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4L30E/5L40E
P0601, P0602 ............................... 41
© 2003 ATRA. All Rights Reserved
GENERAL MOTORS 3
Inhibit 4WD
Illuminate the 4WD light
NOTE: When following the service manual diagnostic procedure, you may be lead
to replace components that are not faulty. The switch resistance values listed in
the service manual maybe incorrect.
Measure Resistance
between Pin 1 and Pin 2
No buttons pushed: 8.63-9.54 ohms
Auto 4wd: 61.7-68.1 ohms
4 HI: 656-670 ohms
2 HI: 1.5-1.53 K ohms
4 LOW: 2.32-2.37 K ohms
Neutral: 1.015-1.035 K ohms
All GM
B1001, B1271, B1780
1996 and later controller replacement and reprogramming is becoming an
increasingly common service procedure for most shops. Several DTCs may be set
when programming or replacing a controller including B1001, B1271 and B1780.
All GM vehicles utilize either a Class 2 or CAN data bus. Serial Data
communications constantly occur between the different controllers on your GM
vehicle. The modules that are common to most applications are:
PCM (Powertrain control module)
BCM (Body control module)
DIM (Dash integration module)
IPC (Instrument panel cluster)
HVAC (Heating, ventalation, A/C module)
SDM (Sensing and deployment module) Airbag
If a B1001 (SDM configuration error) sets, deployment of the air bags will be
inhibited. If a B1271 or a B1780 (Radio theft lock) DTCs are set the radio will no
longer work. These DTC’s will turn on the AIRBAG lamp. In addition, the radio will
display “LOCKED” after your repair.
REPAIR: Several steps should be taken if these DTCs are set including:
1. Make sure the correct part number controllers were used for your
application.
2. Make sure the correct VIN was loaded into the replacement controller
3. After the controller was installed, turn the key off for at least 30 seconds
4. Turn the ignition ON and check for the DTCs. If DTCs B1001 and/or B1271
and/or B1271 are set as “HISTORY” codes do not replace the SDM or the
RADIO. Simply Clear all the stored DTCs.
5. Cycle the key off, then on and monitor the Airbag lamp in the dash. It
should flash 7-9 times and then go off.
NOTE: Clearing the DTCs as described above is a common part of the replacement
and reprogramming procedure on all GM applications.
© 2003 ATRA. All Rights Reserved
GENERAL MOTORS 7
4T40E/45E N-Car
Hard Shifts/ No DTC’S
4T40E/45E applications may exhibit a hard shift concern that may/may not be
intermittent. In some instances an IAT (intake air temperature sensor) DTC may
be set. The PCS commanded/actual amperages will indicate low amperage flow
through the PCS and its circuits. In addition the technician may indicate that he/
she had problems controlling the PCS amperage when using the PCS override
feature on their scan tool.
Several of the 4T40E/45E applications utilize the IAT sensor as part of the engine
torque calculations. Torque modeling is used by the PCM to determine the line
pressure calculation.
The most common causes of this concern are:
Broken wiring, generally the wire is damaged at the sensor connector
Terminal pin tension, terminal crimp damaged
A faulty IAT sensor
4T40E
Saturn Application
Possible P0731 DTC set
Saturn applications use individual DTCs to identify which gear the
transaxle was in at the time a ratio error occurred. P0731 sets if a ratio error
occurs in 1st gear while P0732 will set if a ratio error is present in 2nd, P0733 in
3rd and P0734 will set in 4th.
If a P0731 is set along with any or all of the following DTCs, address the
other DTCs first. Other DTCs which may effect diagnosis include:
If only a P0731 is set, review the stored data relating to the DTC and note
which shifter position the transaxle was in and the VSS values. If the DTC was
set in park and the VSS data indicates a VSS reading (usually around 15-35mph)
the cause of the problem is typically a poor ITCM (Internal Transmission Control
Module) ground (G115 on the back of the engine).
4T40/45E N-Car
VSS Intermittent or Possible DTC
P0502
Erratic speedometer operation, No/Erratic/Intermittent transmission shifts,
intermittent cruise control operation. Possible DTC P0502 may be set. This prob-
lem is most common on the N-body (Grand AM, Alero) applications with the 2.2L
L61 engine and J41 brakes.
A common cause for this is the VSS harness being too long in the area of the
right hand (passenger side) axle shaft area. The extra harness length allows the
harness (circuit 400 and 401) to contact the axle shaft leading to harness chaffing
and the intermittent complaint.
Reposition the conduit for the wiring leg to allow clearance at the top of the
engine rather than at the axle area. Secure the harness in the mounting clip.
VSS harness
the right hand
(passenger side)
axle shaft area.
4T40E/4T45E
Driveability Concerns N-Car 2.2L/
3.4L
Pontiac Grand AM/Oldsmobile Alero applications with the 2.2L or 3.4L engine
and the 4T40E or 4T45E transmission may experience any of the following con-
cerns in any combination:
No start
Drivability conditions (engine miss, etc.)
MIL on
Possible DTCs
Cooling Fan inoperative
ABS inoperative
Any of the above concerns can be intermittent in nature
A common cause for these concerns are Ground G-103 being loose or cor-
roded. Remove the ground from the bell housing. Clean and reinstall the ground.
You may want to install a star washer to assure proper ground continuity. The
ground strap is located on the right upper bell housing bolt on the drivers side.
Located on
the upper right
hand side of the
bell housing.
4T40E/45E
P0741 Set N-Car 3.1L (RPO LG8)
1995-2002 Chevrolet Malibu “N” body, may have the SES light is on and
P0741 (TCC stuck off) DTC set in memory. On 1995-2001 applications this
condition may not have occurred until the PCM was recalibrated for some other
concern.
The calibration loaded in the 2002 Malibu and any calibration updates that
were done on early model Malibu applications during the 2002 model year may
have a software problem. The 2002 calibration tables allowed the P0741 to falsely
set.
An updated 2003 calibration is now available to repair this concern. Visit the GM
web site to see if your vehicle requires recalibration.
http://calid.gm.com/vci/
4T40E/45E
P1815 Set N-Car
Code P1815 may also be set in conjunction with other PSA DTCs such as a
P1810. In may instances the PSA has already been replaced for this condition. If
the P1815 is set in conjunction with other PSA DTCs the problem is probably
caused by metal contamination. This can be from the manufacture or possibly
from the transmission itself. If the P1815 is set with no other DTCs it may be a
false code.
4T60E
Ratio and Application Chart
The 4T60E utilizes several different final drive, drive/driven sprocket, speed
sensor and torque converter combinations. Installing the wrong transmission,
drive/driven sprockets, final drive, speed sensor or toque converter can result in
ratio error or slip DTC’s . If a ratio error or a TCC slip DTC is present, and the
unit has been previously repaired or replaced, the converter, final drive ratio,
speed sensor and/or drive to driven sprocket ratio could possibly be incorrect for
your application. Refer to our chart to determine what transmission should be
used for your application. As with other GM vehicles the engine, transmission and
final drive ratio information for your specific vehicle model is located on the
regular production option label (RPO). The RPO label should be used exclusively to
determine which transmission fits in which vehicle body style and application
4T60E
Ratio and Application Chart
Drive/Driven Final Drive Speed Sensor
Application Year Model Codes SRTA Part #
Sprockets SRTA Part # Teeth
Cad E/K
1A2W
Body
1991 1AM 37/33 3.33 30 8686931
4.9
1A2
L28
Cad C/K
1A4W
Body
1991 1AP 37/33 3.33 30 8686932
4.9L
1A4
L26
Cad E/K
Touring 1A7W
1991 37/33 3.33 30 8686933
4.9L 1AY
L26 1A7
BUICK E
1YPW 8651955
BODY 1991 35/35
1YP
3800
2B1W
1BT 8686916
C-BODY 1991/1992 37/33 3.33 31
2BT
2B1
2C1W
C/H BODY
1992 2CL 35/35 2.84 30 8686918
TOUR
2C1
2C2W
C/H BODY
1992 2CS 35/35 3.06 30 8686919
TOUR
2C2
2C3W
C/H
1992 2CT 35/35 3.06 31 8686920
BODY
2C3
1CW
2C4W
W BODY 1991/1992 33/37 3.06 30 8686921
2CW
3.4L
2C4
C BODY 2C5W
8686922
3800 1992 2CX 37/33 3.33 31
TOUR 2C5
H BODY 2C6W
8686923
SSE,SSEI 1992 2CZ 37/33 3.33 31
TOUR 2C6
2P1W
H BODY 3.33
1992 2PH 37/33 31 8686924
SSE
2P1
© 2003 ATRA. All Rights Reserved
GENERAL MOTORS 15
4T60E
Ratio and Application Chart
F in a l D r iv e
Speed
M odel D riv e /D r iv e - SRTA Part SR TA Part
Ap p lic a tio n Ye a r Sensor
Codes n S p r o c k e ts # #
T e e th
C /H/W 2W 1W
BO DY 1992 2WA 3 5 /3 5 3 .0 6 31 8686925
3800 2W 1
2 Y LW
C /H B O D Y
1992 2Y L 3 5 /3 5 2 .8 4 31 8682926
3800
2Y 1
2Y 2W
C /H B O D Y
2Y M
3800 1 9 9 1 /1 9 9 2 3 5 /3 5 2 .8 4 30 8686927
2Y 2
1Y M
1Y Z
C /H B O D Y 2Y Z
1 9 9 1 /1 9 9 2 3 5 /3 5 3 .0 6 30 8686929
3800 2Y 4
2Y 4W
2B2W
H BO DY
1992 2BY 3 5 /3 5 3 .0 6 31 8686917
SSE
2B2
C A D E /K
2A7W
T O UR 1992 3 7 /3 3 3 .3 3 31 8686913
2 AY
L26
CAD C 2AB
BO DY 2A1 8651986
1 9 9 2 -1 9 9 3 3 7 /3 3 3 .0 6 30
T O UR 3ABW
L26 3AB
2AM
C A D E /K 2A2
1 9 9 2 /1 9 9 3 3 7 /3 3 3 .3 3 31 8651987
L26 3AM W
3AM
CAD C 2AN
BO DY 2A3
1 9 9 2 /1 9 9 3 8651988
T O UR 3AN 3 7 /3 3 3 .3 3 30
L26 3 A NW
C A D E /K 2AP
BO DY 2A4
3 7 /3 3 3 .3 3 31 8651989
EXPO RT 1 9 9 2 /1 9 9 3 3AP
L26 3APW
1AH
1 AV
CAD C
2 AV
BO DY 1 9 9 1 -1 9 9 3 3 7 /3 3 3 .0 6 30 8651990
2A5
L26
3 AV
3 AV W
© 2003 ATRA. All Rights Reserved
16 GENERAL MOTORS
4T60E
Ratio and Application Chart
4T60E
Ratio and Application Chart
4T60E
Ratio and Application Chart
F in a l
D r iv e / D r i- Speed
M odel D r iv e SRTA
A p p lic a t io n Ye a r ven Sensor
Codes SRTA Part #
S p r o c k e ts T eeth
P art #
H BO DY
4PF 8686940
3800 1994 3 5 /35 3 .0 6 31
4PFW
L27
C /H B O D Y
4W A
3800 1994 3 5 /35 3 .0 6 31 8686941
4 W AW
L27
CAD K
4 AT
BO DY
1 9 9 4 /1 9 9 5 5 AT 3 7 /33 3 .0 6 31 24201790
4 .9 L
5 AT W
L26
N BO DY
5PC
2 .3L 1995 3 3 /37 3 .2 9 29 24201792
5PCW
LD2
A BO DY
4AJ
EXPO RT
1 9 9 4 /1 9 9 5 5AJ 3 7 /33 3 .3 3 29 24201788
3 .1L
5AJW
L82
A BO DY 4 PA
3 .1L 1 9 9 4 /1 9 9 5 5 PA 3 7 /33 3 .3 3 29 24201789
L82 5 PAW
L /N B O D Y
5W F
3 .1L 1995 3 7 /33 3 .2 9 29 24201791
5W FW
L82
W BO DY 4PB
3 .4L 1 9 9 4 /1 9 9 5 5PB 3 3 /37 3 .0 6 30 24200941
LQ 1 5PBW
W BO DY 4BL
3800 1 9 9 4 /1 9 9 5 5BL 3 5 /35 3 .0 6 31 24200589
L27 5 B LW
G BO DY
5CA
3800 1995 3 5 /35 3 .0 5 31 24202030
5 C AW
L36
G BO DY
5BF
3800 1995 3 7 /33 3 .2 9 31 24200590
5BFW
L67
4KU
U VA N
1 9 9 4 /1 9 9 5 5KU 3 5 /35 3 .0 6 31 24201793
3800
5 K UW
L27
U VA N 4PM
EXPO RT 1 9 9 4 /1 9 9 5 5PM 3 5 /35 3 .0 6 30 24201794
3800 5PM W
L27
© 2003 ATRA. All Rights Reserved
GENERAL MOTORS 19
4T60E
Ratio and Application Chart
F in a l
S p e ed
M odel D r iv e /D riv e n D r iv e SRTA
Ap p lic atio n Ye ar Se n s or
C od e s S p ro ck ets SRTA P art #
Te e th
P ar t #
C /H B O D Y
5AC
38 0 0 1 9 95 3 5/3 5 3 .06 30 24 2 02 03 3
5A C W
L3 6
C /H B O D Y
5AS
38 0 0 1 9 95 3 5/3 5 2 .84 30 24 2 02 02 8
5A S W
L3 6
H BO DY 4Y Z
24 2 02 02 9
38 0 0 19 94 /1 99 5 5Y Z 3 5/3 5 3 .06 30
L2 7 5Y ZW
H BO DY
5BX 24 2 02 0 31
38 0 0 1 9 95 3 5/3 5 3 .06 31
5B X W
L3 6
H BO DY
5BK
38 0 0 1 9 95 3 5/3 5 3 .06 31 24 2 02 03 2
5B K W
L3 6
4Y M
H BO DY
5Y M 3 5/3 5 2 .84 30
38 0 0 19 94 /1 99 5 24 2 02 02 7
5Y M W
L2 7
C /H B O D Y 4Y C
24 2 02 03 4
38 0 0 19 94 /1 99 5 5Y D 3 7/3 3 3 .33 31
L6 7 5Y D W
H BO DY
4KH
SSEI 24 2 02 03 5
19 94 /1 99 5 5Y N 3 7/3 3 3 .33 31
38 0 0
5Y NW
L6 7
A BO DY
6 PA 24 2 04 17 5
3 .1L 1 9 96 3 7/3 3 3 .33 30
6 PAW
L8 2
L BO DY
6W F
3 .1L 1 9 96 3 7/3 3 3 .29 30 24 2 04 17 7
6W FW
L8 2
W BO D Y
6PB 24 2 04 17 9
3 .4L 1 9 96 3 3/3 7 3 .06 30
6P B W
LQ 1
U VA N
6PK
3 .4L 1 9 96 3 5/3 5 3 .29 30 24 2 04 18 6
6P K W
LA 1
G BO DY
6CA
38 0 0 1 9 96 3 5/3 5 3 .05 30 24 2 04 18 3
6C AW
L3 6
© 2003 ATRA. All Rights Reserved
20 GENERAL MOTORS
4T60E
Ratio and Application Chart
Final
S peed
M odel D rive/D riven D rive S R TA
Application Year S ensor
C odes S prockets S R TA P art #
Teeth
Part #
C /H B O D Y 6AC
3800 1996 6A C W 35/35 3.06 30
24204174
L36
C /H B O D Y
6A S
3800 1996 35/35 2.84 30 24204181
6A S W
L36
H BO D Y
6BX
3800 1996 35/35 3.06 30 24204173
6B X W
L36
C /H B O D Y
6Y L 24204191
3800 1996 37/33 3.29 30
6Y LW
L67
H BO D Y
6Y R 24204192
3800 1996 37/33 3.29 30
6Y R W
L67
G BO DY
6C T
3800 1996 37/33 3.29 30 24204193
6C T W
L67
N BO D Y 6C U
2.4L 1996/1997 7C U 33/37 3.05 30 24206839
LD 9 7C UW
4A F
W BO D Y 5A F
3.1L 1994-1997 6A F 35/35 3.33 30 24206840
L82 7A F
7AFW
W BO D Y
7A F 24206841
3.1L 1997 35/35 3.29 30
7A HW
L82
N BO D Y
6B S 24206842
3.1L 1996/1997 37/33 3.29 30
7B S
L82
7B S W
U VAN
1997 7YA 24206844
3.4L 35/35 3.29 30
7YAW
LA 1
H BO D Y
7AC
3800 1997 35/35 3.06 30 24206845
7A C W
L36
© 2003 ATRA. All Rights Reserved
GENERAL MOTORS 21
4T60E
Ratio and Application Chart
Final
Speed
Model Drive/Driven Drive SRTA
Application Year Sensor
Codes Sprockets SRTA Part #
Teeth
Part #
H BODY
7AS
3800 1997 35/35 2.84 30 24206846
7ASW
L36
W CAR
7AW 24206847
3800 1997 35/35 3.29 30
7AWW
L36
H BODY
SSE 7BX 24206848
1997 35/35 3.06 30
3800 7BXW
L36
6HB
W BODY
6AV 24206849
3800 1996/1997 35/35 3.05 30
7HB
L36
7HBW
W BODY
8AH
3.1L 1998 37/33 3.29 30 24211255
8AHW
L82
N BODY
2,4L 8CU
1998 33/37 3.05 30 24211256
LD9 8CUW
U VAN 8DK
24214260
3.4L 1998 8YA 35/35 3.29 30
LA1 8DKW
W BODY 9AH
24213669
3.1L 1999 9AHW 35/35 3.29 30
L82
4T65E Update
2002-2003Changes
Many changes have occurred in the 4T65E pump assembly to reduce
costs.These changes were implemented on June 24th 2002 on some models. These
changes include:
A new three-piece pump design. The new design eliminates all the selective
rotors and slides available for the previous design pump. All of the rotors use a
tapered, random pumping chamber design (staggered spaces in the rotor).
The valve body sleeve that supported the rotor in the previous design pump
has been moved to the pump body on the three-piece pump. In addition, some of
the valve bodies are designed for a fully contented PSA while others are designed
for de-contented PSAs.
A new internal wiring harness with revised wire lengths for the PWM and
PCS as well as a new connector design for the new pressure control solenoid and
PSA on 2003 models.
New Sleeve to
support the rotor
4T65E Update
2002-2003 Pump Changes (Continued)
Earlier Design
4T65E Update
2002-2003 Pump Changes
2002 2nd design three-piece pump (Part # 24225894) For all 2BCB and
2RNB models with an update level of “4” and 2RDB models with an update level of
“7” use the 24225894 pump assembly.
2003-1st design 2 piece pump (Part # 24221299) For all 2003 models with
an update level LESS than three and for model 3BCB model with update level
“4”use the 24221299 pump assembly.
Late Design
4T65E Update
2002-2003 Pump Changes
2003-2nd design 3 piece pump (Part # 24225894) For all 2003 models with an
update level GREATER than “3” use the 24225894 pump assembly. ( except the
3BCB model with an update level of “4”)
As of July 15 2002 (Julian date 196) all models use the updated 2nd design pump
and valve body assembly
If a model is not listed above it uses the 1st design 2 piece pump assembly.
As mentioned the valve body was also changed when the pump was changed.
Part numbers are as follows:
2002-1st design valve body with support (Part # 24218255) For all 2002 models
including 2RDB with update level LESS than “7” but not a 2BCB or 2RNB models
with update levels GREATER than “3” use the 24218255 valve body assembly.
4T65E Update
2002-2003 Valve Body Changes
2002 2nd design valve body without the support (Part # 24225924) For all 2BCB
and 2RNB models with an update level of “4” and 2RDB models with an update
level of “7” use the 24225924 pump assembly.
Valve Body
without support
and Six pressure
holes
4T65E Update
2002-2003 Valve Body Changes
2003-1st design valve body with support (Part 24225443) For all 2003 models
with an update level LESS than “3” and for model 3BCB model with update level
“4”use the 24225443 valve body assembly.
Valve Body
without support
and one pressure
holes
4T65E Update
2002-2003 Valve Body Changes
2003-2nd design valve body without support (Part # 24225926) For all 2003
models with an update level GREATER than “3” use the 24225926 valve body
assembly. ( except the 3BCB model with an update level of “4”)
Remember, the valve body update not only includes changes to the sleeve area
but also changes to the PSA area to accommodate or not to accommodate the de-
contented PSA assembly so always refer to the above information before ordering
parts.
The 24225926 part number is for a “new valve body”. At a future date the part
number will likely be changed as a remain valve body becomes available. Check
with your parts person to be sure your ordering the correct part number in the
future.
4T65E Update
2002-2003 Changes
An IMS (Internal Mode Switch) was added to all 4T65Es. A new design re-
placed the previous design that used a nut to hold the design together. The update
was done as a cost savings.
The new design will back service the 99 and later model 4T65Es that utilized
an IMS. As with the previous design, make sure the IMS is properly positioned on
the rooster comb before installing the transmission in the vehicle!! The IMS part
number is 24213847
.
Fastening Nut
was removed on
the new switch
4T65E Update
2002-2003 Changes
A new PSA was added to all models for 2003. This Change meant the valve
body machining, and the wiring harness/connector also changed to accommodate
the new design PSA. The update was done because of contamination issues with
the PSA. The vehicle software was also updated eliminating the PSA DTC P1810.
The new design PSA and wiring harness will not back service the previous
applications as the valve body machining has drastically changed. The part num-
ber for the previous design PSA is 24203699, the part number for the de-con-
tented PSA is 24216426
4T65E Update
2002-2003 Changes
A new design PCS was introduced for the 2003 applications. The vendor was
changed from Delphi to Bosch. To accommodate the new design solenoid, the
torque signal regulator valve spring tension was significantly increased. This new
design will become common on all applications in the years to come.
GM does not recommend interchanging the two solenoids. If the old design is
installed in a unit designed for the updated solenoid a slipping concern may oc-
cur. If the updated design is installed in an early model unit hard shift concerns
may occur. The Delphi PCS part number is 10478146, the part number for the
Bosch PCS is 24225825
4T65E Update
2002-2003 Changes
A running change is planned for the input housings on all 4T65E models. The
new housing will accommodate a new design input housing washer (End play
washer) which is wider, to fully support the sprocket support thrust bearing. The
Housing machining diameter where the washer sets is now smaller (54.5mm).
Selective Washer
4T65E Update
2002-2003 Changes
The input and 3rd one way clutches were updated as of July 17th 2002 on
some models. Full implementation is scheduled for February 2003. The new one
way clutches are a “PAWL” design (commonly refered to as a diode) rather than
the sprag design that has been used since the 4T65E was introduced in 1997. In
addition, the new pawl design assembly requires new design input clutches. The
new clutch plates utilize a wave design spline and are thicker than the previous
design components. This update was done because of durability problems with the
previous design components.
The pawl design one way clutches are not currently serviced other than as an
assembly. In other words, the pawl components are not available as individual
pieces. The clutches must be changed if the pawl design one ways are installed in
a previous design application. The pawl one way clutch part numbers are
24216516 for the input and 24216517 for the 3rd. The new input clutch part num-
ber is 24216502.
4T65E Update
2002-2003 Changes
A mid year change for the 4th clutch is planned. The 4th clutch apply plate
has an additional mounting tab added to it for easier installation. In order to ac-
commodate this change the channel plate was also updated.
The previous design channel plate cannot be used to service the updated
design with the new apply plate. The Updated design channel plate will back
service previous applications. The updated disc/plate designs will not back
service unless the channel plate is also changed. GM is planning on releasing the
parts as a service package which will include the channel plate, apply plate and
friction plates.
4T65E Update
2002-2003 Changes
Mid year change included a 2ND lock ramp was added to the pass through
connector. This design prevents the connector from side loading.
This change has no effect on service as the harness was only updated for
the new 2003 harness applications.
4T65E
Harsh or Soft Forward or Reverse
Engagment
When rebuilding a 4T65E make sure you have the correct servo springs as-
sembled in their correct locations. Because the 4T65E uses a Forward and Re-
verse servo for engagement if the springs were switched acidently you may
experiance a harsh or soft forward or reverse engagement.
Reverse Band
Length-3.079” Servo Spring
Width-2.033” Length-1.249”
Wire Dia.-0.173 Width-1.214”
Wire Dia.-0.183”
Length-1.675”
Width-1.582”
Wire Dia.-0.149”
Length-2.769”
Width-2.120”
Wire Dia.-0.219”
Length-1.500”
Width-1.613”
Wire Dia.-0.181” Forward Band
Servo Spring
4T80E
TCC Concern
Lock-up on the 2-3 Shift, Erratic TCC Operation
When encountering a TCC concern with a 4T80E transaxle, make sure you
have the correct TCC PWM solenoid installed. To verify the correct solenoid check
the Julian date. This date may be located in a number of different places includ-
ing, top cover, connector top / bottom, or body assembly. To ensure you have the
correct solenoid make sure the Julian dates are NOT within 1137-1171. If you
have a solenoid between these numbers you will need to replace the solenoid
asssembly. Part # 24212690
4T80E
Hard Shifts Possible DTCs Set
Northstar Application
Oldsmobile and Cadillac vehicles exhibiting any or all of the following condi-
tions:
Surge especially when TCC is applied
Engine backfire
Hard shifts
SES lamp or message displayed on DIC
Any combination of the following DTCs may be set, P0335, P0385,
P1372, P0341, P1599
The Northstar engine applications utilize two crank sensors and one cam
sensor. The crank sensors are different part numbers and are also different colors
(Grey and Black plastic) If one of the crank sensors fail or if a loss of signal occurs
the PCM will raise line pressure resulting in harsh shift concerns. If the Cam
sensor fails, DTCs may set and drivability concerns may be present, but shift feel
will remain normal.
Inspect the sensor connector pin tension and the terminal crimp. If pin ten-
sion is good replace the suspect sensor.
4T80E
MAF DTC, Poor Drivability, Surge
with TCC ON Under load, Lack of
Power
Oldsmobile/Cadillac G, K and K special applications with the Northstar en-
gine and the 4T80E transmission may exhibit any or all of the following condi-
tions:
Surge with TCC ON. This is most common at low speeds when you are
crowding the accelerator on a slight incline. The surge is most
commonly felt during throttle“Tip In” acceleration and generally goes
away as the throttle is held steady.
Possible Lean fuel trim DTCs, MAF DTCs, Misfire DTC’s and/or Pre cat
DTC’s may be set.
Cause: Two common causes for this condition exist, they are:
2. The air cleaner air box may be filled with water or other contaminants.
4T80E
MAF DTC, Poor Drivability, Surge
with TCC ON Under load , Lack of
Power (Continued)
Skewed MAF sensors are quite common with these applications. Generally,
fuel trim values will be around +20% when the surge is present. If this occurs,
clean or replace the MAF sensor and clear any DTCs that may be set.
If the concern is on a 95-97 application, check the air cleaner air box for
water and other contaminants. If water is present enlarge the air box water drain
hole to at least ½”.
4L30E/5L40E
P0601/P0602
1999-2002 4L30E/5L40E applications may set DTCs P0601 and/or P0602.
These codes indicate a failure in comunication with the TCM/ECM. In most in-
stances the transmission will have clutch damage. If these DTCs are set due to
their default values.
The DTCs will react as follows:
If a P0601 is set:
The TCM will flash the sport mode lamp and it will send an MIL request
message to the ECM on the second consecutive trip in which a failure
occurs.
The ECM records the freeze frame and failure record information and turns
on the MIL lamp.
The TCM defaults the transmission by, raising line pressure to maximum,
commanding 4th gear (4L30E), or 5th gear (5L40E) while inhibiting TCC and
freezing adapts. NOTE: Even though the units default to high gear, if
manual ranges are selected the unit will start in lower gears. If the
customer does not manually override the default high gear start, damage to
the transmission clutches may occur
4L30E/5L40E
P0601/P0602 (Continued)
P0602 will set if:
The PCM was not correctly programmed or has not had a calibration loaded
If a P0602 is set, the ECM will turn on the MIL and record a freeze frame
regarding the failure on the 1st drive cycle the failure is present. Possible EMI
(Electromagnetic Interference)during power up or a faulty TCM (if a P0601 is also
present). If a P0602 is present the ECM may not be properly calibrated.
Repair the EMI condition or replace the TCM if a P0602 was set. When diag-
nosing a P0601 and/or a P0602 set in the TCM do not attempt to reprogram the
TCM.
If a new TCM is required simply install it and clear the ECM DTCs that are
set. If the P0602 resets update the ECM software with the latest calibration de-
signed to address P0602 concerns.
4L60E
Slips When Cold
The Chevrolet Trailblazer, GMC Envoy and Oldsmobile Bravada utilize a new
style cooling fan. The new electronic viscous clutch fan is computer controlled. A
design characteristic of the viscous coupling may lead the customer to
misinterpret the fan operation as a possible transmission slippage condition.
Some cold start fan noise is normal, but it’s possible that the unit may exhibit
excessive noise if the vehicle has been left sitting overnight or for extended periods
of time.
It is common for the viscous coupling to leak fluid from its internal
reservoir into the coupling, leading to tremendous amounts of noise on a cold
start, or as the vehicle is accelerated.
An updated electronic clutch fan has been released to address this concern.
The new part was introduced as a running change on the 2003 model year
applications.
4L60E
Shift Complaints
2002 Trailblazer/Envoy/Bravada
Several shift quality concerns have arisen with this application including:
Delayed downshifts
4L60E
Intermittent neutral or flare, bump
when accelerating from a stop
1999 and later 4L60E applications (Silverado, Tahoe, Yukon, Suburban, Si-
erra) may exhibit a neutral condition while in D4 range and the vehicle is acceler-
ated from a stop. In addition, a complaint that the transmission neutrals, then
bangs into gear (harsh engagement) when accelerated from a stop.
First try making an adjustment, if you determain the cable is stretched re-
place the transmission shift cable and adjust.
4L60E
Surge/Shudder/Miss
1995-2002 Trucks with 4.3L (RPO L35 or LU3) engine may experience a rough
running, or surge/shudder/miss problem. This condition may be associated with
a DTC P0300. Many times this condition has been confused with a transmission
related concern.
The problem is often caused by moisture leaking from the A/C line onto the
distributor. On several of the applications, the A/C line is routed directly over the
distributor.This moisture leads to corrosion, and crossfire within the cap.
Locate the AC
hose above the Dis-
tributor and install
a foam conduit over
the hose which will
allow the water to
drain off the sides.
4L60E
Surge/Shudder/Miss (Continued)
Rotor: Inspect for black streaks on the plastic surface of the rotor or
green spots on the copper surface of the rotor terminal.
If you find evidence of corrosion replace the cap/rotor and the distributor if
deemed necessary. Take 8" of foam pipe insulation (you can buy it a hardware
store) and wrap the a/c pipe above the distributor with the pipe insulation.
4L60E
1-2 Shift Shudder Hot
2000-2002 C/K Trucks with a concern of a shift shudder during the 1-2 shift is
mostly common under light throttle conditions, after the vehicle has reached full
operating temperature and ambient temperature is high.
The problem is usually caused by a frequency signal riding on the generator
output . The signal is causing interference problems with the PCM circuitry.
4L60E
Multiple DTC’S
Some 1995-2000 M/L (Astro, Safari) vans may experience DTCs setting re-
lated to the transmission or possibly engine related systems. The most common
DTC is P0758 (3-2 solenoid) but others may set as well.
The wiring harness runs along the bell housing area and over the engine. In
many instances the harness contacts the A/C accumulator which leads to a rub-
through condition. Depending on which wires have insulation damage, a DTC will
likely set for that circuit.
The wiring harness for the front axle circuit may be chaffed near the A/C
compressor.
4L60E
Delayed Downshift
2002 Trailblazer, Envoy, Bravada, T truck 4.2L (LL8) applications may experience
“any or all” of the following conditions:
4L60E/4L65E
Updated PCS
A new pressure control solenoid was used for all 2003 model units. The ven-
dor for the solenoid is now Borg Warner and will be available in two versions. The
1st design utilizes only one flat on the aluminum body of the solenoid while the 2nd
design has two flats on the solenoid body. The 2nd design will replace the 1st de-
sign and is scheduled for use in other transmission applications starting in the
2004 model year. In addition to the solenoid change, the harness was also
changed to accommodate the updated solenoid.
The 1st design solenoid went into production at SOP (Start of Production) 2003
while the 2nd design was introduced in December 2002 as a running change for
the 2003 model year. The part number for the 1st design solenoid is 24219308
while the 2nd design part number is 24224905. The harness was updated to pre-
vent someone from interchanging the Borg Warner solenoid with the previous
Delphi solenoid. The updated harness part number is 24222891.
4L60E/4L65E, 4L80E/4L85E,
LCT 1000
DTC U1241 SET
Most OBDII equipped vehicles have DTCs related to data line problems.
Some technicians may notice a DTC U1241 set in history on vehicles equipped
with a BCM. U1241 may be stored in several of the various modules. In addition,
the technician may have noted that the DTC may have not been present until after
DTCs were requested or displayed .
U1241 DTC is caused by a loss serial data. The loss of data is caused by
your scan tool interface with some of the modules on the vehicle. When your scan
tool requests DTCs from some of the modules it becomes the master module
which results in other modules setting the U1241 in memory.
4L80E/4L85E
P0706 Set
Vehicles with a 4L80E/85E transmission may set a code P0706 (Transmission
Range Switch Performance) and may exhibit a no start condition.
In many instances the P0706 is not caused by a faulty switch. On 1999 and
later applications check for a possible recalibration for this condition prior to
replacing the switch.
Before part repairs are done check the web site http://calid.gm.com/vci/ for
updated calibration to repair the false P0706.
4L80E
TCC surge or chuggle when road
speed is between 40-50 mph
On 1994 and later Diesel 4L80E applications, customers may complain of a
surge or chuggle condition which occurs only when the TCC is applied and the
vehicle is between 40 and 50 mph. If the TCC is disabled, the surge/chuggle is
typically eliminated. You will also find that disconnecting the EGR on 6.5L Diesel
applications (RPO L56) may also eliminate the concern.
The typical cause of this concern is retarded pump timing. Checking the
pump timing requires a scan tool.
To determine if the timing is correct, note the data parameter known as “TDC
offset” using a scan tool. The value should be minus -.75 or less. A minus
number on the scan tool indicates the timing is advanced while a plus (+) value
indicates the timing is retarded. For proper operation, fuel economy and power,
the timing TDC offset should read -1.25 to -1.50. If the timing is not correct a
TDC relearn procedure should be performed after the timing has been set. . (Note:
to perform a TDC relearn on a 1994-95 application you must use a scan tool. It
should be noted that not all scan tools are capable of performing a TDC relearn
procedure)
4L80E
TCC surge or chuggle when road
speed is between 40-50 mph
(Continued)
If the Timing is incorrect:
Shut the engine off and loosen the pump bolts slightly. Using the proper
adjustment tool move the pump slightly (.040" of movement = 1 degree of timing
change). Move the pump toward the drivers side of the vehicle to advance the
timing and toward the passenger side of the vehicle to retard the timing. Once the
pump is moved slightly, tighten the pump bolts and perform the TDC offset learn
procedure using a scan tool.
Start the engine, Press the button on the scan tool to engage the TDC offset
procedure and note the value when the scan tool locks in the TDC offset value. It
should read between –1.25 and –1.50. If so, no further adjustments are needed.
Once the relearn is complete, check the TDC offset value displayed on the scan
tool again. If the offset value is not correct, shut off the engine, loosen the pump
bolts and rotate it in the desired direction. Tighten the bolts and repeat the above
TDC offset learn procedure.
4L80E
TCC surge or chuggle when road
speed is between 40-50 mph
(Continued)
To perform the TDC offset procedure on the 1996 and Later applications:
1. Turn on the ignition key and clear all DTC’s
2. Depress the throttle to the WOT position and hold it there for at least
4-5 seconds
3. Key off and then close the throttle
4. Wait 30 seconds minimum
5. Key on and start the engine
6. The TDC offset will be automatically learned when the coolant
temperature reaches 170-172 degrees Fahrenheit.
7. If the vehicle is already above the minimum 170 degree CTS value,
TDC learn will automatically update as soon as the engine is started
in step five.
4L80E
TCC surge or chuggle when road
speed is between 40-50 mph
(Continued)
Note: On most 1996 applications the value displayed on the scan tool (TDC offset)
will remain at 0.00 (At step 5) until the TDC learn has been completed. On most
1997 and later applications, the value displayed on the scan tool will remain at the
previous value until the TDC learn has been completed.
TDC offset should read between –1.25 and –1.50. Once the relearn is complete,
check the TDC offset value displayed on the scan tool again. If the offset value is
not correct, shut off the engine, loosen the pump bolts and rotate it in the desired
direction, tighten the bolts and repeat the TDC offset learn procedure.
On L56 (EGR equipped 6.5L Diesel) applications, if the timing is correct and the
problem is eliminated when the EGR is disconnected, replace the EGR with part
number 12530288.
4L80E
Planetary gear noise in 1st and 2nd
gears only
Some 4L80E transmissions may exhibit excessive planetary gear noise when
operating in 1st and 2nd gears. This noise will resemble the noise developed from
HD 4L80E applications which use straight-cut gears. Upon inspection, you will
notice some irregular wear lines on the reaction planetary carrier pinion teeth and
possibly on the sun and ring gear teeth. These wear lines run parallel to the
transmission center line. The wear may look like dark lines on the gear teeth,
grooves in the gear teeth or bronze lines on the gear teeth.
This concern can be caused by either:
A reduction in the volume of lube oil feeding the planetary. This prob-
lem is typically caused by pump cavitation, a restricted filter or damaged oil pan,
or a cooler flow rate problems.
4L80E
Planetary gear noise in 1st and 2nd
gears only
If shaft alignment is suspected on a 4wd application, inspect the 4wd adapter.
We have measured brand new adapters that have had excessive offset! To inspect
the transfer case adapter measure the transfer case pilot inside and outside diam-
eter. The outside diameter specification is 4.799"-4.801" while the inside diameter
specification is 4.899”-4.900”.
If the measurements are not correct, replace the adapter. On 2wd applications
a common cause of the concern is the position of the output shaft bushing. If the
bushing or bore was machined off center, side loading of the shaft will occur. On
2wd applications, you will typically be able to see that the bushing is worn off
center. Replace the bushing or the case as necessary.
4L80E HD/4L85E
Product Updates
Several midyear changes were made to the 2001 4L80E HD model
transmissions. These changes were also carried over to the 4L85E transmission.
The changes were designed to improve the transmissions durability. These
changes include:
Some of the components are only available by ordering an upgrade kit part
number 24222160
4L85E
2002 Models
The 4L80E HD has been replaced by the 4L85E. The 4L85E is used in vehicles
equipped with the 8.1 L gas engine (RPO L18).
Identification
Model Tag:02CAP or 02CCP
RPO Code: MN8
Features:
4L85E
2002 Models (Continued)
The 4L85E uses a five-Pinion reaction and output carrier.
(NOTE: The straight cut gears used in the 4L80HD applications are no longer
available from GM. If a 4L80E HD planetary requires replacement, update the
unit with the part numbers listed above for the 4L85E applications.
LCT 1000
Incorrect Pressure Switch Assembly
Readings
Allison transmissions used in GM truck applications may indicate the wrong
pressure switch assembly readings for 5th gear and/or reverse range. Vehicles that
have had the TCM reprogrammed or vehicles built after March 2001 may have an
incorrect switch sequence. Incorrect values may be displayed when monitoring the
transmission operation with a scan tool when those values are compared to the
listings in the shop manual. This may lead to misdiagnosis of the PSA or its cir-
cuits.
Programming changes dealing with the scan tool interface can lead to the
incorrect sequence for the application. The chart below lists the correct sequence
for the LATER (after March 0f 2001) Allison calibrations.
NOTE: Switch C/D and E are normally open while switch R is normally closed.
Your scan tool may display the switch values as open/closed or as on/off.
On=closed, Off=open
On applications built after March 2001 or on units that have been reprogrammed,
Switch “C” will read “Open” (OFF) when the transmission is in reverse while those
built earlier will read “Closed” (ON).
LCT 1000
Incorrect Pressure Switch Assembly
Readings
Switch R
Range Switch C Switch D Switch E
Open/OFF
5th - Late Closed/ON Open/OFF Closed/ON
Open/OFF
5th - Early Open/OFF Open/OFF Closed/ON
Open/OFF
4th Closed/ON Open/OFF Closed/ON
Open/OFF
3rd Closed/ON Open/OFF Open/OFF
Open/OFF
2nd Open/OFF Open/OFF Open/OFF
Open/OFF
1st Open/OFF Closed/ON Open/OFF
Open/OFF
Neutral Closed/ON Closed/ON Closed/ON
Closed/ON
Reverse-Late Open/OFF Closed/ON Closed/ON
Leakage in the C5 clutch or its circuit: If you perform a clutch test using
your scanner, you will generally notice the condition when the 2-1
downshift is commanded. This will be indicated by a delay in line
pressure response when the C5 Clutch is commanded to apply.
2. Using jumper wires connect two wires at a time between the appropriate pin
in connector C1 and pin D in connector C2 (with the key on). Leave the
other two pins in connector C1 open. Alternate the pins as shown in the
chart below. The PRNDL and the scan tool should show the range indicated
in the chart.
2. Using jumper wires connect two wires at a time between the appropriate pin
in connector C1 and pin D in connector C2 (with the key on). Leave the
other two pins in connector C1 open. Alternate the pins as shown in the
chart below. The PRNDL and the scan tool should show the range indicated
in the chart.
LCT 1000
Quicklearn Procedure
The Allison LCT series transmission utilizes a quick learn (Also known as
Fast learn) procedure designed to shorten the amount of time that it takes for the
TCM adaptive-learning strategy to adjust for variations in clutch volume and apply
time. By performing the quick learn functions, the amount of time that is required
for TCM adaptive learning is reduced significantly. The Quick learn function
requires a compatible fully functional scan tool. Quick learn should be preformed
if:
The transmission was replaced/rebuilt or repaired
PARK MODE: With the vehicle in the park range the scan tool will
repeatedly cycle the C3/C4 and C5 clutches on/off. This function will not only
purge air from the system but it will also adjust for engagement time variation due
to return spring load values, solenoid flow rates as well as seal/bushing leakage.
DRIVE: With vehicle in drive range the scan tool will cycle the C1
clutch to adjust for engagement time variation due to return spring load values,
solenoid flow rates as well as seal/bushing leakage.
LCT 1000
Quicklearn Procedure (continued)
3RD/4TH : Following the above procedures clutch volume for the C2
clutch requires the vehicle now be driven. To properly learn the C2 clutch volume
the vehicle must complete at least three 3-4 shifts at steady throttle. This
procedure does not require the use of a scan tool.
Now follow the instructions on the scan tool for the “FAST” (Quick) learn
procedure.
The most common cause of this problem is related to the coolant temperature
sensor reading. Generally, ECT DTC’s will not be set.
FORD Contents
AX4S No Line Rise .........................................119
Vibration After Overhaul .............................. 76
Slipping in 2nd and 4th .......................... 120
New Pump Bearings .................................... 77
4F27E
Harsh 1-2 Shift ............................................ 79 Jump Testing the Trans .......................... 121
Check Ball and Relief Valve Final Drive Gear Set ............................. 124
Locations .................................................... 87
2/4 Band Adjustment ............................ 126
CD4E
No Movement After Overhaul ...................... 90 4R44E/55E and 5R44E/55E
Low Line Pressure at WOT .................. 129
Valve Body Mismatch .................................. 91
5R55N
Valve Body Interchange ............................... 82 Clutch and Band App. .......................... 133
Proper Sprag Rotation ............................... 101 Downshifts at High Speeds ................... 144
Solenoid Firing Order ................................ 104 Intermediate Clutches Burnt .................. 148
High or Low Pressure ................................ 108 Incorrect VSS Reading ......................... 152
Ratio Error Codes ..................................... 110 Mazda to Ford Conversions .............. 164
AX4S
Vibration After Overhaul
(3.8L Only) Possible Broken Flexplate
AX4S/AX4N
New Pump Bearings
When replacing the pump bearing on a AX4S or AX4N use the new updated
bearing assembly which has a built in seal. The seal is used to enhance lubrica-
tion to the bearing for longer life expectancy.
AX4N
Part# XF1Z-7G184-AA
AX4S
Part# XF2Z-7G184-AA
AX4S/AX4N
New Pump Bearings
OLD
NEW
SEAL
Install the seal away
from the pump rotor
AX4N
Harsh 1-2 Shift
There are a number of problems related to this symtom including:
Wrong Gaskets
AX4N
Harsh 1-2 Shift
Seperator Plate and Gasket
Lincoln 1995-97................................ (stamped 11) part #F50Z-7Z490-A
Lincoln 1998..................................... (stamped 84) part #F80Z-7Z490-AA
Lincoln 1999-00 ................................ (stamped 90) part #FX3Z-7Z490-AA
Taurus/Sable 1994-95 w/3.0L ......... (no stamp) part #F5DZ-7Z490-A
Taurus/Sable 1996-97 w/3.0L 2V .... (stamped 13) part #F6DZ-7Z490-B
Taurus/Sable 1998-99 w/3.0L 2V .... (stamped 87) part #F8DZ-7Z490-BA
Taurus/Sable 1996-97 w/3.0L 2V .... (stamped 14) part #F6DZ-7Z490-A
Taurus/Sable 1998-99 w/3.0L 4V .... (stamped 86) part #F8DZ-7Z490-AA
Taurus SHO 1996-97 w/3.4L ............ (stamped 15) part #F6DZ-7Z490-D
Taurus SHO 1998-99 w/3.4L ............ (stamped 85) part #F8DZ-7Z490-CA
Taurus/Sable 2000 .......................... (stamped 03) part #YF1Z-7Z490-CA
Taurus/Sable 2001-03 ..................... (stamped 05) part #1F1Z-7Z490-AA
AX4N
Harsh 1-2 Shift
Damaged Accumulator Piston
A Damaged Accumulator Piston assembly can cause a number of shifting
problems from late, early, harsh, soft and more. When reassembling this unit pay
close attention to the housing and piston areas. If the piston is worn or the hous-
ing scored the chances of the piston cocking in the bore are increased.
AX4N
Harsh 1-2 Shift
Wrong Accumulator Spring
AX4N
Harsh 1-2 Shift
Accumulator Hydraulic Circuits
Fluid under pressure in the pump circuit moves to the line modulator valve,
where it enters the accumulator circuit. The accumulator circuit provides variable
hydraulic backpressure to the accumulators for five apply components. The vari-
able pressure of fluid in the TV circuit is controlled by the pcm and changes the
position of the line modulator valve. When TV pressure is lower, accumulator
circuit pressure is lower. The results in softer shift feel provided by the accumula-
tors during shifts when engine input torque is lower. When TV pressure is higher,
accumulator circuit pressure is higher. This results in firmer shift feel provided by
the accumulators during shifts when engine torque is higher. Damage to the Line
Modulator Valve can result in no moulation of the valve and allowing direct line oil
to influence the Accumulator.
AX4N
Harsh 1-2 Shift
Valve Body Wear
Check for wear at the Line Pressure Modulator valve and sleeve assembly. If
the sleeve is damaged you can replace it with an E4OD Line Pressure Modulator
Valve and Sleeve assembly. The E4OD Line Pressure Modulator valve is smaller in
size and allows less oil to the back side of the Accumulator apply side during op-
eration resulting in a softer shift.
Damage to the Line Modulator Valve may result in a Slide Bump, Harsh Shift,
or dragging shifts.
AX4N
Harsh 1-2 Shift
Incorrect Clutch Pack Clearance
1995-96
Forward Clutch (.040-.059) wave spring
Direct Clutch (.050-.069)
Intermediate (.050-.069) wave spring
Reverse (.038-.064) wave spring
Low-intermediate clutch (.050-.075) wave spring
1997-98
Forward Clutch (.050-.059) wave spring
Intermediate Clutch (.050-.069) no wave spring SHO
Direct Clutch (.050-.069)
Reverse 97 all (.038-.064) wave spring
Reverse 98 SHO (.049-.072) wave spring
Reverse 98 except SHO (.040-.063) wave spring
Low-intermediate clutch (.050-.075) wave spring
1999
Forward Clutch (.050-.069) wave spring
Intermediate (.050-.069) no wave spring SHO
Direct Clutch (.050-.069)
Reverse Clutch SHO (.050-.072) wave spring
Reverse Clutch except SHO (.040-.063) wave spring
Low-intermediate Clutch (.050-.075) wave spring
2000-03
Forward Clutch (.040-.059) wave spring
Intermediate Clutch (.050-.069) wave spring
Direct Clutch (.050-.069)
Reverse Clutch (.050-.072) wave spring
Low-intermediate clutch (.050-.075) wave spring
© 2003 ATRA. All Rights Reserved
86 FORD
AX4N
Harsh 4-3 Downshift
Wrong Seperator Plate
Many times the wrong seperator plate may be changed inenvertantly. Pay
close attention to the O/D Servo exhaust orifice size, these sizes are not all the
same.
00.095”
00.218”
AX4N
Check Ball and Relief valve
Locations
The locations of the check balls haven’t changed over the years, however the
springs have gone through some changes. Listed on the previous page are the
spring sizes and weights.
Modulator
Check
Valve and
Solenoid
Regulator
TCC
Modulator
Manual Low Check
Relief Valve Valve and
and Cooler Drainback
AX4N
2001-On Check Ball and Relief Valve
Location
Modulator Modulator
Manual Low Check Check
Relief Valve Valve and Valve and
and Cooler Drainback Solenoid Spring
Bypass Spring Spring Regulator TCC
Fliter Fliter
AX4N
Check Ball Location
CD4E
No Movement After Overhaul
High Pressure caused by excessive clearance in the pressure regulator bore is
causing the pump shaft to twist.
Pump Shaft
CD4E
Valve Body Mismatch
The Seperator plate can be an easy identification tool when interchanging the
valve bodies. The location of the Forward feed hole is much larger on the 98’ and
later valve bodies.
94’-98’ Models
0.090” No Wave plate
in FWD clutch
CD4E
Valve Body Interchange
A wrong gear start from a stop or fourth gear in manual low condition may
ocur if the valve body was replaced with the wrong valve body. Early, 1994-’97 and
Late (1998-on) valve bodies can be identified by the Pull-In valve assembly and are
not interchangeable? They must match vehicle.
CD4E
Valve Body Interchange with Harsh
Forward Engagement or 3-4 Bind
Forward clutch assemblies with a wave plate are intended for use on later
style valve bodies with the larger Forward feed orfice. Forward clutch assemblies
without the wave plate are intended for use on earlier style valve bodies with the
small forward feed orfice. If the Earlier style Drum assembly is installed to a Late
model vehicle a harsh Froward engagement may be felt. This is due toe the large
feed hole in the Seperator plate assembly.
CD4E
Valve Body Interchange with Harsh
Forward Engagement or 3-4 Bind
1st 2nd
Design Design
W/ W/
shallow deep
dish dish
1st
Design
0.315”
2nd
Design
0.400”
CD4E
Valve Body Interchange with Harsh
Forward Engagement or 3-4 Bind
CD4E
Valve Body Interchange with Harsh
Forward Engagement or 3-4 Bind
A 3-4 Bind may be caused the Clearance of the Coast Clutch being incorrect.
Install the coast clutch piston into the forward piston, then stack 2 coast clutch
steels, 2 frictions and the forward apply plate on top. Clearance should be around
0.050” in.
CD4E
Drives Forward in Nuetral, Binds in
Reverse
After rebuild, when hot car drives forward in Neutral and binds in Reverse.
This problem occurs after a Forward/Direct drum has been replaced. Care needs
to be taken when replacing the forward/direct clutch drum. Make sure that the
piston slides into the drum bore with a top clearance (top of drum bore for outer
seal) of at least .010 or more. Always feel outer seal riding surface for being
smooth. If it appears that the top area of the drum where the seal rides is bal-
looned inward and not a true straight flat surface, do not use this drum as it will
swell when hot locking the forward piston from returning to its relaxed position.
This creates a mechanical bind on the piston not releasing the forward clutches
CD4E
Ratio Error Codes P0732, P0733, etc.
Turbine Speed Sensor Application
Some of the most troublesome codes to deal with are ratio error codes. These
codes can be caused by a number of different concerns:
Poor Line Pressure
Sliping Clutches
Bad Solenoids
Wrong Fluid
Bad Input from Engine Sensor
Ignition Noise or Alternator Noise entering the VSS signal
Make sure you have the correct Turbine Speed sensor on the transaxle, the
older sensors have a much broder range of voltage then the new sensors.
1S7Z-7M101-KA F7RZ-7M101-KA
CD4E
Pump Shaft Identification
Pump, Converter, Engine Damage
It is very important to make sure you use the correct pump shaft and input
shaft for the correct application. Mismatching the Input or Pump shafts may cause
damage to the Pump, Crank Shaft Thrust Bearing, Converter and other internal
parts.
The Shafts are different in length between the 4Cyl. and 6Cyl. engines.
4 Cylinder 14.00”
4 Cyl
4 Cylinder 8.25”
6 Cylinder 9.00”
6 Cyl
6 Cylinder 14.75”
© 2003 ATRA. All Rights Reserved
100 FORD
CD4E
Fluid Leaks Out Of The Dipstck
Tube
The most common cause of this problem is the Chain cover not properly as-
sembled. The chain cover has Four (4) snaps that connect to the shield. This sheild
is typically misplaced or not installed at all.
CD4E
Proper Sprag Rotation
No Forward movement or Binds in fourth can be caused by the Forward sprag
damaged or incorectly installed
F4E-III
Clutch and Band Application
F4E-III
Pressure Specifications
F4E-III
Solenoid Firing Order
F4E-III
Solenoid Failure Chart
F4E-III
Solenoid Failure Chart
F4E-III
Solenoid Specifications
1-2 Solenoid
EPC Solenoid
2-3 Solenoid
F4E-III
High / Low Pressure
High Pressure caused by Pressure Regulator bore wear.
High pressure
check these
areas for wear
Low Pressure
check these
ares for wear
F4E-III
No Movement in all Gears after
Rebuild
Typically caused by a damaged Pressure Regulator circuit, this problem is
usually assosiated with a plant failure. During your rebuild proceedure make sure
the Pressure Regulator Valve assembly is not damaged. A damaged PR Valve can
create high line pressure, this can cuase no cooler flow resulting no movement.
F4E-III
Ratio Codes
Ratio codes can be very difficult to diagnose because of the many different
components that can cause this problem. Diagnostic Trouble Codes P0781, P0782,
P0783, P1731, P1732, P1733 indicate incorect ratios and no specific gear. In order
for these codes to set, the problem has to happen four times consecutivly. Diag-
nostic Trouble Codes P0741 or P1728 are also ratio codes that can be percieved as
only torque converter codes. In order for these codes to set the problem has to
happen five times consecutively. Here are some of the items to look at when diag-
nosing Ratio Codes:
Fluid Pump
Filter
Seals
Drums
Speed Sensors
Accumulators
F4E-III
Ratio Codes (Continued)
Pump
The front pump support and gear provides the volume of fluid required to
charge the torque converter, main control valve body, cooling system, lubrication
system, and hydraulic apply devices. The front pump support and gear is shaft
driven by the torque converter cover. The sideclearance should be no more then
.002, .0015 or less is prefered.
Check pump
areas closely
for damage
F4E-III
Ratio Codes (Continued)
Filter
F4E-III
Ratio Codes (Continued)
Valve Body Wear
The valve body consists of four sections: the upper control valve body, main
control valve body, premain control valve body, and the lower control valve body.
The main control valve body also contains the electronic pressure control solenoid.
Wear in the 1-2 shift valve can cause a ratio code simply by not stoking prop-
erly and slowing down the timing the PCM is expecting.
Solenoid
Regulator Manual
valve valve
1-2 Shift
valve
© 2003 ATRA. All Rights Reserved
114 FORD
F4E-III
Ratio Codes (Continued)
Seals and Drums
A bad seal or drum can be a difficult problem to diagnose. Some areas to look
at are the sealing surfaces of the piston and drum assembly. A slipping Forward
clutch can cause sluggish engagements into Drive. Here again knowing what’s
applied will help you diagnosis this unit quickly.
F4E-III
Ratio Codes (Continued)
Speed Sensors
The vehicle speed sensor (VSS) is located above the differential on the trans-
mission case. The VSS rotates a cable and the instrument cluster generates a DC
signal and sends the signal to the PCM, in some cases the VSS generates the
signal to the PCM. The TSS sensor provides converter turbine shaft speed informa-
tion for torque converter clutch (TCC) control strategy. The information is also
used in determining static electronic pressure control (EPC) pressure setting dur-
ing shifts. The values below are approximate, the important point is that the fre-
quency rise is linear and smooth.
Failure: All or some shifts missing, erratic shift pattern, Stall when put
into gear, late/early shift speeds,no TCC, Erratic pressure rise.
80mph-170 Hz +/-
60mph-130 Hz +/-
30mph- 75 Hz +/-
15mph- 40 Hz +/-
00mph- 00 Hz +/-
F4E-III
Ratio Codes (Continued)
Accumulators
Accumulators — 1-2
RED
Spring
Length 3.425
Diameter 0.630
Coil 0.080
Accumulators — 2-3
GREEN
F4E-III
Ratio Codes (Continued)
Accumulators — N-D
GREEN
Accumulators — N-R
BLUE
F4E-III
Accumulator Reference
1-2 Accumulator
(Red)
2-3 Accumulator
(Green)
F4E-III
No Line Rise W/ Good EPC
Command
No Line rise can be caused by a sticking pressure modifier valve or a dam-
aged spring. The Line Pressure Modulator Valve is responsible for modulating the
EPC pressure and distributing it to the appropriate valves.
Check the valve for scoring and make sure the valve bore is clean
of debris.
F4E-III
After Rebuild, Slipping 2nd and 4th,
No 2nd and 4th
F4E-III
Jump Testing the Transmission
F4E-III
Jump Testing the Transmission
F4E-lll connector assembly veiwed from the terminal side.
+ #7 indicates TCC
4F27E
Servo Seal Damaged
It is important to install the Servo seal to the Valvebody correctly make sure
there are no tears in the lip of the seal and that there is no knicks on the
Valvebody seal surface. Make sure you torque the Valvebody to specifications and
air check the unit after. A loose valve body can cause the seals to tear from the oil
pressure passing the feed.
4F27E
Final Drive Gear Set
A reprogram is availible for the PCM (Powertrain Control Module) to accept an
ealier gearset in a late vehicle. In Ealy 2002 Ford introduced a reprogram for this
interchange.
If the transaxle has a part number on it that starts with an X for the year
2000 (ex:XS4P) it contains the older gear set. Transaxles with part numbers that
begin with 1 for the year 2001 (ex: 1S4P) it contains a newer gear set.
To identify the correct reprogram locte the tear tag on the door and match the
tag number with the following chart.
The early output gear has 87 teeth and the transfer gear has 83
teeth
The late output gear has 59 teeth and the new transfer gear has
57 teeth.
Transfer Output
Gear Gear
4F27E
Final Drive Gear Set
4F27E
2 / 4 Band Adjustment
Band adjustment is crucial during a rebuild. Many times a repeat failure of
the band will occur because the specified bolt was not installed. This tool can be
purchased from the after market.
OTC# 307-416
4F27E
2 / 4 Band Adjustment
When an adjustment is necessary be sure to follow the procedure listed below:
Holding the tool bolt in position, lightly seat the nut and washer
against the transaxle case
Remove the tool without changing the position of the nut on the
bolt
4F27E
2 / 4 Band Adjustment
Compair the 2/4 band anchor bolt with the measurement tool
If the adjustment is off use the chart to verify the correct pin
Low line pressure at WOT, seperator plate gasket blown, erratic EPC pressure
are some common problems with 1995 -2002 4R and 5R series transmissions.
Some other complaits may be:
No Line Rise at WOT
No 2nd Gear
No 3rd Gear
No engine breaking in Manual 1
Slipping shifts and/or delayed engagements
DTCs P0732, P0733, or P1762 may be present
The seperastor plate orifice sizing has been changed to repair this problem, a
new Seperator plate is now availible from Ford. In some cases due to heavy con-
tamination the Valve Body will need to be replaced if there isn’t a heavy amount
debris in the pan refer to chart for specific seperator part number.If it is
determaned the valve body needs replacing refer to chart on the opposite page.
Old Plug
New Plug W/
Blow Off
Remove and
discard these
parts
5R55N
Clutch and Band Application
A=Applied
ANE=Applied but Not Effected
5R55N
Sprag Application
5R55N
Pressure Specification
5R55N
Pressure Specification
Alternate Main
Line Tap
5R55N
Soleniod Application Chart
5R55N
Solenoid Failure Chart
1=Manual 1=Manual
1=Manual 1=Manual
5R55N
Solenoid Failure Chart
1=Manual
1=Manual
5R55N
Pressure Control Solenoid Failure
1=Manual 1=Manual
5R55N
Pressure Control Solenoid Failure
1=Manual
© 2003 ATRA. All Rights Reserved
142 FORD
5R55N
Intermediate Sprag Rotation
A damaged intermediate sprag will cause a bind in third and fourth or no third
or fourth condition.
ROTATES CLOCKWISE
HOLD
ROTATE
4R70W
Solenoid Codes P0750, P0751, etc.
and/or Erratic Shifting
Intermittent TCIL flashing may be caused by the internal solenoid hard shell
harness being distroted or not being fully seated between the solenoid and the
harness.
This Pin is
damaged
4R70W
Downshifts at High Speeds
4R70W
Downshifts at High Speeds
There are a few differances between the TransmissionRange sensor and the
Manual Lever Position Sensor. The TR sensor refers to four pins at the PCM, where
as the MLP refers only to one pin at the PCM.
4R70W
Repeat Intermediate Diode Failure
Typically caused by flooding solenoids this problem can give you trouble if not
diagnosed completely. The Diode sprag is considerably stronger then the older
roller one-way clutches, however the cause is still the same. During a forced down
shift from 4-2, SS1 and SS2 are commanded OFF. If the solenoids are worn or
inoperative they don’t exhaust properly causeing the solenoids to flood and hold
the 3-4 valve in its 4th gear position (no Forward clutch fill). Because the PCM
command for second gear happens the 2-3 shift valve is stroked to the 2nd gear
position and the 3-4 shift valve is held up in the 4th gear position, this causes the
feel of Nuetral, O/D Band applied, direct clutch applied, no intermediate, no
forward. When this happens the customer or technician removes his/her foot from
the accelerator the line pressure drops and the intermediate clutches catch. When
this happens the Sprag is hammered and wear or breakage occurs.
4R100
2nd Gear slips or No 2nd
The common cause for this problem is duability of the Intermediate Diode
sprag. A new drum and sprag assembly was introduced last year in ATRA Bulletin
#642. When a replacemnet is necessary you may need to replace the piston and
return spring also. The new Drum deletes the thrust washer assemly and has a
smaller piston travel area.
Part #’s
E9TZ-7A089-B .................................. Intermaediate sprag
1C3Z-7B164-BA ............................... Clutch Plates
YC3Z-7D044-AA ............................... 4 Plate Drum 5.4L and 6.8L
YC3Z-7D044-BA ............................... 5 Plate Drum 7.3L only
F3TZ-7G401-AA ............................... Thrust Washer#7
4R100
Intermediate Clutches Burnt
A common failure of the Intermediate clutch is almost always caused by lack
of feed oil to the piston, typically due to case damage, one modification you can do
is install a rubber gasket/seal around the feed hole of the Inermediate clutch
drum. There are a few things your going to need to do before this repair.
Parts needed:
1 = PC 7/32” 16 mml oil resistant hose
1 = Razor Blade
1 = C6 Direct Clutch Return Spring
4R100
Intermediate Clutches Burnt
Seat hose at
the bottom
of the
channel
case
4R100
Intermediate Clutches Burnt
4R100
No/Slipping Reverse, No/Slipping
Manual Low
A No Reverse or Manual low condition can be caused by the Low/Reverse
plate bolts being too long and bottoming out in the case. Signs of this are evident
when initial inspection shows the tip of the bolt and the bottom of the case having
signs of damage
4R100
Vehicle Speed Sensor Input when
Vehicle is Stationary
An erratic 1-2 upshift or 2-1 downshift may be caused by a VSS input while
the vehicle is stationary. Monitor the VSS on you scanner, if the scanner shows a
VSS signal with the KEY ON and the ENGINE OFF. It may be necessary to install a
jumper kit from FORD. This kit replaces the computer’s current ground wires with
a single body ground cable.
Part # 1C3Z-13N850-AA
4R100
Vehicle Speed Sensor Input when
Vehicle is Stationary
To install the jumper kit:
4R100
Vehicle Speed Sensor Input when
Vehicle is Stationary
5. Remove the PCM connector and sheild.
6. Remove the RED locking plate from the front of the connector.
7. Remove the wires from pins 3, 23, 24, 51, 76, 77, 103.
8. Install the jumper kit to the PCM in the loctations that you removed in the
previous step.
9. Reinstall all the neccessary componets and retest the system.
TorqShift 5R110W
Description
The transmission features include:
six speeds.
a fully automatic transmission.
direct electronic shift control.
optional power take-off.
5R110W
Clutch Application Chart
5R110W
Clutch Application Chart
5R110W
Pressure Specification
Pressure can be measured at the main line tap on the drivers side of the
transmisison. All of the other pressures are going to be monitered using your
scanner.
5R110W
Pressure Specification
5R110W
Solenoid Specification Chart
1 PC-A 4.7 ohms +/- (line pressure)
5R110W
Solenoid Specification Chart
11 12
5 6 7
10
13
4 3 2 1
9 8
© 2003 ATRA. All Rights Reserved
162 FORD
5R110W
Valve Body Wiring
Connector
shown from the
valve body
connector side
5R110W
Valve Body Wiring
NOTES:
NOTES:
Chrysler Contents
31TH 413, 670, 727, 904,
Delayed Engagement ................ 170 RH and RE Units
No Response From TCM ............ 176 42, 44, 46, 47, RH and RE
45RFE
Transmission Quality
Enhancments ........................... 178
47RE
Harsh Engagements When
The TCC is Applied ................... 179
31th
Delayed Engagement
Some 2000 Dodge (NS) Caravan, Plymouth (NS) Voyager, Dodge (PL) Neon,
Plymouth (PL) Neon, Dodge (P2) Neon (Export Market), Plymouth (P2) Neon (Export
Market) vehicles may exhibit intermittent delayed transaxle engagement of greater
than 30 seconds on an initial cold start in –1°C (30°F) or colder temperatures. This
may be due to interference between the front pump assembly and transaxle case.
Here are a few things to check before the replacement of the pump.
If the answers to the above questions were YES, the most likely cause of the
condition is due to interference between the pump housing and the transaxle case.
Perform the following Repair Procedure. If the answers were NO, further diagnosis
will be required to determine the cause of the condition.
Parts Required
Qty. Part Number Description
1 05016410AB Pump Assembly
1 04269661AB Pump Gasket
Part # 05014473AA….41TE Splice Kit (Modifies 1998 and earlier vehicle TRS
harness to be compatible with a 1999 transaxle)
Part # 05014474AA….42LE Splice Kit (Modifies 1998 and earlier vehicle TRS
harness to be compatible with a 1999 transaxle)
41TE 42LE
KIT # 05014473AA KIT # 05014474AA
41TE
Transaxle Cooler Line Splice Kit
Application: Chrysler (JR) Sebring, Sebring Convertible, Dodge (JR) Stratus
Sedan, Plymouth (PL) Neon, Chrysler (PT) PT Cruiser, Chrysler (RG) Voyager (In-
ternational Market), Chrysler (RS) Town & Country, Voyager, and Dodge (RS)
Caravans
A connector kit has been released to make transaxle cooler line service easier.
This kit should be installed whenever a service is performed that requires cooler
line removal from the transaxle. This will make the lines easy to remove and install
should service be required at a later time. An instruction sheet is included with
each kit that details installation procedures.
Parts Required
Qty. Part Number Description
1 05016918AA Kit, Transmission Cooler Line Connector
41TE
Auxiliary Differential Vent
An auxiliary vent tube assembly has been released for service on 1993-2000
Chrysler (LH) Concorde, LHS, New Yorker, 300M, 1993-2000 Dodge (LH) Intrepid,
1993-2000 Eagle (LH) Vision, and 1997-2000 Plymouth (PR) Prowler to provide
improved differential case venting. In cold climate areas, under certain driving
conditions, pressure can build up in the differential case forcing fluid out through
the primary vent tube at the top of the differential. Fluid can collect on the top of
the differential case and/or drip to the ground.
Parts Required
Qty. Part Number Description
1 05011589AA Vent Tube Assembly Kit
Note: Be sure vent tube is not contacting any metal surfaces on differential
cover.
41TE/AE, 42LE
No Response From TCM When
Using Generic Scan Tools
2000 Chrysler (GS) Voyager (European Market), Chrysler (JA) Cirrus, Dodge
(JA) Stratus, Plymouth (JA) Breeze, Chrysler (JX) Sebring Convertible, Chrysler
(NS) Town & Country, Dodge (NS) Caravan, Plymouth (NS) Voyager, Plymouth (PR)
Powler built prior to the dates in the above table may not respond properly to
diagnostic requests from some aftermarket generic scan tools. In these cases, the
aftermarket generic scan tool may indicate that the Transmission Control Module
(TCM) is not responding. This may lead to unnecessary diagnostic procedures and
or replacement of good TCM’s.
Parts Required
Qty. Part Number Description
1 04669020 Label, Authorized Software Update
1 04275086 Label, Authorized Modification
41TE
Erroneous Body Control Module
Diagnostic Trouble Code
Town & Country, Caravan, and Voyager units with 41TE transaxles may ex-
hibit erroneous body module codes caused by the PRNDL switch. Determine if
each PRNDL indicators in the dash turn on when the ignition is turned on for
about 10 seconds (illuminated at the same time). After 10 seconds they should go
out. If all PRNDL indicators DO NOT become boxed at the same time, the DTC is
erroneous and the DTC should be cleared, it is not necessary to replace the BCM.
Note: Chrysler has not received any reports of this DTC being set by an actual
failure in the PRNDL system.
45RFE
Transmission Quality Enhancements
for the 1-2, 2-3, and 4-3 Shifts
Some 2000 Dodge Dakota, Durango 1999-2000 Jeep Grand Cherokee vehicles
equipped with a 45RFE transmission may experience the following shift quality
issues:
A harsh 4-3 kickdown shift during low speed, light throttle conditions.
The revision of the TCM software addresses the above shift quality conditions
for all vehicles, and adds a final gear ratio to the Grand Cherokee transmission
only.
This involves selectively erasing and reprogramming the Dakota, the Durango,
or the Grand Cherokee Transmission Control Module or TCM (with calibration
99Ver9.0, 00Ver8.5, or 00Ver9.0). And reprogramming the Grand Cherokee
Powertrain Control Module or PCM (with calibration 99Call9A or 00Call6A).
47RE
Harsh Engagement When the TCC is
Applied
Some 2000-2001 Dodge Ram Truck owners may complain that their transmis-
sion exhibits a harsh engagement. This harsh engagement will occur when the
transmission is in or enters 3rd gear or overdrive (O/D). The customer may not be
able to determine whether the harsh engagement is the result of a gearshift or is
the result of a torque converter clutch (TCC ) engagement.
1)Verify that the transmission fluid level is correct and that the transmission
throttle cable is properly adjusted.
3)Make sure that the transmission is in O/D and the TCC is locked-up. If
necessary, the DRB III may be used to create a custom monitor to display the
needed transmission states.
4)While maintaining a constant speed, lift your foot off of the accelerator pedal
and then reapply the accelerator pedal, but with a deeper (wider) throttle position
while still maintaining O/D. The transmission should not be allowed to shift out of
O/D during this maneuver, but the maneuver should cause the TCC to tempo-
rarily disengage.
47RE
Harsh Engagement When the TCC is
Applied (continued)
5) Allow the vehicle to accelerate until TCC engagement occurs. Note if the
TCC engagement is harsh.
Parts Required
Qty. Part Number Description
1 52118048AB Plate, Valve Body Upper Housing Separator
1 02464324AB Gasket, Transmission Oil Pan
AR (10) 05010124AA ATF-3, Transmission Oil Type 7176 (2000
M.Y.)
AR (10) 05013457AA ATF+4, Transmission Oil Type 9602 (2001
M.Y.)
47RE
Harsh Engagement When the TCC is
Applied (continued)
1)Inspect the new separator plate P/N 52118048AB. The correct plate will
have a 3mm (0.118 inch) wide slot at the torque converter clutch lock-up vent
circuit.
5.9L Diesel
Erratic Torque Converter Clutch
Some 1998-99 Dodge (BR/BE) Ram Trucks may experience a surge like condi-
tion while in 4th gear. This may be caused by the Torque Converter Clutch (TCC)
unlocking and locking when it should be consistently locked. The cause of this
erratic operation has been identified as electrical noise from the Throttle Position
Sensor (TPS) or Alternator.
Drive the vehicle with a helper monitoring the PCM. Warm the engine and
verify the transmission fluid temperature is greater than 32°F and consistent.
Operate the vehicle with an output shaft speed greater than 2200 rpm. Verify that
the brake switch shows a released status that is consistent and verify the park/
neutral status reads D/R and is consistent. While keeping the output shaft speed
above 2200 rpm, hold the throttle so the TPS reads 1 volt. Monitor the TC clutch
status, it should be consistently locked. If the TC clutch status shows unlocking /
locking, look to see if the TPS volts are fluctuating by 0.2 volts or more. If the
conditions are met, perform the REPAIR PROCEDURE. If a surge like condition is
felt but the above test does not confirm the TCC unlocking/locking occurrence,
further diagnosis and testing will be required.
47RE
Delayed Upshift/No TCC
Engagement 30-50 MPH
Some 1999-2000 Dodge (BR/BE) Ram Trucks may experience a condition
where the transmission may seem to have a delayed 3-4 upshift, while moderately
accelerating from 30-50 MPH (48 to 80 KM/H). The customer may also note high
engine rpm’s while operating in 3rd or 4th gear. This condition may be caused by a
delay in the engagement of the transmission torque converter clutch (torque con-
verter lockup).
This involves the replacement of the transmission valve body upper housing
separator plate.
42/44/46/47/ RE and RH
“Buzz”, “Whining”, or “Moaning”
Some vehicles may exhibit an intermittent noise from the transmission when
reverse gear is selected. This noise has been described as a buzz, whining, or
moaning like noise. The noise is most noticeable when transmission fluid tempera-
ture is below 38º C (100º F). This condition is caused by a resonance of the trans-
mission regulator valve system. Other items that can cause this are: Air in valve
system or out of the internal parts. Possible cracked pump housing, a torn pump
gasket, an under filled transmission, restricted filter or cooler flow, or an out of
specification valve and or valve body. Mostly affected transmissions built after Aug
1,1995
Updated (STEEL) Pressure Regulator Valve:
Part # 04130169
44RE
Front Band:
72 in lbs. back off 2 ¼ turns
Rear Band:
72 in lbs. back off 4 turns
46RE 47RE
Front Band: Front Band:
72 in lbs. back off 2 7/8 turns 72 in lbs. back off 1 7/8
Rear Band: Rear Band:
72 in lbs. back off 2 turns 72 in lbs. back off 3 turns
44RE
Front Band:
72 in lbs. back off 1 7/8 turns
Rear Band:
72 in lbs. back off 4 turns
© 2003 ATRA. All Rights Reserved
188 CHRYSLER
Procedure: Cut the head and thread section off of the bolt leaving just the
shoulder section to work with. Out of the round stock that you now have in your
hands, you need to make the overall length .627 long! Carefully do this at the
grinding wheel keeping a cup of water handy so you do not burn your fingers. This
is the same measurement of the Miller tool C3763 used for the Throttle valve
adjustment. Drill through the side of the round slug with a 1/8 drill and install roll
pin with a length of at least 3" into gauge slug. Measure up from the bottom of the
roll pin 1-5/16" and file or cut into the roll pin a notch for measuring the Pressure
Regulator spring height. Now you have a tool that does both jobs so no need hunt-
ing down 2 separate tools!
Bolt
Roll Pin
42/44/46/47/ RH and RE
Throttle Valve Cable Adjustment
When adjusting the Throttle Cable on any Chrysler/Dodge with the 42 series
through 47 series RE and RH transmissions, the procedure is the same. The cable
must be adjusted to the minimum side of the adjustment. The throttle lever on the
transmission and the throttle plate at engine must move simultaneously. Adjust-
ment is made at throttle body. Unsnap the cable from the throttle body. The cable
end and the centering ball on the throttle body must line up together. If not, re-
lease cable snap-lock and adjust to achieve this measurement.
Honda/Acura Contents
Honda/Acura
Honda / Acura
TCC does not lockup during cold
weather
1996-97 Civic with A24A and Accord with AOYA or MPOA. When ambient
temperature is less than 30°F, the PCM will not allow Lockup. If the coolant tem-
perature never exceed 176°F during normal driving, replace the thermostat.
Honda / Acura
Grinds in Reverse
1998-up Prelude and Accord units with three shift solenoids and two CPC
solenoids with this concern can be caused by installing the Reverse sleeve upside-
down. Make sure that all the Reverse gears are installed correctly.
Reverse Selector
Honda / Acura
Solenoid Information
97 and Later All except CVT Electrical System
Honda / Acura
Solenoid Information
1997 and Later All (except CVT)
Honda / Acura
Solenoid Information
Honda / Acura
Solenoid Information
When checking the solenoids for resistance the resistance is measured at 5
ohms from terminal to terminal. If you measure the resistance from the terminal
to the housing the resistance will read open.
NOTE: Before
disassembly turn the
CPC spring seat in
counting the turns in
until it bottoms out.
Simply reverse the
order during
reassembly.
Most Fall
between 3-4
Turns
O-Ring
Measure the
turns and record
for reassembly
Honda / Acura
Bushing Damage
It is very common for these models to have a bind in Reverse. This problem
may be caused by a worn bushing in the 4th clutch tube. ATRA recommends that
this bushing be replaced during overhaul.
Honda only services the bushing as part of the support shaft. However they
are availible through the aftermarket
Honda
CVT Preliminary Information
Honda Civic HX models starting in 1996 have been using a CVT transmission.
Its use of a metal segmented belt and variable width pulleys is similar to the
Subaru Justy ECVT.
Honda
CVT Information
The START clutch couples the driven pulley to the secondary gear shaft of the
final drive gear. The START clutch is released when the vehicle is stopped. As soon
as acceleration is needed the START clutch applies. Torque from the driven pulley
is transferred to the final drive gear via the secondary gear shaft.
Park Gear
Start Clutch
Drum
Secondary
Start Clutch Drive Gear
Hub
Honda
CVT Information
In the forward range, the correct gear ratio for the vehicle is achieved by the
drive and driven pulleys. Pressure to control the width of both pulleys comes from
the Pressure High-Pressure Low (PH-PL) valve. This valve responds to control
signal oil from the Shift Control Linear Solenoid.
The PH-PL valve maintains the correct pressure between both drive and driven
pulleys. This is important to keep the belt in contact with both pulleys. At low
speeds the drive pulley narrows and the belt rides high. At high speeds the drive
pulley widens and the belt rides lower. Remember, the PH-PL valve is also making
the driven pulley width change, but opposite of the drive pulley.
When pressure in both drive and driven pulleys are equal, the belt will ride in
the middle of both pulleys and the ratio will be about 1:1.
Honda
CVT Information
Fail Safe
When the computer detects a circuit or transmission fault, the “D” light stays
on. The transmission will still drive forward and reverse. All solenoids are turned
off. The only ratio available in failsafe is the high or overdrive ratio. A Pitot tube,
located inside a “spinning trough of oil” allows the vehicle to hydraulically apply
and release the start clutch.
Honda
Retrieving Codes
Since the transmission starts out in a high ratio, the start clutch generates a
lot of heat while taking off from a stop. It’s very important to correct and clear
computer problems as the start clutch will fail under prolonged failsafe operation.
These units have been known to have erratic solenoid and valve body prob-
lems, even when no codes are present. To confirm that the unit works in failsafe,
unplug the wiring. If the unit starts out in the high range in forward and reverse,
suspect a solenoid or computer related problem. If the unit still operates errati-
cally, suspect internal pressure, valve body or clutch problems.
Honda
CVT Pressures
There are 6 pressure ports. Use the following pressure chart to confirm hy-
draulic operation. Note: in failsafe the driven pulley pressure may be above
500psi.
Reverse Brake
Pressure Tap
(Marked with “LUB”)
Honda
CVT Pressures
Honda
CVT Stall Speeds
A stall test can be used to detect problems in the start, forward or reverse
clutches. Follow these steps:
Stall Specifications
Gear Range Normal Accepted Range
D 2500rpm 2350-2650rpm
L, S & R 3000rpm 2800-3100rpm
RESULTS
Stall too high in D, L & S Check fluid, filter, Stuck PH
Regulator, Slipping Forward
Or Start Clutches
Honda
CVT Break in Procedure
After overhaul of the engine or transmission, or any transmission computer
related work has been done, the start clutches need to be calibrated.
A simple
jumper wire
can be used
for this
procedure
When the following parts are repaired or replaced, the PCM or TCM must
memorize the feedback signal for the start clutch control.
• PCM or TCM
• Transmission assembly
• Lower valve body assembly
• Engine assembly or overhaul
Procedure for 1996 model only:
Caution: Do not use this procedure for 1997 and newer vehicles.
1. Engage the parking brake, and block the front wheels securely.
Honda
CVT Break in Procedure
3. Start the engine and warm it up to normal operating temperature (the
radiator fan comes on twice.)
4. Fully depress the brake pedal and accelerator for 20 seconds with the
gear selector in the D position (full power stall).
5. Shift into N or P. To store the engine negative pressure in memory, let
the engine idle in N or P for one minute under the following condi
tions:
• With the brake pedal depressed.
• With the A/C switch off.
• With the combination light switch off.
• With the heater fan switch off.
• Turn OFF all other electrical accessories.
6. Shift into “D” position and let the engine idle for two minutes to store the
feedback signal in memory under the same conditions as in step 5.
7. Connect a scantool and verify the TCM has completed the start clutch
calibration.
NOTE: The TCM will not store the feedback signal when the CVT fluid tempera-
ture is below 104° F (40°C) even if the engine coolant temperature reaches normal
operating temperature.
The TCM (‘97-’98 vehicles) and PCM (‘99 and newer) memorize the feed back
signal when you drive the vehicle as follows:
Honda / Acura
Noise Idling in Reverse
A certain amount of noise should be expected while the unit is idling in
reverse. You may need to explain what is taking place to a customer who
questions the noise.
Mitsubishi Contents
Eclipse
Scanner Access .................... 218
R/V4A51
Pressure Tap Location
and Specification .................. 220
Ecplise
Scanner Access
On 1995-1998 Eclipse 2.0L vehicles equipped with the 41TE transaxle must
be scanned using the Domestic Primary Cartridge. The MITSU-1 Y-cable must be
connected to the OBD-II and the Mitsubishi twelve pin diagnostic connector. Per-
sonality Key number seven must be installed in the OBD-II adapter. Use VIN#
chart below to manipulate the scanner to access codes. It is not necesary to install
the 2nd, 3rd,or 8th digets for the 97-98 cartridges.
F4A41/42/51
Internal Harness Change
The internal harness was changed in September of 2000. The ATF Tempera-
ture sensor is now an integral part of the harness. The old harness is still used in
the truck series and the sensor is still availible.
Part# MR528943
R/V4A51
Pressure Tap Location and
Specifications
Torque Torque
Second
Gear Engine Underdrive Reverse Overdrive Low-Reverse Converter Converter
Brake
Selected RPM (UC) (RC) (OC) Brake (LB) Release Apply
(2B)
(TR) (TA)
75-100
Reverse 2500 185-255 185-255
NOTE: Torque Converter apply pressure can vary between 0-50 PSI during gear changes while driving
when the Torque Converter is not applied.
R/V4A51
Pressure Tap Location and
Specifications
Measurement
Standard Hydraulic Pressure MPa (psi)
Condition
Torque
Underdrive Reverse Overdrive Direct Low-Revers- Second Reducti-
Selector Engine Convert-
Shift Clutch Clutch Clutch Clutch e Clutch Brake on Brake
Lever Speed er
Positon Pressure Pressure Pressure Pressure Pressure Pressure Pressure
Position (r/min) Pressure
(UD) (RV) (OD) (DIR) (LR) (2ND) (RED)
(DR)
1.01 -
0.25 -
0.22 - 0.36 1.05
P - 2,500 - - - - - 0.39 (37
(32-52) (147 -
- 57)
152)
1.27 -
0.50 -
1.27-1.77 1.27-1.77 1.77
R Reverse 2,500 - - - - 0.70 (73
(185-256) (185-256) (185 -
- 101)
256)
0.22 - 0.25 -
0.22 - 0.36
N - 2,500 - - - - - 0.36 (32- 0.39 (37
(32-52)
52) - 57)
R/V4A51
Air Test Points
R/V4A51
No Park Engagement
The split roll pin used in the park rod assembly may break due to fatigue in
the roll pin. The pin should be inspected during repairs. A ratcheting noise may
be heard while transmission is put into park. A stuck in park may also be noticed
due to the pin breaking and leaving the rod in the transmission tail park lever
assembly.
R/V4A51
Overheating Problems, Foaming
Concerns
Most overheating problems with 1999-2001 model Motero Sports are caused
by improper fluid levels. The early dipstick level-full area is difficult to read, be-
cause of this, a new dipstick and pan were introduced to lower the level in the
pan.
NOTE: All of the 1999 models flash the “N” indicator light 2 times per second to
indicate overheating conditions. The 2000-2001 two wheel drive models also
use the “N” indicator. The 2000-2002 four wheel drive models have a seperate
ATF temperature light.
NOTES:
Nissan Contents
RE4F04A
Harsh 1-2 Shift ....................... 228
Subaru
Identification ........................... 229
Nissan
Harsh 1-2
RE4F04A
Make sure the 1-2 accumulator control check ball is in the correct location.
There is another pocket near this one which orifices the 3-2 servo release oil. But
this pocket has never had a check ball installed here in the RE4F04A units.
No ball here
No ball here
Subaru
1999 Subaru 4-AT
Since 1999, Subaru vehicle are equipped with a modified EC8 transmission.
The 2-4 Band is replaced with a 2-4 Brake Clutch. Lockup apply is modulated and
capable in all forward ranges. The accumulators are now part of the valve body.
There are a total of seven solenoids. Four of the solenoids control similar
circuits found in the EC8 transmission. One of the additional solenoids modulate
the Low Clutch (Forward Clutch) apply rate. The other two solenoids modulate
and control the 2-4 Brake Clutch and one TFT sensor.
Subaru
Clutch and Brake Operation
Subaru
Low High Low/ One-Way
Range 2-4 Brake Reverse
Clutch Clutch Reverse Clutch
Park
R A A
N
D4 A A A
D3 A A
D2 A A
D1 A
M1 A
Subaru
Pressure Specifications
Pressure Specifications
Pressure Specifications
Transfer
Test
Selector Pressure
Condition
AWD Mode
In Park at
FWD Mode zero psi
2000 rpm
Subaru
Pressure Port Identification
Subaru
Pressure Port Identification
Nissan/Subaru
Case Passage Port Identification
Subaru
Solenoid Information
Solenoid Information
Solenoid
Solenoid No.1 Solenoid No. 2
Command
1st Gear On On
2nd Gear Off On
3rd Gear Off Off
4th Gear On Off
Subaru
Valvebody Information
Accumulator
Check balls
Upper V/B
High Clutch
Low Clutch
2-4 Brake
Middle V/B
2-4 Brake
Reverse
Orifice
High Clutch
Anti
Drainback
© 2003 ATRA. All Rights Reserved
NISSAN 237
Subaru
Valvebody Information
Lower V/B
Solenoid Feed Screens
Subaru
Code Retieval
Codes maybe obtained with a scan tool through the Data Link Connector
located behind a cover at the lower dash panel. Codes can also be obtained manu-
ally by using the AT Oil Temp Light. Manual code method can only retrieve some
of the codes.
Normally the AT Oil Temperature light should stay lit for 2 seconds then go
out, after the ignition is switched on. If a malfunction is present, the AT Oil Temp.
Light keeps blinking for 8 seconds.
When you complete the following steps, the AT Oil Temperature light will
display long and short flashes. The Long flashes will equal the number 10, the
short flashes will equal the number 1.
To clear codes, remove No. 4 fuse located in main fuse box behind hood re-
lease.
Subaru
Subaru 4-AT DTC
DTC Definitions
AT Temp. Light/OBDII Definition
11/P0725 Engine rpm
27/P0710 ATF Temp. Sensor
31/P1700 TPS
33/P0720 VSS No. 2
36/P0715 TSS
38/P1106 or P1106 Engine Torque Signal
45/P0100 MAP
71/P0753 Shift Solenoid No. 1
72/P0758 Shift Solenoid No. 2
73/P1703 Low Clutch Timing Solenoid
74/P1704 2-4 Brake Timing Solenoid
75/P0748 Line Pressure Solenoid
76/P1705 2-4 Brake PWM Solenoid
77/P0743 Lockup PWM Solenoid
79 Transfer Clutches Solenoid
93/P0500` VSS No. 1
P0703 Brake Switch
P0705 Range Sensor
P0731 1st Gear Ratio Incorrect
P0732 2nd Gear Ratio Incorrect
P0733 3rd Gear Ratio Incorrect
P0734 4th Gear Ratio Incorrect
P0740 TCC Malfunction
P1115 Engine Torque Control Cut Signal Input High
P1116 Engine Torque Control Cut Signal Input Low
P1701 Cruise Control Set Signal Incorrect
P1702 Transaxle Diagnosis Input Signal Circuit Input Low
P1722 Transaxle Diagnosis Input Signal Circuit Input
High
P1742 Transaxle Diagnosis Input Signal Circuit
Malfunction
All Other Codes…………………………………………………...Engine Related
Subaru
Subaru TCU Pin Charts
Subaru
Subaru TCU Pin Charts
Check with Ignition ON.
Resistance
Terminal
Content Connector Measuring conditions Voltage (V) to body
No.
(ohms)
Throttle fully closed 0.2—1.0
Throttle position sensor B55 2 —
Throttle fully opened 4..2—4.7
Throttle position sensor Ignition switch ON (with
B55 1 4.82—5.3 —
power supply engine OFF)
ATF Temperature 68°F
1.6—2.0 2.1k—2.9k
ATR Temperature (20°C)
B55 11
sensor ATF Temperature 176°F
0.4—0.9 275—375
(80°C)
Vehicle stopped 0
Rear vehicle speed
B55 3 Vehicle speed at least 450—650
sensor More than 1 (AC range)
12MPH (20km/h )
Vehicle stopped 0
Front vehicle speed
B55 5 Vehicle speed at least 450—650
sensor More than 1 (AC range)
12MPH (20km/h )
Engine idling after
0
Torque converter warmup (D range)
B55 12 450—650
turbine speed sensor Engine idling after
More than 1 (AC range)
warmup (N range)
Vehicle speed output Vehicle speed at most
B55 13 Less than 1< More than —
signal 6MPH (10km/h )
Ignition switch ON (with
More than 10.5
engine OFF)
Engine speed signal B55 4 —
Ignition switch ON (with
8—11
engine ON)
When cruise control is
Less than 1
set (Set lamp ON)
Cruise set signal B54 11 —
When cruise control is
More than 6.5
not set (Set lamp OFF
Ignition switch ON (with
Torque control signal 1 B54 13 More than 4 —
engine ON)
Ignition switch ON (with
Torque control signal 2 B54 21 More than 4 —
engine ON)
Torque control cut
B54 2 Ignition switch ON 8 —
signal
Intake manifold Engine idling after
B54 20 0.4—1.6 —
pressure signal. warmup
© 2003 ATRA. All Rights Reserved
242 NISSAN
Subaru
Subaru TCU Pin Charts
Check with Ignition ON.
Resistance
Terminal
Content Connector Measuring conditions Voltage (V) to body
No.
(ohms)
Subaru
Subaru TCU Pin Charts
Check with Ignition ON.
Resistance
Terminal
Content Connector Measuring conditions Voltage (V) to body
No.
(ohms)
Throttle fully closed (with
engine OFF) after More than 8.5
warming up
Line pressure dropping resistor B54 18 2.0—4.5
Throttle fully open (with
engine OFF) after Less than 0.5
warming up
VOLVO
Table Of Contents
AW50-42LE
Cracked Input Drum ........... 246
AW50-42LE
Cracked Input Drum
A common failure on these units is a cracked input drum. This part is not
serviced separately. Besides buying a complete unit from Volvo, the only option
has been to buy a good used one.
The Difference between the Daewoo drum and the Volvo drum is in the weld
area. The weld area for the new drum from Daewoo has a stepped area for
durability.
Volvo Daewoo
AW50-42LE
Cracked Input Drum
The Daewoo Leganza also uses a similar FWD AW transmission. Internal
transmission parts for the Leganza are available. The Daewoo part number for the
input drum is 3570150A021. The discount price from a local dealer is about
$350.00. This part has the identical dimensions as the Volvo part with the
addition of a widened support flange where the shaft is welded to the drum.
The other option is to buy the matching forward piston (part no.
3560250A010) and direct piston (part No. 3560650A011) from Daewoo for about
$130.00 for both parts.
Volvo
Rear of Original C1 Clutch
AW50-42LE
Hard or Slow Engagemnet Forward
and/or Reverse
This maybe caused by worn seal rings in the rear cover. These rings control
the oil to the C1 and C2 clutches. The C1 clutch is one of the forward elements.
The C2 clutch is one of the reverse elements. Both these clutches are enclosed in
the input shaft and drum. To check the C1 and C2 clutches, attach two pressure
gauges to the transmission as shown. Move gear selector to “D”. The C1 clutch
pressure should be 57 psi and the C2 clutch pressure stay at zero. Move gear
selector to “N”. Wait three seconds and check the pressures again.
AW50-42LE
Hard or Slow Engagemnet Forward
and/or Reverse
Move the gear selector to “N”. Wait three seconds and move gear selector to
“R”. The C2 pressure gauge should read 85 psi and the C1 pressure stay at zero.
Move gear selector to “N”. Wait three seconds and check the pressures again.
If the clutch pressures do not work right, the seal rings or ring support are
worn. A new rear transmission cover with a steel ring support is available from
Volvo. The kit part No. is 9463445 and cost about $180.00. This kit includes a
rear cover, three Teflon rings, an O-ring, a steel washer, four seals and eight
mounting bolts.
The rear cover can be replaced with the transmission on the car. Volvo
allows their technicians 2.5 hours to R & R the cover.
Volkswagen Contents
096/01M Scanning for Codes ................... 273
Transaxle Identification ............. 254
VAG Code Definitions ................ 275
Model and TCM Application ....... 255
Generic Codes ........................... 277
Clutch Apply Chart ................... 257
Kills The Engine in Gear Code
Servicing ................................... 258 P1582 ....................................... 278
096/01M
Transaxle Identification
In 1993, VW vehicles used an 096 Phase 2 transaxle. As early as 1994, the
O1M transaxle was installed. This transaxle used a different shift strategy and
TCC was PWM controlled. The Identification tags can be found on the side of the
transaxle or underneath the filter. The chart below will help you identify the gear
ratio of the unit you’re working on.
Gear Ratios
096
2.0L (CNK) 4.22
2.8L (CFF) 3.70
01M
1.8L (CKX) 4.53
2.0L (CLK, DYK) 4.22
2.8L (CCB, DCE, ECM) 3.70
Diesel (CK2, ECN) 3.27
The TCM application is based on the PCM. This is because some TCMs
recieve the TPS signal from ECM. The location of a 4-cylinder engine code is
shown here on top of the engine block below the intake manifold, 6-cylinder
engine codes are located at the front of the block
K1 = Fwd Clutch
096 Phase 2
K2 = Rev. Input (096); Rev. Input
and 3rd Clutch (01M)
B2 = 2nd/4th Brake
Servicing
There is no dipstick on the Phase 2 096 and 01M transaxles. A standpipe is
located in the oil pan. The oil level is correct when the level of oil in the pan is
even with the top of the standpipe. If the oil is too high, the excess oil will spill out
when the inspection plug is removed. The following steps must be followed for the
level to be correct.
Step 1) Make sure the vehicle is level.
Step 2) Start the engine and warm it up to about 85-95 degrees F.
Step 3) Run the gear selector through all ranges ending in Park.
Step 4) Remove the inspection plug.
Step 5a) Allow excess oil to run out and replace inspection plug.
Step 5b) If needed, remove RED fill cap and add oil.
Order the replacement RED cap under VW 014 301 485 (cost $2.00)
Or in a service kit 01M 398 998
The service capacity is about 3 qts (an overhaul takes about 6 qts.)
Allow
transmission
oil to run out
of the stand
pipe.
01M / 096
Rebuilding Tips
This unit can be a money maker. The owners like driving their VWs, and these
cars hold their resale value. The dealers charge $4,000-5,000 for an exchange
unit plus any computer and/or electrical repairs the car may need. In some areas,
the closest dealer maybe 100+ miles away.
The truth is, this unit is very easy to build. Service parts, information and
scan tools are now readily available. The aftermarket has or will soon release
replacement parts for the valve body. Most of the units don’t require any more
than a master kit, filter, a couple of solenoids, a new wire harness, converter and
don’t forget $100.00 in VW ATF (if it’s an 01M). This still leaves at least a $3,000
margin. The most common hard part damage seems to be the K3 clutch, the
pump and occasionally the planets. The only red herring left is the valve body. If
it’s worn out or can’t be fixed, the only options would be to spend $500.00 at the
dealer or get a guarranted valve body from a supplier.
01M / 096
Rebuilding Tips
Pump Warpage
To check for proper clutch operation, air check the clutches stacked on top of
oil pump before disassembly and during reassembly. This checks for leaks in the
oil pump assembly.
K2
K3
© 2003 ATRA. All Rights Reserved
VOLKSWAGEN 263
01M / 096
Rebuilding Tips
Stator Support Thrust Washer
Always replace the Stator Support thrust washer during the rebuild. This
washer retains a major amount of heat and becomes very brittle. Failing to replace
this washer may lead to premature failure of the washer after overhaul and major
damage to the transmission.
Thrust Washer
The VW part
number is
095-321-285
01M / 096
Rebuilding Tips
B1 clutch
During the assembly of the B1 clutch make sure to install the diaphragm
spring with the cone up. Always be aware of the location of the wave spring. If the
wave spring is installed incorrectly a clutch failure or harsh/soft engagements
may be felt.
Wave
Spring
Location
01M / 096
Rebuilding Tips
B2 clutch
During the assembly of the B2 clutch make sure the wave plate is installed
against the B2 piston.
Make sure
the wave
plate sits
under the
thick
pressure
plate
01M / 096
Rebuilding Tips
Solenoid Description (NXX shown on scanner)
#1 N88 = K1/B1 Shift Solenoid (EV1)
#2 N89 = B2 Shift Solenoid (EV2)
#3 N90 = K3 Shift Solenoid (EV3)
#4 N91 = TCC Solenoid (EV4) (Non-PWM on 096 / PWM on 01M)
#5 N92 = Shift Apply Feel Solenoid (EV5)
#6 N93 = EPC Solenoid (EV6)
#7 N94 = 3rd and 4th Control Solenoid (EV7) (O96)
#7 N94 = K1 Clutch Kickdown Control Solenoid (EV8) (O1M)
Valve Description
A = Manual Low Valve
B = Manual Valve
C = TCC Modulator Valve
D = K3 Shift Valve
E = B1/Shift Control Valve
F = K1/B1 Shift Valve
G = B2 Shift Valve
H = B2 Orifice Control Valve
I = 3-4 Regulator Valve
J = 2-3 Regulator Valve (O96)/Blocked (O1M)
K = K1 Orifice Control Valve
L = K2 Orifice Control Valve
M = Boost Control Valve (Not Shown)
N = Main PR
O = Converter Regulator Valve
P = Solenoid Feed Limit Valve
Q = Manual 1 Regulator Valve
01M / 096
Rebuilding Tips
01M Valve Body Exploded View
7 6 Q P
A
4 B
3 C O
5 D N
E M*
1 F L
2 G K
H I J
096 Valve First
01M Spring First
* M - Not Shown
01M / 096
Rebuilding Tips
01M Check Ball Locations
K2
Checkball Low & Reverse
Checkball
B1 Orifice
Checkball
Orifice K1 B2 Exhaust
Checkball Checkball
01M / 096
Rebuilding Tips
Check Ball Locations
01M / 096
Rebuilding Tips
01M Check Ball Locations
Another way to identify the checkball location is to locate the “Dimples” in the
separator plate. However not all separator plates will have these dimples, locate
the check ball area if a check ball was in the valve body it will surly leave a mark
on the separator plate.
01M / 096
Rebuilding Tips
Adjusting the Manual Valve
If the line pressure in D is low, but correct in Manual 3, suspect a misadjusted
manual valve. To Adjust the manual valve properly you must first:
1. Select the Park position
2. Loosen the Torx screw
3. Bottom out the Manual Valve in the Valvebody
4. Tighten Torx screw
Manual
Valve
Lever
Torx
Screw
Manual Valve
© 2003 ATRA. All Rights Reserved
272 VOLKSWAGEN
01M / 096
Rebuilding Tips
Rebuild Specifications
Clutch Clearances
B1 5 Clutches .047"
B2 5 or 6 .070"-.076"
Endplay
.
Planet geartrain / carrier
009"-.014"
K2 to K1 .023"-.040"
Torque Specifications
¹ personnel observations
© 2003 ATRA. All Rights Reserved
VOLKSWAGEN 273
Electronic Diagnosis
Scanning for Codes and Data
In order to scan the TCU, you must have a VAG1551/2 or VAG compatible
scanner. VAG stands for Volkswagen Audi Group. Depending on your current shop
equipment, you can get one from Ross-Tech for $250.00. Their software is down-
loaded into your PC or laptop. AST, BAUM and others, offer similar software or
stand alone scanners from $650.00-2,500.00. Or you could take the car to a
dealer (if they are local) to get codes and scan data.
Why buy a specialized scanner? My current scanner can access the TCU un-
der Generic.
Using your current scanner under Generic mode will clear codes and retrieve
select codes. A VAG type scanner will retrieve all codes, display the data stream
and reset the TCU base values. These cars are known to have lots of connector
and wiring problems. With a scanner, you can pinpoint the problem. Also, when
the battery is disconnected, these cars may stay in limp until the TCU is reset or
all codes are cleared.
Electronic Diagnosis
Scanning for Codes and Data (continued)
Limp Mode
Limp mode on a 096 or 01M is 3rd gear in any forward range and Reverse. In
limp mode, either the D position light stays on no matter where the gear selector
is moved to or all PRNDL positions will light up.
Electronic Diagnosis
Scanning for Codes and Data (continued)
VAG Code Definitions
Electronic Diagnosis
Scanning for Codes and Data (continued)
Electronic Diagnosis
Scanning for Codes and Data (continued)
Generic Codes
Use this chart to convert generic codes to VAG codes. Some codes are not
available under generic mode.
Example: A very common code is 00652 for gear ratio or gear slip code. Only a
VAG type scan tool can display this code.
01M / 096
Kills Engine in Gear and/or Engine
Code P1582 (Idle Too Low)
This problem is usually caused by a clogged TCC solenoid #4 or a worn TCC
boost valve and sleeve. Since the TCU has the ability to turn lockup on in any
forward gear, a short circuit or bad TCU may also cause the TCC to kill the engine
in gear.
#4
01M / 096
Neutral or Flare on Take Off
This is usually caused by no line rise. Using a VAG scanner, make sure the
computer commands lower amperage during acceleration. If not, check TPS, scan
the PCM and TCM to locate the electrical problem. If the TCU works correctly,
replace or clean the# 6 EPC solenoid.
#6 EPC Solenoid
01M / 096
Momentary 3-4 Bind or Flare
If a momentary bind occurs, the K1 clutch may not be exhausting fast
enough. Make sure solenoid #1 and solenoid #7 are not plugged. Check the K1
shift valve, 3-4 shift control and K1 orifice control valves can stroke freely in their
bores .
If a flare occurs, the B2 or K3 clutch circuits are coming on too slow. If 2nd
gear works good, check solenoid #3 and make sure it’s not plugged. Make sure
the K3 shift valve strokes freely in it’s bore. If the K3 shift valve stokes freely and
you still have this problem try installing a lighter shift valve spring. If 2nd gear is
also soft, install a 20-30% stronger B2 orifice control spring.
#7
#3
#1
#2
K1 Orifice
B2 Shift Valve
01M / 096
Hard or Slide Bump 1-2
This is a common complaint after overhaul. The driver may have “lived” with
this problem for a long time. It’s usually caused by low line rise or general wear in
the valve body. If this is the only complaint and line rise looks good, turn the
boost control valve end cap one turn in. Some builders make a habit of turning
this cap ½ in during overhaul.
01M / 096
Shuttle Shifts 1-2-1-2 or 3-4-3-4
Feels like high gear starts, then bangs after you start rolling. This is usually
an installer created problem. The wiring for the speed sensors are easy to cross
up. Make sure the turbine speed sensor wires are Green and Red and the Output
Speed Sensor wires are Yellow and White. A VAG scanner will display MPH while
sitting still.
If the two speed sensors are installed correctly, check the valve body for
stuck valves or solenoid malfunctions.
OSS =
Yellow and
White Wires
TSS =
Green and
Red Wires
01M / 096
No Forward Except Manual Low
This condition is caused by the K1 clutch not holding. Pull the valve body and
air check the K1 clutch. If it air checks, look for a stuck K1 shift valve or plugged
#1 solenoid.
#1
K1/B1
Solenoid
K1 Shift Valve
Reference Contents
Conversion Tables ........................................................................................ 286
Resistor Values ............................................................................................. 289
Ohm’s Law.................................................................................................... 290
Electrical Power ............................................................................................ 290
Electrical Formulas ....................................................................................... 291
Resistors in a Series Circuit ...................................................................... 291
Two Resistors in a Parallel Circuit ........................................................... 291
Multiple Resistors in a Parallel Circuit ..................................................... 291
Two Capacitors in a Series Circuit ........................................................... 291
Multiple Capacitors in a Series Circuit ..................................................... 291
Capacitors in a Parallel Circuit ................................................................. 291
Schematic Symbols ....................................................................................... 292
Glossary of Electrical Terms ......................................................................... 294
Abbreviations................................................................................................ 298
Numeric Equivalents .................................................................................... 299
Conversion Tables
Area Distance
Multiply By To Obtain Multiply By To Obtain
In² 645.2 mm² in 25.4 mm
In² 6.452 cm² in 2.54 cm
In² 0.0069 Ft² mm 0.0394 in
Ft² 0.0929 m² cm 0.3937 in
Continued…
Resistor Values
If you can read the bands on a ceramic resistor, you can determine its resistance value and its tolerance:
• The first two bands indicate the first two digits of its resistance value.
• The third band indicates the number of zeros to add.
• The fourth band indicates the tolerance.
Resistance Values
Color 1st Band 2nd Band 3rd Band 4th Band
Black 0 0 0 —
Brown 1 1 1 —
Red 2 2 2 —
Orange 3 3 3 —
Yellow 4 4 4 —
Green 5 5 5 —
Blue 6 6 6 —
Violet 7 7 7 —
Gray 8 8 8 —
Brown White 9 9 — —
1% Brown — — — 1%
Gold — — — 5%
Silver — — — 10%
Plain 1234
—
1234 12345
—
12345 1234
—
1234 12345
20%
12345
1234 12345 1234 12345
1234 12345 1234 12345
1234
1234 12345
12345 1234
1234 12345
12345
1234
1234 12345
12345 1234
1234 12345
12345
1234
1234 12345
12345 1234
1234 12345
12345
1234
1234 12345
12345 1234
1234 12345
12345
1234 12345 1234 12345
1234
1234 12345
12345 1234
1234 12345
12345
1234
1234 12345
12345 1234
1234 12345
12345
1234 12345 1234 12345
1234
1234 12345
12345 1234
1234 12345
12345
1234 12345
12345 1234
1234 12345
12345
Ohm’s Law
With Ohm’s Law, as long as you have any two circuit values,
VOLTS you can easily calculate the third:
Volts ÷ Amps = Ohms
Volts ÷ Ohms = Amps
AMPS OHMS Amps x Ohms = Volts
Electrical Power
A measurement of power developed in an electrical circuit.
WATTS Just like with Ohm’s Law, whenever you have two measure-
ments, you can calculate the third.
Watts ÷ Volts = Amps
VOLTS AMPS Watts ÷ Amps = Volts
Volts x Amps = Watts
Electrical Formulas
Resistors in a Series Circuit
RTOTAL = R1 + R2 + R3 …
Schematic Symbols
+ V
+
+
C E C
B B B
E C E
Crystal
Abbreviations
Abbr. Description Abbr. Description
A Ammeter kV Kilovolt
AC Alternating current kW Kilowatt
B, b Base electrode, units with single base kWH Kilowatt hour
°C Degrees Celsius or centigrade lb Pound
C Capacitance, capacitor M Mega; x1,000,000
C, c Collector electrode m Milli; one-one thousanth; 1/1000; 0.001
cm Centimeter mf, mfd Microfarad
cu Cubic MHz Megahertz
db Decibels mm Millimeter
DC Direct current NC Normally closed
dm Decimeter Nm Newton-meter
DPDT Double-pole, double-throw switch NO Normally open
DPST Double-pole, single-throw switch R Resistance; resistor
E, e Emitter electrode SPDT Single-pole, double-throw switch
E, e Voltage SPST Single-pole, single-throw switch
mf Microfarad t Time
°F Degrees Fahrenheit T Temperature
F, f Frequency V, v Volt; voltmeter
flu Fluid VBB Base supply voltage (DC)
FM Frequency modulation VBC Base-to-collector voltage (DC)
g Gram VBE Base-to-emitter voltage (DC)
gnd, grd Ground VCB Collector-to-base voltage (DC)
Hg Mercury VCC Collector supply voltage (DC)
Hz Hertz VCE Collector-to-emitter voltage (DC)
I Current VEB Emitter-to-base voltage (DC)
IB Base current (DC) VEC Emitter-to-collector voltage (DC)
IC Collector current (DC) vee Emitter supply voltage (DC)
IE Emitter current (DC) vF Forward voltage (DC)
k x1000 W Watt; work
kg Kilograms w Watt
kHz Kilohertz wh, whr Watt-hour
Numeric Equivalents
Decimal Fraction Drill Tap Decimal Fraction Drill Tap
Inches Inches Millimeters Size Size Inches Inches Millimeters Size Size
0.0078 1
/128 0.1981 0.1130 2.8702 33 6-40 NF
0.0135 0.3429 80 0.1160 2.9464 32
15
0.0145 0.3683 79 0.1172 /128 2.9769
0.0156 1
/16 0.3962 0.1200 3.0480 31 6-48 NS
1
0.0160 0.4064 78 0.1250 /8 3.1750
0.0180 0.4572 77 0.1285 3.2639 30
17
0.0200 0.5080 76 0.1328 /128 3.3731
0.0210 0.5334 75 0.1340 3.4036 4mm - 0.70
0.0225 0.5715 74 4mm - 0.75
0.0234 3
/128 0.5944 0.1360 3.4544 29 8-32 NC
0.0240 0.6096 73 8-36 NF
0.0250 0.6350 72 0.1405 3.5687 28 8-40 NS
9
0.0260 0.6604 71 0.1406 /64 3.5712
0.0280 0.7112 70 0.1440 3.6576 27
3
0.0292 0.7417 69 0.1470 3.7338 26 /16-24 NC
0.0310 0.7874 68 0.1476 3.7500 4.5mm - 0.75
19
0.0312 1
/32 0.7925 0.1484 /128 3.7694
0.0320 0.8128 67 0.1495 3.7973 25 10-24 NC
0.0330 0.8382 66 0.1520 3.8608 24
0.0350 0.8890 65 0.1540 3.9116 23
5
0.0360 0.9144 64 0.1563 /32 3.9700
3
0.0370 0.9398 63 0.1570 3.9878 22 /16-32 NF
0.0380 0.9652 62 0.1590 4.0386 21 10-32 NF
0.0390 5
/128 0.9906 61 0.1610 4.0894 20
21
0.0400 1.0160 60 0.1641 /128 4.1681
0.0410 1.0414 59 0.1650 4.1910 5mm - 0.90
0.0420 1.0668 58 0.1660 4.2164 19
0.0430 1.0922 57 0.1690 4.2926 5mm - 0.80
0.0465 1.1811 56 0.1695 4.3053 18
11
0.0469 3
/64 1.1913 0-80 NF 0.1719 /64 4.3663
0.0520 1.3208 55 0.1730 4.3942 17
0.0547 7
/128 1.3894 0.1770 4.4958 16 12-24 NC
23
0.0550 1.3970 54 0.1797 /128 4.5644
0.0595 1.5113 53 1-64 NC 0.1800 4.5720 15
1-72NF 0.1653 4.2000 5.5mm - 0.80
0.0625 1
/16 1.5875 0.1820 4.6228 14 12-28 NF
0.0635 1.6129 52 0.1850 4.6990 13 12-32 NEF
3
0.0670 1.7018 51 0.1875 /16 4.7625
0.0700 9
/128 1.7780 50 2-56 NC 0.1890 4.8006 12
2-64 NF 0.1910 4.8514 11
0.0730 1.8542 49 0.1935 4.9149 10 14-20 NS
25
0.0760 1.9304 48 0.1953 /128 4.9606
0.0781 5
/64 1.9837 0.1960 4.9784 9
0.0785 1.9939 47 3-48 NC 0.1990 5.0546 8
1
0.0810 2.0574 46 0.2010 5.1054 7 /4-20 NC
0.0820 2.0828 45 3-56 NF 14-24 NS
13
0.0860 11
/128 2.1844 44 4-36 NS 0.2031 /64 5.1587
0.0890 2.2606 43 4-40 NC 0.2040 5.1816 6
0.0935 2.3749 42 4-48 NF 0.2050 5.2070 6mm - 1.00
0.0938 3
/32 2.3825 1
/8-32 NC 0.2055 5.2197 5
1
0.0960 2.4384 41 0.2090 5.3086 4 /4-24 NS
27
0.0980 2.4892 40 3mm - 0.50 0.2109 /128 5.3569
1
0.0995 2.5273 39 0.2130 5.4102 3 /4-28 NF
7 1
0.1015 2.5781 38 1
/8-40NF 0.2188 /32 5.5575 /4-32 NEF
5-40NC 0.2210 5.6134 2
29
0.1016 13
/128 2.5806 0.2266 /128 5.7556
1
0.1040 2.6416 37 5-44 NF 0.2280 5.7912 1 /4-40 NS
0.1065 2.7051 36 6-32 NC 0.2340 5.9436 A
15
0.1094 7
/64 2.7788 0.2344 /64 5.9538
0.1100 2.7940 35 0.2380 6.0452 B
0.1110 2.8194 34 6-36 NS 0.2400 6.0960 7mm - 1.00
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300 2003 TECHNICAL SEMINAR