Printed in U.S.A. 9500537-01Sections of these instructions include copyrighted material from Ford Service Manuals. Reprinted with permisson of Ford Motor Company

Installation Instructions1980-1992 Ford AOD

Shift Improver KitPart No. 40263

©B&M Racing & Performance Products 1997

IMPORTANT: We recommend thatyou read through the instructions com-pletely before beginning the installa-tion so you can familiarize yourselfwith the installation procedure andtools required.

Check the tool list at the end ofthese instructions for the tools re-quired to install your B&M AOD ShiftImprover Kit.

Installation of the B&M AOD ShiftImprover Kit can be accomplishedby anyone with minimum mechanicalexperience. It is however, importantto closely follow the instructions. Readeach step carefully before proceed-ing, if you do not understand, go backand read the step again.NOTICE: The B&M AOD Shift Im-prover Kit is not a cure-all for anailing transmission. If your transmis-sion is slipping, chatters or is in poorgeneral shape, the installation of thisShift Improver Kit may worsen thecondition. However on a properly op-erating transmission in average con-dition, the B&M AOD Shift ImproverKit will provide the kind of transmis-sion performance you are looking for.

INTRODUCTION

The B&M AOD Shift Improver Kitcan be installed in a few hours bycarefully following the instructions.Transmission components are preci-sion fit, work slowly and do not force

any parts. Burrs and dirt are the num-ber one enemies of an automatic trans-mission. Cleanliness is very impor-tant, so a clean work surface fromwhich oil can easily be removed isnecessary.

This kit contains the parts neces-sary to obtain two different levels ofshift performance, depending on thevehicles intended use. In several ofthe steps different instructions aregiven for each level:1. Heavy Duty; Towing, campers,and 4-wheel drive vehicles. Heavyduty level produces firm noticeableshifts.2. Street; Dual purpose performancevehicles, street and strip performancecars. Street level produces firm, posi-tive shifts.

When installing your B&M AODShift Improver Kit there are severalother B&M products you may wish toconsider:TRANSMISSION OIL COOLER Wefeel that it is very important that everyvehicle used in heavy duty and hiperformance applications (racing, tow-ing, RV, etc.) should have an oil cooler.Heat is the major cause of transmis-sion failures, and an oil cooler is aninexpensive safeguard against over-heating and transmission failure. B&Moffers a wide variety of transmissioncoolers to suit every application. Avail-able at your B&M dealer.

TRICK SHIFT PERFORMANCE ATFTrick Shift performance automatictransmission fluid is the industry’sonly real performance ATF. A spe-cially blended oil with foam inhibitors,extreme pressure agents and shiftimprovers, this fluid assures protec-tion while delivering the fastest pos-sible shifts. You literally “Pour in per-formance.” Available at your B&Mdealer.DRAIN PLUG KIT 80250 The AODtransmission is not factory equippedwith a drain plug. The B&M Drain plugkit is inexpensive and easy to install.It eliminates the mess of pan removaland gasket replacement normally re-quired when changing fluid.B&M SHIFTERS; B&M manufacturesa complete line of automatic trans-mission shifters ideally suited for usewith the AOD. These shifters provideyou with positive transmission controlas well as stylish appearance for yourvehicles interior.TEMPERATURE GAUGE KIT 80212Most transmission and converter fail-ures can be traced directly to exces-sive heat. The B&M transmission tem-perature gage can save you a costlyrepair bill by warning you ahead oftime of an overheated transmission.The B&M temperature gage is ex-tremely accurate and dependable, itcomes with all necessary hardwareand is easy to install.

DISASSEMBLYAutomatic transmissions nor-

mally operate at temperatures be-tween 150 F and 250 F. We recom-mend that the vehicle be allowed tocool for several hours before at-tempting disassembly to avoid seri-ous burns from hot oil and parts.The vehicle should be raised sothere is at least 2 feet ground clear-ance for ease of installation andsafety.

MAKE SURE THE VEHICLE ISRIGIDLY AND SECURELY SUP-PORTED, JACK STANDS, WHEELRAMPS OR A HOIST WORK BEST,DO NOT USE JACKS ALONE.

Have an oil drain pan ready to catchoil and a clean tray on which to put smallparts so they won’t get lost or dirty.

STEP 1. Since the AOD is not factoryequipped with an oil pan drain pluguse the following technique to drainthe transmission fluid. Position yourdrain pan beneath the transmission tocatch the oil. Remove all but the two(2) front bolts from the oil pan. Nextloosen but do not remove the twofront center bolts allowing the rear ofthe pan to drop down. If the pan sticksto the gasket, insert a flat screwdriverbetween the pan and case and prydown gently to break pan loose. Nowslowly back the bolts out to permitdraining the remaining oil. Removeall old pan gasket material from thepan and case.STEP 2. Remove three (3) screwsholding the oil filter then pull the filterstraight down from the valve body.

Figure 1

2

Removeold filtergaskets

L L L L

LL

L

LL

L

LL

L

L

L

L

S

S

S S

S

S

S

S

"S"=(8) Short M6x30mm shoulder bolts"L"=(16) Long M6x40mm shoulder bolts

Remove the filter grommet and gas-ket material from valve body. (SeeFigs. 1 & 2.)STEP 3. Remove all of the valvebody bolts except one near the center(See Fig. 1). Hold valve body up

Figure 2

Gasket

Filter grommet

3

Use shoulder boltfor alignment

Use shoulder boltfor alignment

Reinforcement plates

Separatorplate

Gasket

Valve body

against case and remove the last bolt.When removing valve body watchout for about a pint of oil trappedabove it. Place the valve body on aclean work surface. WARNING: Donot place the valve body on the groundor a dirty surface. The valve bodyconsists of precision fit valves andwill not tolerate dirt or burrs. Any dirtentering the fluid circuits will jam theshift valves and prevent the transmis-sion from shifting.

VALVE BODY DISASSEMBLY

IMPORTANT: Pay special attentionin the following steps where somesteps refer to both Heavy Duty andStreet level modifications, while othersteps refer only to Heavy Duty orStreet level modifications. If neither

performance level is specifically re-ferred to it means both Heavy Dutyand Street levels. It is a good idea toretain all replaced parts (springs, etc.)for reference until after the installa-tion is complete and the vehicle issatisfactorily road tested.STEP 4. Remove 12 bolts holdingseparator plate to valve body (SeeFig 3). Remove (3) reinforcementplates and separator plate, (1) large(orange) and (6) small (black) checkballs, and (2) relief valves with springs(See Fig. 4). NOTE: Early 1980 valvebodies may have (7) black check balls.Carefully remove any remaining gas-ket material from reinforcement platesand valve body surfaces. Make surenone of the gasket debris remains inthe valve body channels to contami-

nate the valves. Rinse off valve bodywith clean solvent to remove any dirtor grit.

VALVE BODY MODIFICATIONS

IMPORTANT HINT: The retainingclips at the end of the valve bodybores can fly off during removal. Toprevent losing the retaining clips placea small rag over the clip when remov-ing it, this will help prevent the clipfrom flying off and becoming lost.B&M does not stock replacement re-taining clips. If yours are lost or dam-aged see your local Ford parts sup-plier or try a transmission shop.STEP 5. Heavy Duty and Street;Pressure regulator. Remove the re-taining clip at the end of the pressureregulator bore (See Fig. 4) Use a

Detent springguide bolt

Figure 3

screwdriver to hold the pressure regu-lator assembly in while removing theretaining clip. If the sleeves stick inthe bore, lightly punch the sleeve witha small rod and a mallet allowing it tosnap back out of the bore. RemoveSleeve with Boost Valve and the out-ermost pressure regulator spring. Re-place the stock outer pressure regula-tor spring with the RED spring sup-plied in the kit. Reassemble pressureregulator in reverse order of disas-sembly.STEP 6. Heavy Duty Only; 1-2 Ca-pacity Modulator. Remove the re-taining clip at the end of the 1-2Capacity Modulator bore (See Fig.4). Remove the bore plug, 1-2 Capac-ity Modulator valve and spring frombore. On later model valve bodiesuse the M4x40 (4mm metric screwsupplied in kit) in tapped hole to assistremoving bore plug. Early valve bod-ies do not have a hole in the bore plugso you will have to pry the plug outwith a small screw driver. Replace thestock spring with the YELLOW spring

supplied in kit. Reassemble spring,valve and bore plug (tapped hole fac-ing out) and install retaining clip.STEP 7. Street Only; 1-2 CapacityModulator. Remove the retaining clipat the end of the 1-2 Capacity Modu-lator bore (See Fig. 4). Remove thebore plug, 1-2 Capacity Modulatorvalve and spring from bore. On latermodel valve bodies screw the M4x10(4mm metric screw supplied in kit) intapped hole to assist removing boreplug. Early valve bodies do not havea hole in the bore plug so you will haveto pry the plug out with a small flatscrew driver. Replace the stock springwith the GREEN spring supplied inkit. Reassemble spring, valve andbore plug (tapped hole facing out) andinstall retaining clip.

SEPARATOR PLATEMODIFICATIONS

STEP 8. Heavy Duty and Street;Drill holes shown as in Figure 5. Re-move all sharp burrs from plate sur-face with a fine flat file. Burrs can be

4

#2

#5

#6

#1 orangecheck ball

Note: #2 through #8 check balls areblack rubber.

#7 checkball is not used.

Boost valve

Pressure regula-tor valve

Retainer

Retainingclip

Figure 4

Converter relief valve,long stem (green orblue spring)

Replace stock outer pres-sure regulator spring withred spring in kit. See step 5.

1-2 Capacity modulatorvalve. Located in firstbore on this end of valvebody.

Bore plug(tapped holefaces out)

Replace stock springwith spring from kit.See steps 6 or 7

#8

#4

#3

Pay close attention to componentlocation and orientation when

removing valve trains from bores.

removed from around the edge of theholes by lightly pressing a slightlylarger drill bit to the hole and spinningit with your fingers. Wash and wipeany loose chips from theseparatorplate.IMPORTANT: Drill only the holes in-dicated. Replacement AOD separa-tor plates are NOT available fromFord, so be very careful not tomislocate any of the holes. If youshould damage your separator plateyou will have to find a complete usedvalve body of same year and model ata junk yard or transmission shop (leastexpensive) or purchase a new valvebody from Ford. Alternatetively, youcan purchase a B&M universal AODseparator plate which can be modi-fied to fit any model year AOD trans-mission.

VALVE BODY ASSEMBLY

STEP 9. Check ball placement (SeeFig. 4) Place check balls in the valvebody in the positions shown. Use adab of grease or petroleum jelly to

Short stem TV pres-sure relief valve(green spring)

Retaining clipgroove

Inner pressureregulator spring

Retainingclip

Boost valvesleeve

Retaining clipgroove

5

hold check balls in position. Thegrease will have no effect ontransmission operation and will dis-solve after an hour or two of opera-tion. Note the location of the OR-ANGE #1 check ball. The orangeand black check balls are not inter-changeable.STEP 10. Reinstall original con-verter and TV pressure relief springsand valves (See Fig. 4). Pay closeattention to the spring color andrelief valve stem length. The longstem converter relief valve can haveeither a green or blue spring.STEP 11. Visually check separatorplate gaskets against the modifiedAOD separator plate to make sureno holes in the separator plate are

The shoulder bolts must be installedin the holes indicated for properalignment. Install (3) reinforcingplates with (11) short bolts tighten-ing the bolts finger tight. Install (1)M6x30mm (1.16") detent springguide bolt. (See Fig. 3.)With all bolts just finger tight makesure all plate and gasket holes lineup with valve body holes and thetwo alignment shoulder bolts canslide in and out freely. Torque the(12) bolts to 80-100 lb.in. (9-11 Nm).If you do not have a low range torquewrench, run the bolts down untilthey stop (wrist tight) then turn boltan additional one eighth (1/8) turn.Remove the (2) shoulder bolts usedfor alignment.

covered by the gasket. NOTE:There will be holes in the gasketthat do not have corresponding holesin the separator plate.

If your gaskets become dam-aged anytime during the installationof the kit, replace them. Purchasestock Ford gaskets for your spe-cific year and model vehicle.STEP 12. Position separator plategasket then separator plate on valvebody. Align gasket and separatorplate holes with those in valve body.Insert (2) long (1.56") valve bodyshoulder bolts through separatorplate and valve body as illustratedin Figure 3. The shoulder bolts arerequired to maintain gasket andplate alignment during assembly.

Figure 5

1/8"( .125)

1/8" (.125)

Drill this hole only ifpresent ! 1988-1992

3/32" (.094) Heavy Duty1/8" (.125) Street

1/8" (.125)

Caution: Be careful to drill ONLY those holes shown.See step 8 for details.

SEPARATOR PLATE MODIFICATIONS

There are three versions of AODseparator plates. Your separatorplate may differ slightly from thisillustration.The holes to be modifiedare common to all three versions.

STEP 15. Street only; Replacestock 2-3 accumulator spring withthe BLUE spring supplied in kit.Install BLUE 2-3 accumulator spring,B&M 2-3 accumulator spacer, coverand retaining ring (See Fig. 6).

FINAL ASSEMBLYSTEP 16. Check your parts beforeproceeding, you should have (3) stocksprings and no check balls (except 1 for1980 models) or relief valves left over.Make sure the (12) valve body platebolts are properly torqued.NOTE: If you are installing a B&Mshifter in other than a Mustang, this is agood place to install the new shift lever.STEP 17. Remove all old gasket ma-terial from the case surface. Install (2)M6x40mm (1.56") alignment pins(supplied in kit) into the holes shown(See Fig. 6). Install case to separatorplate gasket over alignment pins. Usea few dabs of grease to hold thegasket against the case.CAUTION: Valve body installationis one of the most important stepsto insure proper operation of theAOD transmission. The valve bodymust be located flush against thecase and carefully torqued exactlyas described in the following step.Failure to follow this procedurecan result in sticking valves andunpredictable transmission opera-tion. If the valve body is warped ordamaged due to improper assem-bly it is not repairable and shouldbe replaced.STEP 18. Install valve body up to casebeing careful to align manual valve withpin in detent plate (See Fig. 7). Youalso have to manually engage the TVlever between the valve body and TVplunger. DO NOT try to force the valvebody into place, it will go right into placewith a little patience. With the valvebody sitting flush against the caseinstall (1) bolt to hold the valve body inplace. Make sure the detent plate pinand internal TV lever are properly posi-tioned then install (8) short M6x30mm(1.16") and (16) M6x40mm (1.56")shoulder bolts (See Fig. 1). Removethe alignment pins only after all but thelast two bolts have been installed. In-stall ALL bolts FINGER TIGHT. Theshort bolts are installed (4) in front (1) incenter and (3) in rear of valve body.

2-3 ACCUMULATORMODIFICATIONS

STEP 13. Remove retaining ring, 2-3accumulator cover, 2-3 accumulatorspring and 2-3 accumulator pistonfrom 2-3 accumulator bore (See Fig.6). Remove (2) seal rings from accu-mulator piston. Coat the (2) square

cut rubber rings supplied in kit withclean ATF then install rings on piston.Install piston back into bore.STEP 14. Heavy Duty only; Replacestock 2-3 accumulator spring with theBLUE spring supplied in kit. Install BLUE2-3 accumulator spring, cover and retain-ing ring into bore (See Fig. 6).

6

Figure 6

2-3 Accumulator modifications

Retaining ring

Cover

2-3 Accumulator spring.Replace stock spring with

blue spring from kit

Install spacer onstreet level only

B&M piston seal ringInstall on piston

2-3 accumulator piston

B&M piston sealring

Install on piston

Alignment pin

Alignment pin

7

Detent leverspring

Forwardclutch tap

Left side of case

Detent spring bolt

Detent lever pin

Internal TVlever

Manual valveTV

plunger

Figure 7 Figure 8

Right sideof case

TV torsion spring inseparator plate V notch

Ford Service Manuals available fromHelms Inc., Detroit, MI., (313) 865-5000.

Ford service tools available fromOTC Tool and Equip., Owatonna,MN., (507) 455-7050.

One of the shoulder bolts holds thedetent lever spring. Starting at the cen-ter and working outward torque bolts to80-100 lb.in. (9-11 Nm). If you do nothave a low range torque wrench, runthe bolts down until they stop (wristtight) then turn bolt an additional oneeighth (1/8) turn.STEP 19. Position the TV torsion springagainst the separator plate ‘V’ notch(SeeFig. 7). The TV torsion spring pushesthe TV lever against the TV plunger.Failure to position this spring prop-erly will result in erratic shifting.STEP 20. Make sure rubber grommet isinstalled in the filter. Install the cork filtergasket on filter using a dab of grease tohold it in place (See Fig. 2.). Coat the filtergrommet with clean ATF and install filteron valve body. Push the filter straight onto avoid damaging the rubber grommet.Install (3) M6x16 (0.63") bolts and torqueto 80-100 lb.in. (9-11 Nm).STEP 23. Remove any old pan gasketmaterial from pan and case pan rail.

Clean inside of pan with solvent. If yourecall what a mess draining the panwas, you may want to install a B&MDrain plug kit (80250) at this time.Install the new pan gasket on the panand align the holes. Use grease orpetroleum jelly to help hold the gasketin place during installation of pan. Placepan up to case, align holes and install allbolts finger tight. After all bolts havebeen installed, torque bolts to 72-124lb. in. (8-14 Nm). If the bolts are overtightened the gasket will deform exces-sively and lead to oil leaks.STEP 21. Fill transmission with freshautomatic transmission fluid to the fullmark on the dip stick. We recommendB&M Trick Shift transmission fluid forall applications, particularly for StreetLevel applications. You will need ap-proximately 6 to 8 quarts.

TV Linkage AdjustmentSTEP 22. TV Linkage Adjustment:Normally the TV linkage does notneed to be adjusted after installing

the valve body. Proper installation ofthis kit will not change the setting ofthe linkage (follow instruction proce-dures). The linkage normally requiresadjustment only when the transmis-sion has been removed and is rein-stalled in the vehicle or when there isa new carburetor or throttle body in-stalled. We recommend, however,performing a Line and TV pressurecheck to check whether or not the TVLinkage is properly adjusted (See OilPressure Chart). If the pressurecheck indicates TV linkage adjust-ment is required see the TV linkageadjustment section on the followingpages. The pressure test will alsogive you a good indication of thetransmissions condition.STEP 23. Inspect the transmissionfor leaks with engine running. Lowervehicle and check fluid level againadjusting level as required. Test drivevehicle and recheck for leaks whiletransmission is hot.

Direct clutch tapTV pressure tap

Line pressure tap

8

Oil Pressure Specifications

Selector Line Pressure TV Limit Pressure

Position PSI (kPa) PSI (kPa)

At idle

In Reverse 109-129 (751-890) 0 0

All Other Ranges 74-94 (510-648) 0 0

At W.O.T. (Stall)

In Reverse

3.8L & 4.9L 264-304 (1820-2096) 74-86 (510-593)

All other engines 275-315 1896-2172) 79-91 (545-627)

All Other Ranges

3.8L & 4.9L 200-220 (1379-1517) 74-86 (510-593)

All other engines 209-229 (1441-1579) 79-91 (545-627)

Line Pressure Test Results

Low at idle in all ranges: Check for low fluid level, cloggedor damaged filter, loose valve body bolts, stuck pressureregulator valve, missing pressure regulator spring or oiltemperature too hot from excessive W.O.T. test.Low at W.O.T. but O.K. at idle: Check for low oil level,clogged filter, damaged or out of adjustment TV linkage,Sticking TV or TV limit valve in valve body.

Slow initial engagement Low line pressureFluid level low

Harsh initial engagement Engine idle too highLoose U-joint or engine mountHigh line pressureSticking valves in valve body2-3 accumulator valve stuck

No drive in any selector Valve body leaking internallyposition Valve body bolts loose

Sticking valves in valve bodyManual valve pin not engagedFluid level low

No drive forward, Worn or stuck governorbut has reverse Valve body bolts loose

Sticking valves in valve bodyDamaged 2-3 accumulator seal

Slips or chatters in 1st gear TV linkage out of adjustment(Selector in “OD”) Low line pressure

Valve body bolts looseSlips or chatters in 2nd gear Defective intermediate clutch(Selector in “OD”, OK in 1st) Sticking valves in valve bodySlips or chatters in Reverse Low line pressure

Valve body bolts looseStarts in 2nd or 3rd Sticking governor

Sticking valves in valve bodyCross channel leaks betweencase or separator plateand valve body

Incorrect shift points TV linkage out of adjustmentWorn governorSticking valves in valve body

NO 1-2 upshift TV linkage out of adjustmentGovernor valve stickingSticking valve in valve body

Mushy 1-2 shift Out of tune engineDefective intermediate clutchTV linkage out of adjustmentLow line pressure

No 2-3 upshift Defective direct clutchConvertor damper hub brokenSticking valve in valve body

Mushy 2-3 upshift Defective 2-3 accumulatorpiston or sealsLow line pressure

Mushy or rough Out of tune engine3-4 upshift Defective OD band or reverse drum

TV linkage out of adjustmentNo forced down Defective clutch or bandshifts TV linkage damaged or out of adjustment

Sticking valve in valve bodyTransmission Overheated engineoverheats Restriction in cooler or lines

Converter overrun clutch seizedSticking valves in valve body

Transmission noise Relief valve buzzingOil pump cavitation

TROUBLESHOOTING GUIDE FOR THE FORD AOD TRANSMISSIONThe troubleshooting guide is intended to help you identify possible causes of malfunctions that could be related to

incorrect assembly or adjustment of the transmission hydraulic system (valve body and accumulator) and or mechanicalcontrols. We recommend that you obtain an AOD service manual for problems related to the torque converter ortransmission hard parts.

Line Pressure check*On the AOD transmission two pressure readings

must be taken: One at idle (closed throttle, Zero TVPress.) and another at wide open throttle (W.O.T.,Full TV Press.).

*Engine and transmission should be at normal operat-ing temperature for test.

*During test at W.O.T. (stall) the wheels must belocked to prevent any vehicle motion.

*DO NOT operate at W.O.T. Stall for more than 10seconds at a time, followed by at least 2 minutes inNeutral at 1000 RPM to cool the oil.

*Connect a 0-300 PSI (0-2000 kPa) pressure gage tothe line pressure port located just above the controllevers on the right side of the transmission (See Fig.8). The gage hose must be long enough to read gagewhile operating engine.

*Connect a 0-100 PSI (0-690 kPa) gage (300 PSI gagewill work if it’s all you have) to the TV Pressure tapon the right hand side of the transmission (See Fig.8). The gage hose must be long enough to read gagewhile operating engine.

*Idle pressure must be read with throttle off the fastidle cam.

*Pressures listed apply to stationary vehicle only. In3rd and 4th gears line pressure is lower (cut back) thanshown for “all other ranges”.

Three different types of Throttle Valve (TV) linkageshave been used on the Ford AOD transmission since itsintroduction. The earliest linkage consisted of a bent rigid rodconnecting the carburetor and transmission while most latemodel AOD’s use one of two different flexible cable typelinkages. NOTE: Special tools and a pressure gage will berequired depending on the particular TV linkage type you areworking on. Adjustment procedure for each of the TV linkagetypes are presented in the following sections.1. Carburetor adjustment

Perform the following steps prior to adjusting TV linkage.1.1Check/adjust the engine curb idle speed to specification.

Refer to the Engine/Emissions Diagnosis manual forprocedures to adjust throttle solenoid applications. Makesure the curb idle speed is set to specification with andwithout the throttle solenoid positioner (anti-dieselingsolenoid) energized, if so equipped.

1.2Shut engine off. Remove air cleaner.1.3De-cam the fast idle cam on the carburetor so that the

throttle lever is against the idle stop or throttle solenoidpositioner stop.

Rod type TV control system.

The TV control linkage system consists of a linkage leveron the carburetor, the TV control rod assembly and anexternal TV control lever on the transmission. (See Fig. 9.)The TV control rod transmits motion between the carburetorlinkage lever and the TV control lever on the transmission.The carburetor linkage lever has an adjustment screw forlimited TV linkage Adjustment. The external TV control leveractuates the internal TV control mechanism which regulatesTV control pressure.

The TV control rod is set to its proper length during initialassembly using the sliding trunnion block at the transmissionend of the TV control rod assembly. Under normal circum-stances it should not be necessary to alter this Adjustment.Any required adjustment can normally be made using theadjustment screw on the carburetor linkage lever.

When the linkage is correctly adjusted, the TV controllever on the transmission will be at its internal stop positionwhen the carburetor lever is at its minimum idle stop. Therewill be light contact force between the throttle lever and theend of the linkage lever adjustment screw. Due to theflexibility in the TV linkage the adjustment screw would haveto be backed out several turns before a gap between thescrew and throttle lever could be detected.

Before any engine TV linkage adjustment can be done,the throttle lever at the carburetor (or throttle body) must bepositioned at its minimum idle stop.2. Linkage Adjustment at CarburetorAdjust the TV control linkage at the carburetor using thefollowing procedure (See Fig. 9.):2.1Set carburetor at minimum idle stop as described in steps

1 thru 3. Place shift lever in NEUTRAL and set parkingbrake. CAUTION: The transmission selector lever mustbe in NEUTRAL in when adjusting the TV linkage.

9

TV LINKAGE ADJUSTMENT

2.2Back (turn CCW) the linkage lever adjusting screw all theway out (until screw end is flush with lever face).

2.3Turn the adjusting screw in (CW) until a thin shim of.127mm (0.005 inch) maximum, or piece of writing paperfits snug between end of screw and throttle lever. NOTE:To eliminate effect of friction, push linkage lever forward(tending to close gap) and release before checkingclearance between end of screw and throttle lever. Do notapply any load on levers with tools or hands whilechecking gap.

2.4Turn the adjusting screw in (CW) an additional threeturns. (Three turns are preferred. One turn minimum ispermissible if screw travel is limited).

2.5 If it is not possible to turn in adjusting screw at least oneadditional turn (from initial gap) or if there was insufficientscrew adjusting capacity to obtain an initial gap in Step 5,refer to Linkage Adjustment at Transmission.

Idle Speed AdjustmentWhenever it is required to adjust idle speed by more than 50rpm, the adjustment screw on the linkage lever at thecarburetor should also be readjusted as follows:Idle Speed Change Linkage Adjustment

at Carburetor50 rpm or more Check TV lever adjustmentdecrease at carburetorLess than 50 rpm No change required50 rpm or more Check TV lever adjustmentincrease at carburetorAfter making any idle speed adjustments, always verify thatthe linkage lever and throttle lever are in contact with thethrottle lever at its idle stop (or throttle solenoid positioner)and the shift lever is in NEUTRAL.3. Rod Linkage Adjustment at Transmission

The linkage lever adjustment screw has limited adjust-ment capability. (See Fig. 9.) If it is not possible to adjust theTV linkage using this screw, the length of the TV control rodassembly must be readjusted using the following procedure.This procedure must also be followed whenever a new TVcontrol rod assembly is installed.

Figure 9

This procedure requires raising the vehicle to give accessto the linkage components at the transmission TV controllever.3.1Set carburetor at its minimum idle stop as described in

steps 1-3. Place shift lever in NEUTRAL and set parkingbrake. Turn engine off.

3.2 Set the carburetor linkage lever adjustment screw atapproximately half-travel.

3.3 If a new TV control rod assembly is being installed,connect the rod to the linkage lever at the carburetor.

CAUTION: The following steps involve working inclose proximity to the exhaust system. Allow theexhaust system to cool before proceeding.3.4Raise vehicle so there is at least 2 feet ground clearance

for ease of access. MAKE SURE THE VEHICLE ISRIGIDLY SUPPORTED ON JACK STANDS OR WHEELRAMPS IF A HOIST IS NOT AVAILABLE. DO NOTUSE JACKS ALONE TO SUPPORT VEHICLE.

3.5Loosen the bolt on the sliding trunnion block on the TVcontrol rod assembly. Remove corrosion and road grimefrom the control rod and free-up the trunnion block so thatit slides freely on the control rod.

3.6Push up on the lower end of the control rod to ensure thatthe linkage lever at carburetor is touching firmly againstthe throttle lever. Release force on rod. Rod must stay up.

3.7Push the TV control lever on the transmission up againstits internal stop with a firm force, approximately 22 N (5lbs). Tighten the bolt on the trunnion block. Do not relaxforce on lever until bolt is tightened.

3.8Lower the vehicle and verify that the throttle lever is stillagainst the minimum idle stop or throttle solenoid posi-tioner stop. If not, repeat Steps 14 and 15.

4 Rod type Linkage Adjustment Using TV ControlPressure

Note: This procedure requires the use of TV PressureGauge with Hose (0-60 psi) T86L-70002-A or equivalent.The results of the adjustment procedure depends on theaccuracy of the pressure gauge.

The following procedure may be used to check and/oradjust the throttle valve (TV) control linkage using the TVcontrol pressure. (See Fig. 10.)4.1Check/adjust the engine curb idle speed to specification

required. Refer to the Engine/Emissions Diagnosismanual for appropriate procedure. Ensure the curb idlespeed is set to specification with and without the throttlesolenoid positioner (anti-diesel solenoid) energized, if soequipped.

4.2Attach Pressure Gauge (0-60 psi) with Hose T86L-70002-A and Adapter Fitting D80L-77001-A or equiva-lent, to the TV port on the transmission. The pressuregauge should have 2.4m (8 feet) of flexible hose to makethe gauge accessible while operating the engine.

4.3Obtain TV Control Pressure Gauge Block D84P-70332-A or fabricate a block .394" ± 0.007") thick. The followingdrill bit shanks may also be used in order of preference:Letter X (.397 inch), 10mm (.3937 inch) or 25/64 (.3906inch).

4.4Operate the engine until normal operating temperature is

10

reached and the throttle lever is off fast idle. Thetransmission fluid temperature should be approximately38o - 72o C (100o - 150o F). Do not make pressure checkif transmission fluid is cold or too hot to touch.

4.5Set parking brake, place shift selector in NEUTRAL,remove air cleaner and shut off air conditioner. Ifequipped with a vacuum operated throttle modulator,disconnect and plug the vacuum line to this unit. Ifequipped with a throttle solenoid positioner or an idlespeed control, do not disconnect either of these compo-nents.

NOTE: The following pressure check must be made with theengine idling at normal curb idle in NEUTRAL, parkingbrake set and with no accessory load on engine. Do notmake pressure check in PARK.

4.6With engine idling in NEUTRAL, insert gauge block ordrill shank between the carburetor throttle lever andadjust screw on the transmission linkage lever. The TVpressure should be between 207 and 276 kPa (30 and 40psi). For best transmission function, use the adjustingscrew to set the pressure as close as possible to 227 kPa(33 psi). Since the TV pressure goes up approximately14 kPa (2 psi) when the shift lever is moved fromNEUTRAL to a forward gear, this will result in a TV

Figure 10

the transmission, and the cable mounting brackets at thethrottle body and transmission. (See Figs. 11 & 12.)

On 3.8 L EFI Thunderbird/Cougar vehicles, there is alsoa bellcrank assembly mounted on the transmission bellhousing in the area of the TV lever and bracketry holding thecable in the upper bell housing area (same as 5.0 LThunderbird/Cougar vehicles with column shift).

As the throttle is moved from idle to wide open throttle(WOT), the TV control cable pulls the transmission TVcontrol lever from idle to WOT. Return of the cable andtransmission lever toward idle is accomplished by the returnspring on the transmission end of the cable assembly. Thisspring and the end of the cable assembly is protected by aflexible rubber boot. The transmission external TV controllever actuates the internal TV control mechanism whichregulates the TV control pressure. The travel of this lever iscontrolled by stops internal to the transmission.

The TV control cable is set and locked to its proper lengthduring initial assembly by pushing down on the locking leverat the throttle body end of the cable assembly. When thelever is unlocked, the cable is released for adjustment. Thetake-up spring at this end of the cable automatically tensionsthe cable when released. With the slack taken up and thelocking lever pushed, the take-up spring plays no part in theoperation of the system.

Under normal circumstances, it should not be necessaryto alter or readjust the initial setting of the TV control cable.Situations requiring readjustment of the TV control cableinclude maintenance involving the removal and/or replace-ment of the throttle body, transmission, TV cable assemblyor installing a new main control assembly. Readjustment ofthe TV control cable would also be necessary to correctcomplaints of poor transmission shift quality that would havebeen caused by a misadjustment of the TV control cable.

When the TV control cable is properly set, the transmis-sion TV control lever will be at its internal idle stop (lever torear as far as it will travel) when the throttle lever is at its idlestop.Idle Speed Affect on TV Control CableThe EFI (Electronic Fuel Injection) engine uses an AirBypass (ISC) that does not affect throttle position. There-fore, idle automatic setting does not affect TV cable adjust-ment.5. Manual locking cable adjustment using TV ControlPressure.5.1Attach TV pressure gauge (60 PSI) with hose T86L-

70002-A or equivalent to TV pressure tap (See Fig. 8).5.2Obtain Cable TV Gauge tool T86L-70332-A or equiva-

lent.5.3Insert tapered end of the tool between the crimped slug

on the end of cable and plastic cable fitting that attachesto the throttle lever. (See Fig. 13.) Push in Cable TVGauge Tool T86L-70332-A, or equivalent forcing thecrimped slug away from the plastic fitting. Ensure gaugeblock is pushed in as far as it will go.

WARNING: THIS PROCEDURE REQUIRES WORKINGIN CLOSE PROXIMITY TO THE EGR SPACER ASSEM-BLY WHICH MAY BE HOT.

11

pressure setting near the desirable 241 kPa (35 psi inforward gear. Do not attempt to set TV pressure withthe transmission in gear. Turning the screw in will raisethe pressure 10.3 kPa (1.5 psi) per turn. Backing-out thescrew will lower the pressure. If equipped with idle speedcontrol, some “hunting” may occur and an averagepressure reading will have to be determined. If theadjusting screw does not have enough adjustment rangeto bring TV pressure within specification, adjust rod at thetransmission.

4.7Remove gauge block, allowing TV lever to return to idle.With engine still idling in NEUTRAL, TV pressure must beless than 34 kPa (5 psi). If not, back-out adjusting screwuntil TV pressure is less than 34 kPa (5 psi). Install gaugeblock and check that TV pressure is not below 207 kPa(30 psi).

Manual-Locking type cable Throttle Valve (TV)Control Cable System.

3.8 L (Thunderbird/Cougar) EnginesThe throttle valve (TV) control cable system consists of

a cable attaching stud on the throttle body throttle lever, theTV control cable assembly, the external TV control lever on

Figure 11

Figure 12

5.4Operate engine until normal operating temperature isreached. The transmission fluid temperature should beapproximately 38-72oC (100-150oF). Do not make pres-sure check if transmission fluid is cold or too hot to touch.

5.5Set parking brake and place shift selector in NEUTRAL.With gauge tool in place and engine idling in NEUTRAL,the TV pressure should be between 207 and 276 kPa (30and 40 psi). For best transmission operation, set TVpressure as close as possible to 227 kPa (33 psi), usingthe following procedure.

5.6Since the TV pressure goes up approximately 14 kPa (2psi) when the shift lever is moved from NEUTRAL to aforward gear, this will result in a TV pressure setting nearthe desirable 241 kPa (35 psi) in forward gear. Do notattempt to set TV pressure with the transmission in gear.NOTE: Do not check or set TV pressure in PARK.

5.7Using a screwdriver or pointed tool, pry up white togglelever on cable adjuster located immediately behind thethrottle body cable mounting bracket. (See Fig. 14.) Theadjuster preload spring should cause the adjusting sliderto move away from the throttle body and TV pressureshould increase.

5.8Push on the slider from behind bracket until TV pressureis 227 kPa (33 psi). While still holding slider, push downon toggle lever as far as it will go, locking slider in position.(See Fig. 15.) NOTE: Toggle lever must be completelydown (lying flat in adjuster assembly) to lock properly.

5.9Remove gauge tool, allowing cable to return to its normalidle position. With engine still idling in NEUTRAL, TVpressure must be at or near 0 kPa (0 psi) (less than 34 kPa(5 psi)). If not, reinstall gauge and repeat Steps 7 and 8but set TV pressure to a pressure less than 227 kPa (33psi) but no less than 207 kPa (30 psi). Remove gauge tooland recheck TV pressure to determine if it is at or near 0kPa (0 psi).

Self-locking type cable Throttle Valve (TV) ControlCable System.

5.0 L HO and SEFI EnginesThe throttle valve (TV) control cable system consists of acable attaching grommet on the throttle body throttle lever,the TV control cable assembly, the external TV control leveron the transmission, and cable mounting brackets at thethrottle body and transmission. (See Figs. 16, 17, 18 & 19.)

On Thunderbird/Cougar vehicles with column shift and3.8 L engines, there is also a bellcrank assembly mounted onthe transmission bell housing in the area of the TV lever andbracketry holding the cable in the upper bell housing area.

As the throttle is moved from idle to wide-open throttle(WOT), the TV control cable pulls the transmission TVcontrol lever from idle to WOT. Return of the cable andtransmission lever toward idle is accomplished by the returnspring on the transmission end of the cable assembly. Thisspring and the end of the cable assembly is protected by aflexible rubber boot. The transmission external TV controllever actuates the internal TV control mechanism whichregulates the TV control pressure. The travel of this lever iscontrolled by stops internal to the transmission.

12

Figure 13

Figure 14

Figure 15

Figure 16

13

Figure 18

Figure 17

14

Figure 19

Figure 20

Figure 22

The TV control cable is set and locked to its proper lengthduring initial assembly when the grooved pin on the upperend of the cable assembly is inserted in the grommet on thethrottle body lever. To release the cable locking mechanism,it is necessary to pry the grooved pin out of the grommet andpush out the white locking pin. The take-up spring at the end

of the cable assembly tensions the cable and takes up theslack in the system. When the grooved pin is reinserted in thegrommet, the white locking tab is pushed in, automaticallylocking the cable to its correct length. When the cable islocked, the take-up spring plays no part in the operation of thesystem.

Under normal circumstances, it should not be necessaryto alter or readjust the initial setting of the TV control cable.Situations requiring readjustment of the TV control cableinclude maintenance involving the removal and/or replace-ment of the throttle body, transmission, TV cable assemblyor installing a new main control assembly. Readjustment

Figure 21

15

of the TV control cable would also be necessary to correctcomplaints of poor transmission shift quality that would havebeen caused by a misadjustment of the TV control cable.

When the TV control cable is properly set, the transmis-sion TV control lever will be at its internal idle stop (lever torear as far as it will travel) when the throttle lever is at its idlestop.Idle Speed Affect on TV Control CableThe 5.0L and 5.0L HO (302 CID) SEFI engine uses an AirBypass (ISC) that does not affect throttle position. Therefore,idle automatic setting does not affect TV cable adjustment.6. Self-locking TV Cable Linkage Adjustment6.1Remove air cleaner cover and inlet tube from throttle

body inlet to access throttle lever and cable assembly.6.2Using a wide-blade screwdriver, pry grooved pin on cable

assembly out of grommet on throttle body lever. (SeeFig. 20.)

6.3Using a small screwdriver, push out white locking tab.6.4Check to ensure plastic block with pin and tab slides

freely on notched rod. If it does not slide freely, the whitetab may not be pushed out far enough. (See Figs. 21 &22.)

6.5While holding throttle lever firmly against its idle stop,push grooved pin into grommet on throttle lever as far asit will go. NOTE: While pushing pin into grommet, makesure you do not move throttle lever away from idle stop.(See Fig. 23.)

6.6Install air cleaner cover and air inlet tube.7. Self-locking TV cable adjustment using TV ControlPressure.7.1Attach TV pressure gauge (0-60 PSI) T86L-70002-A or

equivalent to TV pressure tap (See Fig. 8).7.2Obtain Cable TV Gauge tool T86L-70332-A or equiva-

lent.7.3Insert tapered end of the tool between the crimped slug

on the end of cable and plastic notched rod, also on endof cable assembly. Push in Cable TV Gauge Tool T86L-70332-A or equivalent forcing the crimped slug awayfrom the plastic rod. Ensure gauge block is pushed in asfar as it will go. (See Fig. 24.)

WARNING: THIS PROCEDURE REQUIRES WORKINGIN CLOSE PROXIMITY TO THE EGR SPACER ASSEM-BLY WHICH MAY BE HOT.7.4Operate engine until normal operating temperature is

reached. The transmission fluid temperature should beapproximately 38-72oC (100-150oF). Do not make pres-sure check if transmission fluid is cold or too hot to touch.

7.5Set parking brake and place shift selector in NEUTRAL.With gauge tool in place and engine idling in NEUTRAL,the TV pressure should be between 207 and 276 kPa (30and 40 psi). NOTE: Do not check or set TV pressure inPARK.

7.6If TV pressure meets specification in Step 5, removegauge tool allowing cable to return to its normal idleposition. With engine still idling in NEUTRAL, TV pres-sure must be at or near zero (less than 34 kPa (5 psi)).

7.7If TV pressure does not meet specification in either orboth Steps 5 and 6, remove gauge tool and readjust cable

as outlined under Self-locking TV Cable Adjustment.Then repeat steps 3 through 6.

7.8If TV pressure still does not meet specification, it will benecessary to modify adjustment as follows.

7.9Remove gauge tool and pry grooved pin out of grommeton throttle lever. (See Fig. 25.)

7.10Mark or measure location of plastic block on notchedrod. (See Fig. 26.)

7.11Push out locking tab. (See Fig. 27.)7.12Using mark or measurement on plastic block as a

reference, move plastic block towards throttle bodymounting bracket to raise TV pressure, or move it awayfrom bracket to lower TV pressure. Push in white lockingtab to lock block in position. (See Fig. 28.)

7.13Insert grooved pin back into grommet. (See Fig. 29.)7.14Check TV pressure. Refer to Steps 3 through 6. NOTE:

For best transmission function, the TV pressure shouldbe set as close as possible to 227 kPa (33 psi) inNEUTRAL with gauge tool installed. Since the TVpressure goes up approximately 14 kPa (2 psi) when theshift lever is moved from NEUTRAL to a forward gear,this will result in a TV pressure setting near the desirable241 kPa (35 psi) in forward gear. Do not attempt tocheck TV pressure with the transmission in gear.When the gauge tool is removed, the TV pressureshould drop to less than 34 kPa (5 psi). If the TV pressuredoes not drop to less than 34 kPa (5 psi), reset the TVpressure to a value less than 227 kPa (33 psi) with gaugetool installed but no less than 207 kPa (30 psi). Verifythat the TV pressure is less than 34 kPa (5 psi) withgauge tool removed.

Figure 23

16

Figure 24

Figure 25

Figure 26

Figure 27

LOCK TAB

THEN PUSH IN LOCK TAB

Figure 28

Figure 29

Hydraulic jackGasket scraperJack stands or Wheel ramps3/8" Drill motorOil drain panFine cut flat file3/8" drive ratchet wrench3/8" drive, 4" extension

8mm, 10mm, 13 mm, SocketsWet or Dry sand paperGrease or petroleum jellyNeedle nose pliersTorque wrenchSmall flat screwdriverFunnel

TOOL LIST

PARTS LIST

Spring, Red Pressure regulator 1Spring, Green 1-2 capacity modulator valve 1Spring, Yellow 1-2 capacity modulator valve 1Spring, blue 2-3 accumulator 1Spacer, gold 2-3 accumulator 1Seal ring 2-3 accumulator 1Seal ring 2-3 accumulator 1Drill 1/8" 1Alignment pin M6 X 40mm 2Screw M4 X .7 X 10mm 1Nut M6 hex 2Gasket Plate to case 1Gasket Plate to valve body 1Gasket Oil pan 1Gasket Oil filter 1