Borg warner 71c service manual

If you have drain back, correct the installation. A seasonal oil change is recommended In pleasure boats. Move the transmission shift lever to the extreme position where the spring-loaded ball enters the chamfered hole in the side of the shift lever and properly locates it in the reverse position, Fig.

With the shift lever SO located, oil at regulated pressure flows the control valve into porting in transmission case, thence back to the adapter and into the reverse clutch cavity. The resulting movement of the revel-se clutch piston and the reverse clutch pressure plate locks the reverse clutch plate to the transmission case.

The stationary reverse clutch plate, through connectors, thus prevents rotation of the ring gear. With the ring gear held and the sun gear rotating Fig. Shift Lever Positions at input speed, the pinions of the compound planetary are free to rotate about their own axes and reveee the direction of rotation of the carrier and output shaft. With the shift lever so Velvet ive gear maintains adequate cooling lubrica- located, oil at pressure from the control tion.

This in turn prevents rotation of the planetary pinions about their own axes and thus locks the When operating the at low temperatures or input shaft, ring output shaft together, causing excessive speeds pressures of PSI may be obtained. In this way, input shaft speed and direction of rotation transmitted A maximum transmission oil temperature of is directly to the output shaft. Move the transmission shift lever to the center position where the spring-loaded hall chamfered hole in the side of shift lever and properly locates it the position, Fig.

With the shift lever so cd, of oil to the clutches is blocked at the control valve. The clutches also vented, by different portion of the control valve, to the sump inside the transmission case and thus free-running open clutches are insured.

Place valve and spring assembly in a suitable holder, Fig. Remove oil filler plug located below ring is free to be removed. The the shift lever on rear left side of components of the valve and spring transmission case. If space permits, place container having approximately two 2 quart NOTE: The control valve assembly capacity under drain cap, located can also be disassembled by using an as shown in Unscrew the arbor press with suitable tools as drain plug and cooler return tube shown in Fig.

Allow oil to drain into pan. Remove the four front pump attaching bolts, Fig. Remove three 3 hex head bolts, over the protruding input shaft, lockwashers, valve cover and valve Fig. Remove pump drive gear, front pump Remove shift lever and associated g a s k e t , and Woodruff key, Fig.

Tap with soft hammer on exposed threaded shaft, upon which shift NOTE: Two different pump assemblies lever was mounted, and pull valve are used. One includes a backing plate which must be removed before the gears are exposed. For addi- tional information and description see pages 40 and For the pump assembly with the backing plate, remove the one flat head machine screw, Fig.

Mark gears to identify for proper relocation of gear faces during reassembly, Figs. Remove the four 4 cap screws 12 with soft hammer. The drive gear point 'head , Fig. Lift the and forward clutch hub assembly adapter and reverse clutch piston, will pass through the ring gear Fig.

If necessary, tap the and forward clutch assembly to adapter with hammer to remove. To avoid damage, prevent pressure plate from Remove bearing from clutch cylinder dropping.

Force compressed air into reverse Remove ring gear snap clutch cavity while holding piston, as shown in Fig. While holding ring gear, tap with will pop up out of reverse clutch soft blunt tool on exposed face of cavity. Forward clutch cylinder Remove sealing rings as shown in will move forward to disassemble out Figs. Thrust washer can now be lifted from Piston can be removed from forward position shown in Fig. Remove clutch pressure plate as clutch cavity through one of three shown in Fig.

The twelve 12 pressure plate holes are blocked. Grasp the exposed front end of the input gear and lift straight up; drive gear and clutch assembly parts easily lift out of opening in front, Fig. Remove thrust located be- tween drive gear and planetary carrier, Fig. Stand drive gear and clutch assembly in suitable fixture and remove in- ternal external snap rings at ball bearing from the drive gear and clutch cylinder, Figs.

Do not permit drive gear to move forward after the above snap rings Fig. Disassembling Reverse Clutch are removed.

Remove forward clutch sealing rings, as shown in Figs. Remove main shaft nut shown in Fig. Using bearing puller, pull coupling from output shaft. Remove six 6 hex head bolts and lockwashers, Fig.

NOTE: The following paragraphs 30 Place transmission, with front face 31 describe alternate methods of clown, on arbor press. Using suit- removing the rear bearing. Either able tool, press down on exposed end method is equally desireable.

Protect Using grasp bearing pinion cage and output shaft from by exposed groove in outside dia- damage from fall during this opera- meter and gently pull bearing from tion. The following list contains a number 4.

Installation of adapter on trans- of assembly problems which it is mission case should follow the felt requires special attention procedures outlined, Page 39, during the reassembly of the direct Paragraph for tightening the drive transmissions. The informa- capscrews. If bolts are not alter- tion below includes the locations in nately tightened a small amount, the manual where information and damage can result to the needle instructions are available on these bearing and its input shaft race.

Protection of pump seal during 1. Installation of proper pinion cage assembly of pump assembly over input and output shaft assembly in trans- drive gear, Page 41, Paragraph Mounting pump to correspond to the rotation, Page 42, Paragraph 2.

Selection of the proper clutch. Check input shaft to insure that it rotates freely when turned by 3. Selection of the proper ring gear hand after transmission is assem- snap ring, Page 33, Paragraph bled Page 42, Paragraph.

Cleanliness is absolutely necessary 4. Oil seals and bearings are best in- during assembly to insure proper stalled by using an arbor press, functioning of transmission. Trans suitable fixtures, and tools to mission case passages should always properly align parts being assembl- have pipe plugs removed to allow for ed. Hammering seals and bearings thorough cleaning. When available, into position can severly damage use compressed air to dry parts be- parts.

Do not wipe parts with rags to clean or dry 5. Automatic transmission fluid type them as lint from the cloth may s u f f i x b e u s e d t o cause erratic valve action. Petroleum jelly may be used on 2. Inspect all parts for damage or gaskets or other parts that must be wear. Replace defective parts. A l l rubber parts will slide more 3. All gaskets, oil seals and rubber freely if lubricated. Tighten all bolts and screws evenly Judgement should then be exercised to the recommended torque, See page as to the need for replacing these Caution should be observed to insure 1.

Using arbor press and suitable tool, as shown in Fig. Place front of bearing retainer seal into the bearing retainer until on arbor press table. Apply a suit- the rear face o f t h e o i l s e a l i s able sealant to the outside diameter flush with the rear face of the of seal before installing squarely bearing retainer,.

Installing Oil Seal. Insert the baffle inside the trans- 6. Place the pinion cage and output mission case with the notched side shaft assembly on a 5 inch diameter toward the front and the curve by long assembly tool, which of baffle toward the bottom the i n t u r n i s mounted on an arbor transmission case, Fig.

Press down on t h e h a f f l e a n d s n a p NOTE: I f t h e transmission case the rectangular at each end does not have bronze bushings for on to the cast, bosses at each side the output shaft journal, use only O S the case, F i g. These the output shafts of the design with bosses will position and hold the three o i l g r o o v e s a s shown in baffle in its proper place. See page 52 paragraphs 1 8 for further information. Place the transmission case over the pinion cage and output shaft assemb- ing until clean and lubricate with l y s o t r a n s m i s s i o n c a s e r e s t s automatic transmission fluid, type , squarely on arbor press table which , suffix A, before assembly.

With the groove on the outside dia- meter of the bearing located toward the rear of the transmission, as a. Inspect the bearing bore for possi- shown in Fig. Inspect the rear bearing for scored or damaged balls and races and for Using an assembly tool designed to loose or cracked ball retainer.

Inspect the bearing for presence of dirt. Inspect and lubricate the hub dia- Place bearing retainer gasket on meter of rear coupling which runs rear of transmission case as shown in contact withtherubber lip of oil in Fig. Gasket may be coated seal. If this surface is scratched with petroleum jelly for easier or burred, replace the part with a assembly. Place bearing retainer in place on rear of case as shown in Install six 6 lockwashers and After lubricating the splined por- six 6 hex head bolts; tion of coupling, assemble the tighten bolts to a torque of splined coupling onto the externally pounds-feet.

When the coupling has been aligned squarely on the output shaft and hand assembly has proceeded as far as possible, place a suitable tool on the coupling, Fig. Assemble main shaft nut in place on output shaft and tighten to pres- cribed torque of to feet. This should bring inner race of bearing solidly in contact with the shoulder on output shaft and eliminate any detectable end play in the coupling and output shaft combination, Fig.

Install clutch pressure plate Place the ring gear on a clean sur- front with flat face down in con- face with the external teeth up, as tact with clutch plate, as shown in shown in Fig. Remove all dirt and solid particles Install clutch spring snap ring, from the shoulder inside the gear Fig. Assembly is complete formed by the top of the internal when snap ring is squarely and firm- helical gear, Fig.

With the smoothly ground face in the splines. With the concave side of the clutch with the sealing ring; remove all spring down, install in ring gear, burrs or scratches and lubricate as shown in Fig. Assembly is before assembly. Install in forward clutch cylinder a snap ring. Lubricate entire forward clutch cylinder before continuing Assemble on the forward clutch assembly. Installing Clutch Sealing Ring. After aligning the assembled forward While maintaining load from arbor clutch piston squarely on the assem- press, assemble ring gear snap ring, bled forward clutch cylinder, press Fig.

Tap ring while in place the clutch piston into the forward to insure full seating of ring in c l u t c h c y l i n d e r , as shown in Fig. This is a hand assembly and should not require pounding by ham- mer or pressing on arbor press. Place the combined parts, as assemb- led in steps 18 through 24 in- on a support which has been placed on an arbor press, Fig. Center the clutch spring in the ring gear. Place the parts assembled in steps 25 through 27 inclusive into the open top of the assembly described i n s t e p 2 8 , F i g.

Place a suitable assembly tool squarely on top of the forward clutch cylinder and press down with the arbor press until the forward clutch cylinder is firmly seated on the snap ring and the groove for the snap ring is fully exposed.

Check, by looking into rear of ring gear, to be sure that the clutch spring bearing ring is properly assembled on the forward clutch piston. Installing Ring Gear Snap Ring. Place the forward clutch hub on a in the forward clutch Assemble Woodruff key in the snap ring is fully uncovered. Lubricate the outside diameter of the drive gear on that area which Invert the parts referred to in step 34 and install snap ring in the presses into the forward clutch hub.

Tap ring after assembly with suitable tool to insure full seating in groove. Install two 2 forward clutch seal- ing rings in grooves provided on drive gear, Fig.

After in- stalling rings in groove, hook ends and turn rings to insure freedom of rotation. Place bearing over protruding drive gear With drive gear and clutch hub in and squarely into bore at front of assembly tool as shown in Figs.

Lower ring gear and clutch assembly u n t i l i n t e r n a l t e e t h o f c l u t c h plates begin to engage teeth on for- ward clutch hub. Rotate ring gear to align teeth of plates with teeth on clutch hub. Do not force ring as damage to teeth on plates will result. When ring gear and clutch are in correct position, rear end of ring gear should be against the assembly tool or flush with the rear thrust face of drive gear, as shown in Fig.

Do not re- move drive gear and clutch assembly from assembly tool or move drive gear forward until steps 39, 40 and 41 are completed. Any movement of the drive gear forward will result in the clutch plates becoming dis- engaged with clutch hub and sealing rings moving out of position. Assembling Ring Gear and Clutch Fig. Place the parts assembled in steps 1 through 17 inclusive, on a smooth, clean surface in the upright posi- tion indicated in Fig.

In this position, the rear face of rear coupling will provide sufficient base to enable assembly to proceed. Install external snap ring on drive gear, Fig.

Install internal snap ring in clutch cylinder, Fig. Coat the drive gear thrust washer with petroleum jelly and assemble into pinion cage and output shaft assembly, as shown in Fig. Center the washer carefully over bore provided for rear of drive gear. After lubricating the rear end of the drive gear and checking centered position of the thrust washer, in- stall the drive gear and clutch assembly into the case and pinion cage and output shaft assembly, Fig.

Care and proper center- ing must be exercised at this point to prevent damage to the bushings when the rear diameter of the drive gear enters the output shaft. Install ing Snap Ring.

The holes should be free from dirt and all springs should be firm- ly seated. Coat the three 3 dowel pins with petroleum jelly and assemble them in the three 3 grooves provided at the outside diameter of the reverse clutch cavity, Fig. Assembly is complete when the dowel pin is firmly seated on end and into the groove, as far as groove contour will permit. A proper- ly assembled reverse pressure plate will appear as shown in Fig.

I f p r e s s u r e p l a t e does not drop down to position, approximately flush with transmission case front face, check the 3 dowel pins for possible misalignment. Install reverse clutch plate over exposed teeth of ring gear. Clutch must be firmly and evenly seated on the case face form- ing the rear of the reverse clutch cavity, Fig. Install the reverse clutch pressure plate with the twelve 12 holes in the downward position. Align the cast slot in the pressure plate with the large oil hole in the front face of the transmission case, Fig.

Since the twelve 12 pressure plate springs are not evenly spaced, the slot and oil hole alignment are Fig. Oil passages free from pre- sence of dirt and obstruction. Reverse clutch cavity outer wall, smooth clean surface free from scratches or burrs and coated generously with petroleum jelly. Coat sealing ring with petroleum jelly and install in groove of adapter hub, as shown in Fig. After lubricating sealing ring with petroleum jelly, assemble in groove of reverse clutch piston, as shown in Fig.

Coat thrust washer with petroleum jelly and assemble, as shown in Fig. Assembling Sealing Ring. Place the reverse clutch piston, as assembled in step 51 on the adapter, as assembled in step 50, Fig. Press down on reverse clutch piston while pulling a smooth, clean screw- driver blade around the exposed portion of the sealing ring.

This will aid the chamfered bore in the adapter to compress the sealing ring PASSAGE into the groove in the outside dia- meter of the piston. Assembly can be completed by using hand pressure Fig. Exposed face of clutch piston should be flush with adjacent surrounding surface on adapter when assembly is completed. With parts assembled, in steps 1 through 49 inclusive, resting on the rear face of coupling, coat the ex- posed front of the transmission case with petroleum jelly and assemble the adapter gasket, Fig.

The adapter can now be pulled down squarely, until contact with the case is made, by alternately tightening the cap screws a small amount and checking frequently for binding. Installing Reverse Clutch Piston in Adapter. Lift combined parts assembled in steps 50 through 53 inclusive, above parts assembled in steps 1 through 49 inclusive, as shown in Fig.

Align the oil holes as indicated in Fig. When the shoulder on the rear of the adapter has entered the mating bore in the reverse clutch cavity, locat- ed in the front of the transmission case, and a check of the gap between case and adapter indicates the Fig. Mounting Adapter to Case. If the pump assembly on your OIL SEAL transmission includes a back- ing plate see page 48 para- graphs 5 through 10 for im- portant information concern- ing its assembly and service.

The front pump assembly without the backing plate can only be used with the new adapter Fig. Collect the parts shown in Fig. Oil seal lip for brittle condition, cracks and cuts. Oil seal outside diameter for dents or scratches. Gear teeth for burrs. Place pump housing squarely on arbor IN press table. Apply a suitable seal- ant to the outside diameter of seal before installing squarely into bore of housing with seal lip positioned as shown in Fig. Caution should be observed to insure that too much sealant is not used, that any excess is wiped away after the seal is installed, and that the sealant does not get on the sealing element.

After seal is assembled, lubricate the pump housing with the proper transmission oil and place as shown in Fig. Install lubricated driven pump gear with identification mark as shown in Fig.

Place parts assembled in steps 1 through 56 inclusive as shown in Fig. Lubricate and install front pump gasket, Fig. Cover the splined portion of the input drive gear with asuitable tool to protect the rubber lip on the seal during the assembly of the re- maining front pump parts, Fig.

With the pump driven gear proper Y installed in the front pump housing, assemble the housing and pump driven gear squarely over the protruding input shaft and assembly tool. A slight rotation of the pump housing and pump driven gear will allow en- gagement of pump gear teeth, Fig.

Install Woodruff key, Fig. Install the pump drive gear on the input shaft, with one of the Wood- ruff key slots in drive gear mating with the Woodruff key on the input shaft, Fig. NOTE: The two pump gears should be assembled so that the same gear faces are matched with the machined face of the pump housing as found at disassembly. Marks should have been applied at disassembly to in- sure proper reassembly, Page Fig. With the pump assembled squarely against the adapter and pump gasket, and the seal assembly tool removed, install four 4 hex head bolts, Fig.

Tighten hex head bolts evenly to torque of pounds-feet. Check freedom of rotation of pump gears in pump housing by rotating the input shaft. Orient the pump mounting bolt holes and arrow indicating direction of to correspond with direction of rotation required by the engine, Fig. If not in- stalled for the proper rotation the pump will not produce oil pressure to operate the transmission when engine is started. Collect the valve and spring assemb- ly components, as shown in Fig.

After carefully checking the press- ure regulator valve and the bore in the forward and reverse gear mission valve for dirt and burrs, I! Place parts assembled in steps 1 through 69 inclusive, on clean flat surface. Into the opening provided high on the right-rear side of the transmission case, place the valve and spring assembly, threaded end entering first, Fig.

This is a hand assembly and is completed when the valve and spring assembly bottoms against the shoulder in the case bore. Place the assembled parts in a suit- able assembly fixture, Fig. Turning handle of threaded plunger, compress the regulator valve spring until the groove for the snap in the pressure regulator valve is fully exposed.

Install snap ring shown in Fig. The 0 ring shown in Fig. NOTE : The control valve assembly can also be assembled by using an arbor press with suitable tools, as shown in Fig. Assembly of Valve Cover Fig. To insure neutral positioning of Assemble shift lever and related valve and easier assembly of lever, parts in the order shown in Fig. Torque the hex nut 8 to 11 with bottom bolt hole in pounds-feet, Fig. Rotation of valve cover face of case as shown the valve and spring assembly in Fig.

I f valve cover, lockwashers and hex v a l v e b i n d s i n r o t a t i o n , remove and head bolts as indicated in Fig. The screen end of the oil should be approximately inch below face o f when the assembly is correctly. Installation of Breather Assembly Fig. Neutral switch cam correctly assembled as shown in 1. Unscrew three 3 hex head bolts, Fig.

Discard valve 3. Assemble valve cover and neutral cover, gasket, hex head bolts and switch with neutral switch located lockwashers. Use the three 2.

Shift control lever into neutral 3 inch long hex head position, see page 23 Fig. Tighten hex head bolts to re- switch kit. Assemble neutral switch commended torque of 8 to 11 cam, m a k i n g s u r e t o a l i g n t a n g feet and assemble starter solenoid on cam with slot in valve, as wires to switch. Neutral Switch Parts Fig. Assemble the oil strainer assembly portion of this manual. This re- and cooler line return sults from changes which have been made since the first introduction of bushing in the order shown this model.

In this section the in- in Fig. The small end of oil formation and description is pre- strainer assembly should protrude sented for those features which are out of tapped hole in case approxi- no l o n g e r i n c o r p o r a t e d i n t h e mately inch when installed to current production models. Place oil filler cap and dipstick s h o w n i n F i g. O n assembly in the oil filler tube pro- the other hand, the old bushing vided on rear left side of transmis- is not threaded the entire sion case, Fig.

Either com- screw permits. Installation of Oil Strainer Assembly Fig. In addition to the breather assembly shown in Fig. The above illustrations demon- strate the manner in which these breather assemblies are installed. The breather supplied for those installations where a pressure type breather replaces the breather shown in Fig.

This breather is used with an internally threaded bushing which presses into the case before the installation 87 Installation of Breather Assembly of the threaded breather assembly.

This pump can be used with either of the two different adapter i b u t i t should normally be found assembled on the one shown in Fig. Any of var ver- s i o n s o f t h e i n p u t , shafts may be used with this pump, b u t the proper key must always be used with each shaft See Fig. Collect parts shown in Fig. Oil seal lip for brittle i cracks and cuts. Place pumpsquarely on arbor Installing Seal.

Install the flat head machine screw and tighten to final torque of 25 to 35 pounds-inch, Fig. Check rotation of gears as assembled in pump housing; disassemble and in- spect if gears do not turn freely. Place assembled transmission on rear face of coupling in upright posi- tion, as shown in Fig. I Fig. Install Woodruff key. Use a s u i t a b l e t o o l t o c o v e r the splined portion of the input shaft and thereby protect the rubber lip on the oil seal during assembly of front pump, Fig.

After checking the following items, place the front pump assembly, steps 5 through 10 inclusive, squarely down over the protruding input shaft Fig. Screw through Sacking Plate a Alignment of Woodruff key slot in drive gear with mating Woodruff key on the input shaft. Orientation of pump mounting bolt holes and direction of rotation arrow, depending on desired direction of input rotation, Fig.

Freedom of rotation of pump gears in housing. NOTE : The location of the markings on the pump housing fying the orientation of the pump assembly on the adapter for right left hand rotation will vary depend- ing upon which pump assemblies and adapters are used. The newer pump assembly with backing plate, identified by the rib on the pump housing, w i l l b e p r o p e r l y mounted when the marking on the housing appears as shown in Fig.

If the same pump were mounted on the new adapter Fig. ADAPTER a The older pump assembly with backing plate, identified by the absence of the rib on the pump housing, would appear as i l l u s t r a t e d i n Fig.

This older pump assembly with backing plate could also be mounted on the new adapter Fig. With front pump assembly resting squarely on gasket and seal assembly tool removed, install four 4 l o n g hex head bolts, F i g. Tighten hex head bolts evenly to torque of 17 to 22 pounds-feet. New pressure regulator valves have a relief at the outer dia- meter at the closed end for the elimination of regulator valve buzz, F i g.

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