Please read instructions completely, then follow each step to install valve body.
BTE™ 401100 Kit Contains:
One (1) Turbo 400 Full Manual Valve Body
One (1) Separator Plate and Gaskets
One (1) Pressure Regulator Spring
One (1) 2nd Gear Release Spring
One (1) Vacuum Modulator Plug and O-Ring
Two (2) 1/4" Check Balls
STEP 1: Drain oil and remove transmission from vehicle. Remove oil pan.
STEP 2: Remove transmission filter. There are two types of filters: Early models have a pull-off type filter and Later models have a bolt on and off type filter.
STEP 3: Remove valve body, separator plate, check balls and center support bolt.
STEP 4: Remove pump, forward drum, high gear drum and band. Discard band, it will not be reused. Remove and discard piston and spring assembly. (See Photo 1)
STEP 5: Remove snap ring in case. Remove second gear clutch pack. Remove center support snap ring and center support. Inspect bushing for possible replacement. Remove and discard second seal ring from top (See Photo 2). Reinstall center support assembly and second gear clutch pack. For proper installation refer to a transmission manual.
STEP 6: Modifications to high gear drum: Remove piston from clutch drum. Remove and discard center cushion seal on clutch drum. Reinstall piston into clutch drum. Set clutch pack from .070" to .090" clearance.
STEP 7: Reinstall high gear drum and low gear drum.
STEP 8: Pressure regulator removal (See Photo 3). Push down on the boost valve sleeve and remove snap ring. Slowly remove the booster sleeve assembly. Note: Unit has spring tension - do not let spring assembly fly out of bore. Remove the booster sleeve and valve pressure regulator spring, spring retainer, shims and the pressure regulator valve.
STEP 9: Disassembly and assemble (See Photo 4). Replace pressure regulator spring with BTE spring provided in kit. To install the assembly, slip the retainer in place with the tangs toward the spring. Slip the spring over the small end so it comes in contact with the retainer. Push up on the booster sleeve and reinstall snap ring. Make sure it seats completely into its groove. After modifications are finished, reinstall pump assembly.
STEP 10: Remove six (6) bolts on reverse servo cover. Remove rear servo piston. Remove and discard the two rings from reverse accumulator. (See Photo 5).
STEP 11: Take one of the 1/4" check balls supplied in kit and using a flat punch tap into accumulator drain (See Photo 6)
STEP 12: Make sure surface of rear servo is flat and smooth. If warped please replace. Sandpaper can be used to even out any slight imperfections. After installing rear servo, air check for correct installation.
STEP 13: Install second gear release spring and second check ball supplied in kit. Second gear bore is located next to the center support bolt hole (See Photo 7). Install spring, then install check ball. The check ball will sit on top of the second gear release spring.
Measure the distance from the top of the check ball to the surface of the bore, the check ball must be 1/8" or .125" below the surface. If this measure is not correct, then remove the small spring and grind until the measurement is correct. Reinstall and measure again. When this distance is reached, the modification is complete. It is imperative that this measurement be correct for the transmission to shift properly.
STEP 14: Next install your BTE manual valve body. You must line up the manual valve with the detent lever of your transmission. The OEM manual valve is used with this valve body kit. The manual valve has an opening that the detent will fit into. The detent lever moves the manual valve when you manually shift the vehicle. You are now ready to install the manual valve body. Install gasket, separator plate, gasket, and BTE manual valve body. Bolt valve body to transmission, after hand starting all bolts. Tighten the 5/16" bolts to 15 foot-pounds of torque and the 1/4" bolts to 8 foot-pounds. Check to make sure manual valve moves freely and is connected properly by moving the transmission shifting arm with your hand.
STEP 15: Install filter, o-rings, pan gasket and pan.
STEP 16: Discard vacuum modulator. Remove o-ring from modulator and place on vacuum modulator plug supplied in kit.
STEP 17: Install transmission. Next adjust manual linkage as follows:
(1) Loosen adjusting nut on linkage cable
(2) Place transmission selector lever (car shifter) in park.
(3) Align linkage cable to correct adjustment and tighten nut.
(4) Move shifter to all gear locations and check detent locations on transmission. Some adjustments may be necessary.
STEP 18: Fill transmission with BTE 940600 Super Shift Racing Fluid. Be careful not to overfill. We suggest 4 quarts. Place transmission in neutral and let engine run for a few minutes. Recheck fluid level.
STEP 19: With vehicle jacked up and secure, run transmission through each gear. You will need to apply a light brake pressure to feel the second gear shift. Have the transmission in third gear at about 2200 RPMs for at least 30 seconds. If the transmission binds, shift back to second gear. You may have to repeat this a few times before the transmission fluid fills all sections of the valve body and check ball locations. If the binding continues after a reasonable amount of time, remove the valve body and repeat pressure regulator step, second gear release spring, and valve body alignment steps. Also check to make sure check ball is 1/8" below the surface.
If you have any questions regarding this instruction sheet, please call BTE™ Technical Assistance at 1-800-626-1828