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Introducing the New Aisin-Warner 6-Speed

Introducing the New Aisin-Warner 6-Speed

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Published by: paperotta82 on Dec 18, 2009
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6 GEARS August 2008
Introducing the New Aisin-Warner 6-Speed
ord has a new front wheel drive:the AWF-21. It’s a real gas sav-ing 6-speed transmission. Withgas prices climbing astronomicallyaround the country, that’s an importantconsideration.In this edition of 
 Fun withTransmissions,
we’ll be looking at theAWF-21. This transmission is built inJapan by Aisin-Warner for Ford Motor Company (figure 1A, 1B). Ford usesthe AWF-21 in the Montego, Fusion,Freestyle, Five Hundred, Zephyr andMilan. It’s also used, in different con-figurations, by Volkswagen (09G),Mini Cooper (Aisin TF-60SN) Mazda(AW6A-EL) and Volvo (TF-80SC).To get six speeds, this transmis-sion uses the Lepelletier geartrain. TheLepelletier geartrain can be identified by the stationary sun gear in the input planetary gearset (figure 2). Becausethe front planetary gearset is alwaysrotating around the stationary sun gear,this type of transmission never achievesa 1:1 gear ratio (figure 3). This is thesame geartrain used in Ford’s 6R60 rear wheel drive transmission.
Introducing the
by Bill Brayton
Figure 1AFigure 1BFigure 2
GEARS August 2008 7
The look of the clutch and bandapplication chart is also a departure for Ford. In the past, Ford has used termssuch as
 forward clutch
. The AWF-21 moves away fromthose old Ford names, identifyingthese clutches as C1, C2 and C3.
As with all Aisin-manufac-tured transmissions, any band or clutch pack that locks a spinningcomponent to the case, suchas a planetary gearset, is calleda
(B). The AWF-21 hastwo brakes: The B1 brake is a band which applies in 2ndand6thgears. The B2 brake is aclutch pack splined to the case.The B2 clutch applies in reverseand provides engine braking inmanual low (figure 4).The transmission control mod-ule (TCM) is easy to find on thistransmission. It looks like a manuallever position switch (MLPS), but it’sactually the transmission controller.The vehicle’s harness plugs into theconnector and the TCM plugs into thetransmission (figure 5).You’ll need an up-to-date scan toolwith CAN BUS capability to diagnosethis unit. There are only a few wireson the case connector (figure 6). Youcan remove the TCM and check sole-noid, speed sensor and transmissiontemperature sensor circuits’ continu-ity when needed (figure 7). The TCMshould be reprogrammed with the lat-est calibrations from the factory website — www.motorcraftservice.com — during every rebuild.
Figure 3Figure 4Figure 5Figure 6Figure 7
8 GEARS August 2008
Introducing the New Aisin-Warner 6-Speed
Most Ford-produced transmissions only have atap for checking line pressure, and maybe a tap for EPC pressure. Because the AWF-21 is an Aisin trans-mission, this unit has several taps for checking clutch apply pressures (figures8 and 9). Keep in mind these are mini-mum and maximum pressure specifica-tions. This will make it easier to diag-nose shift problems (figure 10).
Valve Body
The AWF-21 has a complicatedvalve body. It has lots of little partsthat are going to get lost if you aren’textremely careful. The pictures includedhere are the first to be published. FordMotor Company hasn’t produced pic-tures of this valve body, and hasn’tnamed the valves at the time of this writ-ing (figures 11-17).
Figure 8Figure 9Figure 10Figure 11Figure 12Figure 13

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