AMC Coupes/Sedans/Wagons 1975-1988 Repair Information

Adjustments

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LINKAGE



Pacer
COLUMN SHIFT
  1. Detach the shift rods from the shift levers. Insert a 3 / 16 in. (4.76mm) drill through the column shift lever holes.
  2.  
  3. Shift into Reverse and lock the column with the ignition key. Position the First/Reverse shift lever in Reverse.
  4.  
  5. Adjust the shift rod trunnion to a free pin fit in the outer shift lever. Tighten the trunnion locknuts.
  6.  
  7. Unlock the column and move the gearshift to Neutral. Both of the transmission out shift levers should be in the Neutral detent.
  8.  
  9. Repeat Step 3 for the Second/Third shift rod trunnion.
  10.  
  11. Withdraw the drill from the column levers. Shift through all gears and check for a free crossover into Neutral.
  12.  
  13. Shift into Reverse and lock the column. The column should lock without any binding.
  14.  

FLOOR SHIFT
  1. Place the transmission shift levers in Neutral.
  2.  
  3. Loosen the Second/Third transmission lever attaching nut and adjusting bolt.
  4.  
  5. With the First/Reverse shift rod in the Neutral position, align the Second/Third shift rod so that its notch is exactly aligned with the notch in the First/Reverse shift rod.
  6.  
  7. Tighten the adjustment bolt and attaching nut.
  8.  
  9. Shift through all of the gears being particularly careful for binding in the First-to-Second shift.
  10.  
  11. To adjust the back-up light switch, loosen the jam nuts and then slide the switch forward or backward, as necessary. Tighten the jam nuts.
  12.  

Except Pacer

COLUMN SHIFT

See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: On column shift models, make sure the shift levers are properly aligned

  1. Disconnect the shift rods from the transmission shift levers. Insert a 3 / 16 in. (4.76mm) drill through the column shift lever holes.
  2.  
  3. Shift into Reverse and lock the column with the ignition key. Position the transmission First/Reverse shift lever in Reverse.
  4.  
  5. Adjust the shift rod trunnion to a free pin fit in the transmission shift lever. Tighten the trunnion locknuts.
  6.  
  7. Unlock the column and move the gearshift to Neutral. Both of the transmission shift lever should be in the Neutral detent.
  8.  
  9. Repeat Step 3 for the Second/Third shift rod trunnion.
  10.  
  11. Remove the drill from the column levers. Shift through all gears and check for a free crossover into Neutral.
  12.  
  13. Shift into Reverse and lock the column. The column should lock without any binding.
  14.  

3-SPEED FLOORSHIFT

See Figure 2

Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the three-speed floor shift linkage components

  1. Place the transmission shift levers in their neutral positions.
  2.  
  3. Loosen the second/third lever adjuster.
  4.  
  5. Keeping the first/reverse shift rod and transmission lever in the neutral position, align the second/third rod so the shift notch is exactly aligned with the first/reverse shift notch. Tighten the adjuster.
  6.  
  7. Operate the linkage and check for full engagement of all gears and a smooth crossover from first to second.
  8.  
  9. If there is a reverse lockup rod to the steering column, loosen both of the locknuts about 1 / 2 in. (12.7mm) each. Shift into reverse and lock the column. You may have to rotate the lever at the bottom of the column up into the locked position. Tighten the lower locknut until it contacts the trunnion. Tighten the upper locknut while holding the trunnion centered. Unlock the column and shift through gears. Shift into reverse and lock the binding.
  10.  

REMOVAL & INSTALLATION - Except Eagle



Open the hood to avoid damage when the rear crossmember is removed. If the overdrive and transmission are to be separated, first engage then disengage the overdrive with the clutch pedal depressed and the engine running.

  1. Matchmark the driveshaft and rear axle yoke for correct installation. Split the rear universal joint and slide the driveshaft off the back of the transmission. Support the transmission with a jack.
  2.  
  3. Detach the column shift mechanism linkage from the transmission, and disconnect the clutch linkage and speedometer cable; disconnect the back-up light switch wiring, and TCS switch wiring, also.
  4.  

On a floorshift, remove the shift lever. Remove the boot and unbolt the lever. Detach the column reverse lockup rod. Pull the lever and gauge out together. Support the engine.

  1. Disconnect the overdrive wiring. Remove the rear transmission support cushion bolts. Also remove the starter on four cylinder models.
  2.  
  3. On Pacers with overdrive, remove the cotter pin from the parking brake equalizer and disconnect the front cable from the equalizer. Remove the cable adjuster and hooks from the floorpan bracket and lower equalizer and rear brake cables to provide clearance. Also, remove the ground strap from the floorpan.
  4.  

On V8 models with dual exhaust or dual catalytic converters, exhaust pipes must be disconnected from manifolds and lowered to gain working clearance.

  1. On HR1s, remove the throwout lever protective boot and disengage the clutch cable from the lever. Also remove the inspection cover at the front of the clutch housing.
  2.  
  3. Remove the transmission support crossmember except on Pacers; remove the crossmember with the transmission on those models. Remove the two lower studs which hold the transmission to the bell housing and replace these two studs with two long pilot studs on 150Ts and SR4s. On the HR1, remove the catalytic converter support bracket attaching bolts from the transmission rear support.
  4.  
  5. Remove the two top studs and slide the transmission assembly along the pilot studs and out of the car. On HR1s, support the engine and remove the clutch housing to engine bolts and remove the clutch and transmission as an assembly.
  6.  

To install:
  1. Fill the slots in the inner groove of the throwout bearing with light temperature grease and soak the crankshaft pilot bushing wick in engine oil. Fit the throwout bearing and the sleeve assembly in the clutch fork. Center the bearing over the clutch lever. Shift 150Ts and SR4s into first gear.
  2.  
  3. Install two pilot studs in the clutch housing, instead of the lower clutch housing cap screws on 150Ts and SR4s.
  4.  
  5. Carefully slide the transmission into place. Be careful not to damage the clutch driven plate splines while mating them with the transmission input shaft. It may be necessary to raise the front of the engine for the HR1.
  6.  
  7. Install the upper screws, which attach the case to the housing. Remove the pilot studs and install the lower cap screws.
  8.  
  9. If the car is equipped with a floor shift, install the shift lever retainer and shift rods, if removed.
  10.  
  11. Attach the speedometer cable, connect the back-up light switch wires and the Transmission Controlled Spark (TCS) wire, if so equipped. On the HR1, connect the clutch cable and adjust as necessary. Also install the inspection cover and the catalytic converter bracket bolts.
  12.  
  13. Raise the transmission. Attach the rear crossmember and support to the transmission. Fasten the crossmember to the side sills and finger-tighten the bolts. Install and tighten the crossmember-to-support bolts. Tighten the crossmember stud nuts. Install the parking brake cables and ground strap on Pacer.
  14.  
  15. Attach the exhaust pipes to the exhaust manifolds, on V8 engines, if they were removed.
  16.  
  17. Install the front U-joint yoke on the transmission. Do the same for the rear U-joint at the differential. Be sure the alignment marks made earlier line up.
  18.  
  19. Connect the shift rods on the column shift transmissions and the reverse lockup rod on the floorshift transmission. Check the transmission oil level and add lubricant, as needed.
  20.  
  21. Remove the supports and lower the car.
  22.  
  23. Install the shift lever if the car is a floorshift transmission.
  24.  
  25. Adjust the shift linkage, if it was disturbed.
  26.  

1980-81 Eagle

  1. Shift the transmission into neutral.
  2.  
  3. Remove the screws attaching the gearshift lever bezel and boot to the floorpan.
  4.  
  5. Slide the bezel and boot upward on the gearshift lever to provide access to the lever attaching bolts.
  6.  
  7. Remove the bolts attaching the gearshift lever to the lever mounting cover on the transmission adapter housing and remove the gearshift lever.
  8.  
  9. Remove the bolts attaching the gearshift lever mounting cover to the transmission adapter and remove the mounting cover to provide access to the transfer case upper mounting stud nut in the transmission adapter housing.
  10.  
  11. Remove the nut from the transfer case upper mounting stud located inside the transmission adapter housing.
  12.  
  13. Raise the automobile.
  14.  
  15. Remove the skid plate.
  16.  
  17. Remove the speedometer adapter retainer bolt and remove the retainer, adapter, and cable. Discard the adapter O-ring and plug the adapter opening in the transfer case to prevent excessive oil spillage.
  18.  

Mark the position of the speedometer adapter for assembly alignment reference before removing it.

  1. Mark the driveshafts and axle yokes for assembly alignment reference and disconnect the driveshafts at the transfer case.
  2.  
  3. Disconnect the back-up lamp switch wire.
  4.  
  5. Place a support stand under the engine.
  6.  
  7. Support the transmission and transfer case using a transmission jack.
  8.  
  9. Remove the rear crossmember.
  10.  
  11. Remove the catalytic converter bracket from the transfer case.
  12.  
  13. Remove the bolts attaching the transmission to the clutch housing.
  14.  
  15. Remove the transmission and transfer case as assembly.
  16.  
  17. Remove the nuts from the transfer case mounting studs and remove the transmission from the transfer case.
  18.  

To install:
  1. Install the transmission on the transfer case. Install and tighten all the transfer case mounting stud nuts to 26 ft. lbs.
  2.  
  3. Support the transmission/transfer case assembly on a transmission jack.
  4.  
  5. Align the transmission clutch shaft with the throwout bearing and clutch disc splines and seat the transmission against the clutch housing.
  6.  
  7. Install and tighten the transmission-to-clutch housing attaching bolts to 55 ft. lbs.
  8.  
  9. Connect the driveshafts to the transfer case yokes. Tighten the clamp strap bolts to 15 ft. lbs.
  10.  
  11. Install the rear crossmember. Tighten the crossmember attaching bolts to 30 ft. lbs.
  12.  
  13. Connect the back-up lamp switch wire.
  14.  
  15. Install the replacement O-ring on the speedometer adapter and install the adapter and cable, and the retainer. Tighten the retainer bolt to 100 in. lbs.
  16.  


WARNING
Do not attempt to reuse the original adapter O-ring. The ring is designed to swell in service to improve its sealing qualities, and could be cut or torn during installation if reuse is attempted.

  1. Attach the catalytic converter bracket to transfer case. Tighten the retaining nuts to 26 ft. lbs.
  2.  
  3. Check and correct the lubricant levels in the transmission and transfer case if necessary.
  4.  
  5. Install the skid plate. Tighten the skid plate attaching bolts to 30 ft.lb. torque.
  6.  
  7. Remove the stand used to support the engine and remove the transmission jack if not removed previously.
  8.  
  9. Lower the automobile.
  10.  
  11. Clean the mating surfaces of the gearshift lever mounting cover and the transmission adapter housing.
  12.  
  13. Apply RTV type sealant to the gearshift lever mounting cover and install the cover on the transmission adapter housing. Tighten the cover bolts to 13 ft. lbs.
  14.  
  15. Install the gearshift lever on the mounting cover. Be sure the lever is engaged with the shift rail before tightening the lever attaching bolts. Tighten the lever attaching bolts to 18 ft. lbs.
  16.  
  17. Position the gearshift lever boot and bezel in the floorpan and install the bezel attaching screws.
  18.  

1982-88 Eagle See Figure 3

Click image to see an enlarged view

Fig. Fig. 3: The transfer case upper mounting bolt is located under the lever coverEagle models

  1. Shift the transmission into Neutral.
  2.  
  3. Remove the screws attaching the gearshift lever bezel and boot to the floorpan.
  4.  
  5. Slide the bezel and boot upward on the gearshift lever to provide access to the lever attaching bolts.
  6.  
  7. Remove the bolts attaching the gearshift lever to lever mounting cover on transmission adapter housing and remove the gearshift lever.
  8.  
  9. Remove the bolts attaching the gearshift lever mounting cover to the transmission adapter, and remove the mounting cover to provide access to the transfer case upper mounting stud nut in the transmission adapter housing.
  10.  
  11. Remove the nut from the transfer case upper mounting stud located inside the transmission adapter housing.
  12.  
  13. Raise the automobile.
  14.  
  15. Remove the skid plate.
  16.  
  17. Remove the speedometer adapter retainer bolt and remove the retainer, adapter, and cable. Discard the adapter O-ring and plug the adapter opening in the transfer case to prevent excessive oil spillage.
  18.  

Mark the position of the speedometer adapter for assembly alignment reference before removing it.

  1. Mark the driveshafts and axle yokes for assembly alignment reference and disconnect the driveshafts at the transfer case.
  2.  
  3. Disconnect the back-up lamp switch wire.
  4.  
  5. Place a support stand under the engine.
  6.  
  7. Support the transmission and transfer case using a transmission jack.
  8.  
  9. Remove the rear crossmember.
  10.  
  11. Remove the catalytic converter bracket from the transfer case and the brace rod from the bracket.
  12.  
  13. Remove the bolts attaching the transmission to the clutch housing.
  14.  
  15. Remove the transmission and transfer case as assembly.
  16.  
  17. Remove the nuts from the transfer case mounting studs and remove the transmission from the transfer case.
  18.  

To install:
  1. Install the transmission on transfer case. Install and tighten all the transfer case mounting stud nuts to 26 ft. lbs.
  2.  
  3. Support the transmission/transfer case assembly on a transmission jack.
  4.  
  5. Align the transmission clutch shaft with the throwout bearing and clutch disc splines and seat the transmission against the clutch housing.
  6.  
  7. Install and tighten the transmission-to-clutch housing attaching bolts to 55 ft. lbs.
  8.  
  9. Connect the driveshafts to the transfer case yokes. Tighten the clamp strap bolts to 15 ft. lbs.
  10.  
  11. Install the brace rod and the rear crossmember. Tighten the attaching bolts to 30 ft. lbs.
  12.  
  13. Connect the back-up lamp switch wire.
  14.  
  15. Install a replacement O-ring on the speedometer adapter and install the adapter and cable, and retainer. Tighten the retainer bolt to 100 inch lbs.
  16.  


WARNING
Do not attempt to reuse the original adapter O-ring. The ring is designed to swell in service to improve its sealing qualities and could be cut or torn during installation if reuse is attempted.

  1. Attach the catalytic converter bracket to the transfer case. Tighten the retaining nuts to 26 ft. lbs.
  2.  
  3. Check and correct the lubricant levels in the transmission and transfer case, if necessary.
  4.  
  5. Install the skid plate. Tighten the skid plate attaching bolts to 30 ft.lb. torque.
  6.  
  7. Remove the stand used to support the engine and remove the transmission jack if not removed previously.
  8.  
  9. Lower the automobile.
  10.  
  11. Clean the mating surfaces of the gearshift lever mounting cover and the transmission adapter housing.
  12.  
  13. Apply RTV type sealant to the gearshift lever mounting cover and install the cover bolts to 13 ft. lbs.
  14.  
  15. Install the gearshift lever on the mounting cover. Be sure the lever is engaged with the shift rail before tightening the lever attaching bolts. Tighten the lever attaching bolts to 18 ft. lbs.
  16.  
  17. Position the gearshift lever boot and bezel in the floorpan and install the bezel attaching screws.
  18.  

 
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