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SERVICE PROCEDURES (Continued)
CAUTION: The transmission oil cooler requires a
two stage flushing procedure due to an internally
mounted thermostat. Failure to follow the procedure
can result in severe transmission damage.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1–1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER
IN
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906A
(1) Remove cover plate filler plug on Tool 6906A.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents. DO NOT use solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906A.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Remove the transmission oil cooler from the
vehicle. Refer to the Group 7, Cooling System, for the
proper procedures.
THE
AREA
WHERE
AW–4 AUTOMATIC TRANSMISSION
(8) Remove the transmission oil cooler thermostat.
Refer to the Group 7, Cooling System, for the proper
procedures.
(9) Re-install the thermostat cover onto the oil
cooler and install the snap ring.
(10) Re-connect the oil cooler to the transmission
cooler lines.
(11) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
NOTE: This flushes the bypass circuit of the cooler
only.
(12) Turn pump OFF.
(13) Remove the thermostat cover from the oil
THE
cooler.
(14) Install Special Tool Cooler Plug 8414 into the
transmission oil cooler.
(15) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
NOTE: This flushes the main oil cooler core pas-
sages only.
(16) Turn pump OFF.
(17) Remove the thermostat cover from the oil
cooler.
(18) Remove Special Tool Cooler Plug 8414 from
the transmission oil cooler.
(19) Install a new thermostat spring, thermostat,
cover, and snap-ring into the transmission oil cooler.
(20) Install the transmission oil cooler onto the
vehicle.
(21) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(22) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(23) Place CLEAR suction line into a one quart
container of Mopar ATF Plus 3, type 7176 automatic
transmission fluid.
(24) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(25) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum trans-
mission case and valve body can be repaired by the
use of Heli-Coils, or equivalent. This repair consists
of drilling out the worn-out damaged threads. Then
tap the hole with a special Heli-Coil tap, or equiva-
lent, and installing a Heli-Coil insert, or equivalent,
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