1. For rebuild of these components, refer to SM1502EN, Automatic Electric Shift Compo-nents Rebuild Manual.
2. For testing of these automatic electric shift components, see Paragraphs 3–21e, f, and g.
6–5. SPG-CONTROL SHIFT SELECTOR
a. Disassembly (Foldout 35)
1. Remove four screws 44 that retain light socket plate assembly 39.
2. Carefully pull plate assembly 39 from shift se-lector body 6. If necessary, remove lamp 42 and sealring 43 from the socket.
3. If light socket plate assembly 39 or wiring is to be replaced, cut the heat-shrink tubing from the wire terminals and disconnect the plate assem-bly.
4. If resistor 40 (in 24V systems) requires re-placement, remove it.
5. Remove two screws 45 and lockwashers 46 that retain cover 47.
6. Remove sealring 48 and the cover.
7. Remove the heat-shrink tubing from the leads of wiring harness 29. Disconnect the leads.
8. Remove indicator support 58.
CAUTION:
Do not use liquid or vapor cleaning methods on any electrical components.
9. Remove screw 54 and lockwasher 55 that re-tain the cover.
10. Pull cover 56 from body 6. Remove the heat-shrink tubing from the power lead terminals.
Disconnect the terminals. Disconnect the fuse lead.
11. Remove fuse holder assembly 50 from cover 56 if replacement is necessary.
12. Remove three socket head screws 8 and lock-washers 9 that retain the body. Remove body 6 and its attached parts from mounting bracket 21.
13. Remove sealring 18 from mounting bracket 21.
Remove 4-pin connector 33 from body 6 if re-placement is necessary.
14. Remove nut 11 from pin 36. Remove pin 36 from rotary key 37. Remove handle 14 and knob 15 from rotary key 37. Remove leveler 2 and spring 3. Remove spacer plate 13, if present.
15. Push rotary key 37 from body 6. Remove seal-ring 12 from rotary key 37.
16. If bushing 10 requires replacement, press the bushing from body 6.
17. Remove four screws 26 and washers 25 that re-tain switch cover 24. Remove cover 24 and cover seal 23.
18. Loosen set screw 35 that retains drive adapter 16 on the switch shaft. Remove drive adapter 16. Remove shim(s) 17 from the switch shaft.
19. Disconnect all of the wiring harness leads from the switch assembly. Remove two screws 19 and washers 20 that retain microswitch assem-bly 22. Remove microswitch assemassem-bly 22. The microswitch assembly is not a serviceable as-sembly. If present, remove relay 7.
20. Remove 4-pin socket 34 if replacement is nec-essary.
21. Remove four screws 28 that retain wiring har-ness 30. Remove wiring harhar-ness 30 from mounting bracket 21.
22. Remove sealring 27 from wiring harness 30.
b. Assembly (Foldout 35) 1. If removed, install relay 7.
REBUILD OF SUBASSEMBLIES
2. If 4-pin socket 34 was removed from mounting bracket 21, install a new socket. Push the socket into the flat side of mounting bracket 21 until it is flush with the adjacent area. Note that the projection on the socket body indexes with a notch in the mounting bracket.
3. Install 11⁄2 inch sealring 27 over the wires and onto the shoulder of main wiring harness 30.
Insert the wires through the bottom of mount-ing bracket 21. Push 16-pin connector 30 into mounting bracket 21, with the index key to-ward the flat side of the mounting bracket. Re-tain the connector with four new 6-32 x 3⁄8 inch self-tapping screws 28.
4. Connect the electrical components as shown in Figure 6–14. Note the wiring diagram is for CAUTION:
Hand tighten all mating connectors. Use of tools will damage the components.
shift selectors with R-N-DR-5-4-3-2-1 se-quence. The view in the wiring diagram is at the front (mating side) of the socket, and the order of installation is counterclockwise.
5. Re-check the connections to make sure they are correct.
6. Install microswitch assembly 22 onto mounting bracket 21. Position microswitch assembly 22 on mounting bracket 21 so the microswitch num-bers (1 through 8) are not inverted. Retain mi-croswitch assembly 22 with two 6-32 x 3⁄4 inch screws 19 and washers 20. The screw holes in the switch assembly should be approximately midway in the elongated holes in the mounting bracket when the screws are tightened.
CAUTION:
Do not use acid or acid-core solder. Use only rosin-core solder.
Figure 6–14. Automatic-Electric Shift Selector Assembly (Selectors With R-N-DR-5-4-3-2-1 Sequence) 1
5600, 5800, 5900, 6000, 6600 SERIES TRANSMISSIONS
7. Follow the wiring diagram (Figure 6–14) to connect the wiring harness leads to the switch assembly.
8. Install one shim 17, darker side first, onto the switch shaft. More shims may be required.
This will be determined in Step (11).
9. Install drive adapter 16. Position the adapter lightly against mounting bracket 21 and tighten set screw 35 against the flat on the switch shaft.
10. If bushing 10 was removed from selector body 6, press a new bushing 10 into body 6 until it is flush with the hub of the body. Hone or ream the bushing bore until rotary key 37 will fit the bore and can be rotated with finger torque only.
Install rotary key 37 (without sealring 12). In-stall shift selector body 6 onto mounting bracket 21, engaging the tongue of drive adapter 16 with the slot in rotary key 37. Re-tain body 6 with three 5⁄16-18 x 5⁄8 inch socket head screws 8 and lockwashers 9.
11. Using a gauge, determine the end play of ro-tary key 37. If the end play exceeds the thick-ness of one shim 17, remove the selector body and drive adapter and install an additional shim (or more, if required). Shims must not hinder rotary actuation of the rotary key and mi-croswitch.
12. When shim adjustment is completed, remove selector body 6 to complete assembly.
NOTE:
For assembly of shift selector components use Tex-aco Marfak® No. 2 or equivalent grease.
13. Install the 9⁄16 inch sealring 12 into the groove of rotary key 37. Lubricate rotary key 37 and sealring 12 lightly with grease. Put a small quantity of grease into the spring recess of the rotary key. Coat spring 3 and leveler 2 lightly with grease, and install them into rotary key 37.
Install knob 15 and handle 14 (and spacer plate 13, if used) into the slot of rotary key 37. Push threaded pin 36 through the holes in the rotary key and handle 14 (and spacer plate 13, if used). Secure the pin with nut 11. Tighten the nut only enough to eliminate end play of the pin. Do not bind the movement of the handle in rotary key 37.
14. Install 4-pin connector 33 into shift selector body 6. Push the connector into the mounting face of the body until it is flush with the adja-cent area. Note there is a projection on the con-nector body that indexes with a notch in the shift selector body for angular alignment of the connector.
15. Install the 211⁄16 inch sealring 18 onto mounting bracket 21.
16. Install the assembled body section of the shift selector assembly onto the assembled switch section. Install three 5⁄16-18 x 5⁄8 inch socket head screws 8 and lockwashers 9 to retain the two sections.
17. Install fuse holder 50 into body cover 56. Re-tain it with nut 53. Connect the fuse lead (Fig-ure 6–14) to the single lead of the fuse holder.
Connect the power lead to the lead of the fuse holder.
18. Install cover 56 onto body 6. Retain the cover with one 1⁄4-20 x 1 inch screw 54 and lock-washer 55.
19. If necessary, install a new indicator 57 onto in-dicator support 58. Install the inin-dicator support onto body cover 56.
20. Install a 21⁄8 sealring 48 and cover 47. Retain the cover with two 1⁄4-20 x 11⁄2 inch screws 45 and lockwashers 46.
21. With cover 47 installed, check the shift handle for freedom of movement in both upshift and downshift directions.
22. Attach any leads to the proper wiring harnesses and insulate each connection with a short length of heat-shrink tubing (Figure 6–14).
23. Replace lamp 42, sealring 43, and resistor 40 if needed, in light socket plate assembly 39.
Connect the lead on the plate assembly with the remaining free lead in the shift selector assembly and insulate the connection with heat-shrink tubing.
24. Install light socket plate assembly 39, being careful that wires do not touch the lamp. Retain the plate assembly with four 6-32 x 3⁄8 inch screws 44.
25. Install an SFE 9A fuse 49 into the fuse holder.
26. Check the circuitry and operation of the shift se-lector assembly as outlined in Paragraph 3–21.
REBUILD OF SUBASSEMBLIES
27. Install cover seal 23 and switch cover 24. Re-tain cover 24 with four 10-24 x 5⁄8 inch screws 26 and washers 25.
6–6. SPG-CONTROL THROTTLE POTENTIOMETER
NOTE:
For testing refer to Paragraph 3–21c.
a. Disassembly (Foldout 34) 1. Loosen clamp bolt 11.
2. Remove four screws 17. Rotate seal 12 coun-terclockwise (viewed from lever end of assem-bly) until it is free of potentiometer and coupling assembly 14.
3. Remove Items 14 through 19 as a unit. This will free lever 10 and seal 12. Remove lever 10 and seal 12. Remove spacer 19 from assembly 14.
Potentiometer and coupling assembly 14 is not a serviceable assembly. Do not attempt to make an adjustment within assembly 14.
4. Remove four screws 18. Separate potentiome-ter and coupling assembly 14, gasket 15, and cover 16.
5. Remove bearing 21 from housing 20 if replace-ment is necessary.
6. Remove sealring 13 from seal 12.
b. Assembly (Foldout 34)
1. Install bearing 21. Press it into housing 20 until flush with the bottom of the counterbore (at the lever end of the assembly).
2. Assemble spacer 19, potentiometer and cou-pling assembly 14, gasket 15, and cover 16, and secure them with four 4-40 x 5⁄16 inch screws 18.
3. Install the potentiometer shaft into housing 20, placing seal 12 (with new sealring 13 installed) and lever 10 on the shaft when the shaft ex-tends through the housing.
4. Thread seal 12 onto the potentiometer threads, guiding the pin of the potentiometer into a matching hole in housing 20.
5. Tighten seal 12. Install four 10-24 x 7⁄16 inch screws 17.
6. Center lever 10 on the shaft in the available space between bearing 21 and seal 12.
7. Using needle-nosed pliers between lever 10 and bearing 21, tighten 1⁄4 -20 x 3⁄4 inch bolt 11 until an adjustment is reached that will give a resis-tance reading of 275 Ohms at the full throttle position (refer to Paragraph 3–21c).
6–7. ELECTRONIC-CONTROL SHIFT SELECTOR — LEVER-TYPE
NOTE:
• All the screws in this assembly are patchlock screws. When removing the screws, check the pre-vailing torque. Compare the actual prepre-vailing torque with the chart on Foldout 36,A to determine if new screws will be required at assembly.
• Disassemble the shift selector only to the extent necessary for access to replacement parts (e.g., housing cover does not need to be removed to re-place lamps).
a. Disassembly (Foldout 36,A)
1. Place the shift selector lever in the central posi-tion (fifth or second range) (Figure 6–15).
2. Remove selector lever end cap cover 36.
3. Remove four 6-32 x 5⁄8 inch screws 1 from bezel 2.
NOTE:
If the bezel is being removed only to access the lamps or to replace the legend or cover, skip Step (4). Removal of the bezel requires slight spreading to slide it off the lever and end cap.
4. Lift the bezel up to the lever end cap, then turn the bezel 90 degree to remove it (Figure 6–16).
5. Remove two 6-32 x 1⁄2 inch screws 3 from the legend cover. Remove legend cover 5 and gas-ket 7. Remove legend strip 6 from the cover only if replacement is necessary.
Figure 6–15. Typical Lever Shift Selector
Figure 6–16. Removing Bezel
6. To replace lamps 20, pull the burnt-out lamps straight out of the sockets (in the removal pro-cess, the lamps may be destroyed).
7. If the shift latch cover needs to be replaced, break away both half-covers 31 and remove pin 30.
8. Remove two 6-32 x 5⁄16 inch screws 35 and end cap 34. Remove spring 33 and rod 32.
9. Remove nine 6-32 x 3⁄8 inch flat head screws 9 from housing cover 10. Remove cover 10 and gasket 11.
10. Do not remove bearing 12 from inside of cover 10 unless the bearing is damaged.
H00930.01
END CAP COVER SELECTOR LEVER
BEZEL
SCREW (4), 6-32 x 5⁄8 in.
H00931.01
SELECTOR LEVER
BEZEL SCREW (2),
6-32 x 1⁄2 in.
GASKET LEGEND STRIP
LEGEND COVER
END CAP
NOTE:
To remove magnet holder and range indicator as-sembly 14, roller 13 must be removed. If roller 13 is not exposed enough to grip it with pliers, grip the shift selector and lever assembly and squeeze the le-ver against the selector body to release the force from roller 13. If end cap 34 has not been removed, to gain access to roller 13, it may also be necessary to lift upward on the shift latch to release the force from spring 33 and rod 32.
11. Being careful not to damage the electrical con-nector at the base of the selector body, bump the selector assembly against the work table to expose roller 13 enough to grip the roller with pliers. Remove roller 13.
12. Remove magnet holder and range indicator as-sembly 14 from shaft 18 while removing selec-tor lever 29 along with attached parts from the other side.
13. If replacement is necessary, remove two 6-32 x
3⁄8 inch screws 15 and range indicator 16 from magnet holder assembly 17.
14. Remove two 6-32 x 1⁄2 inch screws 22, spring backplate 24, and spring 26.
15. Using a pin punch, drive out roller 27. Remove shaft 18.
16. Do not remove bearing 19 unless it is damaged.
NOTE:
Before removing screws 28 and cam stops 25, note and record the location of screws 28 so that the same location of cam stops 25 can be maintained at as-sembly.
17. Remove six 6-32 x 3⁄8 inch screws 28 and two cam stops 25.
18. Remove three 8-32 x 7⁄16 inch screws 23 and detent plate 21.
19. Do not attempt any further disassembly of the shift selector body or electronic components.
b. Assembly (Foldout 36,A)
1. Install detent plate 21, flat side first, and se-cure it with three 8-32 x 7⁄16 inch screws 23.
Begin to tighten screws 23. Prevailing torque must be no greater than 12 lb in. (1.4 N·m). If prevailing torque of screws 23 is greater than 12 lb in. (1.4 N·m), remove screws 23 and get new ones. Tighten screws 23 to 33–41 lb in.
(3.7–4.6 N·m).
2. Install two cam stops 25 and six 6-32 x 3⁄8 inch screws 28 in the same locations from which they were removed. Begin to tighten screws 28.
Prevailing torque must be no greater than 8 lb in. (0.9 N·m). If prevailing torque of screws 28 is greater than 8 lb in. (0.9 N·m), remove screws 28 and get new ones. Tighten screws 28 to 11–15 lb in. (1.3–1.7 N·m).
3. If removed, install bearing 19. Lubricate the ID of bearing 19 with Lubriplate®.
4. Install shaft 18, round end into selector lever base and flat side downward. Install roller 27 to retain shaft 18 in base of selector lever. Tap the roller to 0.050 inch (1.27 mm) above the sur-face at both ends of the roller.
5. Install spring 26, raised dimple outward. In-stall backplate 24 and two 6-32 x 1⁄2 inch screws 22. Begin to tighten screws 22. Pre-vailing torque must be no greater than 8 lb in.
(0.9 N·m). If prevailing torque of screws 22 is greater than 8 lb in. (0.9 N·m), remove screws 22 and get new ones. Tighten screws 22 to 11–15 lb in. (1.3–1.7 N·m). Lubricate spring 26 with Lubriplate®.
6. Lubricate center bore seal, shaft 18, and detent plate 21 with Lubriplate®.
7. Install range indicator 16, bent tab outward, onto magnet holder assembly 17. Install two 6-32 x 3⁄8 inch screws 15. Begin to tighten screws 15. Prevailing torque must be no greater than 8 lb in. (0.9 N·m). If prevailing torque of screws 15 is greater than 8 lb in. (0.9 N·m), remove screws 15 and get new ones. Tighten screws 15 to 19–23 lb in. (2.1–2.6 N·m).
8. Hold magnet holder and range indicator assem-bly 14 in place.
9. Install selector lever 29, along with attached parts, carefully guiding shaft 18 through center bore seal, bearing 19, and magnet holder as-sembly 17.
NOTE:
To retain shaft 18 and magnet holder assembly 17, roller 13 must be installed. If the pin hole in shaft 18 is not aligned well enough to install roller 13, grip the shift selector and lever assembly and squeeze the lever against the selector body to align the holes.
If end cap 34 is in place, it may also be necessary to lift upward on the shift latch to release the force from spring 33 and rod 32.
10. Align the pin holes in the shaft and magnet holder and install roller 13. Tap the roller to 0.050 inch (1.27 mm) above the surface at both ends of the roller.
11. If removed, install bearing 12 into the bore on the inside of cover 10. Lubricate bearing 12 with Lubriplate®.
12. Install gasket 11. Install housing cover 10, guiding bearing 12 over the end of shaft 18.
13. Install nine 6-32 x 3⁄8 inch flat head screws 9.
Begin to tighten screws 9. Prevailing torque must be no greater than 8 lb in. (0.9 N·m). If prevailing torque of screws 9 is greater than 8 lb in. (0.9 N·m), remove screws 9 and get new ones. Tighten screws 9 to 19–23 lb in.
(2.1–2.6 N·m).
14. Lubricate rod 32 with Lubriplate®. Install rod 32 into lever 29. Install spring 33.
15. Install end cap 34 and two 6-32 x 5⁄16 inch screws 35 (Figure 6–17). Begin to tighten screws 35. Prevailing torque must be no greater than 5 lb in. (0.6 N·m). If prevailing torque of screws 35 is greater than 5 lb in. (0.6 N·m), re-move screws 35 and get new ones. Tighten screws 35 to 6–8 lb in. (0.7–0.9 N·m).
Figure 6–17. Replacement of Shift Latch Cover
16. If the shift latch cover was removed, install pin 30 and one half-cover 31 (Figure 6–17). Put the other half-cover in place using Loctite® Su-per Bonder (No. 495) to hold the two halves to-gether. Clamp the two halves together until the adhesive is dry.
17. For smooth operation, apply Lubriplate® to the lever where the shift latch moves.
18. Install new lamps 20 by pushing them straight into the sockets.
19. If removed, install a new legend strip 6 onto the underside of legend cover 5 (Figure 6–16).
Install gasket 7 and the legend cover. Retain the cover with two 6-32 x 1⁄2 inch screws 3. Be-gin to tighten screws 3. Prevailing torque must be no greater than 8 lb in. (0.9 N·m). If prevail-ing torque of screws 3 is greater than 8 lb in.
(0.9 N·m), remove screws 3 and get new ones.
Tighten screws 3 to 11–15 lb in. (1.3–1.7 N·m).
20. Slip bezel 2 over end cap 34 (Figure 6–16), then rotate it 90˚ to install it onto the shift selector (Figure 6–15). Install four 6-32 x 5⁄8 inch screws 1. Begin to tighten screws 1. Prevailing torque must be no greater than 8 lb in. (0.9 N·m). If pre-vailing torque of screws 1 is greater than 8 lb in.
(0.9 N·m), remove screws 1 and get new ones.
Tighten screws 1 to 11–15 lb in. (1.3–1.7 N·m).
21. Install selector lever end cap cover 36.
H00932.01
SELECTOR LEVER
SHIFT LATCH HALF-COVER
PIN
SCREW (2), 4-40 x 5⁄16 in.
END CAP
6–8. ELECTRONIC-CONTROL SHIFT SELECTOR — TOUCH-PAD
a. Disassembly (Foldout 36,B)
NOTE:
If a lamp or lamp circuit board assembly replace-ment is required, do Steps (1) through (6). If only the cover assembly needs to be replaced, do Steps (1) and (7).
1. Place the shift selector (Figure 6–18) on a flat surface, face side down (Figure 6–19). Remove four screws 1 and washers 2 that retain cover assembly 8 to housing assembly 3.
2. Carefully separate the cover assembly and housing assembly just enough to permit re-moval of lamp circuit board assembly 9 or 10 (Figure 6–20).
3. Carefully pry the lamp circuit board assem-bly from the housing assemassem-bly with the tip of a small screwdriver (Figure 6–20). The cir-cuit board assembly is retained to the housing assembly by a multiple pin connector. Re-move the lamp circuit board assembly. Do not separate the cover-to-housing pin connec-tor (Figure 6–21).
Figure 6–18. Typical Touch-Pad Shift Selector SHIFT SELECTOR
H00695.01
Figure 6–19. Rear of Touch-Pad Shift Selector
Figure 6–20. Removing Lamp Circuit Board Assembly
4. Figure 6–22 illustrates the three types of lamp circuit board assemblies. In earlier models, both lamps and lamp holders are replaceable.
In later models, only the lamps are replaceable and the lamp holders are soldered in place.
H00933.01
HOUSING ASSEMBLY COVER ASSEMBLY SCREW (4),
6-32 x 1⁄2 in.
WASHER (4)
H00934
COVER ASSEMBLY
LAMP CIRCUIT BOARD ASSEMBLY (EARLIER MODELS)
CONNECTOR
HOUSING ASSEMBLY
Figure 6–21. Cover-to-Housing Pin Connector
5. For earlier models, if lamp holder replacement is necessary, compress the two locktabs on lamp holder 7 (Figure 6–23). Holding the two locktabs in a compressed position, push the lamp holder downward until it is clear of its socket and remove it.
6. Remove lamps 6 as necessary. The lamps are the only parts in the circuit board assembly that are replaceable. If any other damage has oc-curred to the circuit board assembly, replace the entire circuit board assembly.
7. If replacement is necessary, grasp the cover as-sembly in one hand and the housing asas-sembly in the other hand, and gently separate the two components (Figure 6–21).
b. Assembly (Foldout 36,B)
NOTE:
When installing a new cover assembly, it may be de-sirable to remove the lamp circuit board assembly.
This will provide free access to mate the cover as-sembly connector to its mating connector in the housing assembly.
H00935
COVER
CONNECTOR PINS CONNECTOR
HOUSING ASSEMBLY
Figure 6–22. Lamp Circuit Board Assembly Configurations
Figure 6–22. Lamp Circuit Board Assembly Configurations