing the oil from

the leak to that on the engine or transmission dip stick

(when viewed by black light) will determine the source

of the leak.

Oil leaks around the engine and transmission are gen-

erally carried toward the rear of the car by the air

stream. For example, a transmission "oil filter tube

to case leak" will sometimes appear as a leak at the

rear of the transmission. In determining the source of

an oil leak it is most helpful to keep the engine running.

The mating surfaces of servo cover, converter housing,

transmission case and transmission case extension

should be carefully examined for signs of leakage. The

vacuum modulator must also be checked to insure that

the diaphragm has not ruptured as this would allow trans-

mission oil to be drawn into the intake manifold. Us-

ually, the exhaust will be excessively smoky if the

diaphragm ruptures due to the transmission oil added to

the combustion. The transmission case extension rear

oil seal should also be checked. All test plugs should be

checked to make sure that they are tight and that there

is no sign of leakage at these points. The converter

underpan should also be removed. Any appreciable quan-

tity of oil in this area would indicate leakage at the pump

square seal ring, pump seal assembly, or pump bolt

sealing washers.

BASIC PRESSURE CHECKS

Four basic pressure checks are used for diagnosis and

operational checks for the Aluminum Powerglide trans-

mission. All checks should be made only after thoroughly

warming up the transmission.

• Wide Open Throttle Upshift Pressure.

• Idle Pressure in "Drive" Range.

• Manual "Low" Range Pressure.

• "Drive" Range Overrun (Coast) Pressure.

It is not recommended that stall tests be conducted

which would result in engine vacuum falling below 10" Hg.

Pressure gauge hose connections should be made at

the low servo apply (main line) test point (fig. 14PG).

Run the gauge line into the driving compartment by

pushing aside the mast jacket seal. The line out of the

way of the drivers feet and connect to pressure gauge

J-21867.

• Wide Open Throttle Upshift Pressure Check

Refer to the pressure check chart for upshift pressure
SERVO APPLY

PRESSURE

Fig.
14PG - Pressure Test Plug

points as indicated on the lower servo apply (main line)

gauge.

• Idle Pressure in "Drive" Range

In addition tp the oil pressure gauges, a vacuum gauge

is needed for this check.

With the parking brake applied and the shift selector

lever in "Drive", low servo apply (main line) pressure

should be as shown on the pressure check chart.

If pressures are not within these ranges, the following

items should be checked for oil circuit leakage:

1.
Pressure regulator valve stuck.

2.
Vacuum modulator valve stuck.

3.
Hydraulic modulator valve stuck.

4.
Leak at low servo piston ring (between ring and

bore).

5.
Leak at low servo piston rod (between rod and bore).

6. Leak at valve body to case gasket.

7.
Leak at valve body gaskets.

8. Front pump clearances.

9. Check passages in transmission case for porosity.

• Manual "Low" Range Pressure Check

Connect a tachometer, apply the parking brake, place

the selector lever in "Low" range, and adjust the engine

speed to 1000 rpm with the car stationary.

Low servo apply (main line) pressure should be as

shown on the pressure check chart.

Pressures not within this range can indicate the fol-

lowing possibilities:

1.
Partially plugged oil suction screen.

2.
Broken or damaged ring low servo.

CHEVROLET CHASSIS SERVICE MANUAL

CLUTCH AND TRANSMISSIONS 7-37

LI.
- LI Range can be selected at any vehicle speed,

and the transmission will shift to second gear

and remain in second until vehicle speed is re-

duced to approximately 40 MPH, .depending on

axle ratio. LI Range position prevents the trans-

mission from shifting out of first gear.
It is very important that any communication concerning

the Turbo Hydra-Matic always contain the transmission

serial number and that all transmission parts returned

to Chevrolet Motor Division always be tagged with the

transmission serial number.

MAINTENANCE AND ADJUSTMENTS

TRANSMISSION FLUID

Transmission fluid level should be checked with trans-

mission warm and selector lever in "P" Park position,

every time engine oil level is checked or as specified in

Section 0 when engine oil is changed.

CAUTION: Since the Turbo Hydra-Matic trans-

mission is very sensitive to oil level, special

precautions should be taken when checking the

oil level, to insure against an overfifE

Transmission fluid should be changed as specified in

Section 0.

FLUID LEVEL INDICATOR

The fluid level indicator is located in the filler pipe at

the right rear corner of the engine. To bring the fluid

level from the add mark to the full mark add 1 pint.

Fluid level should be to the full mark with transmission

at normal operating temperature. With cold fluid the

level should be at the add mark or slightly below.

SHIFT CONTROL LINKAGE ADJUSTMENT

Adjust linkage as shown below and in Figure 2.

1.
The shift tube and lever assembly must be free in the

mast jacket See Section 9 for alignment of steering

column assembly if necessary.

2.
To check for proper shift linkage adjustment, lift the

transmission selector lever towards the steering

wheel. Allow the selector lever to be positioned in

drive (D) by the transmission detent.

NOTE: Do not use the indicator pointer as a

reference to position the selector lever. When

performing linkage adjustment, pointer is ad-

justed last.

3.
Release the selector lever. The lever should be in-

hibited from engaging low range unless the lever is

lifted.

4.
Lift the selector lever towards the steering wheel,

and allow the lever to be positioned in neutral (N) by

the transmission detent.

5.
Release the selector lever. The lever should now be

inhibited from engaging reverse range unless the

lever is lifted.

6. A properly adjusted linkage will prevent the selector

lever from moving beyond both the neutral detent,

and the drive detent unless the lever is lifted to pass

over the mechanical stop in the steering column.

See schematic diagram.

7.
In the event that an adjustment is required, place the

selector lever in drive (D) position as determined by

the transmission detent. See Steps 2 and 3.

8. Loosen the adjustment swivel at the cross-shaft, and
rotate the transmission lever so that it contacts the

drive stop in the steering column.

9. Tighten the swivel and recheck the adjustment. See

Steps 2 and 6. -

l(h Readjust indicator needle if necessary to agree with

the transmission detent" positions. See Section 9.

11.
Readjust neutral safety switch if necessary to pro-

vide the correct relationship to the transmission de-

tent positions. See Section 12.

12.
When properly adjusted the following conditions must

be met by manual operation of the steering column

shift lever:

a. From reverse to drive position travel, the trans-

mission detent feel must be noted and related to

indicated position on dial.

b.
When in drive and reverse positions, pull lever

rearward (towards steering wheel) and then re-

lease. It must drop back into position with no

restrictions.

NEUTRAL SAFETY SWITCH ADJUSTMENT

The neutral safety switch must be adjusted so that the

car will start in the park or neutral position, but will not

start in the other positions. For replacement refer to

Section 12 of this Manual.

DRAINING AND REFILLING TRANSMISSION

Drain oil immediately after operation before it has had

an opportunity to cool.

To drain oil proceed as follows:

1.
Remove bottom pan attaching screws, pan, and gas-

ket.

2.
Remove oil strainer. Remove "O" ring seal from

pick-up pipe and discard.

3.
Discard strainer if dirty.

4.
Install new "O" ring seal on pick-up pipe and install

strainer and pipe assembly.

5.
Thoroughly clean bottom pan.

6.. Affix new gasket to bottom pan with petroleum jelly.

7.
Install bottom pan with attaching screws and torque

to specifications;

8. If only the pan has been removed, pour approximately

7-1/2 pints of fluid into the transmission. If the

valve body has also been removed use 9-1/2 pints.

After a complete overhaul approximately 19 pints

are required. Be sure container, spout, or funnel is

clean.

9. Start engine and let idle (carburetor off fast idle

step).
Place selector lever in P position and apply

hand brake.

10.
With transmission warm (approximately 150°F), add

fluid to bring level to full mark on indicator.

CAUTION: Do not overfill. Foaming will re-

sult.

CHEVROLET CHASSIS SERVICE MANUAL

CLUTCH AND TRANSMISSIONS 7-41

CAUTION: Use converter holding ToolJ-5384

when lowering transmission or keep rear of

transmission lower than front so as not to lose
converter.

The installation of the transmission is the reverse of

the removal.

TURBO HYDRA-MATIC DIAGNOSIS PROCEDURE

Accurate diagnosis of transmission problems begins

with a thorough understanding of normal transmission

operation. In particular, knowing which units are in-

volved in the various speeds or shifts so that the specific

units or circuits involved in the problem can be isolated

and investigated further. Analytical diagnosis will pro-

tect the technician from come backs and certainly will

improve owner satisfaction.

An important and often overlooked aspect of diagnosis

is finding out specifically what the customer is com-

plaining of. For this purpose a short ride with the cus-

tomer will often prove beneficial. It may be found that

the condition the customer wants corrected is standard

and should not be altered.

The following sequence, based on field experience, pro-

vides the desired information quickly and in most cases

actually corrects the malfunction without requiring the

removal of the transmission. Details of the items listed

in this sequence are covered further in the text.

SEQUENCE FOR TURBO HYDRA-MATIC

DIAGNOSIS PROCEDURE

1.
Check oil level and condition.

2.
Check and correct detent switch.

3.
Check and correct vacuum line and fittings.

4.
Check and correct manual linkage.

OIL LEVEL AND CONDITION CHECK

Always check the oil level before road testing. Oil

must be visible on dip stick prior to operating the ve-

hicle. Erratic shifting, pump noise, or other malfunc-

tions can in some cases be traced to improper oil level.

Oil level should be checked with the selector lever in

the Park (P) position, engine running, and the vehicle on

level pavement.

Fluid level should be to the FULL mark with the trans-

mission at normal operating temperature (170°-190°
F.).

With warm fluid (room temperature), the level should be

at or slightly below the ADD mark.

If oil level was low, refer to Oil Leaks.

The condition of the oil is often an indication of whether

the transmission should be removed from the vehicle, or

to make further tests. When checking oil level, a burned

smell and discoloration indicate burned clutches or bands

and the transmission will have to be removed.

MANUAL LINKAGE

Manual linkage adjustment and the associated neutral

safety switch are important from a safety standpoint

The neutral safety switch should be adjusted so that the

engine will start in the Park and Neutral positions only.

With the selector lever in the Park position, the park-

ing pawl should freely engage and prevent the vehicle

from rolling. The pointer on the indicator quadrant

should line up properly with the range indicators in all

ranges.
OIL LEAKS

Before attempting to correct an oil leak, the actual

source of the leak must be determined. In many cases,

the source of the leak can be deceiving due to "wind flow"

around the engine and transmission.

The suspected area should be wiped clean of all oil be-

fore inspecting for the source of the leak. Red dye is

used in the transmission oil at the assembly plant and

will indicate if the oil leak is from the transmission.

. The use of a "black light"* to identify the oil at the

source of leak is also helpful. Comparing the oil from

the leak to that on the engine or transmission dip stick

(when viewed by black light) will determine the source

of the leak.

Oil leaks around the engine and transmission are gen-

erally carried toward the rear of the car by the air

stream. For example, a transmission "oil filler tube to

case leak" will sometimes appear as a leak at the rear of

the transmission. In determining the source of an oil

leak it is most helpful to keep the engine running.

POSSIBLE POINTS OF OIL LEAKS

• 1. TRANSMISSION OIL PAN LEAK

a. Attaching bolts not correctly torqued.

b.
Improperly installed or damaged pan gasket.

c. Oil pan gasket mounting face not flat.

2.
REAR EXTENSION LEAK

a. Attaching bolts not correctly torqued.

b.
Rear seal assembly — damaged or improperly

installed.

c. Gasket seal — (extension to case) damaged or

improperly installed.

d. Porous casting.

3.
CASE LEAK

a. Filler pipe "O" ring seal damaged or missing;

misposition of filler pipe bracket to engine —

"loading" one side of
"O"
ring.

b.
Modulator assembly "O" ring seal
—
damaged or

improperly installed.

c. Governor cover, gasket and bolts — damaged,

loose; case face leak.

d. Speedo gear
—
"O" ring damaged.

e. Manual shaft seal — damaged, improperly in-

stalled.

f. line pressure tap plug — stripped, shy sealer

compound.

g. Parking pawl shaft cup plug
—
damaged, improp-

erly installed.

h. Vent pipe (refer to Item 5).

i. Porous case.

4.
FRONT END LEAK

a. Front seal - damaged (check converter neck for

nicks,
etc., also for pump bushing moved for-

ward);
garter spring missing from pump to con-

verter seaL

b.
Pump attaching bolts and seals
—
damaged, miss-

ing, bolts loose.

CHEVROLET a
SERVICE

FUEL TANK AND EXHAUST SYSTEMS 8-2

COMPONENT PART REPLACEMENT

FUEL TANK

Draining Tank

The absence of a drain plug in the gas tanks makes it

necessary to siphon fuel from the tank when draining is

needed. The following procedure is recommended.

1.
Obtain approximately 10 feet of 3/8" I.D. hose and

cut a flat-type slit 18" from one end. Make this cut

on the hose in the direction "toward the shorter end

(See Figure 2).

2.
Insert a small pipe nipple (slightly larger O.D. than

the hose I.D.) into the opposite end of hose.

3.
Insert the nipple end of the siphon hose into the fuel

tank filler neck with the natural curl of the hose

pointing down. Insert until the hose is heard to strike

bottom of the tank.

4.
With the opposite end of the hose in a suitable con-

taner insert an air hose in downward direction in the

flap-type slit and trigger the flow of fuel.
FUEL FLOW

-If*
APPROX.-1 >SUT «<>«
AS SHOWN

10 FEET APPROX.-

Fig. 2—Siphon Construction

FWD
V-8

VIEW B

Fig. 3-Fuel Lines

CHEVROLET CHASSIS SERVICE MANUAL

STEERING 9-6

Fig.
11
—Corvette Telescoping Wheel Option

5.

7.
NOTE:
If steering wheel only is to be replaced,

perform Step 5 below only. If directional signal

cancelling cam is to be replaced, omit Step 5

and proceed with Steps 6 and 7.

Remove six screws securing steering wheel to hub

and remove wheel.

Remove nut and washer from shaft and using steering

wheel puller Tool J-2927, remove steering wheel and

hub from vehicle.

Slide cancelling cam and spring off shaft.

Installation

NOTE:
Refer to torque specifications at rear of

manual for correct torque values.

1.
If necessary, slide cancelling cam and spring on end

of shaft.

2.
If hub was removed from steering wheel, attach hub

to steering wheel with screws removed during dis-

assembly.

3.
Place steering wheel and hub assembly in position

and secure to column with washer and nut.

4.
Position spacer on steering wheel.
5. Position lock knob on steering wheel.

6. Install lock screw through lock knob, turn into shaft,

and adjust to lock position.

7. Attach spacer to wheel with three screws.

8. Place lock knob in lock position and attach to lock

screw with two screws.

9. Remove three screws holding spacer. Attach horn

contact to spacer and steering wheel with three

screws.

10.
Install horn button cap.

11.
Connect steering column harness at chassis plug.

STEERING COUPLING (Fig. 12)

Removal

NOTE:
Chevy n models are equipped with a

clamp arrangement rather than the conventional

"rag joint" steering coupling. Refer to Steering

Gear - Chevy II, for service procedures.

1.
Remove nuts and washers securing steering coupling

to flanged end of steering column (fig. 12).

2.
Remove coupling clamp bolt (fig. 12) and slightly

spread coupling clamp.

CHEVROLET CHASSIS SERVICE MANUAL

STEERING 9-20

Fig.
40-Removing Pivot Pins Using Pivot Pin Removal Tool J-21854

13.
Pull up on tilt release lever to disengage lock shoes.

Remove bearing housing and hang with signal switch,

if present, until further disassembly. If signal switch

and wires were removed earlier, bearing housing

may be completely removed. Remove tilt release

lever.

14.
Remove steering shaft flange bolt and flange from

lower end of shaft.

15.
Remove retaining ring, washers, sleeve and plunger

assembly and spring from lower end of shaft.

16.
Slide steering shaft out of top end of jacket.

17.
If necessary to disassemble steering shaft, proceed

as follows:

a. Slide bearing and race off top of shaft.

b.
Turn upper shaft slightly from center line of

lower shaft.

c. Using a narrow blade screwdriver, work pre-

load spring out of upper shaft and remove spring

(fig. 41).

d. Turn upper shaft 90° from center line of lower

shaft and remove shaft.
e. Rotate centering spheres and remove spheres and

wave washer from lower shaft.

18.
Remove screws securing the support assembly to the

lockpjate and mast jacket and remove support.

19.
Remove shift tube retaining ring with a screwdriver.

Remove thrust washer (fig. 42).

20.
Remove lower bearing adapter from bottom of shift

tube by depressing plastic fingers, one at a time, and

pulling adapter out.

21.
Remove nuts securing back-up lamp, neutral start

switch to column, if so equipped, and remove switch.

Retain these mounting nuts.

22.
Remove shift tube assembly from bowl using shift

tube remover Tool J- 22551 (fig. 43). Insert the

hooked end of the tool into the notch of the shift tube

below the bowl key. Pilot sleeve into upper end of

shift tube. Force shift tube out of bowl by turning

SHIFT TUB

RETAINING RING

Fig.
41—Removing'Preload Spring from Centering Spheres
Fig. 42—Shift Tube Retaining Ring and Lower Bushing

CHEVROLET CHASSIS SERVICE MANUAL