Delayed Engagement Into Reverse - 722.3, 722.5

COMPLAINT DESCRIPTION:
After engaging shift selector into reverse gear position, transmission seems to momentarily freewheel during throttle application. Reverse then engages with harsh engagement quality.

REMEDY:
1. Remove valve body and large intermediate plate. Carefully disassemble valve body to separate valve body small intermediate plate and damper housing from shift valve housing.

Observe extreme cleanliness!

Figure 1:

2. Remove valve body ball from position indicated by arrow (1, figure 1) in illustration (this ball is not reinstalled).
3. Seal hole in valve body from which ball was remove (step 2) using pop rivet, part no. 910001 00415.

NOTE:
It may be necessary to slightly reduce pop rivet head diameter to ensure a tight fit against valve body ball seat. Due to the depth of the pop rivet placement, a small spacer (e.g. threaded spark plug end) may be place onto the pop rivet nail to assist pop rivet tool in flaring the pop rivet.

4. Reassemble valve body.
5. 722.3 ONLY
Install new large intermediate plate, part no. 140 277 14 14.
Original large intermediate plate gasket may be reused if undamaged.

5.1 722.5 ONLY
Modify original large intermediate plate.

Figure 2:

Reduce diameter of bore indicated in illustration (item 1, Figure 2 inset) down to 2.1 mm diameter.
Original large intermediate plate gasket may be reused if undamaged.

5.1 Modification Technique:
Using two steel balls of approx. 7 mm diameter (eg: CIS-E mixture adjusting tower ball bearing), position one ball below and one, ball above indicated bore of large intermediate plate. By lightly striking upper ball, it is possible to reduce diameter of bore (1, Figure 2) to 2.1mm. Use 2 mm drill bit shank as gauge to verify final bore diameter.
6. Reinstall large intermediate plate, valve body, transmission filter and pan. Correct transmission fluid level.


Production Phase-In Of These Modifications:
Engines 119, 120 as of 6/92 production and transmission No. 03 747000