HYDRA-MATIC 5L40-E

FIVE-SPEED TRANSMISSION

Transmission Type Control Systems

5L40-E = 5: Five Speed Shift Pattern - (3) Two-Way On/Off Solenoids
L: Longitudinal Mount Shift Quality - Pressure Control Solenoid
40: Product Series Torque Converter Clutch - Pulse Width Modulated Solenoid Control
E: Electronically Controlled Gear Ratios
Automatic Overdrive with a Torque Converter Clutch Assembly.
1st 3.42
2nd 2.21
Seven Position Quadrant or Driver Shift Control 3rd 1.60
(P, R, N, D , 4, 3, 2) 4th 1.00
5th 0.75
Pressure Taps Available
Rev 3.03
Line Pressure

Information may vary with application. All information, illustrations and specifications contained in this book are based on the latest
IS-5L40E-1

product information available at the time of publication. The right is reserved to make changes at any time without notice.
 5L40E Cut-Away View and Component Locations

B D E
A C F

A Direct
B Reverse
C Overdrive
D Intermediate
E Low/Reverse
F Second Coast
G Second
H Coast
H I Forward
I J K L M J Forward Sprag
K Intermediate Sprag
L Low Sprag
M Second Sprag

1-2 Shift 2-3 Shift 4-5 Shift TCC

RANGE GEAR Solenoid Solenoid Solenoid Solenoid
Valve Valve Valve Valve On - Solenoid Energized
1 Off On Off Off Off - Solenoid De-Energized
1 Off On On Off @ - The Solenoid's State Follows a
2 On On Off On/Off@ Shift Pattern Which Depends Upon
2 On On On On/Off@ Vehicle speed and Throttle Position.
D432
3 On Off Off On/Off@ It Does Not Depend Upon the Selected Gear
3 On Off On On/Off@
4 Off Off On On/Off@
5 Off Off Off On/Off@
@ @ @
NEUTRAL -
On/Off On/Off On/Off
@ @ @
REVERSE R
On/Off On/Off On/Off Off
@ @ @
PARK - On/Off On/Off On/Off

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 Apply Components
FORWARD CLUTCH SPRAG ASSEMBLY
CLUTCH SPRAG HOLDING
OUTER RACE DRIVING THE INNER RACE Input Forward
Sun Gear Clutch
Shaft Sprag
Assembly Assembly

Outer
A Race
Driving
Inner
Race

Sprag is Viewed From This Direction

CLUTCH SPRAG RELEASED

INNER RACE OVERRUNNING THE OUTER RACE

B Outer
Race
Inner Forward Clutch
Race Sprag Outer Race
Driving

SECOND CLUTCH SPRAG

Second Clutch
CLUTCH SPRAG HOLDING Sprag Inner Race
OUTER RACE HOLDING THE INNER RACE

Outer
A Race

Inner
Race

Sprag is Viewed From This Direction

CLUTCH SPRAG RELEASED
INNER RACE OVERRUNNING THE OUTER RACE

B Outer
Race
Inner
Race
Second Clutch Second Clutch
Sprag Outer Race Sprag Assembly

-3-
 Apply Components Intermediate Intermediate
Clutch Sprag Clutch Sprag

INTERMEDIATE CLUTCH SPRAG ASSEMBLY

CLUTCH SPRAG HOLDING
OUTER RACE HOLDING THE INNER RACE

Outer
A Race
Inner
Race
Sprag is Viewed From This Direction
CLUTCH SPRAG RELEASED
INNER RACE OVERRUNNING THE OUTER RACE

B Outer
Race
Inner
Race
Overdrive and Reverse
Clutch Hub Assembly

LOW CLUTCH SPRAG

CLUTCH SPRAG HOLDING
OUTER RACE HOLDING THE INNER RACE Low Clutch
Sprag Outer Race

Outer Low Clutch

A Race Sprag Inner Race

Inner
Race
Sprag is Viewed From This Direction
CLUTCH SPRAG RELEASED
INNER RACE OVERRUNNING THE OUTER RACE

B Outer
Race

Inner
Low Clutch
Race
Sprag Assembly

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 Hydraulic Control Components

Direct Overdrive
Clutch Clutch
Accumulator Accumulator

A
B * Second
Intermediate
Clutch Clutch
Accumulator Accumulator

A Pressure Control Secondary

B T.C.C. Solenoid
C 1-2 Shift Solenoid
D 2-3 Shift Solenoid
E 4-5 Shift Solenoid

C D

E
Rear
Control
Valve

-5-
 Check Ball Locations

FRONT

"Typical" 5L40E Spacer Plate

P.C.S.
screen

T.C.C.
screen

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 1
3 5
10 7
13
1. Line Pressure
8
2. Regulated Apply 2
3. Throttle Signal
4. Reverse Lock Out
5. Reverse Clutch
6. Low/Rev Clutch or RLO
7. Forward Clutch 14
8. TCC Signal 12
9. Second Clutch
10. Coast Clutch
11. 2nd Coast Clutch
9 11 6 4
12. Intermediate Clutch
13. Direct Clutch
14. Overdrive Clutch

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 Transmission Gear Train Exploded View

2
3

*Note: Solid PTFE Ring

Closest to Converter

20 7 8 9

19
18

13

17
14

15 16

-8-
 4 5
10
1. Converter/Pump Housing
2. Direct/Reverse Clutch Housing
3. Forward/Coast Clutch Housing
4. Forward Sprag/Input Sun Gear
Shaft
5. Direct Clutch Hub
6. O.D. Clutch Hub/Intermediate
Sprag
7. Intermediate/Overdrive Clutch
Housing
11
8. Low Sprag
9. Center Support 2nd Clutch/Low/
Reverse & 2nd Coast Clutch
10. Second Clutch Sprag
11. Planetary Carrier Assembly
12. Output Shaft & Internal Ring Gear
13. Pump to Case Gasket
14. Input Speed Sensor W/O Spacer
-9-
6
12
15. Output Speed Sensor With Spacer
16. Intermediate/O.D. Feed Seal
17. Reverse/Low and Reverse/2nd/
2nd Coast Feed Seal
18. Extension Housing Gasket
19. Extension Housing
20. Intermediate/O.D. Housing Selec-
tive Snap Ring
 Electrical Components

Transmission Fluid Temperature Sensor Shift Solenoids

Temperature Resistance R% (+/-) +/-OC Engine 1-2 2-3 4-5
-40 100000 10.5 1.51 Range Gear Braking Valve Valve Valve

-30 51400 9.69 1.52 1 NO OFF ON OFF

-20 27610 9.02 1.49 1 YES OFF ON ON
-10 15450 8.35 1.49 2 NO ON ON OFF
0 8972 7.74 1.43 2 YES ON ON ON
D432
10 5391 7.16 1.42 3 NO ON OFF OFF
20 3342 6.64 1.42 3 YES ON OFF ON
30 2132 6.19 1.41 4 YES OFF OFF ON
40 1397 5.73 1.39 5 YES OFF OFF OFF
50 938 5.32 1.38 Neutral - -
60 645 4.92 1.35 Reverse R YES ON/OFF
70 453 4.55 1.30 Park - -
80 324 4.19 1.27
90 237 3.89 1.25
100 176 3.59 1.22
110 132 3.25 1.16 Duty Cycle Current Line Pressure
120 101 2.96 1.13 Minimum 0.1 Amps Maximum
130 79 2.66 1.07 Maximum 1.1 Amps Minimum
140 62 2.58 1.09
150 49 2.83 1.26

Shift solenoid valve resistance should measure between 15 and 17 ohms when measured at 20oC (68oF). The resistance should
measure approximately 24 ohms at 150oC (302oF).

Pressure control solenoid valve resistance should measure between 3.5 and 4.6 ohms when measured at 20oC (68oF), and approximately
6 ohms at 150oC (302oF).

TCC PWM solenoid valve resistance should measure between 10.0 and 11.5 ohms when measured at 20oC (68oF). The resistance should
measure approximately 16 ohms at 150oC (300oF).

-10-
 Range Reference Chart
1 2 3 5 4 6 7 8 9 10 11 12 13
Forward Over- Interm. Inter- Low Low and Second Second
RANGE GEAR Engine Direct Coast Reverse Forward Clutch Drive Clutch Mediate Clutch Reverse Second Clutch Coast
Braking Ratio Clutch Clutch Clutch Clutch Sprag Clutch Sprag Clutch Sprag Clutch Clutch Sprag Clutch
1 *No 3.42 Applied Applied LD LD
1 Yes 3.42 Applied Applied LD LD Applied
2 *No 2.21 Applied Applied LD Applied LD
2 Yes 2.21 Applied Applied LD Applied LD Applied
D432
3 *No 1.60 Applied Applied LD LD Applied Applied
3 Yes 1.60 Applied Applied LD Applied LD Applied Applied
4 Yes 1.00 Applied Applied Applied LD Applied Applied
5 Yes 0.75 Applied Applied Applied Applied Applied
Neutral - - -
Reverse R Yes 3.03 Applied Applied
†Reverse
Lock Out
Park - - -

LD - Locked in Drive
* - Engine Braking is Electronically Controlled by the TCM and is Available as Calibrated for Each Model and Application.
† - Reverse Lockout is a Condition that Occurs when TCC Apply is Commanded by the TCM. TCC Signal Fluid From the TCC
PWM Solenoid Valve Applies the Reverse Lockout Valve to Prevent Reverse Clutch or Low and Reverse Clutch Apply Even
if the Manual Valve is in Reverse Position.

NOTE: DESCRIPTIONS ABOVE EXPLAIN COMPONENT FUNCTION DURING ACCELERATION

EXPECTED OPERATING CONDITION IF COMPONENT IN COLUMN NUMBER IS INOPERATIVE:

Column # Condition
1 No Fourth or Fifth Gears
2 No Engine Braking in Overdrive Range - First, Second, Third and
Fourth Gears; or in Manual Fourth, Manual Third and Manual Second Ranges.
3 No Reverse
4 No Forward
5 No Forward
6 No Fifth Gear or No engine Braking in Third Gear - All Forward Ranges
7 No Third Gear
8 No Third, Fourth or Fifth Gears
9 No First Gear
10 No Reverse, No Engine Braking in Manual First
11 No Second, Third, Fourth or Fifth Gears
12 No Second Gear
13 No Engine Braking in Second Gear - All Forward Ranges

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SOME OF THE INFORMATION IN THIS BOOKLET MAY HAVE BEEN PROVIDED
OR APPROVED BY THE AUTOMATIC TRANSMISSION SERVICE GROUP AND/OR
THE AUTOMATIC TRANSMISSION REBUILDERS ASSOCIATION. THE INFOR-
MATION CONTAINED HEREIN IS ACCURATE TO THE BEST OF OUR KNOWLEDGE.
WE ARE NOT RESPONSIBLE FOR ANY INACCURACIES OR WARRANTY CLAIMS
WHICH MAY RESULT FROM THE USE OF THIS INFORMATION.