Throttle Valve Cable/Linkage: Service and Repair
BORG WARNER 66DOWN-SHIFT CABLE
Remove and refit
Service tool: Down-shift cable remover tool CBW 62
Removing
Fig. 19:
Unscrew the union nut (1, Fig. 19), withdraw the dipstick tube. drain and discard fluid. Remove the bolts and plain washers (2, Fig. 19) securing oil pan to transmission case. Lower the oil pan (3, Fig. 19) remove and discard the gasket.
Fig. 20:
Disconnect cable from cam.
Position cable remover tool CBW 62 on plastic ferrule, push the tool upwards until the ferrule, together with the cable is pressed out of the transmission case.
Remove the split pin, washer and clevis pin (1, Fig. 20) securing clevis to throttle linkage, discard the split pin.
Slacken the locknut (2, Fig 20). withdraw downshift cable.
Refitting
If old cable is being refitted, renew the "O" ring on ferrule. Lubricate the ferrule with clean transmission fluid.
CAUTION: Do not lubricate the inner cable.
Press the ferrule into the gear case; connect cable to cam connect clevis to throttle linkage; use a new split pin.
With the accelerator pedal released and the throttle levers resting on the idle speed screws. adjust the cable until the heel of the down-shift cam just makes contact with the down-shift valve.
With the accelerator pedal depressed, check that the lobe of the cam fully depresses the down-shift valve.
Refit the oil pan. smear the new gasket with grease.
Tighten bolts by diagonal selection to the specified torque figure.
CAUTION: Due to the method of construction it is not possible to completely drain the transmission fluid, and this should be taken into account when the transmission is being refilled.
Fill the transmission to the "MAX" mark on the dipstick.
Apply the handbrake and select "P" position.
Run the engine until it reaches normal operating temperature.
Fig. 21:
With the engine still running. withdraw the dipstick (1, Fig. 21). wipe clean and replace.
Immediately withdraw the dipstick and note the reading on the "HOT" side of the dipstick (2.Fig 21).
If necessary, add fluid to bring the level on the dipstick to "MAX" (3, Fig 21).
NOTE: The difference between the "MAX" and "MIN" marks on the dipstick represents approximately 0.75 litre (1� pints. 2 U.S. pints)