2003 TECHNICAL SEMINAR

Automatic Transmission Rebuilders Association
2400 Latigo Avenue Oxnard, CA 93030 Phone: (805) 604-2000 Fax: (805) 604-2005 http://www.atra.com

This manual has been developed by the Automatic Transmission Rebuilders Association (ATRA) Technical Department to be used by qualified transmission technicians in conjunction with ATRA’s technical seminars. Since the circumstances of its use are beyond ATRA’s control, ATRA assumes no liability for the use of such information or any damages incurred through its use and application. Nothing contained in this manual is to be considered contractual or providing some form of warranty on the part of ATRA. No part of this program should be construed as recommending any procedure which is contrary to any vehicle manufacturer’s recommendations. ATRA recommends only qualified transmission technicians perform the procedures in this manual. This manual contains copyrighted material belonging to ATRA. No part of this manual may be reproduced or used in any form or by any means — graphic, electronic or mechanical, including photocopying, recording, electronic or information storage and retrieval — without express written permission from the ATRA Board of Directors. Public exhibition or use of this material for group training or as part of a school curriculum, without express written permission from the ATRA Board of Directors is strictly forbidden. ATRA and the ATRA logo are registered trademarks of the Automatic Transmission Rebuilders Association. Portions of materials contained herein have been reprinted with permission of General Motors Corporation, Service Technology Group. © 2003 ATRA, Inc. All Rights Reserved. Printed in USA.

© 2003 ATRA. All Rights Reserved.

2003 TECHNICAL SEMINAR

© 2003 ATRA. All Rights Reserved.

2003 TECHNICAL SEMINAR

© 2003 ATRA. All Rights Reserved.

2003 TECHNICAL SEMINAR

i

Program Contents
General Motors ................................................ 1-72 Ford ............................................................ 76-164 Chrysler .................................................... 170-191 Honda ....................................................... 194-216 Mitsubishi ................................................. 217-224 Nissan ....................................................... 226-240 Volvo ......................................................... 245-248 Volkswagen ............................................... 252-283 Reference .................................................. 285-301

© 2003 ATRA. All Rights Reserved.

ii

2003 TECHNICAL SEMINAR

ATRA Technical Team

Dennis Madden Chief Executive Officer

Lance Wiggins Technical Director

Creating a Great Seminar… For most of you, a technical seminar is maybe half-a-dozen or so hours of intense technical information… and then, as quickly as it begins, it’s over. But a lot of effort goes in ahead of time, researching, developing and designing a seminar, long before it’s ready to play your town. Long days… late hours… frayed nerves… all part of the process to put a clean, carefully-choreographed presentation in front of a discriminating audience. The folks involved in developing this year’s seminar are the leaders in the transmission repair industry. With over 200 years of combined technical experience, they’ve poured their heart and soul into every page and slide in this program. Whether their contribution involved technical expertise or organizational skills, the culmination of their efforts was an extraordinary educational experience that we’re proud to call the ATRA 2003 Technical Seminar. We hope your experience is as rewarding as it was for us to develop it.

Evelyn Marlow Technical Supervisor

Randall Schroeder Senior Technical Advisor and Seminar Speaker

Steve Garrett Technical Advisor, Seminar Speaker, Service Engineer

© 2003 ATRA. All Rights Reserved.

Semimar Speaker Mike VanDyke Technical Advisor and Seminar Speaker Mike Baird Technical Advisor Mike Brown Technical Advisor Pete Huscher Technical Advisor Cliff McCormick Senior Technican and Multimedia Engineer Kelly Hilmer Director of Online Services Shaun Velasquez OnLine Services © 2003 ATRA.2003 TECHNICAL SEMINAR iii ATRA Technical Team (continued) Bill Brayton Technical Advisor and Seminar Speaker David Skora Technical Advisor. . Seminar Producer. All Rights Reserved.

and printed let alone getting it out to the seminar attendees. Technical Director © 2003 ATRA. Please enjoy the seminar. it would be very hard to accomplish the task at hand. written.iv 2003 TECHNICAL SEMINAR ATRA Staff It’s difficult enough getting the seminar book researched. Lance Wiggins ATRA. pictured. Chief Executive Officer: Executive Director: GEARS PublishingEditor: GEARS Magazine: Dennis Madden Steve Gray Rodger Bland Frank Pasley Jeanette Troub Valerie Mitchell Paul Morton Accounting : Jody Wintermute Nancy Skora Amy Marsh Bookstore: Membership: Mike Helmuth Bill Blair Vanessa Metzner Chris Klein Julia Garcia Joanna Book Jim Spitson Without the ATRA team. edited. All Rights Reserved. This is where the ATRA Staff comes in. .

All Rights Reserved .GENERAL MOTORS 1 © 2003 ATRA.

..... 36 4T80E TCC Concerns ......... 34 2002-2003 Wiring Harness Changes ....................... 26 2002-2003 4th Clutch Changes . 51 4L60E/4L65E Updated PCS ...................... 43 Shift Complaints.................... 6 4T40E Harsh Shifts ........ Shudder.......... 55 Planetary Noise .......................... B1271.... 61 Allison LCT 1000 Incorrect Pressure Switch Assembly ....................................................... Poor Drivability . 39 4L30E/5L40E P0601.................................. 22 2002-2003 Valve Body Changes ..................... 50 Delayed Downshift .................2 GENERAL MOTORS General Motors Contents T-Truck 4X4 Light On ............. 48 Multiple DTC’s .......... 54 TCC Surge . 49 4X4 DTC’s On K Truck .......................................................................................................................................... 70 Harsh Downshift ................................ 12 4T60E Ratio and Application Chart . 38 MAF DTC.. 4 All GM B1001..................................... 41 © 2003 ATRA.......................................................................................................... B1780 ....................... 52 GM Truck Application DTC U1241 ...... 45 Surge......................................... 11 P1815 Set ..... 72 ..... 59 Product Updates ................................................... 53 4L80E/4L85E P0706 ... 46 1-2 Shift Shudder ........... 13 4T65E 2002-2003 Pump Changes ....... 64 Flare When Accelerating From a Stop ................................... 37 Hard Shifts Possible DTC’s .................. 8 4T40E/45E VSS Intermittent............ 68 Quicklearn Procedure ... Possible P0502 ................................................................. All Rights Reserved 4L60E Slips When Cold .................................................... Miss ... 44 Intermittent Neutral or Flare...................... 9 Drivability Concerns ............. 7 Possible P0731 ............. 10 P0741 Set ................................... 35 Harsh or Soft Forward or Reverse Engagements ................ 66 PRNDL Inoperative ... P0602 ............

GENERAL MOTORS 3 © 2003 ATRA. All Rights Reserved .

4 GENERAL MOTORS Service 4wd Light On. as these are not PCM related DTC’s. This condition may effect 1999-2003 Full size GM trucks and sport utility vehicles such as Silverado. Once the DTC is set. Possible DTC B2725 set A compliant of the “Service 4WD” light is on in the instrument cluster or the transfer case “shifts by itself”. DTC B2725 will set if: The TCCM detects low voltage (Less than 1 volt) on the transfer case range switch circuit for longer than 5 minutes. the transfer case will not shift into 4WD. In addition complaints of incorrect reading in the transfer case switch assembly is illuminated. Tahoe. Avalanche and Suburban applications with the NV 246 transfer case (RPO NP8) and/or the 2002/2003 Trail Blazer/Envoy with the NV236 transfer case. Escalade. Yukon XL. If B2725 is set the TCCM will: Inhibit 4WD Illuminate the 4WD light © 2003 ATRA. All Rights Reserved . Yukon. NOTE: Your scan tool must be capable of communicating with the vehicle body computer/TCCM (Transfer Case Control Module) in order for you to read the codes.

The switch resistance values listed in the service manual maybe incorrect.63-9.54 ohms 61.GENERAL MOTORS 5 Service 4wd Light On. you may be lead to replace components that are not faulty. The correct control switch resistance values are as follows: Measure Resistance between Pin 1 and Pin 2 No buttons pushed: Auto 4wd: 4 HI: 2 HI: 4 LOW: Neutral: 8.015-1. Possible DTC B2725 set Possible causes for this code can be: A faulty transfer case control switch (which is mounted in the dash) A short to ground in the wiring between the control switch assembly mounted in the dash and the TCCM A faulty TCCM TCCM Reprogm updat for 2003 NOTE: When following the service manual diagnostic procedure.7-68.37 K ohms 1. All Rights Reserved .035 K ohms © 2003 ATRA.5-1.1 ohms 656-670 ohms 1.32-2.53 K ohms 2.

After the controller was installed. Both the PCM and the BCM require programming before they will function. 2. Make sure the correct part number controllers were used for your application. The most common cause of this problem happens when attempting to interchange a module from another vehicle. B1780 1996 and later controller replacement and reprogramming is becoming an increasingly common service procedure for most shops.6 GENERAL MOTORS All GM B1001. A/C module) SDM (Sensing and deployment module) Airbag If a B1001 (SDM configuration error) sets. In addition. ventalation. B1271 and B1780. All Rights Reserved . 5. NOTE: Clearing the DTCs as described above is a common part of the replacement and reprogramming procedure on all GM applications. B1271. but also a possible no start condition. © 2003 ATRA. 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. This can result in not only the DTCs described above setting. All GM vehicles utilize either a Class 2 or CAN data bus. deployment of the air bags will be inhibited. Make sure the correct VIN was loaded into the replacement controller 3. If DTCs B1001 and/or B1271 and/or B1271 are set as “HISTORY” codes do not replace the SDM or the RADIO. Cycle the key off. Simply Clear all the stored DTCs. turn the key off for at least 30 seconds 4. REPAIR: Several steps should be taken if these DTCs are set including: 1. the radio will display “LOCKED” after your repair. then on and monitor the Airbag lamp in the dash. Another cause is the wrong VIN loaded into the NEW PCM or BCM. These DTC’s will turn on the AIRBAG lamp. It should flash 7-9 times and then go off. Turn the ignition ON and check for the DTCs. If a B1271 or a B1780 (Radio theft lock) DTCs are set the radio will no longer work. Several DTCs may be set when programming or replacing a controller including B1001.

terminal crimp damaged A faulty IAT sensor © 2003 ATRA. Several of the 4T40E/45E applications utilize the IAT sensor as part of the engine torque calculations. 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.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. The most common causes of this concern are: Broken wiring. Torque modeling is used by the PCM to determine the line pressure calculation. All Rights Reserved . In some instances an IAT (intake air temperature sensor) DTC may be set. generally the wire is damaged at the sensor connector Terminal pin tension. The PCS commanded/actual amperages will indicate low amperage flow through the PCS and its circuits.

Other DTCs which may effect diagnosis include: P0716 (Turbine speed electrical interference/noise) P0717 (No turbine signal) P0745 (Low line pressure) P0722 (No VSS signal). All Rights Reserved .8 GENERAL MOTORS 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. © 2003 ATRA. address the other DTCs first. P0733 in 3rd and P0734 will set in 4th. If only a P0731 is set. If a P0731 is set along with any or all of the following DTCs. 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). P0731 sets if a ratio error occurs in 1st gear while P0732 will set if a ratio error is present in 2nd. review the stored data relating to the DTC and note which shifter position the transaxle was in and the VSS values.

Alero) applications with the 2. © 2003 ATRA. The extra harness length allows the harness (circuit 400 and 401) to contact the axle shaft leading to harness chaffing and the intermittent complaint.2L L61 engine and J41 brakes. Secure the harness in the mounting clip. VSS harness the right hand (passenger side) axle shaft area. Reposition the conduit for the wiring leg to allow clearance at the top of the engine rather than at the axle area. Possible DTC P0502 may be set. A common cause for this is the VSS harness being too long in the area of the right hand (passenger side) axle shaft area. This problem is most common on the N-body (Grand AM. No/Erratic/Intermittent transmission shifts.GENERAL MOTORS 9 4T40/45E N-Car VSS Intermittent or Possible DTC P0502 Erratic speedometer operation. All Rights Reserved . intermittent cruise control operation.

4L Pontiac Grand AM/Oldsmobile Alero applications with the 2. © 2003 ATRA.10 GENERAL MOTORS 4T40E/4T45E Driveability Concerns N-Car 2.4L engine and the 4T40E or 4T45E transmission may experience any of the following concerns in any combination: No start Drivability conditions (engine miss. etc. The ground strap is located on the right upper bell housing bolt on the drivers side. You may want to install a star washer to assure proper ground continuity.) 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 corroded. Located on the upper right hand side of the bell housing.2L or 3. Clean and reinstall the ground. Remove the ground from the bell housing.2L/ 3. All Rights Reserved .

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. An updated 2003 calibration is now available to repair this concern.gm. The 2002 calibration tables allowed the P0741 to falsely set. http://calid. All Rights Reserved .com/vci/ © 2003 ATRA. Visit the GM web site to see if your vehicle requires recalibration. On 1995-2001 applications this condition may not have occurred until the PCM was recalibrated for some other concern. may have the SES light is on and P0741 (TCC stuck off) DTC set in memory.1L (RPO LG8) 1995-2002 Chevrolet Malibu “N” body.GENERAL MOTORS 11 4T40E/45E P0741 Set N-Car 3.

If the P1815 is set with no other DTCs it may be a false code. If the P1815 is set in conjunction with other PSA DTCs the problem is probably caused by metal contamination. Visit the GM web site to obtain the correct calibration for your application.gm. If the P1815 is set but there are no other codes. All Rights Reserved . In may instances the PSA has already been replaced for this condition.12 GENERAL MOTORS 4T40E/45E P1815 Set N-Car Code P1815 may also be set in conjunction with other PSA DTCs such as a P1810. update the PCM with the calibration designed to prevent a false P1815 from setting. http://calid. This can be from the manufacture or possibly from the transmission itself. Updated procedures are now being followed by the vendor to prevent contamination.com/vci/ © 2003 ATRA. D4 or reverse range is indicated at start up The condition lasts for longer than 25 seconds P1810 will set if: The PCM detects an invalid gear range The condition lasts for longer than 60 seconds If the problem is related to contamination replace the PSA. P1815 will set if: D2.

2L Engine 3.4L Engine 3. and the unit has been previously repaired or replaced. the converter. final drive.48 Ratio 2.3L Engine 3800 Super Charged MXO 4 Speed FRQ F16 3.53 Ratio FW9 3. Refer to our chart to determine what transmission should be used for your application. All Rights Reserved . Installing the wrong transmission.29 Ratio LD9 LA1 F68 FVO 2.1L Engine 2. drive/driven sprocket.97 Ratio 3. speed sensor and/or drive to driven sprocket ratio could possibly be incorrect for your application. transmission and final drive ratio information for your specific vehicle model is located on the regular production option label (RPO). If a ratio error or a TCC slip DTC is present. As with other GM vehicles the engine.67 Ratio RPO L26 L27 LHO LD2 L67 Definition 4.1L Engine 3800 Engine 3.53 Ratio © 2003 ATRA. speed sensor or toque converter can result in ratio error or slip DTC’s . final drive ratio.4L DOHC Engine 2.61 Ratio 2.29 Ratio 2.84 Ratio 4T60E 3.GENERAL MOTORS 13 4T60E Ratio and Application Chart The 4T60E utilizes several different final drive.06 Ratio 3. The RPO label should be used exclusively to determine which transmission fits in which vehicle body style and application RPO Codes for the 4T60E Applications RPO L82 L67 LQ1 L40 L36 L27 LN2 FX8 F17 M13 FW2 F13 F79 F83 FR9 Definition 3. drive/driven sprockets. speed sensor and torque converter combinations.9L Engine 3800 Engine 3.43 Ratio F16 2.45L Ratio 3.31 DOHC Engine 3800 Engine 3800 Engine 2.05 Ratio 3.4L Engine 3.

33 30 8686932 1991 1A7W 1AY 1A7 1YPW 1YP 2B1W 1BT 2BT 2B1 2C1W 2CL 2C1 2C2W 2CS 2C2 2C3W 2CT 2C3 1CW 2C4W 2CW 2C4 2C5W 2CX 2C5 2C6W 2CZ 2C6 2P1W 2PH 2P1 37/33 3.06 31 8686920 W BODY 3.33 31 8686916 C/H BODY TOUR C/H BODY TOUR C/H BODY 1992 35/35 2.9 L28 Cad C/K Body 4.33 30 8686933 1991 35/35 8651955 C-BODY 1991/1992 37/33 3.33 30 8686931 1991 37/33 3.4L C BODY 3800 TOUR H BODY SSE.06 30 8686919 1992 35/35 3.84 30 8686918 1992 35/35 3.9L L26 BUICK E BODY 3800 Year Model Codes 1A2W 1AM 1A2 1A4W 1AP 1A4 Drive/Driven Sprockets Final Drive SRTA Part # Speed Sensor Teeth SRTA Part # 1991 37/33 3. All Rights Reserved .9L L26 Cad E/K Touring 4.33 31 8686923 1992 37/33 3.14 GENERAL MOTORS 4T60E Ratio and Application Chart Application Cad E/K Body 4.33 31 8686922 1992 37/33 3.33 31 8686924 © 2003 ATRA.06 30 8686921 1992 37/33 3.SSEI TOUR H BODY SSE 1991/1992 33/37 3.

3 3 31 8686913 1 9 9 2 -1 9 9 3 3 7 /3 3 3 .3 3 30 8651988 1 9 9 2 /1 9 9 3 3 7 /3 3 3 .0 6 31 8686917 1992 3 7 /3 3 3 .3 3 31 8651989 CAD C BO DY L26 1 9 9 1 -1 9 9 3 3 7 /3 3 3 .3 3 31 8651987 1 9 9 2 /1 9 9 3 3 7 /3 3 3 . All Rights Reserved .0 6 30 8651990 © 2003 ATRA.0 6 31 8686925 1992 3 5 /3 5 2 .8 4 30 8686927 C /H B O D Y 3800 1 9 9 1 /1 9 9 2 3 5 /3 5 3 .GENERAL MOTORS 15 4T60E Ratio and Application Chart Ap p lic a tio n Ye a r M odel Codes D riv e /D r iv e n S p r o c k e ts F in a l D r iv e SRTA Part # Speed Sensor T e e th SR TA Part # C /H/W BO DY 3800 C /H B O D Y 3800 C /H B O D Y 3800 2W 1W 2WA 2W 1 2 Y LW 2Y L 2Y 1 2Y 2W 2Y M 2Y 2 1Y M 1Y Z 2Y Z 2Y 4 2Y 4W 2B2W 2BY 2B2 2A7W 2 AY 2AB 2A1 3ABW 3AB 2AM 2A2 3AM W 3AM 2AN 2A3 3AN 3 A NW 2AP 2A4 3AP 3APW 1AH 1 AV 2 AV 2A5 3 AV 3 AV W 1992 3 5 /3 5 3 .0 6 30 8686929 H BO DY SSE C A D E /K T O UR L26 CAD C BO DY T O UR L26 C A D E /K L26 CAD C BO DY T O UR L26 C A D E /K BO DY EXPO RT L26 1992 3 5 /3 5 3 .0 6 30 8651986 1 9 9 2 /1 9 9 3 3 7 /3 3 3 .8 4 31 8682926 1 9 9 1 /1 9 9 2 3 5 /3 5 2 .

16 GENERAL MOTORS 4T60E Ratio and Application Chart © 2003 ATRA. All Rights Reserved .

GENERAL MOTORS 17 4T60E Ratio and Application Chart © 2003 ATRA. All Rights Reserved .

3L LD2 A BO DY EXPO RT 3 .0 6 31 24201793 1 9 9 4 /1 9 9 5 4PM 5PM 5PM W 3 5 /35 3 .0 6 31 8686941 1 9 9 4 /1 9 9 5 3 7 /33 3 .0 6 31 24200589 1995 3 5 /35 3 .9 L L26 N BO DY 2 .18 GENERAL MOTORS 4T60E Ratio and Application Chart A p p lic a t io n Ye a r M odel Codes D r iv e / D r iven S p r o c k e ts F in a l D r iv e SRTA P art # 3 .3 3 29 24201788 1 9 9 4 /1 9 9 5 3 7 /33 3 .2 9 31 24200590 1 9 9 4 /1 9 9 5 3 5 /35 3 .2 9 29 24201792 1 9 9 4 /1 9 9 5 3 7 /33 3 .0 6 31 24201790 1995 3 3 /37 3 .0 6 30 24200941 1 9 9 4 /1 9 9 5 3 5 /35 3 .1L L82 W BO DY 3 .3 3 29 24201789 1995 3 7 /33 3 .0 5 31 24202030 1995 3 7 /33 3 . All Rights Reserved .1L L82 A BO DY 3 .4L LQ 1 W BO DY 3800 L27 G BO DY 3800 L36 G BO DY 3800 L67 U VA N 3800 L27 U VA N EXPO RT 3800 L27 4PF 4PFW 4W A 4 W AW 4 AT 5 AT 5 AT W 5PC 5PCW 4AJ 5AJ 5AJW 4 PA 5 PA 5 PAW 5W F 5W FW 4PB 5PB 5PBW 4BL 5BL 5 B LW 5CA 5 C AW 5BF 5BFW 4KU 5KU 5 K UW 8686940 1994 3 5 /35 31 1994 3 5 /35 3 .0 6 30 24201794 © 2003 ATRA.0 6 Speed Sensor T eeth SRTA Part # H BO DY 3800 L27 C /H B O D Y 3800 L27 CAD K BO DY 4 .1L L82 L /N B O D Y 3 .2 9 29 24201791 1 9 9 4 /1 9 9 5 3 3 /37 3 .

GENERAL MOTORS 19 4T60E Ratio and Application Chart Ap p lic atio n Ye ar M odel C od e s D r iv e /D riv e n S p ro ck ets F in a l D r iv e SRTA P ar t # 3 .33 30 24 2 04 17 5 1 9 96 3 7/3 3 3 .06 31 24 2 02 0 31 1 9 95 3 5/3 5 3 .06 S p e ed Se n s or Te e th SRTA P art # C /H B O D Y 38 0 0 L3 6 C /H B O D Y 38 0 0 L3 6 H BO DY 38 0 0 L2 7 H BO DY 38 0 0 L3 6 H BO DY 38 0 0 L3 6 H BO DY 38 0 0 L2 7 C /H B O D Y 38 0 0 L6 7 H BO DY SSEI 38 0 0 L6 7 A BO DY 3 .33 31 24 2 02 03 5 1 9 96 3 7/3 3 3 .33 31 24 2 02 03 4 19 94 /1 99 5 3 7/3 3 3 .05 30 24 2 04 18 3 © 2003 ATRA.06 30 24 2 02 02 9 1 9 95 3 5/3 5 3 .29 30 24 2 04 17 7 1 9 96 3 3/3 7 3 .06 31 24 2 02 03 2 19 94 /1 99 5 3 5/3 5 2 .06 30 24 2 04 17 9 1 9 96 3 5/3 5 3 . All Rights Reserved .1L L8 2 W BO D Y 3 .4L LA 1 G BO DY 38 0 0 L3 6 5AC 5A C W 5AS 5A S W 4Y Z 5Y Z 5Y ZW 5BX 5B X W 5BK 5B K W 4Y M 5Y M 5Y M W 4Y C 5Y D 5Y D W 4KH 5Y N 5Y NW 6 PA 6 PAW 6W F 6W FW 6PB 6P B W 6PK 6P K W 6CA 6C AW 1 9 95 3 5/3 5 30 24 2 02 03 3 1 9 95 3 5/3 5 2 .29 30 24 2 04 18 6 1 9 96 3 5/3 5 3 .1L L8 2 L BO DY 3 .4L LQ 1 U VA N 3 .84 30 24 2 02 02 7 19 94 /1 99 5 3 7/3 3 3 .84 30 24 2 02 02 8 19 94 /1 99 5 3 5/3 5 3 .

29 30 24206844 1997 35/35 3.84 30 24204181 1996 35/35 3.1L L82 N BO D Y 3.20 GENERAL MOTORS 4T60E Ratio and Application Chart Application Year M odel C odes 6AC 6A C W D rive/D riven S prockets Final D rive S R TA Part # 3.29 30 24204192 1996 37/33 3.1L L82 U VAN 3.29 30 24204193 1996/1997 33/37 3.29 30 24206842 1997 35/35 3.06 30 24206845 © 2003 ATRA.05 30 24206839 1994-1997 35/35 3.4L LD 9 W BO D Y 3.1L L82 W BO D Y 3.4L LA 1 H BO D Y 3800 L36 1996 35/35 30 24204174 1996 6A S 6A S W 6BX 6B X W 6Y L 6Y LW 6Y R 6Y R W 6C T 6C T W 6C U 7C U 7C UW 4A F 5A F 6A F 7A F 7AFW 7A F 7A HW 35/35 2.29 30 24204191 1996 37/33 3.06 S peed S ensor Teeth S R TA P art # C /H B O D Y 3800 L36 C /H B O D Y 3800 L36 H BO D Y 3800 L36 C /H B O D Y 3800 L67 H BO D Y 3800 L67 G BO DY 3800 L67 N BO D Y 2.33 30 24206840 1997 35/35 3.06 30 24204173 1996 37/33 3.29 30 24206841 1996/1997 6B S 7B S 7B S W 7YA 7YAW 7AC 7A C W 37/33 3. All Rights Reserved .

29 30 24211255 1998 8CU 8CUW 8DK 8YA 8DKW 9AH 9AHW 33/37 3.84 Speed Sensor Teeth SRTA Part # H BODY 3800 L36 W CAR 3800 L36 H BODY SSE 3800 L36 W BODY 3800 L36 W BODY 3.GENERAL MOTORS 21 4T60E Ratio and Application Chart Application Year Model Codes Drive/Driven Sprockets Final Drive SRTA Part # 2.29 30 24214260 1999 35/35 3.4L LD9 U VAN 3.1L L82 N BODY 2.05 30 24211256 1998 35/35 3.29 30 24206847 1997 7BX 7BXW 6HB 6AV 7HB 7HBW 8AH 8AHW 35/35 3.1L L82 1997 7AS 7ASW 7AW 7AWW 35/35 30 24206846 1997 35/35 3. All Rights Reserved .05 30 24206849 1998 37/33 3.06 30 24206848 1996/1997 35/35 3.4L LA1 W BODY 3.29 30 24213669 © 2003 ATRA.

In addition. random pumping chamber design (staggered spaces in the rotor). New Sleeve to support the rotor © 2003 ATRA. 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. All of the rotors use a tapered. These changes include: A new three-piece pump design.These changes were implemented on June 24th 2002 on some models. All Rights Reserved . The new design eliminates all the selective rotors and slides available for the previous design pump. 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.22 GENERAL MOTORS 4T65E Update 2002-2003Changes Many changes have occurred in the 4T65E pump assembly to reduce costs. some of the valve bodies are designed for a fully contented PSA while others are designed for de-contented PSAs.

the pump would then be able to back service previous design units. All Rights Reserved . Earlier Design © 2003 ATRA. however. Since this is a very confusing mid-year change we recommend that you refer to the following to identify which design pump should be in your transmission: 2002-1st design two-piece pump (Part # 24221299) For all 2002 models including model code 2RDB with update level LESS than “7” but not 2BCB or 2RNB models with update levels GREATER than “3” use the 24221299 pump assembly. if you can successfully remove the sleeve.GENERAL MOTORS 23 4T65E Update 2002-2003 Pump Changes (Continued) GM recommends the new pump not be installed on earlier design applications.

Late Design © 2003 ATRA.24 GENERAL MOTORS 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. All Rights Reserved .

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. As mentioned the valve body was also changed when the pump was changed. All Rights Reserved .GENERAL MOTORS 25 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. © 2003 ATRA.

Valve Body without support and Six pressure holes © 2003 ATRA.26 GENERAL MOTORS 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. All Rights Reserved .

GENERAL MOTORS 27 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. All Rights Reserved . Valve Body without support and one pressure holes © 2003 ATRA.

( except the 3BCB model with an update level of “4”) Remember. All Rights Reserved . 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 decontented PSA assembly so always refer to the above information before ordering parts. © 2003 ATRA. Check with your parts person to be sure your ordering the correct part number in the future.28 GENERAL MOTORS 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. At a future date the part number will likely be changed as a remain valve body becomes available. The 24225926 part number is for a “new valve body”.

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 © 2003 ATRA. A new design replaced the previous design that used a nut to hold the design together. All Rights Reserved .GENERAL MOTORS 29 4T65E Update 2002-2003 Changes An IMS (Internal Mode Switch) was added to all 4T65Es. 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.

The new design PSA and wiring harness will not back service the previous applications as the valve body machining has drastically changed. The update was done because of contamination issues with the PSA. All Rights Reserved . This Change meant the valve body machining. The vehicle software was also updated eliminating the PSA DTC P1810. the part number for the de-contented PSA is 24216426 Early style PSA with Six switches Late style PSA with one switch © 2003 ATRA. The part number for the previous design PSA is 24203699.30 GENERAL MOTORS 4T65E Update 2002-2003 Changes A new PSA was added to all models for 2003. and the wiring harness/connector also changed to accommodate the new design PSA.

To accommodate the new design solenoid. If the old design is installed in a unit designed for the updated solenoid a slipping concern may occur. The Delphi PCS part number is 10478146. GM does not recommend interchanging the two solenoids. If the updated design is installed in an early model unit hard shift concerns may occur. All Rights Reserved . The vendor was changed from Delphi to Bosch. the torque signal regulator valve spring tension was significantly increased.GENERAL MOTORS 31 4T65E Update 2002-2003 Changes A new design PCS was introduced for the 2003 applications. This new design will become common on all applications in the years to come. the part number for the Bosch PCS is 24225825 © 2003 ATRA.

The updated washer must be used with the updated input housing due to the machining changes.5mm). All Rights Reserved . The new design washer is available in 10 selective thickness. The Housing machining diameter where the washer sets is now smaller (54. The new housing will accommodate a new design input housing washer (End play washer) which is wider. Selective Washer © 2003 ATRA.32 GENERAL MOTORS 4T65E Update 2002-2003 Changes A running change is planned for the input housings on all 4T65E models. to fully support the sprocket support thrust bearing. The input housing is interchangable with earlier years.

The pawl design one way clutches are not currently serviced other than as an assembly. the new pawl design assembly requires new design input clutches.GENERAL MOTORS 33 4T65E Update 2002-2003 Changes The input and 3rd one way clutches were updated as of July 17th 2002 on some models. In other words. 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. The new clutch plates utilize a wave design spline and are thicker than the previous design components. In addition. This update was done because of durability problems with the previous design components. Full implementation is scheduled for February 2003. The clutches must be changed if the pawl design one ways are installed in a previous design application. the pawl components are not available as individual pieces. All Rights Reserved . The pawl one way clutch part numbers are 24216516 for the input and 24216517 for the 3rd. © 2003 ATRA. The new input clutch part number is 24216502.

In order to accommodate this change the channel plate was also updated. The updated disc/plate designs will not back service unless the channel plate is also changed. All Rights Reserved . The Updated design channel plate will back service previous applications. apply plate and friction plates. © 2003 ATRA. The 4th clutch apply plate has an additional mounting tab added to it for easier installation. The previous design channel plate cannot be used to service the updated design with the new apply plate.34 GENERAL MOTORS 4T65E Update 2002-2003 Changes A mid year change for the 4th clutch is planned. GM is planning on releasing the parts as a service package which will include the channel plate.

This change has no effect on service as the harness was only updated for the new 2003 harness applications.GENERAL MOTORS 35 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. Make sure your new harness has the new clip © 2003 ATRA. All Rights Reserved .

All Rights Reserved Forward Band Servo Spring .149” Length-2.36 GENERAL MOTORS 4T65E Harsh or Soft Forward or Reverse Engagment When rebuilding a 4T65E make sure you have the correct servo springs assembled in their correct locations.249” Width-1.-0. Length-3.-0.214” Wire Dia.033” Wire Dia.769” Width-2.181” © 2003 ATRA.173 Reverse Band Servo Spring Length-1.183” Length-1.079” Width-2.675” Width-1.500” Width-1.582” Wire Dia.219” Length-1.-0.-0.-0.613” Wire Dia.120” Wire Dia. Because the 4T65E uses a Forward and Reverse servo for engagement if the springs were switched acidently you may experiance a harsh or soft forward or reverse engagement.

or body assembly. connector top / bottom. Erratic TCC Operation When encountering a TCC concern with a 4T80E transaxle. make sure you have the correct TCC PWM solenoid installed. To ensure you have the correct solenoid make sure the Julian dates are NOT within 1137-1171.GENERAL MOTORS 37 4T80E TCC Concern Lock-up on the 2-3 Shift. If you have a solenoid between these numbers you will need to replace the solenoid asssembly. top cover. To verify the correct solenoid check the Julian date. Part # 24212690 Do Not Use Solenoids With The Numbers Between 1137 and 1171 Part numbers may be on the top hat or on the back side of the connector © 2003 ATRA. This date may be located in a number of different places including. All Rights Reserved .

If the Cam sensor fails. but shift feel will remain normal. P0341. P1599 The Northstar engine applications utilize two crank sensors and one cam sensor. P0335. P1372. P0385. Inspect the sensor connector pin tension and the terminal crimp. NOTE: If a crank sensor is replaced the “RELEARN PROCEEDURE” for the crank sensor must be performed using a scan tool. DTCs may set and drivability concerns may be present. If pin tension is good replace the suspect 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.38 GENERAL MOTORS 4T80E Hard Shifts Possible DTCs Set Northstar Application Oldsmobile and Cadillac vehicles exhibiting any or all of the following conditions: 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. All Rights Reserved . Failure to relearn the crank sensor value will result in a DTC being set and possible drivability concerns Crank Sensor Crank Sensor © 2003 ATRA.

© 2003 ATRA. Lack of Power Oldsmobile/Cadillac G. This is most common at low speeds when you are crowding the accelerator on a slight incline. K and K special applications with the Northstar engine and the 4T80E transmission may exhibit any or all of the following conditions: Surge with TCC ON.GENERAL MOTORS 39 4T80E MAF DTC. The air cleaner air box may be filled with water or other contaminants. Misfire DTC’s and/or Pre cat DTC’s may be set. they are: 1. Surge with TCC ON Under load. Possible Lean fuel trim DTCs. The MAF sensor is dirty or skewed 2. MAF DTCs. A possible lack of power may also be present Cause: Two common causes for this condition exist. The surge is most commonly felt during throttle“Tip In” acceleration and generally goes away as the throttle is held steady. Poor Drivability. All Rights Reserved .

40

GENERAL MOTORS

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”.

Look for contamination in the inlet air hole

© 2003 ATRA. All Rights Reserved

GENERAL MOTORS

41

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 instances the transmission will have clutch damage. If these DTCs are set due to their default values. The DTCs will react as follows: P0601 will set if: The TCM check sum is incorrect (internal software check) 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

© 2003 ATRA. All Rights Reserved

42

GENERAL MOTORS

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 diagnosing 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 designed to address P0602 concerns.

© 2003 ATRA. All Rights Reserved

GENERAL MOTORS

43

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.

The new part number is 15192192.

© 2003 ATRA. All Rights Reserved

44

GENERAL MOTORS

4L60E
Shift Complaints
2002 Trailblazer/Envoy/Bravada Several shift quality concerns have arisen with this application including: Hard/soft garage shifts Delayed downshifts Harsh 1-2 shifts Several calibrations have been released to address these concerns. The latest update is calibration number 12579253. Make sure to visit the GM calibration web site at: http://calid.gm.com/vci/

© 2003 ATRA. All Rights Reserved

GENERAL MOTORS

45

4L60E
Intermittent neutral or flare, bump when accelerating from a stop
1999 and later 4L60E applications (Silverado, Tahoe, Yukon, Suburban, Sierra) may exhibit a neutral condition while in D4 range and the vehicle is accelerated from a stop. In addition, a complaint that the transmission neutrals, then bangs into gear (harsh engagement) when accelerated from a stop. Generally the problem is not related to the internal transmission components (Sprag, roller, forward clutch). The most common cause of this concern is the transmission shift cable or the shift cable adjustment. First try making an adjustment, if you determain the cable is stretched replace the transmission shift cable and adjust.

© 2003 ATRA. All Rights Reserved

This moisture leads to corrosion. the A/C line is routed directly over the distributor. On several of the applications. and crossfire within the cap. or surge/shudder/miss problem. © 2003 ATRA. Many times this condition has been confused with a transmission related concern.46 GENERAL MOTORS 4L60E Surge/Shudder/Miss 1995-2002 Trucks with 4. All Rights Reserved .3L (RPO L35 or LU3) engine may experience a rough running. or on higher mileage units brown residue Locate the AC hose above the Distributor and install a foam conduit over the hose which will allow the water to drain off the sides. Inspect for the following: White corrosion/residue on the cap wall. This condition may be associated with a DTC P0300. The problem is often caused by moisture leaking from the A/C line onto the distributor.

Note: The distributor is refered to as an HVS “high voltage switch” by General Motors.GENERAL MOTORS 47 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. © 2003 ATRA. All Rights Reserved . Distributor housing/base: Inspect for excessive levels of rust on the shaft or surface contamination on the cam sensor hold down screws. 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. If you find evidence of corrosion replace the cap/rotor and the distributor if deemed necessary.

four-cavity connector from the alternator 3. Remove the two-wire. All Rights Reserved . Remove the wires from the connector pack and discard wires “B” and “C” 5. Install a sense lead for the Alternator as follows: Parts: Connector replacement pack 15306009 1 ring connector pack 02984172 (sold as packs of 10) RTV sealer Procedure: 1. Install the brown wire from the vehicle harness into cavity B of the service connector. 8. Disconnect the negative battery cable 2.48 GENERAL MOTORS 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. 6. 7. after the vehicle has reached full operating temperature and ambient temperature is high. Install the TPA (Terminal Position Assurance Clip) into the service connector and install the service connector into the alternator. Seal the connector with RTV and connect the negative battery cable. Trim the wire in cavity “A” of the service connector flush 9. Install the gray wire from the vehicle harness into cavity C of the service connector. © 2003 ATRA. Remove the brown wire (cavity B) and the gray wire (cavity C) 4. The signal is causing interference problems with the PCM circuitry. The problem is usually caused by a frequency signal riding on the generator output . Hook the wire in cavity “D” of the service connector to the battery terminal on the alternator using the ring connector.

© 2003 ATRA. Depending on which wires have insulation damage. The most common DTC is P0758 (3-2 solenoid) but others may set as well. All Rights Reserved . Safari) vans may experience DTCs setting related to the transmission or possibly engine related systems. In many instances the harness contacts the A/C accumulator which leads to a rubthrough condition. a DTC will likely set for that circuit.GENERAL MOTORS 49 4L60E Multiple DTC’S Some 1995-2000 M/L (Astro. The wiring harness runs along the bell housing area and over the engine.

50 GENERAL MOTORS 4L60E ATC DTC C0379 Service 4WD Light On K Trucks Some K-trucks with the automatic transfer case may experience the following conditions: Service 4WD light is on DTC C0379 is set The front actuator no longer functions The wiring harness for the front axle circuit may be chaffed near the A/C compressor. All Rights Reserved . © 2003 ATRA. Secure the harness so it can no longer contact the A/C compressor.

2L (LL8) applications may experience “any or all” of the following conditions: Delayed downshifts. Bravada. T truck 4. Envoy. View the GM web site http://calid.com/vci/ to locate the correct calibration number for your application.gm. An updated calibration has been released to address the concerns. erratic downshifts Excessive cooling fan noise SES light ON Any or all the following DTC’s. All Rights Reserved . © 2003 ATRA.GENERAL MOTORS 51 4L60E Delayed Downshift 2002 Trailblazer. P0014 (Cam Phaser Performance) P1683 Low power counter failure) P0116 (High side coolant rationality) This concern is caused by calibration problems.

The updated harness part number is 24222891. The 2nd design will replace the 1st design and is scheduled for use in other transmission applications starting in the 2004 model year. the harness was also changed to accommodate the updated solenoid. The harness was updated to prevent someone from interchanging the Borg Warner solenoid with the previous Delphi solenoid. The part number for the 1st design solenoid is 24219308 while the 2nd design part number is 24224905. The vendor for the solenoid is now Borg Warner and will be available in two versions. All Rights Reserved . In addition to the solenoid change.52 GENERAL MOTORS 4L60E/4L65E Updated PCS A new pressure control solenoid was used for all 2003 model units. Make sure the correct solenoid is used for the correct vehicle © 2003 ATRA. 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 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 technician may have noted that the DTC may have not been present until after DTCs were requested or displayed . U1241 may be stored in several of the various modules. © 2003 ATRA. 4L80E/4L85E. no repairs should be attempted if the condition for setting the DTC is as described above. All Rights Reserved . U1241 DTC is caused by a loss serial data.GENERAL MOTORS 53 4L60E/4L65E. 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. This is a normal condition. LCT 1000 DTC U1241 SET Most OBDII equipped vehicles have DTCs related to data line problems. In addition. Some technicians may notice a DTC U1241 set in history on vehicles equipped with a BCM. The loss of data is caused by your scan tool interface with some of the modules on the vehicle.

In many instances the P0706 is not caused by a faulty switch.54 GENERAL MOTORS 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. All Rights Reserved . NOTE: Always check the connections for melting and wire dammage © 2003 ATRA. Before part repairs are done check the web site http://calid.gm. On 1999 and later applications check for a possible recalibration for this condition prior to replacing the switch.com/vci/ for updated calibration to repair the false P0706.

75 or less. Checking the pump timing requires a scan tool.50. A minus number on the scan tool indicates the timing is advanced while a plus (+) value indicates the timing is retarded. the timing TDC offset should read -1.25 to -1. fuel economy and power.GENERAL MOTORS 55 4L80E TCC surge or chuggle when road speed is between 40-50 mph On 1994 and later Diesel 4L80E applications. note the data parameter known as “TDC offset” using a scan tool.5L Diesel applications (RPO L56) may also eliminate the concern. If the timing is not correct a TDC relearn procedure should be performed after the timing has been set. . For proper operation. If the TCC is disabled. All Rights Reserved . The value should be minus -. the surge/chuggle is typically eliminated. It should be noted that not all scan tools are capable of performing a TDC relearn procedure) © 2003 ATRA. The typical cause of this concern is retarded pump timing. You will also find that disconnecting the EGR on 6. (Note: to perform a TDC relearn on a 1994-95 application you must use a scan tool. To determine if the timing is correct. 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.

56 GENERAL MOTORS 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. loosen the pump bolts and rotate it in the desired direction. 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. 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. To perform the TDC offset procedure on a 1994-95 application Start the engine. Once the pump is moved slightly. If so.25 and –1. Using the proper adjustment tool move the pump slightly (.040" of movement = 1 degree of timing change). no further adjustments are needed. tighten the pump bolts and perform the TDC offset learn procedure using a scan tool. shut off the engine. If the offset value is not correct. © 2003 ATRA. Once the relearn is complete. check the TDC offset value displayed on the scan tool again.50. It should read between –1. All Rights Reserved . Tighten the bolts and repeat the above TDC offset learn procedure.

Key on and start the engine 6. TDC learn will automatically update as soon as the engine is started in step five. 7. Diesel Injector Pump © 2003 ATRA. The TDC offset will be automatically learned when the coolant temperature reaches 170-172 degrees Fahrenheit. All Rights Reserved . Wait 30 seconds minimum 5. Turn on the ignition key and clear all DTC’s 2. Key off and then close the throttle 4. Depress the throttle to the WOT position and hold it there for at least 4-5 seconds 3.GENERAL MOTORS 57 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. If the vehicle is already above the minimum 170 degree CTS value.

Once the relearn is complete. TDC offset should read between –1. tighten the bolts and repeat the TDC offset learn procedure. If the offset value is not correct. On most 1997 and later applications. All Rights Reserved . the value displayed on the scan tool will remain at the previous value until the TDC learn has been completed. check the TDC offset value displayed on the scan tool again.5L Diesel) applications. On L56 (EGR equipped 6. The EGR is located behind the dipstick © 2003 ATRA.00 (At step 5) until the TDC learn has been completed. replace the EGR with part number 12530288.58 GENERAL MOTORS 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. if the timing is correct and the problem is eliminated when the EGR is disconnected.50.25 and –1. loosen the pump bolts and rotate it in the desired direction. shut off the engine.

This problem is typically caused by pump cavitation. Output shaft misalignment. © 2003 ATRA. These wear lines run parallel to the transmission center line. This noise will resemble the noise developed from HD 4L80E applications which use straight-cut gears. All Rights Reserved . Misalignment of the output shaft will cause side loading of the planetary. a restricted filter or damaged oil pan.GENERAL MOTORS 59 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. or a cooler flow rate problems. This concern can be caused by either: A reduction in the volume of lube oil feeding the planetary. This problem generally leads to the technician replacing the planetaries only to have a repeat failure within 5-20 thousand miles. The wear may look like dark lines on the gear teeth. you will notice some irregular wear lines on the reaction planetary carrier pinion teeth and possibly on the sun and ring gear teeth. grooves in the gear teeth or bronze lines on the gear teeth. This concern is the most common cause of the noise on 97 and later applications. Upon inspection.

If the bushing or bore was machined off center. you will typically be able to see that the bushing is worn off center.900”. The outside diameter specification is 4. 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 diameter.60 GENERAL MOTORS 4L80E Planetary gear noise in 1st and 2nd gears only If shaft alignment is suspected on a 4wd application. All Rights Reserved .799"-4. Replace the bushing or the case as necessary. On 2wd applications. On 2wd applications a common cause of the concern is the position of the output shaft bushing. side loading of the shaft will occur. If the measurements are not correct. © 2003 ATRA. replace the adapter. inspect the 4wd adapter.899”-4.801" while the inside diameter specification is 4.

All Rights Reserved . These changes include: Part number call out Overrun clutch housing Overrun clutch spring Overrun clutch snap ring Overdrive roller clutch Overdrive carrier GM part number Included in the kit only Included in the kit only 24216149 12431003 24215530 Some of the components are only available by ordering an upgrade kit part number 24222160 © 2003 ATRA. The changes were designed to improve the transmissions durability.GENERAL MOTORS 61 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.

Identification Model Tag:02CAP or 02CCP RPO Code: MN8 Features: The speed sensor bolts. All Rights Reserved . The 4L85E is used in vehicles equipped with the 8. New part number 24216149 © 2003 ATRA. New part number 24205560 Overrun clutch spring retainer.1 L gas engine (RPO L18).62 GENERAL MOTORS 4L85E 2002 Models The 4L80E HD has been replaced by the 4L85E. New part number 11517516 The forward clutch wave plate.

If a 4L80E HD planetary requires replacement. © 2003 ATRA. update the unit with the part numbers listed above for the 4L85E applications. All Rights Reserved .GENERAL MOTORS 63 4L85E 2002 Models (Continued) The 4L85E uses a five-Pinion reaction and output carrier. Reaction carrier part number 24215026 Output carrier 2WD models part number 24214966 Output carrier 4WD models part number 24215388 (NOTE: The straight cut gears used in the 4L80HD applications are no longer available from GM.

This may lead to misdiagnosis of the PSA or its circuits. All Rights Reserved . Programming changes dealing with the scan tool interface can lead to the incorrect sequence for the application. © 2003 ATRA. NOTE: Switch C/D and E are normally open while switch R is normally closed. Switch “C” will read “Open” (OFF) when the transmission is in reverse while those built earlier will read “Closed” (ON). Your scan tool may display the switch values as open/closed or as on/off.64 GENERAL MOTORS 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. The chart below lists the correct sequence for the LATER (after March 0f 2001) Allison calibrations. 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. On=closed. Vehicles that have had the TCM reprogrammed or vehicles built after March 2001 may have an incorrect switch sequence. Off=open On applications built after March 2001 or on units that have been reprogrammed.

Early Switch C Closed/ON Open/OFF Closed/ON Closed/ON Open/OFF Open/OFF Closed/ON Open/OFF Closed/ON Switch D Open/OFF Open/OFF Open/OFF Open/OFF Open/OFF Closed/ON Closed/ON Closed/ON Closed/ON Switch E Closed/ON Closed/ON Closed/ON Open/OFF Open/OFF Open/OFF Closed/ON Closed/ON Closed/ON Switch R Open/OFF Open/OFF Open/OFF Open/OFF Open/OFF Open/OFF Open/OFF Closed/ON Closed/ON © 2003 ATRA.GENERAL MOTORS 65 LCT 1000 Incorrect Pressure Switch Assembly Readings Range 5th . All Rights Reserved .Late 5th .Early 4th 3rd 2nd 1st Neutral Reverse-Late Reverse.

The most common cause for this concern is: Leakage in the C5 clutch or its circuit: If you perform a clutch test using your scanner. input speed will be present even though the transmission is being commanded to 1st gear with TP and VSS values at 0. All Rights Reserved . Many times. Sticking valves: Most of the sticking-valve-related concerns have proven to be temperature related with this transmission. Check the GM web site to see if your vehicle has been updated with the new calibration. This will be indicated by a delay in line pressure response when the C5 Clutch is commanded to apply. The updated calibration was released in March 2002. when the condition is present. you will generally notice the condition when the 2-1 downshift is commanded. TCM calibration:An updated calibration has been released aimed at improving this condition. http://calid. A harsh engagement may occur as the unit reengages 1st gear.com/vci/ © 2003 ATRA.66 GENERAL MOTORS LCT 1000 (RPO M74) Flare When Accelerating From a Stop LCT 1000 applications may experience a condition described as a “flare” or “neutral” condition when coming to a stop or accelerating from a stop.gm.

GENERAL MOTORS 67 LCT 1000 (RPO M74) FlareWhen Accelerating From a Stop (Continued) C-5 Clutch Asssembly © 2003 ATRA. All Rights Reserved .

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Monitor the NSBU values with a scan tool. 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).GENERAL MOTORS 69 LCT 1000 RPO M74 PRNDL Inoperative To separate switch concerns from the wiring and TCM. replace the switch. Leave the other two pins in connector C1 open. If the proper range is indicated as the jumper sequence is varied. If the proper range is not indicated check the wiring before replacing the TCM. All Rights Reserved . The PRNDL and the scan tool should show the range indicated in the chart. ON= OFF= OPEN CIRCUIT GROUNDED CIRCUIT 3. proceed as follows: Disconnect C1 and C2 connectors 1. © 2003 ATRA. Alternate the pins as shown in the chart below.

If the proper range is not indicated check the wiring before replacing the TCM. Monitor the NSBU values with a scan tool. proceed as follows: Disconnect C1 and C2 connectors 1. Alternate the pins as shown in the chart below. © 2003 ATRA.GENERAL MOTORS 69 LCT 1000 RPO M74 PRNDL Inoperative To separate switch concerns from the wiring and TCM. All Rights Reserved . ON= OFF= OPEN CIRCUIT GROUNDED CIRCUIT 3. replace the switch. 2. The PRNDL and the scan tool should show the range indicated in the chart. Leave the other two pins in connector C1 open. 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). If the proper range is indicated as the jumper sequence is varied.

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. All Rights Reserved . they are: PARK MODE: With the vehicle in the park range the scan tool will repeatedly cycle the C3/C4 and C5 clutches on/off.70 GENERAL MOTORS 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. © 2003 ATRA. solenoid flow rates as well as seal/bushing leakage. the amount of time that is required for TCM adaptive learning is reduced significantly. solenoid flow rates as well as seal/bushing leakage. The Quick learn function requires a compatible fully functional scan tool. By performing the quick learn functions. 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. Quick learn should be preformed if: The transmission was replaced/rebuilt or repaired The solenoids were replaced The TCM was replaced or recalibrated Quick learn is accomplished in 4 parts.

If you were in Drive when the failure occurred. default actions may occur. ranges other than reverse may not be available. All Rights Reserved . Speed sensors are operating correctly 4.GENERAL MOTORS 71 LCT 1000 Quicklearn Procedure (continued) 3RD/4TH : Following the above procedures clutch volume for the C2 clutch requires the vehicle now be driven. To perform a park/reverse/drive quick learn the following conditions must be met: 1. If you were in Reverse when the failure occurred. NOTE: If the scan tool harness becomes disconnected or if you lose communications with the TCM during the quick learn process. TFT is between 104-212 F (40-100c) 5. A compatible scan tool is being used Now follow the instructions on the scan tool for the “FAST” (Quick) learn procedure. Parking brake is set 6. NSBU is operating correctly 3. To properly learn the C2 clutch volume the vehicle must complete at least three 3-4 shifts at steady throttle. NOTE: Block the wheels during the test procedures © 2003 ATRA. Transfer case is in 2wd range 7. This procedure does not require the use of a scan tool. ranges other than drive may not be available. TP values are 0% 8. No DTCs are stored 2.

Generally.72 GENERAL MOTORS LCT 1000 8.1L Engine Harsh Down Shifts. Possible Rich fuel trim DTCs may be set The most common cause of this problem is related to the coolant temperature sensor reading. All Rights Reserved . © 2003 ATRA. Harsh Garage Shifts Some customers may complain of the following symptoms: Harsh 3-2. Replace the ECT sensor Generally the ECT will read about 60°F (15c) with the vehicle at full operating temperature. 2-1 down shifts Harsh garage shifts Temperature Gauge reads low Drivability concerns. ECT DTC’s will not be set.

All Rights Reserved .FORD 73 © 2003 ATRA.

........ 155-163 Mazda to Ford Conversions ...................................... 86 Check Ball and Relief Valve Locations ............................. 124 2/4 Band Adjustment ...... Low ............................................................... 90 Valve Body Mismatch ............. No Man..................................................................... 118 © 2003 ATRA...... 91 Valve Body Interchange ........................................................ 103 Solenoid Firing Order ....................................... 108 No Movement in all Gears After Rebuild .............................. 133 Sprag Application ............................................................................................................................................................ 99 Fluid Leaks Out Of The Vent .......................... 164 ............... 151 Incorrect VSS Reading ....................... 135 Solenoid Application ........ ................ 110 Accumulator Reference ....... 142 4R70W Solenoid Codes .................................. 100 Proper Sprag Rotation .. 134 Pressure Specs ......... 121 Servo Seal Damage ..... 104 Solenoid Specifications ....................................................... 98 Pump Shaft Identification ..................119 Slipping in 2nd and 4th ...... 107 High or Low Pressure .................................... 93 Drives Forward in Neutral.............. 109 Ratio Error Codes ... 97 Ratio Error Codes ........ Chart .. 120 4F27E Jump Testing the Trans ....... 82 Harsh Forward Engagement .... 123 Final Drive Gear Set ............. 148 No Reverse...... All Rights Reserved No Line Rise ............................... 137 Intermediate Sprag Rotation .... 152 5R110W Description ...................... 102 Pressure Specifications .......................... Binds in Reverse .............................74 FORD FORD Contents AX4S Vibration After Overhaul ....... 129 5R55N Clutch and Band App.................................................................... 76 New Pump Bearings .. 101 F4E-III Clutch and Band App........ 77 Harsh 1-2 Shift .................................................................... 147 Intermediate Clutches Burnt ...... 87 CD4E No Movement After Overhaul ......................................................................................... 144 Intermediate Diode Failure ........... 79 Harsh 4-3 Downshift ................................................ 126 4R44E/55E and 5R44E/55E Low Line Pressure at WOT ..... 146 4R100 2nd Gear Slips ...... 143 Downshifts at High Speeds ..................................................

All Rights Reserved .FORD 75 © 2003 ATRA.

8L engines may be caused by the misalignment of the converter to flexplate.76 FORD AX4S Vibration After Overhaul (3.8L Only) Possible Broken Flexplate A Vibration or broken Flexplate on models between 1995-2001 that are equipped with 3. All Rights Reserved . The Flexplate has an alignment paint dot on the flexplate and torque converter from the factory. © 2003 ATRA. This dot is there to ensure proper alignment.

AX4N Part# XF1Z-7G184-AA AX4S Part# XF2Z-7G184-AA © 2003 ATRA.FORD 77 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. All Rights Reserved . The seal is used to enhance lubrication to the bearing for longer life expectancy.

78 FORD AX4S/AX4N New Pump Bearings OLD NEW SEAL Install the seal away from the pump rotor © 2003 ATRA. All Rights Reserved .

All Rights Reserved .FORD 79 AX4N Harsh 1-2 Shift There are a number of problems related to this symtom including: Wrong Gaskets Wrong Seperator Plate Damaged Accumulator Piston Wrong Accumulator Spring Valve Body Wear © 2003 ATRA.

.......... Taurus/Sable 1998-99 w/3..... Lincoln 1999-00 ......... Taurus/Sable 2000 . Taurus SHO 1996-97 w/3..... Taurus/Sable 1998-99 w/3.........0L 2V ...........80 FORD AX4N Harsh 1-2 Shift Seperator Plate and Gasket Lincoln 1995-97...................................... (stamped 11) (stamped 84) (stamped 90) (no stamp) (stamped 13) (stamped 87) (stamped 14) (stamped 86) (stamped 15) (stamped 85) (stamped 03) (stamped 05) part #F50Z-7Z490-A part #F80Z-7Z490-AA part #FX3Z-7Z490-AA part #F5DZ-7Z490-A part #F6DZ-7Z490-B part #F8DZ-7Z490-BA part #F6DZ-7Z490-A part #F8DZ-7Z490-AA part #F6DZ-7Z490-D part #F8DZ-7Z490-CA part #YF1Z-7Z490-CA part #1F1Z-7Z490-AA © 2003 ATRA....... Taurus/Sable 1996-97 w/3.. All Rights Reserved ..... Taurus/Sable 1994-95 w/3.... Lincoln 1998...................0L 2V . Taurus/Sable 2001-03 .............4L .........0L 2V .... Taurus SHO 1998-99 w/3.............0L ............................. Taurus/Sable 1996-97 w/3..4L ..0L 4V ........

harsh. grooves. When reassembling this unit pay close attention to the housing and piston areas. soft and more. or scoring Check the Piston and Rod assembly for wear © 2003 ATRA.FORD 81 AX4N Harsh 1-2 Shift Damaged Accumulator Piston A Damaged Accumulator Piston assembly can cause a number of shifting problems from late. early. Check the Piston housing for wear. All Rights Reserved . If the piston is worn or the housing scored the chances of the piston cocking in the bore are increased.

All Rights Reserved .82 FORD AX4N Harsh 1-2 Shift Wrong Accumulator Spring © 2003 ATRA.

When TV pressure is higher. When TV pressure is lower.FORD 83 AX4N Harsh 1-2 Shift Accumulator Hydraulic Circuits Fluid under pressure in the pump circuit moves to the line modulator valve. The accumulator circuit provides variable hydraulic backpressure to the accumulators for five apply components. accumulator circuit pressure is lower. All Rights Reserved . © 2003 ATRA. accumulator circuit pressure 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. This results in firmer shift feel provided by the accumulators during shifts when engine torque is higher. The variable pressure of fluid in the TV circuit is controlled by the pcm and changes the position of the line modulator valve. The results in softer shift feel provided by the accumulators during shifts when engine input torque is lower. where it enters the accumulator circuit.

or dragging shifts. All Rights Reserved . Damage to the Line Modulator Valve may result in a Slide Bump. 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 operation resulting in a softer shift.84 FORD AX4N Harsh 1-2 Shift Valve Body Wear Check for wear at the Line Pressure Modulator valve and sleeve assembly. Harsh Shift. E4OD Line Pressure Modulator Valve and Sleeve © 2003 ATRA.

075) wave spring 1999 Forward Clutch (.059) wave spring Intermediate Clutch (.075) wave spring 2000-03 Forward Clutch (.064) wave spring Reverse 98 SHO (.050-.050-.050-.050-.050-.069) Reverse Clutch (.050-.072) wave spring Reverse Clutch except SHO (.069) no wave spring SHO Direct Clutch (.040-.050-.050-.049-.050-.038-.050-.050-.069) wave spring Reverse (.069) no wave spring SHO Direct Clutch (.063) wave spring Low-intermediate Clutch (.040-.064) wave spring Low-intermediate clutch (.FORD 85 AX4N Harsh 1-2 Shift Incorrect Clutch Pack Clearance 1995-96 Forward Clutch (.069) Intermediate (.069) wave spring Intermediate (.050-.075) wave spring © 2003 ATRA.072) wave spring Low-intermediate clutch (.040-.040-.059) wave spring Intermediate Clutch (.050-.075) wave spring 1997-98 Forward Clutch (.069) Reverse Clutch SHO (.038-. All Rights Reserved .069) Reverse 97 all (.069) wave spring Direct Clutch (.050-.050-.050-.072) wave spring Reverse 98 except SHO (.063) wave spring Low-intermediate clutch (.059) wave spring Direct Clutch (.

these sizes are not all the same. All Rights Reserved .095” Exahuast orifice from the O/D Servo 00. Pay close attention to the O/D Servo exhaust orifice size. 00.86 FORD AX4N Harsh 4-3 Downshift Wrong Seperator Plate Many times the wrong seperator plate may be changed inenvertantly.218” © 2003 ATRA.

FORD

87

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

Manual Low Relief Valve and Cooler

Modulator Check Valve and Drainback
© 2003 ATRA. All Rights Reserved

88

FORD

AX4N
2001-On Check Ball and Relief Valve Location
Manual Low Relief Valve and Cooler Bypass Spring Modulator Check Valve and Drainback Spring Modulator Check Valve and Spring

Solenoid Regulator Fliter

TCC Fliter

Spring Weight 7.00 lbs. Spring size .634” in

Spring Weight 1.00 lbs. Spring size .754” in

Spring Weight 1.75 lbs. Spring size .673” in

© 2003 ATRA. All Rights Reserved

FORD

89

AX4N
Check Ball Location

Direct Clutch Circuit

© 2003 ATRA. All Rights Reserved

90

FORD

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

Converter end of the shaft

© 2003 ATRA. All Rights Reserved

FORD

91

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.

98’ and later

0.120” With Wave plate in FWD clutch

94’-98’ Models

0.090” No Wave plate in FWD clutch

© 2003 ATRA. All Rights Reserved

92

FORD

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.

© 2003 ATRA. All Rights Reserved

FORD

93

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.

EARLY 94-97

LATE 98-on

© 2003 ATRA. All Rights Reserved

94

FORD

CD4E
Valve Body Interchange with Harsh Forward Engagement or 3-4 Bind
1st Design W/ shallow dish 2nd Design W/ deep dish

1st Design 0.315”

2nd Design 0.400”

© 2003 ATRA. All Rights Reserved

FORD

95

CD4E
Valve Body Interchange with Harsh Forward Engagement or 3-4 Bind
1st Design 0.200” Shallow Dish 2nd Design 0.310” Deep Dish

1st Design 0.595” Shallow Dish 2nd Design 0.680” Deep Dish

© 2003 ATRA. All Rights Reserved

96

FORD

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. Other causes of this may be: Forward Sprag (seized or wrong rotaion) Cracked Forward piston Crossleaks into the Coast Clutch

© 2003 ATRA. All Rights Reserved

FORD 97 CD4E Drives Forward in Nuetral. Make sure that the piston slides into the drum bore with a top clearance (top of drum bore for outer seal) of at least . do not use this drum as it will swell when hot locking the forward piston from returning to its relaxed position. 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. This creates a mechanical bind on the piston not releasing the forward clutches Make sure the Piston can sit in the Drum with a . All Rights Reserved . If it appears that the top area of the drum where the seal rides is ballooned inward and not a true straight flat surface.010” feeler gauge Look at the Ridges in the Drum and Piston surface area © 2003 ATRA. Always feel outer seal riding surface for being smooth.010 or more. Care needs to be taken when replacing the forward/direct clutch drum.

All Rights Reserved F7RZ-7M101-KA . 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. P0733. 1S7Z-7M101-KA © 2003 ATRA.98 FORD CD4E Ratio Error Codes P0732.

Converter. Mismatching the Input or Pump shafts may cause damage to the Pump.FORD 99 CD4E Pump Shaft Identification Pump. Converter and other internal parts.75” © 2003 ATRA. Crank Shaft Thrust Bearing. 4 Cylinder 14. Engine Damage It is very important to make sure you use the correct pump shaft and input shaft for the correct application. All Rights Reserved . and 6Cyl. engines. The Shafts are different in length between the 4Cyl.00” 4 Cyl 4 Cylinder 8.25” 6 Cylinder 9.00” 6 Cyl 6 Cylinder 14.

© 2003 ATRA. All Rights Reserved . This sheild is typically misplaced or not installed at all. The chain cover has Four (4) snaps that connect to the shield.100 FORD CD4E Fluid Leaks Out Of The Dipstck Tube The most common cause of this problem is the Chain cover not properly assembled.

FORD 101 CD4E Proper Sprag Rotation No Forward movement or Binds in fourth can be caused by the Forward sprag damaged or incorectly installed Race freewheels counter-clockwise while holding the sun gear stationary © 2003 ATRA. All Rights Reserved .

102 FORD F4E-III Clutch and Band Application © 2003 ATRA. All Rights Reserved .

D. (psi) R (110-120) (217-248) Stall Speed (140-152) © 2003 ATRA. (psi) P.FORD 103 F4E-III Pressure Specifications Range Idle Line Pressure. L (62-81) Line Pressure. All Rights Reserved . (D).

104 FORD F4E-III Solenoid Firing Order © 2003 ATRA. All Rights Reserved .

All Rights Reserved .FORD 105 F4E-III Solenoid Failure Chart © 2003 ATRA.

106 FORD F4E-III Solenoid Failure Chart © 2003 ATRA. All Rights Reserved .

All Rights Reserved .FORD 107 F4E-III Solenoid Specifications 1-2 Solenoid EPC Solenoid 3-4 Solenoid TCC Solenoid 2-3 Solenoid © 2003 ATRA.

All Rights Reserved . High pressure check these areas for wear Low Pressure check these ares for wear © 2003 ATRA.108 FORD F4E-III High / Low Pressure High Pressure caused by Pressure Regulator bore wear.

All Rights Reserved . this can cuase no cooler flow resulting no movement. this problem is usually assosiated with a plant failure. A damaged PR Valve can create high line pressure. © 2003 ATRA.FORD 109 F4E-III No Movement in all Gears after Rebuild Typically caused by a damaged Pressure Regulator circuit. During your rebuild proceedure make sure the Pressure Regulator Valve assembly is not damaged.

Here are some of the items to look at when diagnosing Ratio Codes: Fluid Pump Filter Valve Body Wear Seals Drums Speed Sensors Accumulators © 2003 ATRA. the problem has to happen four times consecutivly. P0782. P1732. In order for these codes to set the problem has to happen five times consecutively. P1731.110 FORD F4E-III Ratio Codes Ratio codes can be very difficult to diagnose because of the many different components that can cause this problem. In order for these codes to set. Diagnostic Trouble Codes P0741 or P1728 are also ratio codes that can be percieved as only torque converter codes. P1733 indicate incorect ratios and no specific gear. P0783. All Rights Reserved . Diagnostic Trouble Codes P0781.

cooling system. main control valve body. The sideclearance should be no more then . All Rights Reserved . lubrication system.FORD 111 F4E-III Ratio Codes Pump The front pump support and gear provides the volume of fluid required to charge the torque converter.002. (Continued) Check pump areas closely for damage © 2003 ATRA. and hydraulic apply devices. The front pump support and gear is shaft driven by the torque converter cover.0015 or less is prefered. .

112 FORD F4E-III Ratio Codes (Continued) Filter If a transmission repair is being perfromed for a contamination-related failure. but this is not always the case. causing slips. Small particles can become logged in the screen and restrict flow. Many people think that simply cleaning a screen filter will work. © 2003 ATRA. and ratio errors. All Rights Reserved . always use a new filter and grommet.

All Rights Reserved . and the lower control valve body.FORD 113 F4E-III Ratio Codes (Continued) Valve Body Wear The valve body consists of four sections: the upper control valve body. Wear in the 1-2 shift valve can cause a ratio code simply by not stoking properly and slowing down the timing the PCM is expecting. main control valve body. The main control valve body also contains the electronic pressure control solenoid. premain control valve body. Solenoid Regulator valve Manual valve 3-4 Shift valve Low Reducing valve 1-2 Shift valve PR and Boost valve © 2003 ATRA.

Here again knowing what’s applied will help you diagnosis this unit quickly.114 FORD F4E-III Ratio Codes (Continued) Seals and Drums A bad seal or drum can be a difficult problem to diagnose. A slipping Forward clutch can cause sluggish engagements into Drive. All Rights Reserved . © 2003 ATRA. Some areas to look at are the sealing surfaces of the piston and drum assembly.

All Rights Reserved .FORD 115 F4E-III Ratio Codes (Continued) Speed Sensors The vehicle speed sensor (VSS) is located above the differential on the transmission case. the important point is that the frequency rise is linear and smooth. Failure: All or some shifts missing. late/early shift speeds. The VSS rotates a cable and the instrument cluster generates a DC signal and sends the signal to the PCM. Erratic pressure rise. The TSS sensor provides converter turbine shaft speed information for torque converter clutch (TCC) control strategy. The values below are approximate.40 00mph.75 15mph.00 Hz +/Hz +/Hz +/Hz +/Hz +/- VSS 150-250 ohms TSS 150-250 ohms © 2003 ATRA. in some cases the VSS generates the signal to the PCM. Stall when put into gear. erratic shift pattern. The information is also used in determining static electronic pressure control (EPC) pressure setting during shifts. 80mph-170 60mph-130 30mph.no TCC.

078 2.630 Coil 0.580 0.052 © 2003 ATRA. All Rights Reserved .396 0.080 Accumulators — 2-3 GREEN Outer Length Outer Diameter Outer Coil Inner Length Inner Diameter Inner Coil 2.425 Diameter 0.665 0.729 0.116 FORD F4E-III Ratio Codes (Continued) Accumulators Accumulators — 1-2 RED Spring Length 3.

066 3.954 0.050 © 2003 ATRA.420 0.802 0.047 BLUE Outer Length Outer Diameter Outer Coil Inner Length Inner Diameter Inner Coil 4.657 0.384 0.062 2.553 0.FORD 117 F4E-III Ratio Codes (Continued) Accumulators — N-D GREEN Outer Length Outer Diameter Outer Coil Inner Length Inner Diameter Inner Coil Accumulators — N-R 2.580 0.134 0. All Rights Reserved .

118 FORD F4E-III Accumulator Reference N-D Accumulator (Green) N-R Accumulator (Blue) 1-2 Accumulator (Red) 2-3 Accumulator (Green) © 2003 ATRA. All Rights Reserved .

FORD 119 F4E-III No Line Rise W/ Good EPC Command No Line rise can be caused by a sticking pressure modifier valve or a damaged spring. © 2003 ATRA. All Rights Reserved . Check the valve for scoring and make sure the valve bore is clean of debris. The Line Pressure Modulator Valve is responsible for modulating the EPC pressure and distributing it to the appropriate valves.

No 2nd and 4th The Orifice size is . Slipping 2nd and 4th.120 FORD F4E-III After Rebuild.020” in Always take the time to remove the servo apply orifice. All Rights Reserved . © 2003 ATRA.

FORD 121 F4E-III Jump Testing the Transmission © 2003 ATRA. All Rights Reserved .

122 FORD F4E-III Jump Testing the Transmission F4E-lll connector assembly veiwed from the terminal side. All Rights Reserved . + + + + #7 indicates TCC © 2003 ATRA.

Torque Valve Body to 80 lb-in.FORD 123 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. All Rights Reserved . © 2003 ATRA. 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.

All Rights Reserved . 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. In Ealy 2002 Ford introduced a reprogram for this interchange. 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.124 FORD 4F27E Final Drive Gear Set A reprogram is availible for the PCM (Powertrain Control Module) to accept an ealier gearset in a late vehicle. Transfer Gear Output Gear © 2003 ATRA. 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.

FORD 125 4F27E Final Drive Gear Set © 2003 ATRA. All Rights Reserved .

OTC# 307-416 © 2003 ATRA. Many times a repeat failure of the band will occur because the specified bolt was not installed.126 FORD 4F27E 2 / 4 Band Adjustment Band adjustment is crucial during a rebuild. This tool can be purchased from the after market. All Rights Reserved .

lightly seat the nut and washer against the transaxle case Remove the tool without changing the position of the nut on the bolt © 2003 ATRA. All Rights Reserved .FORD 127 4F27E 2 / 4 Band Adjustment When an adjustment is necessary be sure to follow the procedure listed below: Tighten the band select gauge tool to 45 lb-in Back out the gauge 3 ½ turns Holding the tool bolt in position.

All Rights Reserved .128 FORD 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 © 2003 ATRA.

or P1762 may be present The seperastor plate orifice sizing has been changed to repair this problem. Slipping Explorer. seperator plate gasket blown. All Rights Reserved . erratic EPC pressure are some common problems with 1995 -2002 4R and 5R series transmissions.FORD 129 4R44/55E and 5R44/55E Low Line Pressure at WOT. In some cases due to heavy contamination 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. Aerostar. 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. © 2003 ATRA. Mountaineer Low line pressure at WOT. a new Seperator plate is now availible from Ford.If it is determaned the valve body needs replacing refer to chart on the opposite page. P0733. Ranger.

The new plug has a check valve in the plug that allows excessively high EPC oil pressure to escape without damaging the valve body or other internal complaints. remove and discard the old solid plug and clip assembly. Old Plug New Plug W/ Blow Off Remove and discard these parts © 2003 ATRA. All Rights Reserved .130 FORD 4R44/55E and 5R44/55E Low line Pressure at WOT When replacing the separator plate and EPC blow off plug.

FORD 131 4R44/55E and 5R44/55E Low line Pressure at WOT © 2003 ATRA. All Rights Reserved .

All Rights Reserved .132 FORD 4R44/55E and 5R44/55E Low line Pressure at WOT © 2003 ATRA.

All Rights Reserved .FORD 133 5R55N Clutch and Band Application A=Applied ANE=Applied but Not Effected © 2003 ATRA.

All Rights Reserved .134 FORD 5R55N Sprag Application © 2003 ATRA.

All Rights Reserved .FORD 135 5R55N Pressure Specification Main Line Tap © 2003 ATRA.

136 FORD 5R55N Pressure Specification Alternate Main Line Tap © 2003 ATRA. All Rights Reserved .

All Rights Reserved .FORD 137 5R55N Soleniod Application Chart * Failsafe for this unit is Fourth. Second and Reverse © 2003 ATRA.

138 FORD 5R55N Solenoid Failure Chart 1=Manual 1=Manual 1=Manual © 2003 ATRA. All Rights Reserved 1=Manual .

All Rights Reserved .FORD 139 5R55N Solenoid Failure Chart 1=Manual 1=Manual © 2003 ATRA.

140 FORD 5R55N Pressure Control Solenoid Failure 1=Manual 1=Manual © 2003 ATRA. All Rights Reserved .

FORD 141 5R55N Pressure Control Solenoid Failure 1=Manual © 2003 ATRA. All Rights Reserved .

ROTATES CLOCKWISE HOLD ROTATE © 2003 ATRA.142 FORD 5R55N Intermediate Sprag Rotation A damaged intermediate sprag will cause a bind in third and fourth or no third or fourth condition. All Rights Reserved .

etc.FORD 143 4R70W Solenoid Codes P0750. Check the Mating Surfaces This Pin is damaged © 2003 ATRA. P0751. All Rights Reserved . 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.

To verify this concern monitor the MLP/TR sensor on the scanner or at the sensor signal pin. Typical Pin Identification 57=Ground 359=Signal Return 199=MLP to PCM 463=Nuetral Sense (4X4) 32=Starter Circuit 298=Fused Accy Feed 140=Backup Lamp 33=Starter Circuit © 2003 ATRA. All Rights Reserved . If voltage changes during the drive or when road shock is applied make sure the concetions and wiring is good . then replace the sensor.144 FORD 4R70W Downshifts at High Speeds This problem is usually caused by the Manual Lever Position Sensor/Transmission Range Sensor voltage rising because of a bad ground or damaged MLP sensor making the PCM believe the transmission was manually downshifted.

where as the MLP refers only to one pin at the PCM. All Rights Reserved . © 2003 ATRA. The TR sensor refers to four pins at the PCM.FORD 145 4R70W Downshifts at High Speeds There are a few differances between the TransmissionRange sensor and the Manual Lever Position Sensor.

O/D Band applied. direct clutch applied. All Rights Reserved . © 2003 ATRA. During a forced down shift from 4-2. no intermediate. SS1 and SS2 are commanded OFF. 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. this causes the feel of Nuetral. 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. no forward. The Diode sprag is considerably stronger then the older roller one-way clutches. 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). however the cause is still the same.146 FORD 4R70W Repeat Intermediate Diode Failure Typically caused by flooding solenoids this problem can give you trouble if not diagnosed completely.

.............. 1C3Z-7B164-BA .............. YC3Z-7D044-AA ..8L 5 Plate Drum 7............. YC3Z-7D044-BA .......... The new Drum deletes the thrust washer assemly and has a smaller piston travel area.......... F3TZ-7G401-AA ..... Intermaediate sprag Clutch Plates 4 Plate Drum 5......FORD 147 4R100 2nd Gear slips or No 2nd The common cause for this problem is duability of the Intermediate Diode sprag.... Part #’s E9TZ-7A089-B .........3L only Thrust Washer#7 © 2003 ATRA................................... A new drum and sprag assembly was introduced last year in ATRA Bulletin #642.... All Rights Reserved .................4L and 6................. When a replacemnet is necessary you may need to replace the piston and return spring also.......

Parts needed: 1 = PC 7/32” 16 mml oil resistant hose 1 = Razor Blade 1 = C6 Direct Clutch Return Spring © 2003 ATRA. There are a few things your going to need to do before this repair. typically due to case damage.148 FORD 4R100 Intermediate Clutches Burnt A common failure of the Intermediate clutch is almost always caused by lack of feed oil to the piston. All Rights Reserved . one modification you can do is install a rubber gasket/seal around the feed hole of the Inermediate clutch drum.

trim it with the razor blade.FORD 149 4R100 Intermediate Clutches Burnt Seat hose at the bottom of the channel case With hose extended through case. © 2003 ATRA. Make sure it is flush against the case. All Rights Reserved .

150 FORD 4R100 Intermediate Clutches Burnt Cut specification Spring specification Should be less then a 1/8 of an inch above the seperator plate © 2003 ATRA. All Rights Reserved .

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. © 2003 ATRA. Signs of this are evident when initial inspection shows the tip of the bolt and the bottom of the case having signs of damage Discard these types of bolts.FORD 151 4R100 No/Slipping Reverse. Install threadonly bolts. All Rights Reserved .

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 © 2003 ATRA. if the scanner shows a VSS signal with the KEY ON and the ENGINE OFF. Monitor the VSS on you scanner.152 FORD 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. All Rights Reserved .

2. Remove the ground screw from under the dash. (Left side of the brake pedel) 3.FORD 153 4R100 Vehicle Speed Sensor Input when Vehicle is Stationary To install the jumper kit: 1. Disconnect the battery negitive cable. Drill a 6mm (1/4) hole near the original ground screw location and clean to bare metal. Using a new bolt and nut attatch the original ground eyelets to the sheet metel. © 2003 ATRA. (make sure you can attatch a nut behind the bolt) 4. All Rights Reserved .

8. Reinstall all the neccessary componets and retest the system. All Rights Reserved .154 FORD 4R100 Vehicle Speed Sensor Input when Vehicle is Stationary 5. 9. 7. 77. Remove the wires from pins 3. Remove the PCM connector and sheild. Remove the RED locking plate from the front of the connector. 103. 6. © 2003 ATRA. 51. 23. Install the jumper kit to the PCM in the loctations that you removed in the previous step. 76. 24.

six multiple-disc friction clutches. © 2003 ATRA. direct electronic shift control. two mechanical diode one-way clutches (OWC). The main operating components include: a torque converter clutch. All Rights Reserved .FORD 155 TorqShift 5R110W Description The transmission features include: six speeds. optional power take-off. three planetary gear sets. a fully automatic transmission.

All Rights Reserved .156 FORD 5R110W Clutch Application Chart (a) Commanded pressures viewed on scanner (c) 30 psi until 3 mph (d) Clutch applied through the manual valve © 2003 ATRA.

All Rights Reserved .FORD 157 5R110W Clutch Application Chart © 2003 ATRA.

© 2003 ATRA. All of the other pressures are going to be monitered using your scanner.158 FORD 5R110W Pressure Specification Pressure can be measured at the main line tap on the drivers side of the transmisison. All Rights Reserved .

All Rights Reserved .FORD 159 5R110W Pressure Specification © 2003 ATRA.

(coast clutch pressure switch) 0.7 ohms +/.5 ohm +/. All Rights Reserved .7 ohms +/.(overdrive pressure switch) 0.5 ohm +/.5 ohm +/.5 ohm +/.(coast clutch) 4.160 FORD 5R110W Solenoid Specification Chart 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PC-A TCC SSPC-B SSPC-A SSPC-E SSPC-D SSPC-C TFT PS-B PS-A PS-E PS-D PS-C TR-P 4.(intermedate clutch) 200K ohm scale (transmission fluid temperature) 0.(overdrive) 4.(low/reverse clutch) 4.7 ohms +/.(low/reverse pressure switch) 0.7 ohms +/.(direct clutch) 4.7 ohms +/.(line pressure) 4.7 ohms +/.7 ohms+/.(direct clutch pressure switch) 0.5 ohm +/.(torque converter clutch) 4.(intermediate clutch pressure switch) (transmission range sensor) not shown here © 2003 ATRA.

FORD 161 5R110W Solenoid Specification Chart 11 5 10 6 12 7 13 4 3 9 2 8 1 © 2003 ATRA. All Rights Reserved .

All Rights Reserved .162 FORD 5R110W Valve Body Wiring Connector shown from the valve body connector side © 2003 ATRA.

FORD 163 5R110W Valve Body Wiring © 2003 ATRA. All Rights Reserved .

enter your scan tool data as if you were working on a Ford vehicle. © 2003 ATRA.164 FORD Mazda to Ford Conversion Sometimes. This chart will help you with the conversion. you won’t be able to scan Mazda vehicles with the 4R/5R series transmissions using Mazda ID from the VIN. If you run into this. All Rights Reserved .

All Rights Reserved .FORD 165 NOTES: © 2003 ATRA.

166 FORD NOTES: © 2003 ATRA. All Rights Reserved .

CHRYSLER 167 © 2003 ATRA. All Rights Reserved .

............. 44..... 183 Buzz................V.............. 174 Auxiliary Differential Vent .......... 185 413. Moaning Noises .. 46........................................................ No TCC Engagements 30-50 MPH ......... 670........ 191 © 2003 ATRA......... 727...... 904... 190 42........................ 175 No Response From TCM ............... 177 45RFE Transmission Quality Enhancments .......... 176 Erroneous Body Control Module Codes ..........168 CHRYSLER Chrysler Contents 31TH Delayed Engagement ...... 171 Speed Sensor Faults . 173 Cooler Line Splice Kit .................. 182 Delayed Upshift.............. 170 41TE and 42LE 1999-up Transmission Range Sensor Kit .... Whine... 47.............. RH and RE Units Proper Regulator Valve Adjustments ... 188 Proper Throttle Valve Adjustments ........ Valve Adjustment Tool ....... 178 47RE Harsh Engagements When The TCC is Applied .......... 184 Front and Rear Band Adjusments ......................... RH and RE Throttle Valve Cable Adjustment ............ 189 Pressure Regulator Valve and T..... 179 Erratic TCC operation .... All Rights Reserved .....................

CHRYSLER 169 © 2003 ATRA. All Rights Reserved .

Here are a few things to check before the replacement of the pump.170 CHRYSLER 31th Delayed Engagement Some 2000 Dodge (NS) Caravan. This may be due to interference between the front pump assembly and transaxle case. The transaxle date numbers involved are between 3872 to 4058 (10. 2000 (MDH 072100 and 0203XX). the most likely cause of the condition is due to interference between the pump housing and the transaxle case. © 2003 ATRA. Perform the following Repair Procedure. Parts Required Qty. Plymouth (NS) Voyager. 1999 and February 3. Plymouth (PL) Neon.000-day calendar) and 0010 to 0340 (Julian date code). Part Number 1 05016410AB 1 04269661AB Description Pump Assembly Pump Gasket Note: This information applies to models equipped with a 31th transaxle built between July 21. Dodge (PL) Neon. 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. Make sure the fluid level correct? Make sure linkage adjustment correct? Does delay occur in both Drive & Reverse? Does delay occur in –1°C (30°F) or colder weather? Does transaxle engage when RPM is raised? Does transaxle engage properly after the initial cold delay? If the answers to the above questions were YES. If the answers were NO. All Rights Reserved . Dodge (P2) Neon (Export Market). further diagnosis will be required to determine the cause of the condition.

© 2003 ATRA. When installing a 1999 transaxle into a 1998 and prior vehicle a replacement harness must be installed. These vehicles can accept the 1999 transaxle by simply removing the jumper harness. The jumper harness converted the 1999 vehicle harness to accept the 1998 transaxle TRS connector. Early model 1999 vehicles were built with 1998 style transaxles and used a jumper harness.CHRYSLER 171 41TE and 42LE 1999-up Transmission Range Sensor harness kits A new Transmission Range Sensor (TRS) was designed for the 1999 model year transaxles. All Rights Reserved . The outside diameter of the pass through connector was increased as well as the terminals being changed from a pin type to a blade type.

All Rights Reserved .172 CHRYSLER 41TE and 42LE 1999-up Transmission Range Sensor harness kits Important: The replacement harness wire colors may not match the wire colors on the vehicle. Part # 05014473AA…. Use the figure below and only change one wire at a time.42LE Splice Kit (Modifies 1998 and earlier vehicle TRS harness to be compatible with a 1999 transaxle) 41TE KIT # 05014473AA 42LE KIT # 05014474AA © 2003 ATRA.41TE Splice Kit (Modifies 1998 and earlier vehicle TRS harness to be compatible with a 1999 transaxle) Part # 05014474AA….

When a new speed sensor is installed on an early vehicle the terminals may spread resulting in a poor contact. 1998 for the 41TE. Part # 05014471AA Output Speed Sensor connector kit Part # 05014469AA Input Speed Sensor connector kit © 2003 ATRA. Intermittent loss of speed sensor signals. All Rights Reserved . Any time a speed sensor is changed in an early vehicle the connector should also be updated. ratio errors and cruise control complaints may occur. The terminal positions are slightly different between the new and old sensors.CHRYSLER 173 41TE and 42LE Speed Sensor faults and/or Ratio concerns The input and output speed sensor supplier was changed for the 1998 model year 42LE and on August 8.

This kit should be installed whenever a service is performed that requires cooler line removal from the transaxle. Sebring Convertible. All Rights Reserved . This will make the lines easy to remove and install should service be required at a later time. Chrysler (RG) Voyager (International Market).174 CHRYSLER 41TE Transaxle Cooler Line Splice Kit Application: Chrysler (JR) Sebring. and Dodge (RS) Caravans A connector kit has been released to make transaxle cooler line service easier. Plymouth (PL) Neon. Chrysler (RS) Town & Country. Chrysler (PT) PT Cruiser. Parts Required Qty. An instruction sheet is included with each kit that details installation procedures. Part Number 1 05016918AA Description Kit. Voyager. Transmission Cooler Line Connector Cut and remove Hose Install new connectors and reinstall hose © 2003 ATRA. Dodge (JR) Stratus Sedan.

Part Number 1 05011589AA Description Vent Tube Assembly Kit 1) Clean all fluid from the differential case. and 1997-2000 Plymouth (PR) Prowler to provide improved differential case venting. 5) Install the revised differential fill plug from the vent tube kit. 1993-2000 Eagle (LH) Vision. 2) Drain the differential fluid by removing the differential drain and fill plugs. Tighten to 7 N.CHRYSLER 175 41TE Auxiliary Differential Vent An auxiliary vent tube assembly has been released for service on 1993-2000 Chrysler (LH) Concorde. 1993-2000 Dodge (LH) Intrepid.m (60 in-lbs. 6) Install the new vent tube assembly into fill plug and orient the tube between ribs on the differential cover. LHS. Fluid can collect on the top of the differential case and/or drip to the ground. Note: Be sure vent tube is not contacting any metal surfaces on differential cover. New Yorker.). P/N 04549624. 3) Install the differential drain plug. Parts Required Qty. 300M. under certain driving conditions. 4) Fill the differential with 32 ounces of Mopar 75W-90 Gear Lubricant. pressure can build up in the differential case forcing fluid out through the primary vent tube at the top of the differential. In cold climate areas. All Rights Reserved . © 2003 ATRA.

Chrysler (JA) Cirrus. Authorized Software Update Label. Plymouth (NS) Voyager. 42LE No Response From TCM When Using Generic Scan Tools 2000 Chrysler (GS) Voyager (European Market). Authorized Modification This involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software. Part Number 1 04669020 1 04275086 Description Label. Chrysler (NS) Town & Country.176 CHRYSLER 41TE/AE. Plymouth (JA) Breeze. Dodge (NS) Caravan. Parts Required Qty. 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. Chrysler (JX) Sebring Convertible. Dodge (JA) Stratus. Note: This information applies to vehicles equipped with a 41TE/AE or 42LE automatic transaxle built prior to the following dates: © 2003 ATRA. This may lead to unnecessary diagnostic procedures and or replacement of good TCM’s. the aftermarket generic scan tool may indicate that the Transmission Control Module (TCM) is not responding. All Rights Reserved .

it is not necessary to replace the BCM. All Rights Reserved . If all PRNDL indicators DO NOT become boxed at the same time.CHRYSLER 177 41TE Erroneous Body Control Module Diagnostic Trouble Code Town & Country. © 2003 ATRA. Caravan. 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). and Voyager units with 41TE transaxles may exhibit erroneous body module codes caused by the PRNDL switch. After 10 seconds they should go out. Note: Chrysler has not received any reports of this DTC being set by an actual failure in the PRNDL system. the DTC is erroneous and the DTC should be cleared.

and 4-3 Shifts Some 2000 Dodge Dakota. A harsh 1-2 upshift during light or wide open throttle conditions. This involves selectively erasing and reprogramming the Dakota.7L engine and a 45RFE automatic transmission built before August 16. Note: This applies to vehicles equipped with a 4.0.0). Durango 1999-2000 Jeep Grand Cherokee vehicles equipped with a 45RFE transmission may experience the following shift quality issues: A harsh 2-3 upshift causing a powertrain clunk or shudder when accelerating. All Rights Reserved . and adds a final gear ratio to the Grand Cherokee transmission only. or the Grand Cherokee Transmission Control Module or TCM (with calibration 99Ver9. or 00Ver9.178 CHRYSLER 45RFE Transmission Quality Enhancements for the 1-2. The revision of the TCM software addresses the above shift quality conditions for all vehicles.5. 00Ver8. A harsh 4-3 kickdown shift during low speed. light throttle conditions. 1999 (MDH 081600). the Durango. © 2003 ATRA. And reprogramming the Grand Cherokee Powertrain Control Module or PCM (with calibration 99Call9A or 00Call6A). 2-3.

The transmission should not be allowed to shift out of O/D during this maneuver. Note: This applies to vehicles equipped with an 8. but with a deeper (wider) throttle position while still maintaining O/D. 4)While maintaining a constant speed. 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. 1999 and August 14. 2)Drive the vehicle at a constant speed between 28 to 31 KM/H (45 to 50 MPH). lift your foot off of the accelerator pedal and then reapply the accelerator pedal. The following steps are recommended. If necessary. 2000 (MDH 091500 to 081400). © 2003 ATRA. 1)Verify that the transmission fluid level is correct and that the transmission throttle cable is properly adjusted. All Rights Reserved . the DRB III may be used to create a custom monitor to display the needed transmission states. This harsh engagement will occur when the transmission is in or enters 3rd gear or overdrive (O/D).0L gasoline engine and a 47RE automatic transmission built between September 15. but the maneuver should cause the TCC to temporarily disengage. 3)Make sure that the transmission is in O/D and the TCC is locked-up.CHRYSLER 179 47RE Harsh Engagement When the TCC is Applied Some 2000-2001 Dodge Ram Truck owners may complain that their transmission exhibits a harsh engagement. Determine if the harsh engagement is the result of the transmission torque converter clutch engagement.

Transmission Oil Type 9602 (2001 M. 7) If a harsh engagement is noted during TCC lock-up. Transmission Oil Type 7176 (2000 M. Valve Body Upper Housing Separator Gasket.180 CHRYSLER 47RE Harsh Engagement When the TCC is Applied (continued) 5) Allow the vehicle to accelerate until TCC engagement occurs. or if a harsh engagement occurs during the 2-3 or the 3-O/D shift. then perform the REPAIR PROCEDURE. All Rights Reserved . then additional diagnosis is required. Part Number 1 52118048AB 1 02464324AB AR (10) 05010124AA AR (10) 05013457AA Description Plate.) © 2003 ATRA. Note if the TCC engagement is harsh.) ATF+4. 8) If a harsh engagement is not observed during TCC engagement.Y. Transmission Oil Pan ATF-3. Parts Required Qty.Y. 6) Steps 2 through 5 may need to be repeated several times to verify TCC engagement.

. The correct plate will have a 3mm (0. © 2003 ATRA.118 in) wide. Wider slots. Note: The slot in the seperator plate shown below should be approximately 3 mm (0. althought they provide for a quicker TCC apply may make this probmel worse.CHRYSLER 181 47RE Harsh Engagement When the TCC is Applied (continued) 1)Inspect the new separator plate P/N 52118048AB. All Rights Reserved .118 inch) wide slot at the torque converter clutch lock-up vent circuit.

it should be consistently locked. If the TC clutch status shows unlocking / locking. 1998 and December 18.9L 24 valve diesel engine and automatic transmission built between January 1. Warm the engine and verify the transmission fluid temperature is greater than 32°F and consistent. further diagnosis and testing will be required. Monitor the TC clutch status. 1998 (MDH 010198 & 121898).9L Diesel Erratic Torque Converter Clutch Some 1998-99 Dodge (BR/BE) Ram Trucks may experience a surge like condition while in 4th gear. While keeping the output shaft speed above 2200 rpm. © 2003 ATRA.182 CHRYSLER 5. If the conditions are met. perform the REPAIR PROCEDURE. This involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes 98call2 & 99call4). Operate the vehicle with an output shaft speed greater than 2200 rpm. All Rights Reserved . The cause of this erratic operation has been identified as electrical noise from the Throttle Position Sensor (TPS) or Alternator. look to see if the TPS volts are fluctuating by 0. This may be caused by the Torque Converter Clutch (TCC) unlocking and locking when it should be consistently locked. Drive the vehicle with a helper monitoring the PCM. If a surge like condition is felt but the above test does not confirm the TCC unlocking/locking occurrence.2 volts or more. hold the throttle so the TPS reads 1 volt. Verify that the brake switch shows a released status that is consistent and verify the park/ neutral status reads D/R and is consistent. Note: This information applies to vehicles equipped with a 5.

while moderately accelerating from 30-50 MPH (48 to 80 KM/H). © 2003 ATRA. The customer may also note high engine rpm’s while operating in 3rd or 4th gear. Note: This applies to vehicles equipped with a federal market (NAA) 5. This involves the replacement of the transmission valve body upper housing separator plate. This condition may be caused by a delay in the engagement of the transmission torque converter clutch (torque converter lockup).CHRYSLER 183 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.9L – 24V diesel engine and built between March 2. 1999 (MDH 030299) and October 1. All Rights Reserved . 1999 (MDH 100199).

184 CHRYSLER 42/44/46/47/ RE and RH “Buzz”. All Rights Reserved . restricted filter or cooler flow. This noise has been described as a buzz. an under filled transmission. Possible cracked pump housing. This condition is caused by a resonance of the transmission regulator valve system. or an out of specification valve and or valve body. a torn pump gasket. whining. Mostly affected transmissions built after Aug 1. “Whining”.1995 Updated (STEEL) Pressure Regulator Valve: Part # 04130169 © 2003 ATRA. or moaning like noise. The noise is most noticeable when transmission fluid temperature is below 38º C (100º F). Other items that can cause this are: Air in valve system or out of the internal parts. or “Moaning” Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected.

In adjusting. torque the ancor to 72 in lbs and back off number of turns listed. Harsh 1-2.CHRYSLER 185 42RE thru 47RE Front & Rear Band Adjustments It is important to note that Band Adjustments vary from unit to unit. and or Slide Bump on 1-2 shifts as well as reverse engagements problems may occur if this adjustment is done incorrectly. from year to year. Refer to the chart below to know what the band adjustment is for each of these units. All Rights Reserved . © 2003 ATRA.

back off 2 turns 46RE – 47RE Front Band: 72 in lbs. back off 2 7/8 turns Rear Band: 72 in lbs. back off 2 turns 1997 (Jeep and Dodge line) 42RE Front Band: 72 in lbs. back off 2 7/8 turns Rear Band: 72 in lbs. back off 1 7/8 turns Rear Band: 72 in lbs. back off 4 turns © 2003 ATRA. back off 2 7/8 Rear Band: 72 in lbs. back off 2 turns 47RE Front Band: 72 in lbs. back off 3 turns 1998 (Jeep and Dodge line) 42RE Front Band: 72 in lbs. Back off 4 turns 1996 (Jeep and Dodge line) 42RE – 44RE Front Band: 72 in lbs. back off 4 turns 44RE Front Band: 72 in lbs. back off 2 turns 44RE Front Band: 72 in lbs. back off 2 ¼ turns Rear Band: 72 in lbs. back off 3 5/8 turns Rear Band: 72 in lbs. Back off 3 5/8 turns Rear Band: 72 in lbs. back off 3 5/8 turns Rear Band: 72 in lbs. All Rights Reserved .186 CHRYSLER 42RE thru 47RE Front & Rear Band Adjustments 1994 – 1995 Jeep Cherokee 42RE Front Band: 72 in lbs. back off 4 turns 1997 46RE Front Band: 72 in lbs. back off 2 ¼ turns Rear Band: 72 in lbs.

back off 2 turns. back off 4 turns 44RE Front Band: 72 in lbs. back off 2 7/8 turns Rear Band: 72 in lbs. back off 2 turns 47RE Front Band: 72 in lbs. back off 4 turns2 44 RE Front Band: 72 in lbs. back off 1 7/8 Rear Band: 72 in lbs. back off 4 turns 2000 46RE Front Band: 72 in lbs. back off 3 turns 1999 (Jeep and Dodge line) 42RE Front Band: 72 in lbs. 46RE Front Band: 72 in lbs. back off 3 turns Rear Band: 72 in lbs. back off 3 turns Rear Band: 72 in lbs. back off 2 ¼ turns Rear Band: 72 in lbs. back off 1 7/8 turns Rear Band: 72 in lbs.CHRYSLER 187 42RE thru 47RE Front & Rear Band Adjustments 1999 44RE Front Band: 72 in lbs. back off 2 turns 47 RE Front Band: 72 in lbs. back off 4 turns © 2003 ATRA. back off 4 turns 2000 (Jeep and Dodge line) 42RE Front Band: 72 in lbs. back off 1 7/8 turns Rear Band: 72 in lbs. back off 4 turns 46RE Front band: 72 in lbs. back off 3 turns Rear Band: 72 in lbs. back off 3 turns 2001 (Jeep and Dodge) 42RE Front Band: 72 in lbs. back off 2 7/8 turns Rear Band: 72 in lbs. back off 1 7/8 turns Rear Band: 72 in lbs. All Rights Reserved . back off 2 7/8 turns Rear Band: 72 in lbs.

V. Pressure Regulator Valve: From the face of the valve body to the bottom of the adjustor plate for the regulator spring the measurement is 1 5/19". Counterclockwise will raise pressure – clockwise will lower pressure. By adjusting the screw one complete turn will change the line pressure approximately 1 2/3 psi. controlled line rise will have the same adjustments for both the T. RH and RE Proper Regulator Valve adjustments All Chrysler/Dodge units that have a T. Manufacturing tolerances may make it necessary to vary from this dimension to obtain desired pressure.V. 670. 727. valve circuit as well as the Pressure Regulator valve pre-adjustment. 904.188 CHRYSLER 413. Note: The 1 5/16” setting is an approximate setting. © 2003 ATRA. All Rights Reserved .

904. © 2003 ATRA.V. 727. 670. valve (valve bottomed into its bore – no movement). RH and RE Throttle Valve adjustments T. With the tool in place. Valve Adjustment: A special tool from Miller Tools # C3763 is used to measure the gap distance between the throttle lever and the kickdown valve.V. there should be no movement of the T. Note: The kickdown valve spring must be fully compressed and the kickdown valve completely bottomed to obtain correct adjustment. All Rights Reserved .CHRYSLER 189 413.

190

CHRYSLER

413, 670, 727, 904, RH and RE
Pressure Regulator Valve and T.V. Valve adjustments Tool
Parts required: 1: Shouldered bolt (Minimum 1" shoulder 3/8 bolt) 1: Roll Pin (Minimum 3" long 1/8 wide) 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 hunting down 2 separate tools!

Bolt Roll Pin

© 2003 ATRA. All Rights Reserved

CHRYSLER

191

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. Adjustment 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, release cable snap-lock and adjust to achieve this measurement.

Note: Be sure that as the cable is pulled forward and centered on the throttle lever stud. Due to the angle at which the cable housing enters the spring housing, the cable housing may bind slightly and create an incorrect adjustment
© 2003 ATRA. All Rights Reserved

192

CHRYSLER

© 2003 ATRA. All Rights Reserved

HONDA / ACURA

193

© 2003 ATRA. All Rights Reserved

194

HONDA / ACURA

Honda/Acura Contents
Honda/Acura NoTCC Lockup When Cold ...... 196 Grinds in Reverse ................... 197 Solenoid Information .............. 198 A4RA, B4RA, M4RA Harsh Shifts and Engagement Complaints ......... 202 Bushing Damage .................... 204 CVT CVT Primary Information ........ 205 Start Clutch ........................... 206 Correct Gear Range ................ 207 Fail Safe ................................. 208 Retrieving Codes..................... 209 Fluid Specification .................. 210 Pressure Specifications ........... 211 Stall Speeds ........................... 213 Break in Procedure ................. 214 Noise Idling in Reverse ........... 216

© 2003 ATRA. All Rights Reserved

HONDA / ACURA

195

© 2003 ATRA. All Rights Reserved

196 HONDA / ACURA Honda / Acura TCC does not lockup during cold weather 1996-97 Civic with A24A and Accord with AOYA or MPOA. If the coolant temperature never exceed 176°F during normal driving. © 2003 ATRA. the PCM will not allow Lockup. All Rights Reserved . When ambient temperature is less than 30°F. replace the thermostat.

Reverse Selector Reverse Selector Hub © 2003 ATRA. Make sure that all the Reverse gears are installed correctly.HONDA / ACURA 197 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 upsidedown. All Rights Reserved .

198 HONDA / ACURA Honda / Acura Solenoid Information 97 and Later All except CVT Electrical System © 2003 ATRA. All Rights Reserved .

HONDA / ACURA 199 Honda / Acura Solenoid Information 1997 and Later All (except CVT) Shift Control Solenoid Vavle Position Gear Position A Shifting from N position Stays in 1st Shifting gears between 1st and 2nd D4. D3 Stays in 2nd Shifting gears between 2nd and 3rd Stays in 3rd Shifting gears between 3rd and 4th D4 Stays in 4th 2 1 R Stays in reverse P N Park Neutral OFF OFF OFF ON ON ON OFF OFF OFF 2nd 1st Shifting from P and N position OFF ON OFF OFF OFF ON ON ON OFF OFF ON ON ON ON ON OFF ON OFF OFF OFF OFF OFF ON ON ON OFF ON B ON ON ON C ON ON ON © 2003 ATRA. All Rights Reserved .

Note: There should be no continuity from the solenoid body to either terminal © 2003 ATRA.200 HONDA / ACURA Honda / Acura Solenoid Information Lockup Control Valve / Shift Control Solenoid Valve A assmbly Shift Solenoid B and C resistance (between terminals 1 and 2) = 12-25 ohms. All Rights Reserved .

All Rights Reserved . © 2003 ATRA.HONDA / ACURA 201 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.

Most Fall between 3-4 Turns © 2003 ATRA. Simply reverse the order during reassembly. M4RA Models Harsh Shifts and Engagement Complaints A common cause for this complaint is a broken CPC valve spring. These springs are availible through the aftermarket. B4RA. All Rights Reserved . NOTE: Before disassembly turn the CPC spring seat in counting the turns in until it bottoms out.202 HONDA / ACURA A4RA. The spring pressure is calibrated by an adjustable spring seat. Record the location and number of turns while removing the spring seat. Before disassembly it will be necessary to count the number of turns on the spring seat plug to ensure the correct pressure.

M4RA Model Harsh Shifts and Engagement Complaints O-Ring Measure the turns and record for reassembly © 2003 ATRA. B4RA. All Rights Reserved .HONDA / ACURA 203 A4RA.

204 HONDA / ACURA 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. All Rights Reserved . However they are availible through the aftermarket Damaged Bushing area © 2003 ATRA. Honda only services the bushing as part of the support shaft.

333 4.357 2. Its use of a metal segmented belt and variable width pulleys is similar to the Subaru Justy ECVT. Forward and reverse rotation is possible by the application of one of two clutches acting on a Ravigneaux planetary assembly. Secondary………………………… Final………………………………… Variable Forward Ratios……. Fixed Gear Ratios Planetary in Reverse ……….466-.HONDA / ACURA 205 Honda CVT Preliminary Information Honda Civic HX models starting in 1996 have been using a CVT transmission.449 © 2003 ATRA. 2..499 1. All Rights Reserved ..

Park Gear Start Clutch Drum Start Clutch Hub Secondary Drive Gear © 2003 ATRA. The START clutch is released when the vehicle is stopped.206 HONDA / ACURA Honda CVT Information The START clutch couples the driven pulley to the secondary gear shaft of the final drive gear. Torque from the driven pulley is transferred to the final drive gear via the secondary gear shaft. All Rights Reserved . As soon as acceleration is needed the START clutch applies.

the correct gear ratio for the vehicle is achieved by the drive and driven pulleys. At high speeds the drive pulley widens and the belt rides lower. the belt will ride in the middle of both pulleys and the ratio will be about 1:1. 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. All Rights Reserved . This valve responds to control signal oil from the Shift Control Linear Solenoid. Remember. Pressure to control the width of both pulleys comes from the Pressure High-Pressure Low (PH-PL) valve. © 2003 ATRA. The PH-PL valve maintains the correct pressure between both drive and driven pulleys. At low speeds the drive pulley narrows and the belt rides high.HONDA / ACURA 207 Honda CVT Information In the forward range. This is important to keep the belt in contact with both pulleys.

All Rights Reserved . located inside a “spinning trough of oil” allows the vehicle to hydraulically apply and release the start clutch. The transmission will still drive forward and reverse. A Pitot tube. All solenoids are turned off. The only ratio available in failsafe is the high or overdrive ratio. © 2003 ATRA. the “D” light stays on.208 HONDA / ACURA Honda CVT Information Fail Safe When the computer detects a circuit or transmission fault.

To confirm that the unit works in failsafe. even when no codes are present. If the unit starts out in the high range in forward and reverse. These units have been known to have erratic solenoid and valve body problems. suspect internal pressure. It’s very important to correct and clear computer problems as the start clutch will fail under prolonged failsafe operation. unplug the wiring. All Rights Reserved . If the unit still operates erratically. suspect a solenoid or computer related problem. valve body or clutch problems. © 2003 ATRA.HONDA / ACURA 209 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.

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. 203-253 @ 1..... Note: in failsafe the driven pulley pressure may be above 500psi...Reverse…………………..000 rpm Reverse Brake Pressure Tap (Marked with “LUB”) ATF Dipstick Start Clutch Pressure Tap (Marked with “SC”) © 2003 ATRA.. Use the following pressure chart to confirm hydraulic operation..500 rpm Drive Pulley…………. 203-253 @ 1.28-101 @ 1......HONDA / ACURA 211 Honda CVT Pressures There are 6 pressure ports... Neutral……………………....500 rpm Reverse Brake………. All Rights Reserved ... Pressure Port Gear Selector Accepted psi Forward Clutch………. Neutral………………….500 rpm Driven Pulley…………..218-334 @ 1.500 rpm Lubrication……………...Neutral…………………….Drive…………………..Above 30 @ 3.....

212 HONDA / ACURA Honda CVT Pressures Forward Clutch Pressure Tap (Marked with ‘F’) Drive Pulley Pressure Tap (Marked with “DR”) Lube Pressure Tap (Marked with “LUB”) Driven Pulley Pressure Tap (Marked with “DN”) © 2003 ATRA. All Rights Reserved .

Start engine and select D.Make sure A/C is off and engine is at operating temperature.Apply brakes and fully depress accelerator. Stuck PH Regulator. Slipping Forward Or Start Clutches Check fluid. Note engine rpm. Do not stall test transmission longer than 6-8 seconds.Connect a tachometer or scan tool to read engine rpm.Block the front wheels and set the parking brake. 2. L & S Check fluid. Stuck Shift Valve Stall too high in R Stall too low in D. 3.HONDA / ACURA 213 Honda CVT Stall Speeds A stall test can be used to detect problems in the start. 5. Stuck PH Regulator. filter. Slipping Reverse Or Start Clutches Engine Output Low. All Rights Reserved . L. forward or reverse clutches. 6. S & R © 2003 ATRA. 4. Follow these steps: 1.Allow transmission to cool for 2 minutes and repeat test for S. S & R Normal 2500rpm 3000rpm Accepted Range 2350-2650rpm 2800-3100rpm RESULTS Stall too high in D. filter. Stall Specifications Gear Range D L. Faulty Start Clutch. L and R.

(The Service Check Connector is located under the dash on the passenger side of the vehicle. and block the front wheels securely.) © 2003 ATRA. 2. Engage the parking brake. 1. All Rights Reserved . or any transmission computer related work has been done. A simple jumper wire can be used for this procedure When the following parts are repaired or replaced. • 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.214 HONDA / ACURA Honda CVT Break in Procedure After overhaul of the engine or transmission. the PCM or TCM must memorize the feedback signal for the start clutch control. the start clutches need to be calibrated. Jump the Service Check connector as shown.

Connect a scantool and verify the TCM has completed the start clutch calibration. Disconnect the jumper from the Service Check Connector. Turn off all electrical accessories. 6. release the accelerator for 5 seconds. let the engine idle in N or P for one minute under the following condi tions: • With the brake pedal depressed. Shift into “D” position. Repeat these procedures until the start clutch calibration is shown to be completed in scan tool data.p.h. 7. NOTE: The TCM will not store the feedback signal when the CVT fluid temperature is below 104° F (40°C) even if the engine coolant temperature reaches normal operating temperature. 8. • Turn OFF all other electrical accessories. 5. • With the combination light switch off. To store the engine negative pressure in memory.2000 Vehicles: The TCM (‘97-’98 vehicles) and PCM (‘99 and newer) memorize the feed back signal when you drive the vehicle as follows: • • • • • After warming up the engine (the radiator fan comes on). All Rights Reserved • .HONDA / ACURA 215 Honda CVT Break in Procedure 3. Start the engine and warm it up to normal operating temperature (the radiator fan comes on twice. (60 km/h). Drive the vehicle up to 37 m. 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. © 2003 ATRA. Shift into N or P. • With the A/C switch off. Procedure for 1997 . • With the heater fan switch off. Fully depress the brake pedal and accelerator for 20 seconds with the gear selector in the D position (full power stall).) 4. After speed reaches 37 mph (60 km/h).

All Rights Reserved . © 2003 ATRA. You may need to explain what is taking place to a customer who questions the noise.216 HONDA / ACURA Honda / Acura Noise Idling in Reverse A certain amount of noise should be expected while the unit is idling in reverse.

.......... 222 No Park Engagement ..MITSUBISHI 217 Mitsubishi Contents Eclipse Scanner Access ........ 224 © 2003 ATRA............... All Rights Reserved ................................. 220 Air Test Points .......................... 219 R/V4A51 Pressure Tap Location and Specification ............... 223 Overheating Problems and Foaming Concerns. 218 Internal Wiring Harness Changes ...........

....218 MITSUBISHI Ecplise Scanner Access On 1995-1998 Eclipse 2...Y © 2003 ATRA............ 1997 and 1998 Primary Cartridge 10th... It is not necesary to install the 2nd.. Use VIN# chart below to manipulate the scanner to access codes............E 3rd..............use actual vehicle VIN# 5th..U 1999-On Primary Cartridge 10th........ All Rights Reserved ........or 8th digets for the 97-98 cartridges....................... Personality Key number seven must be installed in the OBD-II adapter....0L vehicles equipped with the 41TE transaxle must be scanned using the Domestic Primary Cartridge......................... 3rd..use actual vehicle VIN# 2nd...3 5th......U 8th.. The MITSU-1 Y-cable must be connected to the OBD-II and the Mitsubishi twelve pin diagnostic connector.......................

7-20.0-1.MITSUBISHI 219 F4A41/42/51 Internal Harness Change The internal harness was changed in September of 2000.4-4.9K 3. Part# MR528943 ATF Temperature 32°F 68°F 104°F 176°F 212°F Resistance (Ohms) 16.2K 1.2K .57-0.69K © 2003 ATRA.5K 7. The old harness is still used in the truck series and the sensor is still availible. All Rights Reserved .3-8. The ATF Temperature sensor is now an integral part of the harness.

Torque Converter Release (TR) 30-50 75-100 Torque Converter Apply (TA) Gear Selected Engine RPM Underdrive (UC) Reverse (RC) Overdrive (OC) Low-Reverse Brake (LB) Second Brake (2B) Park Reverse Neutral 1st Gear 2nd Gear 3rd Gear 4th Gear 2500 2500 2500 2500 2500 2500 2500 145-155 145-155 110-130 110-130 110-130 185-255 30-50 185-255 30-50 145-155 145-155 30-50 75-100 75-100 75-100 110-130 75-100 NOTE: Torque Converter apply pressure can vary between 0-50 PSI during gear changes while driving when the Torque Converter is not applied.220 MITSUBISHI R/V4A51 Pressure Tap Location and Specifications Pressure specifications are in PSI. © 2003 ATRA. All Rights Reserved .

36 (3252) Torque Converter Pressure (DR) 0.77 (185-256) - N - 2.MITSUBISHI 221 R/V4A51 Pressure Tap Location and Specifications Standard Hydraulic Pressure Test Measurement Condition Selector Lever Position Shift Positon Engine Speed (r/min) Underdrive Clutch Pressure (UD) Reverse Clutch Pressure (RV) Standard Hydraulic Pressure MPa (psi) Overdrive Clutch Pressure (OD) Direct Clutch Pressure (DIR) Low-Reverse Clutch Pressure (LR) ReductiSecond on Brake Brake Pressure Pressure (RED) (2ND) 1.39 (37 .22 .0.22 0.25 0.57) P - 2.25 0.77 (185 256) 0.27-1.70 (73 .36 (32-52) - © 2003 ATRA.50 0.77 (185-256) - - 1.27-1.57) 0.101) 0.0.39 (37 .27 1. All Rights Reserved .01 1.500 - 1.05 (147 152) 1.36 (32-52) - R Reverse 2.500 - - - - 0.22 .500 - - - - 0.

222 MITSUBISHI R/V4A51 Air Test Points © 2003 ATRA. All Rights Reserved .

MITSUBISHI 223 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. © 2003 ATRA. All Rights Reserved . 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.

The early dipstick level-full area is difficult to read. Part# MR593383. a new dipstick and pan were introduced to lower the level in the pan. The 2000-2001 two wheel drive models also use the “N” indicator. Filter.. © 2003 ATRA.Pan...Dipstick O-Ring NOTE: All of the 1999 models flash the “N” indicator light 2 times per second to indicate overheating conditions..224 MITSUBISHI R/V4A51 Overheating Problems. Dipstick Part# MR951878. because of this. The 2000-2002 four wheel drive models have a seperate ATF temperature light. All Rights Reserved . Foaming Concerns Most overheating problems with 1999-2001 model Motero Sports are caused by improper fluid levels.

All Rights Reserved .NISSAN 225 NOTES: © 2003 ATRA.

. 232 Case Passage Port Identification ... All Rights Reserved .........................226 NISSAN Nissan Contents RE4F04A Harsh 1-2 Shift ................ 231 Pressure Port Identification ........................ 235 Valve Body Information ........ 229 Clutch and Band Application ............. 238 4-AT DTC List.............. 230 Pressure Specifications ............. 239 Pin Chart ... 228 Subaru Identification ........................ 234 Solenoid Information ............................. 236 Code Retrieval ............................... 240 © 2003 ATRA...

All Rights Reserved .NISSAN 227 © 2003 ATRA.

But this pocket has never had a check ball installed here in the RE4F04A units.228 NISSAN 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. All Rights Reserved . No ball here No ball here © 2003 ATRA.

All Rights Reserved . One of the additional solenoids modulate the Low Clutch (Forward Clutch) apply rate. © 2003 ATRA. Four of the solenoids control similar circuits found in the EC8 transmission. The accumulators are now part of the valve body. Subaru vehicle are equipped with a modified EC8 transmission.NISSAN 229 Subaru 1999 Subaru 4-AT Since 1999. The other two solenoids modulate and control the 2-4 Brake Clutch and one TFT sensor. There are a total of seven solenoids. Lockup apply is modulated and capable in all forward ranges. The 2-4 Band is replaced with a 2-4 Brake Clutch.

All Rights Reserved .230 NISSAN Subaru Clutch and Brake Operation Subaru Range Park R N D4 D3 D2 D1 M1 A A A A A A A A A A A Low Clutch High Clutch 2-4 Brake Reverse Low/ Reverse One-Way Clutch © 2003 ATRA.

All Rights Reserved .NISSAN 231 Subaru Pressure Specifications Pressure Specifications Main Line Selector In D Selector In R Selector In 2 At Idle 44-60 psi — — WOT — 220-250 psi 164-190 psi Pressure Specifications Transfer Test Condition AWD Mode Idle 2/3 Throttle FWD Mode In Drive In Drive In Park at 2000 rpm 135-158 psi 31-43 psi zero psi Selector Pressure © 2003 ATRA.

All Rights Reserved .232 NISSAN Subaru Pressure Port Identification © 2003 ATRA.

All Rights Reserved .NISSAN 233 Subaru Pressure Port Identification © 2003 ATRA.

All Rights Reserved .234 NISSAN Nissan/Subaru Case Passage Port Identification © 2003 ATRA.

1 On Off Off On Solenoid No.NISSAN 235 Subaru Solenoid Information Solenoid Information Solenoid Command 1st Gear 2nd Gear 3rd Gear 4th Gear Solenoid No. The colors are different on the vehicle harness side. © 2003 ATRA. 2 On On Off Off Transmission Connector Pin Colors Connector Pin No. 1 2 3 4 5 6 9 11 12 13 16 Circuit Solenoid 1 Solenoid 2 Low Clutch Solenoid 2-4 Timing Solenoid Line Pressure Solenoid Transfer Clutch Solenoid 2-4 Solenid ATF Sensor ATF Sensor Lockup Solenoid Ground Wire Color Green Yellow Gray Black Red Brown Yellow/Red Orange White Blue Black These colors are on the transmission side of the connector. All Rights Reserved .

All Rights Reserved .236 NISSAN 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.

NISSAN 237 Subaru Valvebody Information Lower V/B Solenoid Feed Screens © 2003 ATRA. All Rights Reserved .

STEP 4. remove No.238 NISSAN Subaru Code Retieval Codes maybe obtained with a scan tool through the Data Link Connector located behind a cover at the lower dash panel. after the ignition is switched on. STEP 1. Place gear selector in 1st. If light keeps blinking. Light keeps blinking for 8 seconds. the AT Oil Temp. If a malfunction is present. STEP 2. The Long flashes will equal the number 10. The AT Oil Temperature light should now blink codes. 4 fuse located in main fuse box behind hood release. 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. the short flashes will equal the number 1. STEP 3. Turn ignition off. Codes can also be obtained manually by using the AT Oil Temp Light. Turn ignition off and then back on. All Rights Reserved . Move gear selector in sequence of 2-1-2-3-D. When you complete the following steps. To clear codes. then switch ignition on. © 2003 ATRA. test drive vehicle above 12 MPH then stop. the AT Oil Temperature light will display long and short flashes.

1 Brake Switch Range Sensor 1st Gear Ratio Incorrect 2nd Gear Ratio Incorrect 3rd Gear Ratio Incorrect 4th Gear Ratio Incorrect TCC Malfunction Engine Torque Control Cut Signal Input High Engine Torque Control Cut Signal Input Low Cruise Control Set Signal Incorrect Transaxle Diagnosis Input Signal Circuit Input Low Transaxle Diagnosis Input Signal Circuit Input High P1742 Transaxle Diagnosis Input Signal Circuit Malfunction All Other Codes………………………………………………….. Sensor TPS VSS No.. All Rights Reserved . 1 Shift Solenoid No.NISSAN 239 Subaru Subaru 4-AT DTC DTC Definitions AT Temp. 2 Low Clutch Timing Solenoid 2-4 Brake Timing Solenoid Line Pressure Solenoid 2-4 Brake PWM Solenoid Lockup PWM Solenoid Transfer Clutches Solenoid VSS No. Light/OBDII 11/P0725 27/P0710 31/P1700 33/P0720 36/P0715 38/P1106 or P1106 45/P0100 71/P0753 72/P0758 73/P1703 74/P1704 75/P0748 76/P1705 77/P0743 79 93/P0500` P0703 P0705 P0731 P0732 P0733 P0734 P0740 P1115 P1116 P1701 P1702 P1722 Definition Engine rpm ATF Temp.Engine Related © 2003 ATRA. 2 TSS Engine Torque Signal MAP Shift Solenoid No.

6 23 Measuring conditions Voltage (V) Resistance to body (ohms) — B55 B54 Ignition switch OFF Ignition switch ON (with engine OFF) Select lever in "P" range 10—13 10—13 Less than 1 — "P" range switch B55 23 Select lever in any other than "P" range (except "N" range) Select lever in "N" range — More than 8 Less than 1 — More than 8 Less than 1 — More than 8 Less than 1 — More than 8 Less than 1 — More than 8 Less than 1 — More than 8 More than 8 — More than 8 More than 10. Content Back-up power supply Ignition power supply B54 24 Connector Terminal No.5 — Less than 1 Less than 1 — More than 9 "N" range switch B55 22 Select lever in any other than "N" range (except "P" range) Select lever in "R" range "R" range switch Inhibitor switch B55 17 Select lever in any other than "R" range Select lever in "D" range "D" range switch B55 8 Select lever in any other than "D" range Select lever in "3" range "3" range switch B55 18 Select lever in any other than "3" range Select lever in "2" range "2" range switch B54 10 Select lever in any other than "2" range Select lever in "1" range "1" range switch B54 1 Select lever in any other than "1" range Brake pedal depressed Brake switch AT Oil temp warning light B55 24 Brake pedal released Light On B54 3 Light Off © 2003 ATRA. All Rights Reserved .240 NISSAN Subaru Subaru TCU Pin Charts Check with Ignition ON.

5 More than 4 More than 4 8 0.0 — 2.9 0 450—650 More than 1 (AC range) 0 450—650 More than 1 (AC range) 0 450—650 275—375 4.4—0.3 1.82—5.1k—2.6 — — — — 8—11 Less than 1 — More than 1 (AC range) Less than 1< More than More than 10.2—4. Content Connector Terminal No.NISSAN 241 Subaru Subaru TCU Pin Charts Check with Ignition ON.2—1. Measuring conditions Throttle fully closed Throttle position sensor Throttle position sensor power supply ATR Temperature sensor B55 2 Throttle fully opened B55 1 Ignition switch ON (with engine OFF) ATF Temperature 68°F (20°C) B55 11 ATF Temperature 176°F (80°C) Vehicle stopped Rear vehicle speed sensor B55 3 Vehicle speed at least 12MPH (20km/h ) Vehicle stopped Front vehicle speed sensor B55 5 Vehicle speed at least 12MPH (20km/h ) Engine idling after warmup (D range) B55 12 Engine idling after warmup (N range) B55 13 Vehicle speed at most 6MPH (10km/h ) Ignition switch ON (with engine OFF) Engine speed signal B55 4 Ignition switch ON (with engine ON) When cruise control is set (Set lamp ON) Cruise set signal B54 11 When cruise control is not set (Set lamp OFF Torque control signal 1 Torque control signal 2 Torque control cut signal Intake manifold pressure signal. All Rights Reserved .0 — Resistance to body (ohms) Torque converter turbine speed sensor Vehicle speed output signal © 2003 ATRA..9k Voltage (V) 0.4—1.5 — — 0. B54 B54 B54 B54 13 21 2 20 Ignition switch ON (with engine ON) Ignition switch ON (with engine ON) Ignition switch ON Engine idling after warmup More than 6.6—2.7 4.

242 NISSAN Subaru Subaru TCU Pin Charts Check with Ignition ON.5 More than 8.0—4. All Rights Reserved .0—4.5 Less than 0.5 2. Terminal No.5—5.1 6—16 — More than 9 Less than 1 10—16 Less than 0.0 2.0—4.5 More than 8.5 Less than 1 More than 9 10—16 Content Connector Measuring conditions Voltage (V) 1st to 4th gear Shift solenoid 1 B54 7 More than 9 1.0 2.5 © 2003 ATRA.5 Less than 1 10—16 Less than 0.5 — More than 9.5—4.5 10—17 Less than 0.5 10—17 Lelss than 1 1.5 Less than 1 More than 8. Resistance to body (ohms) 10—16 2nd to 3rd gear 1st to 2nd gear Shift solenoid 2 B54 6 3rd to 4th gear Ignition switch ON (with engine OFF) Throttle fully closed after warn-up Line pressure duty solenoid B54 9 gnition switch ON (with engine OFF) Throttle fully opened after warn-up When lock-up occure Lock-up duty solenoid B54 16 When lock-up is released Fuse on FWD switch Transfer duty solneoid B54 15 Fuse removed from FWD switch (with throttle fully open and with selector lever in 1st gear) Throttle fully closed (with engine OFF) after warming up 2-4 brake duty solenoid B54 8 Throttle fully open (with engine OFF) after warming up 1st gear 2-4 brake timing solenoid B54 5 3rd gear 2nd gear Low clutch solenoid B54 14 4th gear Fuse removed FWD switch B55 14 Fuse installed Throttle fully closed (with engine OFF) after warming up 2-4 brake dropping resistor B54 17 Throttle fully open (with engine OFF) after warming up Less than 0.

5 2.5—15 0 0 — — Less than 1 Less than 0.5 Less than 1 — More than 9 Less than 1 — Voltage (V) Resistance to body (ohms) More than 8. Content Connector Terminal No.NISSAN 243 Subaru Subaru TCU Pin Charts Check with Ignition ON. Measuring conditions Throttle fully closed (with engine OFF) after warming up Line pressure dropping resistor B54 18 Throttle fully open (with engine OFF) after warming up Fused ON FWD switch FWD indicator light B54 12 Fuse removed from FWD switch ABS switch ON ABS signal Sensor ground line 1 Sensor ground line 2 System ground line B55 AT diagnosis signal Data link signal (Subaru Select Monitor) B54 B55 9 4 7 Ignition switch ON — Less than 1< >More than 4 — B54 B55 B55 B55 19 ABS switch OFF 10 21 19 — 0 Less than 1 — — — — 6. All Rights Reserved .5 © 2003 ATRA.0—4.

244 NISSAN © 2003 ATRA. All Rights Reserved .

........ 248 © 2003 ATRA. 246 Hard or Slow Engagement Forward and / or Reverse ..VOLVO 245 VOLVO Table Of Contents AW50-42LE Cracked Input Drum ..... All Rights Reserved .

The weld area for the new drum from Daewoo has a stepped area for durability. Volvo Daewoo © 2003 ATRA. the only option has been to buy a good used one. All Rights Reserved .246 VOLVO AW50-42LE Cracked Input Drum A common failure on these units is a cracked input drum. The Difference between the Daewoo drum and the Volvo drum is in the weld area. This part is not serviced separately. Besides buying a complete unit from Volvo.

We cut a forward piston and found over .065” this will allow you to use the old piston assembly with the new drum.065". The other option is to buy the matching forward piston (part no. Internal transmission parts for the Leganza are available. This relief allows for the additional support flange of the input drum. 3560650A011) from Daewoo for about $130. In order to use this input drum. The Daewoo part number for the input drum is 3570150A021.00 for both parts. All Rights Reserved . 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.825”Diameter 0.VOLVO 247 AW50-42LE Cracked Input Drum The Daewoo Leganza also uses a similar FWD AW transmission. 2. Make sure these areas are cut to .065” Depth Volvo Rear of Original C1 Clutch © 2003 ATRA. the forward piston has to be relief cut .00. 3560250A010) and direct piston (part No. The discount price from a local dealer is about $350.090" of material still left in the piston wall.

To check the C1 and C2 clutches. Both these clutches are enclosed in the input shaft and drum. Move gear selector to “N”. Move gear selector to “D”. The C1 clutch pressure should be 57 psi and the C2 clutch pressure stay at zero. attach two pressure gauges to the transmission as shown.248 VOLVO AW50-42LE Hard or Slow Engagemnet Forward and/or Reverse This maybe caused by worn seal rings in the rear cover. © 2003 ATRA. All Rights Reserved . Wait three seconds and check the pressures again. The C2 clutch is one of the reverse elements. The C1 clutch is one of the forward elements. These rings control the oil to the C1 and C2 clutches.

VOLVO 249 AW50-42LE Hard or Slow Engagemnet Forward and/or Reverse Move the gear selector to “N”. the seal rings or ring support are worn. If the clutch pressures do not work right. All Rights Reserved . Wait three seconds and move gear selector to “R”. Wait three seconds and check the pressures again.00. The rear cover can be replaced with the transmission on the car. Move gear selector to “N”. four seals and eight mounting bolts. The kit part No. is 9463445 and cost about $180. This kit includes a rear cover. three Teflon rings. an O-ring. A new rear transmission cover with a steel ring support is available from Volvo.5 hours to R & R the cover. a steel washer. © 2003 ATRA. The C2 pressure gauge should read 85 psi and the C1 pressure stay at zero. Volvo allows their technicians 2.

250 VOLVO © 2003 ATRA. All Rights Reserved .

All Rights Reserved .VOLKSWAGEN 251 © 2003 ATRA.

...... 263 B1 Clutch . 278 Neutral or Flare on Take Off .......... 258 Pressure and Fluid Specification....... 265 Valve Body Identification .............. 279 Momentary 3-4 Bind or Flare .............. 268 Adjusting the Manual Valve ............ 266 01M/096 Check Ball Locations ....... 1-2 or 3-4........... 255 Clutch Apply Chart .................... 264 B2 Clutch .... 254 Model and TCM Application ... 257 Servicing ................ 277 Kills The Engine in Gear Code P1582 ............................ 3-4 .............................................. 282 No Forward Except Manual Low 283 © 2003 ATRA..................................................... 260 Rebuilding Tips ................. All Rights Reserved ........................................ 262 Stator Support Thrust Washer ................................ 273 VAG Code Definitions ....... 261 Pump Warpage .. 272 Scanning for Codes ................ 281 Shuttle Shift 1-2..252 VOLKSWAGEN Volkswagen Contents 096/01M Transaxle Identification ............. 259 Pressure Response Charts ................................. 275 Generic Codes ............... 280 Hard or Slide Bump on the 1-2 Shift ............. 271 Specifications .................................

All Rights Reserved .VOLKSWAGEN 253 © 2003 ATRA.

Gear Ratios 096 2.70 4. The Identification tags can be found on the side of the transaxle or underneath the filter.8L (CFF) 4.70 3.0L (CLK.0L (CNK) 2. As early as 1994. the O1M transaxle was installed.22 3.53 4. This transaxle used a different shift strategy and TCC was PWM controlled. DYK) 2.254 VOLKSWAGEN 096/01M Transaxle Identification In 1993.8L (CKX) 2.8L (CCB. The chart below will help you identify the gear ratio of the unit you’re working on.27 01M 1. All Rights Reserved . ECN) © 2003 ATRA. VW vehicles used an 096 Phase 2 transaxle. ECM) Diesel (CK2.22 3. DCE.

VOLKSWAGEN 255 Model and TCM Applications The TCM application is based on the PCM. 6-cylinder engine codes are located at the front of the block © 2003 ATRA. All Rights Reserved . 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.

8L ABA AAA ABA AAA ABA AAA 096 096 096 096 096 096 927 927 927 927 927 927 731A 731C 731BH 731CE 731AT 731BA 733 733 733 733 733 733 733 733 733 733 733 733 733 733 733 733 733 733 733 733 EB EA FJ CB CA CB BJ EB EA or CA FJ CB CA CB BJ CA CA CA CA CA CA (ABA) USA Calif 2.0L 2.TCM Part No.8L (Trans.0L (ABA) USA Calif 2.0L 2.0L 2. F1H-T-XXX XXX) 2.0L 2.0L 2.8L (ABA) (AAA) (ABU) (ALH) (ABG) (APP) (AWD) (AWM) (AVH-ABG) 97-98 99 © 2003 ATRA..8L 2. No.8L (ABA) (AAA) (AHU) 01M 927 01M 927 01M 927 01M 927 01M 927 01M 927 01M 927 01M 927 01M 927 01M 927 01M 927 01M 927 01M 927 01M 927 01M 01M 01M 01M 01M 01M 927 927 927 927 927 927 97-99 Jetta 95-96 2.256 VOLKSWAGEN Model and TCM Applications Engine Code ……………………………. All Rights Reserved . No. F1B-S-XXX XXX) (Trans. Golf 1993 1994 1995 95-96 2.8L (AAA) From 1H-S-072 799 From 1H-T-000 001 2.8L 2.0L 2.

Rev. Input and 3rd Clutch (01M) K3 = 3/4 (096). 4th Clutch (01M) B1 = Man. K1 = Fwd Clutch K2 = Rev. the elements in use is different. Brake B2 = 2nd/4th Brake F1 = Low Roller 096 Phase 2 01M Transmission © 2003 ATRA. Note the difference between the 2-3 and 3-4 shifts between the 096 phase 2 and the 01M.VOLKSWAGEN 257 Clutch Apply Chart Even through the 096 and 01M use the same clutch layout. Low and Rev. All Rights Reserved . Input (096).

Step 4) Remove the inspection plug. A standpipe is located in the oil pan.258 VOLKSWAGEN Servicing There is no dipstick on the Phase 2 096 and 01M transaxles.) Allow transmission oil to run out of the stand pipe.00) Or in a service kit 01M 398 998 The service capacity is about 3 qts (an overhaul takes about 6 qts. The following steps must be followed for the level to be correct. © 2003 ATRA. remove RED fill cap and add oil. Step 3) Run the gear selector through all ranges ending in Park. Step 5b) If needed. If the oil is too high. The oil level is correct when the level of oil in the pan is even with the top of the standpipe. All Rights Reserved . Step 1) Make sure the vehicle is level. Step 5a) Allow excess oil to run out and replace inspection plug. Step 2) Start the engine and warm it up to about 85-95 degrees F. the excess oil will spill out when the inspection plug is removed. Order the replacement RED cap under VW 014 301 485 (cost $2.

D R Idle 49-55 94-109 2000 RPM W/ Wiring Disconnected 146 164 334-348 © 2003 ATRA.5L) G 052 162 A2 (1.0L) Use a 0-400 psi pressure gauge.VOLKSWAGEN 259 Pressure and Fluid Specifications The 096 uses Dextron….00/liter VW Synthetic 75 W90 gear oil G 052 145 AI (. All Rights Reserved .5L) G 052 162 A2 (1.01M requires VW synthetic ATF VW Synthetic ATF G 052 162 A1 (..0L) about $15.

and then return to line pressure. There is one valve for each of the following clutches: B2. In Reverse.260 VOLKSWAGEN Pressure Response Charts These charts display the change in line pressure in response to TPS and vehicle speed. All three orifice control valves operate during all forward shifts. Note the drop in pressure during the shift. The pressure can drop down as low as 60-75 lbs. K1 and K2. Each valve bleeds clutch apply oil back to the pan. the number 5 solenoid works to cushion the B1 clutch and the K2 orifice control valve cushions the K2 clutch. the number 5 solenoid is cycled. © 2003 ATRA. This solenoid hydraulically operates three orifice control valves. This is normal. During engagements and each shift. All Rights Reserved .

NOTE: Replace all moulded pistons during overhaul.VOLKSWAGEN 261 01M / 096 Rebuilding Tips This unit can be a money maker. If it’s worn out or can’t be fixed. This still leaves at least a $3. The aftermarket has or will soon release replacement parts for the valve body. The owners like driving their VWs.00 at the dealer or get a guarranted valve body from a supplier. Service parts. converter and don’t forget $100. Most of the units don’t require any more than a master kit. a couple of solenoids. In some areas. the only options would be to spend $500.000 for an exchange unit plus any computer and/or electrical repairs the car may need.00 in VW ATF (if it’s an 01M). information and scan tools are now readily available. The dealers charge $4. and these cars hold their resale value. The most common hard part damage seems to be the K3 clutch. All Rights Reserved . the pump and occasionally the planets. the closest dealer maybe 100+ miles away. this unit is very easy to build.000-5. © 2003 ATRA. a new wire harness. The only red herring left is the valve body. filter. The truth is.000 margin.

Check for leaks between the pump and stator support K1 K2 K3 © 2003 ATRA. All Rights Reserved . This checks for leaks in the oil pump assembly.262 VOLKSWAGEN 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.

VOLKSWAGEN 263 01M / 096 Rebuilding Tips Stator Support Thrust Washer Always replace the Stator Support thrust washer during the rebuild. Failing to replace this washer may lead to premature failure of the washer after overhaul and major damage to the transmission. Thrust Washer Stator and Ring Support The VW part number is 095-321-285 © 2003 ATRA. This washer retains a major amount of heat and becomes very brittle. All Rights Reserved .

If the wave spring is installed incorrectly a clutch failure or harsh/soft engagements may be felt. Always be aware of the location of the wave spring. All Rights Reserved .264 VOLKSWAGEN 01M / 096 Rebuilding Tips B1 clutch During the assembly of the B1 clutch make sure to install the diaphragm spring with the cone up. Wave Spring Location © 2003 ATRA.

VOLKSWAGEN 265 01M / 096 Rebuilding Tips B2 clutch During the assembly of the B2 clutch make sure the wave plate is installed against the B2 piston. All Rights Reserved . Make sure the wave plate sits under the thick pressure plate © 2003 ATRA.

All Rights Reserved .266 VOLKSWAGEN 01M / 096 Rebuilding Tips Solenoid Description (NXX shown on scanner) #1 #2 #3 #4 #5 #6 #7 #7 N88 N89 N90 N91 N92 N93 N94 N94 = = = = = = = = K1/B1 Shift Solenoid (EV1) B2 Shift Solenoid (EV2) K3 Shift Solenoid (EV3) TCC Solenoid (EV4) (Non-PWM on 096 / PWM on 01M) Shift Apply Feel Solenoid (EV5) EPC Solenoid (EV6) 3rd and 4th Control Solenoid (EV7) (O96) 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 © 2003 ATRA.

All Rights Reserved .VOLKSWAGEN 267 01M / 096 Rebuilding Tips 01M Valve Body Exploded View 7 6 Q P A 4 3 5 1 2 C D E F G B O N M* L K H I J 096 Valve First 01M Spring First * M .Not Shown © 2003 ATRA.

268 VOLKSWAGEN 01M / 096 Rebuilding Tips 01M Check Ball Locations K2 Checkball Low & Reverse Checkball B1 Orifice Checkball Orifice K1 Checkball © 2003 ATRA. All Rights Reserved B2 Exhaust Checkball .

All Rights Reserved .VOLKSWAGEN 269 01M / 096 Rebuilding Tips Check Ball Locations 2-3 Regulator & 3-4 Regulator relief checkball and spring © 2003 ATRA.

locate the check ball area if a check ball was in the valve body it will surly leave a mark on the separator plate. All Rights Reserved .270 VOLKSWAGEN 01M / 096 Rebuilding Tips 01M Check Ball Locations Another way to identify the checkball location is to locate the “Dimples” in the separator plate. © 2003 ATRA. However not all separator plates will have these dimples.

Loosen the Torx screw 3. suspect a misadjusted manual valve. Select the Park position 2. All Rights Reserved . Tighten Torx screw Manual Valve Lever Torx Screw Manual Valve © 2003 ATRA. Bottom out the Manual Valve in the Valvebody 4. but correct in Manual 3.VOLKSWAGEN 271 01M / 096 Rebuilding Tips Adjusting the Manual Valve If the line pressure in D is low. To Adjust the manual valve properly you must first: 1.

184 ft.. lbs.075" .047" .060"-. . 44 Inch lbs. 70 Inch lbs.047" 5 Clutches 5 or 6 5 Plates 5 Plates . cover bolt Input shaft / Planet bolt Manual valve lever screw Oil pan bolt Oil pump bolt Transfer gear cover bolt Transfer / Pinion shaft seal retainer Valve body bolt ¹ personnel observations 184 ft. lbs. 150 ft. 108 Inch lbs. 22 ft. lbs.014" .040" .070"-. 35 Inch lbs. 84 Inch lbs.076" . All Rights Reserved .023"-.019"-.080" . lbs. 009"-. + ¼ Turn 70 Inch lbs.070"-.010".272 VOLKSWAGEN 01M / 096 Rebuilding Tips Rebuild Specifications Clutch Clearances B1 B2 K1¹ K2¹ K3 Endplay Planet geartrain / carrier K2 to K1 Input shaft Torque Specifications Drive gear hex head nut Driven gear nut Diff.012" / friction © 2003 ATRA.

when the battery is disconnected. All Rights Reserved .VOLKSWAGEN 273 Electronic Diagnosis Scanning for Codes and Data In order to scan the TCU. Their software is downloaded into your PC or laptop. Why buy a specialized scanner? My current scanner can access the TCU under Generic.500.00-2.00. you can pinpoint the problem. AST. With a scanner. offer similar software or stand alone scanners from $650. These cars are known to have lots of connector and wiring problems. Using your current scanner under Generic mode will clear codes and retrieve select codes. Depending on your current shop equipment. you must have a VAG1551/2 or VAG compatible scanner. A VAG type scanner will retrieve all codes. Also. Or you could take the car to a dealer (if they are local) to get codes and scan data. you can get one from Ross-Tech for $250. © 2003 ATRA. display the data stream and reset the TCU base values.00. BAUM and others. VAG stands for Volkswagen Audi Group. these cars may stay in limp until the TCU is reset or all codes are cleared.

274 VOLKSWAGEN Electronic Diagnosis Scanning for Codes and Data 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. All Rights Reserved . (continued) © 2003 ATRA.

2 Open Or Short to Ground Or Faulty Solenoid No. 4 Open Or Short to Ground Or Faulty Solenoid No. 6 Open Or Short to Ground Or Faulty Solenoid No. 5 Open Or Short to Ground Or Faulty Solenoid No. 3 Open Or Short to Ground Or Faulty Solenoid No. 7 Open In Wiring. Faulty Vehicle Speed Sensor (VSS) Or Impulse Wheel Loose Open In Wiring Or Faulty Transmission Range (TR) Switch Open In Wiring Or Faulty Transmission VSS Open In Wiring Or Faulty Transmission Temperature Sensor Open Or Short In Wiring Or Faulty Throttle Position Sensor 1. 1 Open Or Short to Ground Or Faulty Solenoid No. All Rights Reserved .VOLKSWAGEN 275 Electronic Diagnosis Scanning for Codes and Data VAG Code Definitions VAG DTC 00258 00260 00262 00264 00266 00268 00270 00281 00293 00297 00300 00518 00529 00532 00545 Description Open Or Short to Ground Or Faulty Solenoid No.2 Open In Wiring. Engine Speed Information Missing Battery Faulty Or Poor Voltage Supply To Solenoid Valves Open Or Short To Ground (No Communication Between ECM & TCM) (continued) © 2003 ATRA.

All Rights Reserved . TCM checks signal from TP sensor only.On 6-cylinder or diesel engine models. wire to TCM from TP sensor for signal is also checked. TP signal is sent through ECM to TCM 2 . retrieve ECM DTC and repair first. On Vehicles without CAN-Bus system. © 2003 ATRA. If DTC is retrieved from TCM or TP sensor.On vehicles with CAN-Bus system. not TP sensor operation.276 VOLKSWAGEN Electronic Diagnosis Scanning for Codes and Data VAG Code Definitions 00596 00638 00641 00652 00660 65535 Short In Wiring Between Solenoid Valves Open Or Short To Ground (No Communication Between ECM & TCM) ATF Temperature Too High Or Faulty ATF Temperature Sensor Gear Ratio Error/Hydraulic Malfunction (Clutch Or Valve Body Faulty) Open Wiring Or Incorrect Signal From TP Sensor (Faulty TP Sensor) Faulty TCM (continued) 1 .

Some codes are not available under generic mode. Only a VAG type scan tool can display this code. (continued) Generic DTC Interchange Generic P0120 P0501 P0715 P0722 P0725 P0748 P0753 P0758 P0763 P0768 P0773 P1778 VAG DTC 16505 (00518) 16885 (00281) 17099 (NA) 17106 (00297) 17109 (00529) 17132 (00268) 17137 (00258) 17142 (00260) 17147 (00262) 17152 (00264) 17157 (00266) 18186 (00270) Definition TPS VSS TSS OSS RPM EPC Solenoid 1 Solenoid 2 Solenoid 3 Solenoid 4 Solenoid 5 Solenoid 7 © 2003 ATRA. All Rights Reserved . Example: A very common code is 00652 for gear ratio or gear slip code.VOLKSWAGEN 277 Electronic Diagnosis Scanning for Codes and Data Generic Codes Use this chart to convert generic codes to VAG codes.

278 VOLKSWAGEN 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. All Rights Reserved . a short circuit or bad TCU may also cause the TCC to kill the engine in gear. TCC Solenoid and Valve Assembly #4 © 2003 ATRA.

#6 EPC Solenoid © 2003 ATRA.VOLKSWAGEN 279 01M / 096 Neutral or Flare on Take Off This is usually caused by no line rise. If the TCU works correctly. Using a VAG scanner. scan the PCM and TCM to locate the electrical problem. replace or clean the# 6 EPC solenoid. If not. check TPS. All Rights Reserved . make sure the computer commands lower amperage during acceleration.

Make sure solenoid #1 and solenoid #7 are not plugged. the B2 or K3 clutch circuits are coming on too slow. #7 #3 #1 #2 K1 Orifice B2 Shift Valve © 2003 ATRA. If 2nd gear works good. If a flare occurs. check solenoid #3 and make sure it’s not plugged. All Rights Reserved . If 2nd gear is also soft. 3-4 shift control and K1 orifice control valves can stroke freely in their bores . Check the K1 shift valve.280 VOLKSWAGEN 01M / 096 Momentary 3-4 Bind or Flare If a momentary bind occurs. Make sure the K3 shift valve strokes freely in it’s bore. install a 20-30% stronger B2 orifice control spring. the K1 clutch may not be exhausting fast enough. If the K3 shift valve stokes freely and you still have this problem try installing a lighter shift valve spring.

All Rights Reserved . If this is the only complaint and line rise looks good. Some builders make a habit of turning this cap ½ in during overhaul. The driver may have “lived” with this problem for a long time. turn the boost control valve end cap one turn in.VOLKSWAGEN 281 01M / 096 Hard or Slide Bump 1-2 This is a common complaint after overhaul. Turn Boost Sleeve in One Turn Clockwise © 2003 ATRA. It’s usually caused by low line rise or general wear in the valve body.

If the two speed sensors are installed correctly. check the valve body for stuck valves or solenoid malfunctions. then bangs after you start rolling. OSS = Yellow and White Wires TSS = Green and Red Wires © 2003 ATRA. 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. The wiring for the speed sensors are easy to cross up. All Rights Reserved .282 VOLKSWAGEN 01M / 096 Shuttle Shifts 1-2-1-2 or 3-4-3-4 Feels like high gear starts. This is usually an installer created problem.

#1 K1/B1 Solenoid K1 Shift Valve © 2003 ATRA.VOLKSWAGEN 283 01M / 096 No Forward Except Manual Low This condition is caused by the K1 clutch not holding. All Rights Reserved . Pull the valve body and air check the K1 clutch. look for a stuck K1 shift valve or plugged #1 solenoid. If it air checks.

All Rights Reserved .284 VOLKSWAGEN © 2003 ATRA.

................................. 290 Electrical Power ............... 292 Glossary of Electrical Terms .................................................................................. 289 Ohm’s Law...............2003 TECHNICAL SEMINAR 285 Reference Contents Conversion Tables .................................................................................................. All Rights Reserved........... 299 © 2003 ATRA................................................................................ 291 Multiple Resistors in a Parallel Circuit .................................................................................................................................... 294 Abbreviations............................................. 291 Two Resistors in a Parallel Circuit ... 291 Resistors in a Series Circuit ............................................................................................................................................................................................................................. ......................................................... 291 Schematic Symbols ......................... 291 Multiple Capacitors in a Series Circuit ......................................................................................................................... 286 Resistor Values ................... 290 Electrical Formulas ....................................... 291 Two Capacitors in a Series Circuit .......... 298 Numeric Equivalents .................................................... 291 Capacitors in a Parallel Circuit ........................................................................................................

0929 144.4 2.0294 To Obtain kg/cm² bar kPa PSI PSI PSI mbar Hg PSI PSI PSI kPa bar kg/cm² Hg mbar Temperature (F° – 32) x 5 (C° x 9 9 = C° 5) + 32 = F° Continued… © 2003 ATRA.155 0. All Rights Reserved.0069 0.2233 34.54 0.14503 14.8948 0.0136 0.503 14.2808 1. .14 r = Radius h = Height Pressure Multiply By 0.3048 5280.0703 0.452 0.00155 To Obtain mm² cm² Ft² m² In² Ft² In² In² Distance Multiply in in mm cm ft ft meter mile km By 25.0394 0.6214 To Obtain mm cm in in meter miles ft km mile area of a circle = r² area of a cylinder = r²h = 3.0 3.2 6.286 2003 TECHNICAL SEMINAR Conversion Tables Area Multiply In² In² In² Ft² Ft² m² cm² mm² By 645.6093 0.764 0.0689 6.0 10.3937 0.

. (in3) Liters Cubic cm (cm3) Cubic mm (mm3) By 0.03527 28.3558 0.01639 16. (in3) © 2003 ATRA.152 12.138 0. (in3) Cubic in.06103 To Obtain Liters Cubic cm (cm 3) Cubic mm (mm3) Cubic in.4732 0. (in3) Volume (Liquid Measure) Multiply Quarts Pints Ounces LIters LIters Liters By 0.94633 0.0833 0.20462 0.4536 2000.0 907.02957 1.2003 TECHNICAL SEMINAR 287 Conversion Tables (continued) Torque Multiply in-lbs in-lbs in-lbs ft-lbs ft-lbs ft-lbs Nm Nm kg-cm kg-m By 0.3495 0.81497 To Obtain Liters Liters Liters Quarts Pints Ounces 0.233 To Obtain ft-lbs Nm kg-cm in-lbs Nm kg-m ft-lbs in-lbs in-lbs ft-lbs Multiply Grams Ounces Ounces Pounds Pounds Pounds Tons Tons Kilograms Kilograms Weight By 0.05672 2.0005 0.8679 7.11344 33. (in3) Cubic in. (in3) Cubic in.8507 0.0 0.001102 To Obtain Ounces Grams Pounds Ounces Tons Kilograms Pounds Kilograms Pounds Tons Volume (Cubic Measure) Multiply Cubic in.000061 Cubic in.0 1.387 16387.18 2. All Rights Reserved.113 1.73756 8.0 61.0625 16.025 0.

0 13.0 6.00 6.5 36.5 63.5 72.5 2.0 4.8 2.7 0.75 31.1 1. © 2003 ATRA.5 9.5 0.5 81.25 18.25 27.0 60 57 54 51 48 45 42 39 36 33 30 27 24 21 18 15 12 9 6 3 0 45.0 31.75 22.50 2.00 15.4 7.5 45.00 24.1 8.0 49.4 0.0 76.0 22.0 0 5 90.25 36.9 11.5 27. .25 9.6 4.6 11.75 13.2 3.3 5.50 29. All Rights Reserved.0 67.00 33.75 4.0 13.8 54.0 40.5 9. Variations from this level will affect all of the voltage readings.8 9.75 40.7 7.5 18.00 42.3 12.50 11.0 85.9 4.50 20.2 10.25 0.0 58.288 2003 TECHNICAL SEMINAR Conversion Tables (continued) Duty Cycle/Dwell/Voltage Duty Cycle (%) Feed Controlled Degrees Dwell Voltage* 14.00 Ground Controlled 4-Cyl Scale 6-Cyl Scale 8-Cyl Scale 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 * The voltage values are based on a 14-volt system voltage.50 38.

Resistance Values Color Black Brown Red Orange Yellow Green Blue Violet Gray 1st Band 0 1 2 3 4 5 6 7 8 9 — — — 2nd Band 0 1 2 3 4 5 6 7 8 9 — — — 3rd Band 0 1 2 3 4 5 6 7 8 — — — — 4th Band — — — — — — — — — — 1% 5% 10% Brown 1% White Brown Gold Silver Plain So if the bands are: Blue 6 Red 2 Green 5 Violet 7 Yellow 0. ±20% © 2003 ATRA.000 Silver ±10% Gold ±5% Plain ±20% = = = White Orange 9 3 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 54321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 4321 — — — 20% The resistor value is: 650 kΩ. ±10% 270 Ω. ±5% 930 MΩ.2003 TECHNICAL SEMINAR 289 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. . All Rights Reserved. The fourth band indicates the tolerance.000 Brown 0 Violet 0.000. The third band indicates the number of zeros to add.

whenever you have two measurements. you can easily calculate the third: Volts ÷ Amps = Ohms Volts ÷ Ohms = Amps Amps x Ohms = Volts Electrical Power WATTS VOLTS AMPS A measurement of power developed in an electrical circuit. All Rights Reserved. you can calculate the third. as long as you have any two circuit values. Just like with Ohm’s Law. .290 2003 TECHNICAL SEMINAR Ohm’s Law VOLTS AMPS OHMS With Ohm’s Law. Watts ÷ Volts = Amps Watts ÷ Amps = Volts Volts x Amps = Watts © 2003 ATRA.

. All Rights Reserved.2003 TECHNICAL SEMINAR 291 Electrical Formulas Resistors in a Series Circuit RTOTAL = R1 + R2 + R3 … Two Resistors in a Parallel Circuit RTOTAL = R1 x R 2 R1 + R2 Multiple Resistors in a Parallel Circuit RTOTAL = 1 R1 + 1 1 R2 + 1 R3 … Two Capacitors in a Series Circuit CTOTAL = C1 x C 2 C1 + C2 Multiple Capacitors in a Series Circuit CTOTAL = 1 C1 + 1 1 C2 + 1 C3 … Capacitors in a Parallel Circuit CTOTAL = C1 + C2 + C3 … © 2003 ATRA.

292 2003 TECHNICAL SEMINAR Schematic Symbols + V + – Battery Power Ground Connected Wires Unconnected Wires + – Fuse Circuit Breaker Bulb Meter Pushbutton Switches On/Off Switches NC Switch NO Switch NC Switch NO Switch Transformer (Coil) © 2003 ATRA. All Rights Reserved. Relay .

2003 TECHNICAL SEMINAR 293 Schematic Symbols (continued) Fixed Resistor Variable Resistor Potentiometer Diode Zener Diode LED Photodiode + Fixed Capacitor Fixed Capacitor (Polarized) Variable Capacitor C E C B B B E C E NPN Transistor PNP Transistor Phototransistor Crystal © 2003 ATRA. All Rights Reserved. .

B+ — Battery power. A closed circuit allows current to flow from its source. These systems usually provide spark through a process known as “wastespark”. based on inputs from a series of sensors and switches. so the reading you see is the value taking place right now. instead of a digital output. through the resistances. Analog meters measure constantly. Electrical device that provides measurements of electrical circuits. the other receives spark on its exhaust stroke — that cylinder’s spark is “wasted. Continued… © 2003 ATRA. A diode is a semiconductor. DVOM. Amperage is actually a reading of how many electrons are moving through a circuit at any given moment. One amp is the amount of current that one volt will push through one ohm of resistance. A type of ignition that doesn’t use a distributor to provide spark to the cylinders. Distributorless Ignition System — Also Electronic Ignition. current is measured in amps. Duty Cycle — A signal that varies its relationship between on-time and off-time. duty cycle or on-time. De-energize — To turn off. Device that provides the commands necessary to operate the engine or transmission. Controller — See Computer. Duty cycle signals usually control a computer output device. Digital — On/off signal. . and the magnetic field collapses. Current — Electron flow through a circuit. One cylinder fires.” Ford uses this term to identify one of its electronic ignition system. or amps. and the reading only updates as quickly as the needle can move. Computer — Also controller. using a digital display. But analog meters tend to be less accurate than digital meters. Closed Circuit — A complete electrical path that provides the means for electricity to perform work. microprocessor. Amps — Unit of measurement for reading current flow. or which control a circuit by varying frequency. and back to its source. These devices are commonly used to control the spark that develops when an electromagnetic coil de-energizes. Amperage — Measurement of current flow in a circuit. Amperes. Digital meters and oscilloscopes read a circuit through sampling. the longer the solenoid remains open. such as an electronic pressure control solenoid: The longer the signal on-time. a process which provides spark to two cylinders at once. All Rights Reserved. designed to allow current flow in one direction. Displays measurement in amperes. Digital Volt-Ohmmeter. Diode — An electrical one-way shutoff valve. how accurate your measurement is depends on how many samples the meter takes per second. so the lower mainline pressure becomes. Digital Multimeter — Also DMM. Analog Meter — Measurement device that provides readings using a needle. Conventional Electrical Theory — Electrical circuit model which indicates that electrical flow is from positive to negative. or shut down a circuit or component. but not in the other direction. but most texts still prefer to use the conventional model. which provide information by varying frequency.294 2003 TECHNICAL SEMINAR Glossary of Electrical Terms Ammeter — Electrical test device that measures current flow in a circuit. Digital Volt-Ohmmeter — See Digital Multimeter. A series of pulses that are either on or off. More recent studies show that electrons actually flow from negative to positive.

That’s why it’s important to take precautions — wear a static strap. or cycles. An open circuit prevents current flow. the less effect it will have on the circuit. Grounded Circuit — An electrical circuit failure that keeps the circuit energized all the time. etc. Ohm — Unit of resistance measurement. the number of complete cycles that take place in one second. or the LED won’t light. then not be there the next. a low impedance meter would affect the characteristics of the circuit. Frequency — The number of complete oscillations. Hertz — Also Hz. Engine Control Module — Also ECM. regardless of switch or relay position. it won’t prevent the other legs Continued… © 2003 ATRA. It takes one volt to push one amp of current through one ohm resistance. Open Circuit — An incomplete electrical path that won’t provide the means for electricity to perform work. But. Ohm’s Law — Principle that defines the relationship between pressure (voltage). to show how voltage changes through the component’s operating cycle. If one leg of a parallel circuit opens. When used to test an electronic circuit. Microprocessor — See Computer. Energize — To turn on a circuit or component. flow (amperage) and resistance (ohms). TCM. Unit of measurement for frequency. Ohms x Amps = Volts. A signal that repeats itself 20 times every second has a frequency of 20 Hertz. that occur each second.2003 TECHNICAL SEMINAR 295 Glossary of Electrical Terms (cont) Electrostatic Discharge — Electrical potential that releases suddenly. much like a light bulb. to enable an electrical device to operate. the “shock” you feel when you touch a doorknob on a dry day is electrostatic discharge. Parallel Circuit — An electrical circuit designed with multiple paths through the circuit. High Impedance — Having high resistance to electrical flow. Light-Emitting Diode — Also LED. A semiconductor that lights when energized. Volts ¸ Ohms = Amps. Usually used to describe electrical meters. — when working with electronic devices. Ohmmeter — Electrical device for measuring resistance in a circuit or component. Computer. an LED requires very little current. so the less change it will make to the circuit operation when connected. so the circuit won’t operate. An oscilloscope displays the voltage signal as a picture. Ground — The return side of an electrical circuit. The higher the meter’s impedance. SAE J-1930 term for a device that controls only engine operation. provide with power and ground. Oscilloscope — An electrical test device that maps voltage changes in a circuit over a specific amount of time. . but it’s still the most common model for electrical circuits. All Rights Reserved. More recent studies show that electrons actually flow in the opposite direction of that shown by conventional theory. as defined by the conventional electrical theory. That “shock” can damage or destroy electronic components. Volts ÷ Amps = Ohms. Intermittent — Taking place in an irregular or unpredictable cycle. and that current flow must be in a specific direction. so that not all of the current must pass through all of the loads in the circuit. That’s why intermittent failures are often difficult to isolate. Also known as a short-to-ground. never touch the terminals. See also PCM. Measured in Hertz. An intermittent problem or failure may happen one moment. unlike a light bulb.

or if a clutch is slipping. Energizing a relay energizes an electromagnet. Sensor — A device that provides signals to the computer. . to communication information with other computers or scan tools. these circuits will often burn up. unless protected by a fuse or circuit breaker. A PCM may also control other systems. the longer the solenoid remains open. and control line pressure. so the lower mainline pressure becomes. The computer uses these signals to control engine operation more precisely. Solenoid — An electrical device that turns electrical signals into movement or work. Potentiometers receive a regulated voltage signal to one end of a resistor. Because of this lost resistance. and ground to the other. which opens or closes a set of contacts. Pulse Generator — An AC generator that develops a frequency signal that varies with the rotational speed of an internal transmission component. in such a way that forces all of the current passing through the circuit to travel through all of the loads. and picks up the voltage signal. control lockup. If one load in a series circuit opens. Shrink Tubing — An insulating material that shrinks to seal a connection when you apply heat. it will prevent the other loads from operating. but it must control engine and transmission to be called a PCM. Continued… © 2003 ATRA. based on engine or transmission operating conditions. such as throttle kickers. From this. to allow the transmission to shift gears. Pulse Width Modulated — Also PWM. the computer can determine when to shift. when a shift is complete.. Serial Data — A digital signal from the computer. Short Circuit — An electrical circuit without the resistance necessary to operate properly. Resistance — The ability of a circuit or device to reduce or limit current flow. TCM. Relay — An electrical device that allows a low current circuit to control a high current circuit. Series Circuit — An electrical circuit in which all of the loads are wired end to end. such as an electronic pressure control solenoid: The longer the signal on-time. Potentiometer — A three-wire sensor that modifies a voltage signal based on movement or position. etc. Scan tools can provide the actual sensor readings the computer sees. to provide power or ground to a circuit that would normally require too much current for the device controlling the circuit. See also ECM. antilock brakes. Pulse width modulated signals usually control a computer output device. a wiper slides along the resistor. Resistor — A device that limits or reduces current flow in a circuit. by interpreting serial data signals. A signal that varies its relationship between on-time and off-time. All Rights Reserved. SAE J1930 term for a computer that controls engine and transmission operation. The solenoids you’ll most likely be dealing with open and close to control hydraulic flow. The computer uses this signal to measure the component’s RPM. Powertrain Control Module — Also PCM. Solenoids can control lever movement. such as a sun shell. or can control vacuum or hydraulic flow. based on its position along the resistor. turbine shaft or output ring gear. Not to be confused with a grounded circuit. A/C system. and outputs from the computer. See Duty Cycle.296 2003 TECHNICAL SEMINAR Glossary of Electrical Terms (cont) from operating. including cruise control.

2003 TECHNICAL SEMINAR 297 Glossary of Electrical Terms (cont) Thermistor — A semiconductor that varies resistance based on temperature. One volt of pressure is necessary to push one amp of current through one ohm of resistance. . All Rights Reserved. © 2003 ATRA. The NTC thermistor is more common — as the temperature goes up. Thermistors are the most common type of variable resistor in today’s cars and trucks.” Transistors allow a low current circuit to control power or ground to a high current circuit. Sometimes called the circuit’s potential.or two-wire sensor that modifies a voltage signal based on stress or temperature. its resistance goes down. that pushes current through the circuit. Voltmeter — Electrical test device that measures the voltage potential in a circuit. Variable Resistor — A one. Transistor — A semiconductor that operates as an electronic “relay. Displays its reading in volts. Voltage — The pressure in an electrical system. There are two types of thermistor: negative temperature coefficient (NTC) and positive temperature coefficient (PTC).

000 Milli. work Watt Watt-hour © 2003 ATRA.298 2003 TECHNICAL SEMINAR Abbreviations Abbr. capacitor Collector electrode Centimeter Cubic Decibels Direct current Decimeter Double-pole. double-throw switch Single-pole. All Rights Reserved. single-throw switch Emitter electrode Voltage Microfarad Degrees Fahrenheit Frequency Fluid Frequency modulation Gram Ground Mercury Hertz Current Base current (DC) Collector current (DC) Emitter current (DC) x1000 Kilograms Kilohertz Abbr. mfd MHz mm NC Nm NO R SPDT SPST t T V. voltmeter Base supply voltage (DC) Base-to-collector voltage (DC) Base-to-emitter voltage (DC) Collector-to-base voltage (DC) Collector supply voltage (DC) Collector-to-emitter voltage (DC) Emitter-to-base voltage (DC) Emitter-to-collector voltage (DC) Emitter supply voltage (DC) Forward voltage (DC) Watt. v VBB VBC VBE VCB VCC VCE VEB VEC vee vF W w wh. double-throw switch Double-pole. e mf °F F. 0. f flu FM g gnd. kV kW kWH lb M m mf. whr Description Kilovolt Kilowatt Kilowatt hour Pound Mega. e E.001 Microfarad Megahertz Millimeter Normally closed Newton-meter Normally open Resistance. x1. single-throw switch Time Temperature Volt. A AC B. grd Hg Hz I IB IC IE k kg kHz Description Ammeter Alternating current Base electrode. . units with single base Degrees Celsius or centigrade Capacitance. c cm cu db DC dm DPDT DPST E. b °C C C. 1/1000.000. resistor Single-pole. one-one thousanth.

0520 0.2070 5.1913 1.75 8-32 NC 8-36 NF 8-40 NS /16-24 NC 4.1172 0.0810 0.0890 0.5781 2.1200 0.7112 0.0452 6.0960 0.1660 0.5334 0.7973 3.2380 0.1641 0.5720 4.3894 1.8890 0.9538 6.9837 1.1990 0.8542 1.1875 0.3208 1.2188 0.6416 2.1540 0.0370 0.0700 0.1610 0.5644 4.0595 0.0635 0.1797 0.1015 0.3086 5.0156 0.3053 4.4064 0.3749 2.5080 0.0420 0.1681 4.1.0785 0.7625 4.9906 1.2090 0.7556 5.9606 4.0.0310 0.7694 3.4892 2.1016 0.0135 0.0160 1.2197 5.0225 0.1981 0.0828 2.90 5mm .70 4mm .5687 3.5715 0.7940 2.9784 5.3569 5.0668 1.0160 0.0995 0.5575 5.9652 0.6604 0.1770 0.4572 0.0980 0.0469 0.0550 0.7874 0.50 1 11 /64 7 /128 23 /128 1-64 NC 1-72NF 1 /16 3 /16 9 /128 2-56 NC 2-64 NF 25 /128 5 /64 3.0386 4.2109 0.0894 4.0.1850 0.1094 0.0670 0.8382 0.2340 0.7925 0.3731 3.1405 0.0360 0.5113 1.1476 0.9149 4.8702 2.5944 0.0730 0.00 1 1 12-24 NC 5.6350 0.1440 0.0430 0.3825 2.2003 TECHNICAL SEMINAR 299 Numeric Equivalents Decimal Inches 0.1065 0.3970 1.1953 0.2280 0.2400 Fraction Inches Millimeters 2.9398 0.8194 Drill Size 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 Tap Size Decimal Inches 0.0938 0.1328 0.4544 Drill Size 33 32 31 30 Tap Size 6-40 NF 6-48 NS /128 /16 15 /128 /8 1 1 17 /128 3 /128 29 28 27 26 25 24 23 22 21 20 19 9 /64 1 /32 19 /128 5 /32 5 /128 21 /128 3 /64 0-80 NF 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 3-48 NC 3-56 NF 4-36 NS 4-40 NC 4-48 NF 1 /8-32 NC 3mm .5712 3.6228 4.80 18 17 16 15 14 13 12 11 10 9 8 7 6 6mm .2344 0.9304 1.1495 0.1563 0.0260 0.2926 4.7051 2.3942 4.0625 0.2266 0.0547 0.3429 0.0200 0.1910 0.1690 0.4036 3.1484 0.1844 2.0390 0.7500 3.00 5 4 3 2 1 A B 7mm .0350 0.2040 0.0280 0.75 10-24 NC 3 3 /16-32 NF 10-32 NF 5mm .1587 5.3663 4.0781 0.1890 0.1250 0.1100 0.0180 0.9436 5.2606 2.0.0145 0.0240 0.9878 4.0234 0.0250 0.1590 0.0.0935 0.7780 1.5806 2.7018 1.0400 0.1730 0.1695 0.1570 0.9464 2.6576 3.0922 1.1285 0. .0480 3.9144 0.1360 0.2050 0.0.0860 0.80 12-28 NF 12-32 NEF 14-20 NS 1 /4-20 NC 14-24 NS 11 /128 /32 13 /64 3 /4-24 NS /4-28 NF /4-32 NEF /4-40 NS 27 /128 /32 /128 /64 1 1 /8-40NF 5-40NC 7 13 /128 /64 29 5-44 NF 6-32 NC 6-36 NS 7 15 © 2003 ATRA.5273 2.1340 0.2130 0.1800 0.1130 0.9116 3.0960 4mm .1820 0.0330 0.7338 3.5mm .6096 0.8128 0.0.1816 5.7912 5.1040 0.0574 2.0210 0.0292 0.2164 4.3962 0.1750 3.2639 3.1520 0.0820 0.1935 0.1470 0.4102 5.0546 5.0760 0.0078 0.8514 4.1811 1.1406 0.1653 0.0320 0.1110 Fraction Inches 1 Millimeters 0.8608 3.2031 0.0.1.9700 3. All Rights Reserved.2000 4.3683 0.1650 0.4384 2.2010 0.6990 4.0380 0.2055 0.2210 0.1054 5.9769 3.5mm .7788 2.1960 0.9939 2.8006 4.0312 0.5875 1.0465 0.0410 0.7417 0.6129 1.1160 0.6134 5.0414 1.4958 4.1719 0.1910 4.

3431 7.9375 0.4375 0.5481 6.5590 0.1.3672 0.4453 Fraction Inches 31 Millimeters 6.4219 0.00 P 9mm .3750 0.7028 9.5000 0.0663 17.2875 14.8594 0.2422 0.3390 0.7344 0.6294 6.2734 0.3828 0.9062 0.9531 0.3480 0.6562 0.2720 0.7000 12.4063 0.1.1125 11.0838 10.6614 0.300 2003 TECHNICAL SEMINAR Numeric Equivalents (continued) Decimal Inches 0.25 T U V 11mm .4766 0.0932 9.5087 11.1.1.1468 6.5758 9.8966 10.7069 11.3984 0.7969 0.1.3270 0.00 /8-18NF /8-18NPT 16mm .1120 7.4531 0.8779 0.4000 10mm .2610 0.3200 10.8000 17.6675 16. .1.50 1 11 /64 /32 47 /64 3 /4 49 /64 25 /32 51 /64 13 /16 20.8000 15.5413 7.8437 0.3680 0.2800 0.8425 0.4688 0.2813 0.6934 10.7187 0.7656 0.3020 0.5312 0.8994 7.8750 16.50 14mm .1288 9.6837 14.2969 0.4902 10.1.9687 0.2460 0.1.2420 0.7462 6.1.6875 0.9075 12.2578 0.2950 0.3359 0.1356 8.8913 14.1.3770 0.00 9 /16-12 NC 14mm .4922 0.8906 0.6406 0.7564 6.5278 6.2770 0.2712 16.4290 0.3110 0.0.2.1.2500 0.8000 Drill Size 1 1 Tap Size /2-20 NF /2-24 NS /64 /128 /4 59 1 5 /16-18 NC /128 /32 61 /128 15 33 /128 /64 17 /64 63 /128 1 /2 33 17 31 14mm .3230 0.6708 7.2.5250 9.3430 0.9144 11.3160 0.4210 0.2.3660 7.2.0962 13.2660 0.1.3906 0.25 1 51 /128 /32 13 /16 /64 31 /32 63 /64 1 53 /128 /64 27 55 /128 /16 57 /128 7 /4-18NPT © 2003 ATRA.1920 12.6220 0.3438 0.1.7000 15.4609 0.0358 7.3269 9.4930 7.8044 9.3190 0.5039 0.3281 0.2000 14.6094 0.3594 0.3516 0.8900 8.5781 0.5181 10.9219 0.50 11 /16-11 NS 3 5 8mm .00 /64 47 /128 3 23 27 /16-14 NC /32 55 /64 7 /8 22.0962 13.3038 12.1026 8.1.75 Q R S 10mm .6250 0.3820 0.4844 0.25 9 /16-18 NF 5 /8-11 NC 16mm .1450 7.4141 0.3860 0.5938 0.1056 12.3970 0.9088 6.1374 7.00 35 /128 /64 /32 35 /64 /16 37 /64 19 9 K 5 9 37 /32 /128 /64 /16-32 NEF L M N 9mm .3500 6.4625 17.0825 15.3337 8.4788 15.5787 0.3320 0.8392 8.8750 0.7231 9.4130 0.75 12mm .6106 8.3125 0.3203 0.00 1-12 NF 3 /4-14 NPT 1-14 NS 49 /128 /64 /64 /32 59 /64 15 61 25 /16-20 NF X Y Z 12mm .7163 10.2900 0.5156 0.5625 0.50 W 7 3 19 /32 39 /64 /8 41 /64 21 /32 43 11 5 39 /128 /16 /128 /64 18mm .7008 0.2616 10.50 5 41 /64 /16 45 23 21 /8-24 NF 43 /128 /32 /8-27 NPT 10mm .5319 8.9844 1.1194 10.0000 Fraction Inches 29 Millimeters 11.50 11 /16-16 NS 3 /4-10 NC 18mm .7031 0.4328 8.7325 8.4297 0.3000 57 29 /8 1-8 NC 24mm .7500 0.2810 0.8281 0.1519 6.25 5 /16-24 NF 8mm .6719 0.3106 Drill Size C D E F G H I J Tap Size Decimal Inches 0.50 7 /8-18 NS 24mm .50 1 /2-13 NC 12mm .1.2656 0.5469 0.3047 0.0264 8.7394 7.4040 0.25 3 /8-16 NC O 9mm .9444 7. All Rights Reserved.2484 6.2.3500 0.3058 8.7122 8.7812 0.8000 13.3472 9.5019 12.2042 8.4800 0.8228 0.9375 8.3.8125 0.50 1 /2-14 NPT 3 7 /8-9 NC 45 /128 /64 21.9212 10.2570 0.0 7 7 /8-14 NF 22mm .9306 9.3580 0.2891 0.9000 53 /4-16NF 20mm .1.

2003 TECHNICAL SEMINAR 301 © 2003 ATRA. . All Rights Reserved.

All Rights Reserved.302 2003 TECHNICAL SEMINAR © 2003 ATRA. .

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