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C M Y CM MY CY CMY K
FOR THE TRANSMISSION REBUILDING INDUSTRY
TM
MAY/JUNE 2011
Hybrid Electrical Safety:
Because Your Life May Depend on It!
A Look at the New
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SPECIAL INTEREST & TECHNICAL
4 Hybrid Electrical Safety: Because Your Life May Depend on It!
by Carl Mustari
8 When Electricity Goes Bad by David Skora
14 Sticking Thermal Element Can
Cause Thermal Failure by Mike Souza
18 TRANSTAR, The Mission Possible Force
22 TECHNICALLY SPEAkING: Allison... is that you?
by Lance Wiggins
30 Don t Be Undone By Your To-Do List
by Thom Tschetter
34 A Look at the New MP Transfer Case by Steve Garrett
41 ATRA's Powertrain EXPO 2011, Las Vegas, NV
58 FROM THE TECH DIRECTOR: It s All About Communication
by Lance Wiggins
62 Sometimes a Rebuild Isnt the Only Answer by Steve Bodofsky
64 kEEP THOSE TRANNY S ROLLING: A Lincoln with an Attitude
by Pete Huscher
69 MEMBERSHIP MATTERS: You Made the Call and ATRA Answered
70 ATRA NEWS: Rapid Transmissions Gets Its Party On!
DEPARTMENTS
2 FROM THE CEO: Two Years Later…
A Recipe For Success
by Dennis Madden
72 Powertrain Industry News
77 Shoppers and Classified
84 List of Advertisers
The views expressed in this publication should not necessarily be interpreted
as the official policy of the Automatic Transmission Rebuilders Association (ATRA).
Publication of product information or any advertising does not imply recommenda-
tion by ATRA.
GEARS™ , a publication of ATRA, 2400 Latigo Avenue, Oxnard, CA 93030, is
published for the betterment of the transmission industry and is distributed nine
times per year. No part of this issue may be reproduced without prior written
permission of the publisher. GEARS is distributed to members of the transmis-
sion industry in the United States, Canada, ATRA Members in Mexico & Europe,
and related automotive industry firms and individually. Send changes of address
to GEARS in care of ATRA. Subscriptions are available by contacting GEARS in
care of ATRA.
Advertisers and advertising agencies assume full liability for all content of adver-
tisements printed and also assume full responsibility for any claims arising there-
from against the publisher. The publisher reserves the unqualified right to reject any
advertising copy as it deems appropriate, with or without cause.
GEARS is designed to provide accurate and authoritative information in regard
to the subject matter covered. It is distributed with the understanding the publisher
is not engaged in rendering legal, accounting or other professional service. If legal
advice or other expert assistance, is required, the services of a competent profes-
sional person should be sought— from a Declaration of Principles jointly adopted
by a Committee of the American Bar Association and Committee of Publishers.
GEARS also welcomes articles submitted by members of the industry. GEARS
considers all articles for publication that contribute positively to the welfare of the
transmission industry, and reserves the right to edit all articles it publishes. If you
would like to submit an article to GEARS, include background information about
the author and a telephone number where he/she may be reached. If you want
submissions returned, enclose a self-addressed, stamped envelope.
Chief Executive Officer Dennis Madden
Managing Editor Rodger Bland
Technical Director Lance Wiggins
Advertising Frank Pasley
Senior Designer Jeanette Troub
Contributing Editors: Steve Bodofsky
Carl Mustari David Skora
Thom Tschetter

ATRA Technical Staff: Bill Brayton
Mike Brown Steve Garrett
Pete Huscher Randall Schroeder
Mike Souza

Director of Membership & IT Svc Kelly Hilmer
Seminars & Convention Manager Vanessa Velasquez
Bookstore Manager Shaun Velasquez
Publications Mail Agreement No. 40031403
Return Undeliverable Canadian Addresses to:
Station A, PO Box 54, Windsor, ON N9A 6J5
Email: gears@atra.com
Issue #157 Printed in U.S.A. Copyright ATRA 2011
Editorial and Business Offices
2400 Latigo Avenue,
Oxnard CA 93030
Phone (805) 604-2000
Fax (805) 604-2006
www.gearsmagazine.com
www.atra.com
TABLE OF CONTENTS
FOR THE TRANSMISSION REBUILDING INDUSTRY
G
EARS
MAY/JUNE 2011
PHONE (805) 604-2000 FAX (805) 604-2006
Ads.FH10 Fri Apr 15 16:27:21 2011 Page 1
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C M Y CM MY CY CMY K
On the Cover: TRANSTAR
The Mission Possible Force
Be Sure to Read The
Feature story on page 18.
(Paid Advertisement)
Hybrid Electrical Safety: Because
Your Life May Depend on It!
Page 4
A Look at the New
MP Transfer Case
Page 34
Sticking Thermal Element
Can Cause Thermal Failure
Page 14
2 GEARS May/June 2011
T
wo years ago, in the April 2009
edition of GEARS Magazine,
we discussed the collapse of
the automotive retail industry and the
impact it would have on the trans-
mission repair business. Back then,
roughly 3000 dealerships across the
country were expected to close. And
once they had, we still couldn’t be sure
if the industry had hit rock bottom and
was on its way to recovery.
On top of that, people were genu-
inely panicked over the shape of the
economy and how it would impact
their lives and their businesses. People
weren’t buying new cars, but they
weren’t fixing their broken cars either;
we started to see a glut of broken cars
parked in people’s driveways.
As bad as things were, it seemed
pretty clear that, at some point, people
would be less apprehensive about hav-
ing their cars fixed, and we’d see a rush
of repairs headed to transmission shops
across the country.
And that’s exactly what happened.
Over the last year or two, people who
would otherwise have bought new cars
were spending their money to have their
cars fixed. This was a fantastic boost to
the auto repair business. But it came at
a cost: the apathy of thinking that things
were back to “normal”… that we could
return to business as usual.
It’s not. What you’re seeing, for
the most part, is a huge hump in the
cyclical nature of business. For the past
two years we’ve been enjoying the side
effects of the economic downturn, as
people were forced to cut back on luxu-
ries, such as new cars.
So, two years later we’re begin-
ning to see a recovery in new car sales.
According to Automotive News (www.
automotivenews.com), the 1
st
quarter
of 2011 saw an increase of 13.6% in
new car sales in North America as com-
pared to 2010. This followed a similar
increase over the previous year.
What does that mean to you? If
you haven’t been working on those
community marketing programs we’ve
talked about over the last few years, it’s
time to get started.
During the economic bust we
learned that business owners who reach
out to their community, in the form
of public service, press releases, car
care clinics (last month was National
Car Care month), and similar activi-
ties, were far more successful than
those who relied on traditional market-
ing strategies. It wasn’t complicated:
People were looking for a shop they
could trust.
Traditional marketing focuses on
sales; community-based marketing is
about people. It’s about you and who
you are. It gives potential customers
an opportunity to connect with you and
helps you develop a level of trust with
them.
So how can you take advantage of
community-based marketing? It’s actu-
ally not all that complicated. There are
no special tricks or secret handshakes.
The easiest way to begin is to put your-
self out there and get involved.
Start by joining your local chamber
of commerce or businesspersons asso-
ciation. And don’t just pay the dues:
Attend the meetings. Volunteer your
services. Whether it’s putting up holi-
day lights or serving pancakes at the
annual pancake breakfast, every person
you meet is one more contact for you…
and your business.
Right now shops are still busy, and
ATRA is working hard to keep them
busy. But it starts with you: the shop
owner. It’s about becoming involved
with your community and building on
a reputation of trust… becoming the
go-to guy (or gal) when the chips are
down. It’s about being their “friend in
the business” when they’re in need of
your services.
We’ve been working to improve
ATRA’s reputation and name recogni-
tion. That along with your effort to
build trust among the people in your
community is a recipe for success.
by xxx
members.atra.com
www.atra.com
Two Years Later…
A Recipe For Success
by Dennis Madden
members.atra.com
www.atra.com
FROM THE CEO
Two Years Later…
A Recipe For Success
4 GEARS May/June 2011
W
hen working on any hybrid
vehicle, safety is of utmost
importance. You need to be
aware of the high voltage and take the
necessary precautions.
Before attempting any major repair
work, make sure you’ve been trained in
electrical hybrid vehicle safety, whether
from a local college, tech school, deal-
ership, or I-car safety classes.
While working on these systems
you should always wear class-zero rub-
ber gloves rated to at least 1000 volts.
Inspect those gloves completely before
each use for any defects, such as small
holes or tears. You should also wear
leather gloves over the rubber gloves,
to protect the rubber gloves from punc-
tures (figure 1).
You’ll need to wear these gloves
until you’ve verified the hybrid system
voltage is low or completely disabled.
When not in use, it’s a good idea to
store the gloves in a canvas bag with a
ventilation hole in the bottom.
The American Society for Testing
and Materials has evolved into ASTM
International. Its standards and rat-
ings have been adopted for electrically
insulated gloves.
Vehicle manufacturers common-
ly recommend gloves with ASTM
International’s Class 0 rating for work
on hybrid vehicle high voltage cir-
cuits. This class 0 rating is the mini-
mum required protection (1000V) for
working on hybrids.
OSHA requirements specify that
high voltage gloves be inspected
every six months by a qualified glove
inspection laboratory.
Some dealerships also rope off
the vehicle being serviced to keep
anyone else from entering the work bay
during maintenance on hybrid cars.
Once you’ve prepared to service
the vehicle, you’re ready to approach
the high voltage disconnect switch:
• Rotate the switch from the lock
position to the unlock position.
• Pull the switch out and reset it to
the shipping position (Ford Escape
Hybrid example).
• Wait 60 seconds to allow the capac-
itors in the inverter to discharge.
These capacitors can be rated
Hybrid Electrical Safety:
Because Your Life
May Depend on It!
by Carl Mustari
Figure 1 Figure 2 Figure 3
Whatever It Takes Does!!!
72 72
www.wittrans.com
45RFE / 5-45RFE
RWD 4 & 5 Speed
© Whatever It Takes Transmission Parts, Inc.
510
Body
899
500
898
311B
311
070 519
Front Cover Plate
777
530
544 528 036 520
778
Stator
179
037
211
Pump
Parts
507
381
554 336 341 961 051 971 879
480
880
337 862
334A
334B 574 670
Input Clutch Hub
877 960 970 980 875
560
050
047 378
177
O.Dr. / Reverse
Piston
Input Clutch
Retainer
Input Shaft
561
860
876 102
122 142*
O.Dr. Clutch
100 120 861 140 891 130 110
Reverse Clutch
150 892*
Underdrive Clutch
232 571
052
220 884 331
330
558 883 234 576 214 570
Underdrive Hub O.Dr. Hub Reverse Hub
2nd / 4th Retainer
482
054
121 101
4th Clutch
141 863*
2nd Clutch
124 104
865 968
568
333 332
962
562
874
144*
227*
226
852 978
596 873 238 584 244 612 247 582
Input Planet
251 592 235* 616 241
Reverse Planet
583
586
Reaction Planet
053
058
Input Ring
Gear
886 285 887 885* 154
134
114
Low/Rev Clutch
664 888 654
Low Roller
Clutch
644
577
893 987 977 967
567
338 339 061 557 690 895
Low / Reverse
Housing
Park
Gear
480
013
074
781
770
760
897
271
Ext. Housing
429
996
M304317B
317
438
370
370
436
846
540
Case
Parts
761
Case
782
740
420
342
347
746
V.B.
Parts
741
740
Valve Body
765
300
779
010
379
950
926B
926
352
927
352
371
494
493
Park Pawl Assy.
995
995-2
995-3
995-1
991-4
994
991-6
991-5
761-4
072
991
Linkage
E
D
C
B
A
E
D
C
B
A
1-800-940-0197 • www.wittrans.com
6 GEARS May/June 2011
around 450 volts and 125 amps each.
There are three capacitors in the invert-
er.
All high-voltage checkpoints must
be tested with a Category III voltmeter
rated at 1000 volts to verify the voltage
has dissipated (figure 2).
Never assume there’s no voltage in
the system; always check with a known-
good Category III meter. Remember:
even when the system is discharged,
the 300-volt battery pack can provide
lethal voltages.
Hybrid Battery
Information
Hybrid batteries consist of 250
individual cells, similar in shape
to a size D fashlight battery. Each
individual battery cell is contained in a
stainless steel case. Safety glasses must
always be worn (fgure 3).
Each individual cell can create
1.3 volts. The cells are welded and
wrapped together in groups of fve to
form a module. There are 50 modules in
the battery pack. The total battery pack
voltage potential is 300 volts DC.
The batteries are Ni-MH (Nickel-
Metal Hydride). The battery pack
contains sealed batteries similar to the
batteries used in radio controlled toys,
laptop computers, and cell phones.
The battery case is designed to be
water resistant.
The battery cells contain a base
electrolyte — consisting of potassium
hydroxide as the dominant active ingre-
dient —absorbed in a special paper.
The electrolyte won’t leak from the bat-
tery under most conditions; however, if
the battery is crushed, it’s possible for
small amounts of electrolyte to leak.
If a wrecked hybrid vehicle comes
into your shop, the vehicle’s safety
systems should head off any potential
safety issues. For example:
1. The high voltage disconnect switch
(previously discussed) should have
disconnected automatically.
2. Manufacturers locate the battery
pack where it’s least likely to be
damaged: between the frame rails,
ahead of the rear axle.
3. When the airbag deploys, it imme-
diately cuts off power to the battery
pack. Most emergency medical
technicians (EMTs) have received
training in how to deal with this.
Basic steps for disabling the HV
system include:
1. Make sure the ignition was turned
off and the key removed. This is
important because a full hybrid
runs on its silent electric motor
when stopped and may appear
to be turned off. Backup options
include removing the IGCT relay
or the HV fuse under the hood.
2. Disconnect the 12-volt battery.
3. Wear 1000-volt, Class 0-rated
insulated rubber gloves and follow
any special instructions provided
in the service manual for disabling
the high voltage system (figure
4). Procedures may vary between
vehicles and may include remov-
ing a service plug or removing a
locking tab and flipping a switch.
4. Check orange cables for any cur-
rent using a CAT III certified digi-
tal volt-ohmmeter (DVOM) (figure
5).
Moving Hybrids in
Service Bays
The technicians shown (figure 6)
have the hybrid vehicle on dollies to
avoid charging the condensers in the
inverter while pushing the car in and
out of a service bay.
Submersion
If a hybrid vehicle was fully or
partially submerged, disable the high
voltage battery pack, SRS airbags, and
gasoline fuel pump.
When putting a hybrid vehicle
back into service, check the insulation
before activating high voltage circuits.
You can use an insulation tester, often
called a megaohmmeter, such as the
Fluke 1587, to test the insulation.
Acceptable resistance ratings should be
over 1 million ohms.
If insulation resistance is less than
one million ohms, you’ll need to locate
where insulation may be weak.
Hoisting a Hybrid
When hoisting or using a floor
jack, pay attention to the lift points.
Orange cables run under the vehicle
just inside the frame rails on most
hybrids.
Sound Level Legislation
Hybrid cars are quiet; so quiet you
may not realize the vehicle is moving
because you can’t hear anything.
The federal government and a
handful of states are considering legis-
lation to set minimum sound levels for
hybrid cars.
In April, Representatives Edolphus
Towns (D-NY) and Cliff Stearns
(R-FL) introduced the Pedestrian
Safety Enhancement Act of 2008. The
bill proposes a two-year study to deter-
mine the best strategy for tackling
safety concerns about hybrids among
the visually impaired.
Thanks to Cherokee Ford in
Woodstock, GA for information on the
2011 Ford Fusion Hybrid.
Figure 5 Figure 4 Figure 6
Hybrid Electrical Safety
8 GEARS May/June 2011
T
his article is about how impor-
tant it is to troubleshoot the
electrical devices used to shift
today’s transmissions correctly. Now,
don’t stop reading just because I men-
tioned electricity: We’re not going to
talk about Ohm’s Law or try to get you
to use fancy meters or oscilloscopes.
There are plenty of magazine articles
and textbooks that already cover this
subject very well.
What I notice is that a lot of guys
who are new to this industry don’t start
to learn about electricity until they run
into a problem. I can’t blame them: “If
it ain’t broke, don’t fix it.”
But, in reality, the best time to learn
about electrical circuits is by testing cir-
cuits that are good. That way you know
how they’re supposed to work. The fol-
lowing examples that I’ve come across
may help guide your own troubleshoot-
ing… when electricity goes bad.
Let’s take a look at the basic, on-
off electrical circuit. Remember: these
types of circuits involve a load device
such as a light bulb, a fan, or a trans-
mission solenoid. And they typically
include a power source, a switch, and
a ground, which make the device work.
The textbook examples for a bad
circuit include several scenarios such
as an open or a short in the circuit or a
continuity problem. In the real world,
it usually comes down to the device or
on-off switch is bad, there’s no power,
or no ground. And while you could
spend a lot of time and effort tracking
down the specific problem, very often
it’s not necessary.
Let’s take a look at a few examples
and you’ll see what I mean:
A general repair shop next door
had a customer with 1996 E250 van
equipped with handicap lift and modi-
fied driver controls (figure 1). I noticed
that the tech had been working on this
van for a few days. One day after work
he told me the story. The issue was that
it wouldn’t pass the smog test because
the check engine light was on.
He started in the right direction: He
recorded and cleared the code. During a
test drive, he noticed that it drove fine
until the check engine light came on;
then it started shifting hard. He found
When Electricity
Goes Bad
by David Skora
Technical Director,
Valve Body Pro
Figure 1: Interior of handicapped driver’s van.
Sometimes
isolating an
electrical problem
is as simple as just
looking around.
Ads.FH10 Thu Mar 10 11:56:48 2011 Page 1
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C M Y CM MY CY CMY K
10 GEARS May/June 2011
the same VSS code in memory. He then
verified that the battery, grounds, and
fuses were all okay. He also found out
from the customer that the dash and
parking lights didn’t always work.
At this point he pulled the dash
to check the circuits at the PSOM
(Programmable Speedometer Odometer
Module). Since the power and ground
circuits checked out, he assumed the
PSOM must be bad. He installed a used
dash from a salvage yard. The owner
picked up the van and returned the next
day with the same problem.
The tech told me that the problem
was erratic and seemed to be related to
driving with the lights on. Sure enough,
the wiring diagrams seemed to indicate
a possible relationship between a com-
mon “joined in electrical lingo” voltage
feed to the PSOM and the headlight
switch.
So at this point he installed a new
headlight switch and new turn signal
switch, and was seriously consider-
ing ordering a new dash assembly. I
couldn’t help but feel compelled to
help him — not just for his sake, but
also because I wanted to see the handi-
capped owner get his van back.
The wiring diagrams showed a
relationship between fuse number 1
and fuse number 5 in the dash panel
fusebox. Number one pro-
vided the battery feed to
the PSOM, brake switch,
turn signal switch, and
ABS module.
Fuse number 5 was
an ignition feed to the
transmission range sensor,
turn signal switch, OD
cancel switch, daytime
running light module,
and some other circuits.
He decided that one of
the switches was shorted,
which caused a voltage
drop before the PSOM.
“WOW,” I said,
“that’s amazing.” “Yeah,”
he replied, “it would be, if
I could find what’s doing
it.” I offered to help him
for a few minutes. He’d
been showing me the wir-
ing diagrams to support
his theory. I noticed the
headlight switch hanging
from under the dash.
The first thing I did was check for
battery voltage from fuse number 5 to
the headlight switch. With the ignition
off there was no voltage. When the
ignition switch was on, there was only
8 volts. I think this is what had him
confused.
Clearly, a battery fuse circuit
should always have voltage, whether
the ignition is on or off. To be sure, I
got similar results when I checked for
voltage at the fuse side of the brake
switch.
Since he said he checked the fuse,
I was getting suspicious of an open
between the fuse and the circuits it fed.
So I pulled out the number 5 fuse: Lo
and behold, there was a broken terminal
on the feed side of the fuse (figure 2).
Figure 3: Is this or isn’t this a real 1996 Volkswagen 2.0L engine?
Figure 2: A broken terminal on the fuse feed side misled troubleshooting.
When Electricity Goes Bad
12 GEARS May/June 2011
He’d probed the fuse test sockets on top
of the fuse and it tested good, and he
hasn't seen the van back again.
This next example involves a look
at a 2000 VW Jetta that occasionally set
a VAG 00652 slip code.
The owner was told by the first
shop that he needed a transmission
because it was setting a slip code.
The vehicle owner was skeptical: He
wanted a second opinion from another
transmission shop. The owner of the
second shop told me the transmission
worked perfectly until the computer
system went into limp mode.
As soon as they cleared the slip
code, the transmission would drive
and shift great. These symptoms didn’t
seem to indicate the transmission need-
ed to be rebuilt. Even though the TCM
hadn’t set any other codes, we did a
wiggle test on the OSS (Output Speed
Sensor).
All of a sudden an OSS code set. A
new OSS fixed the problem, and it cost
a lot less than a complete transmission
rebuild. Remember, just because there’s
no a trouble code doesn’t mean electric-
ity can’t go bad.
Let’s take a short review of com-
puter related troubleshooting: For a
computer to control a transmission, it
needs sensors to monitor the physi-
cal conditions the vehicle is under at
every moment. Unless a code sets for
one of the sensors, a lot of techs seem
to ignore the potential problems a bad
sensor can create.
Remember, the speed sensors,
temperature sensors, pressure sen-
sors, engine load sensors, driver inputs
(Tiptronics), and more supply vital
information for the computer to control
shift timing and shift feel.
This final example illustrates what
sort of extreme situations you may
come across. I was asked by a friend
of a friend (always a bad sign) to fix
a 1996 VW that seemed to be in limp
mode. The complaint sounded like the
transmission only drove forward in
high gear and would back up okay in
reverse.
An initial check revealed several
engine codes. It was hard to believe
the engine would even start and run.
Someone had wired the fuel pump to
run all the time; otherwise the engine
wouldn’t even start.
Since the engine was able to run,
his concern was getting the transmis-
sion to shift. As the story unfolded
and I spent several hours diagnosing,
troubleshooting, and testing circuits, I
concluded that this was going to take
a lot more time, money, and parts to
fix than it was probably worth. Here’s
why:
The previous owner had replaced
the engine with a used one (figure
3). My friend’s friend bought it this
way and assumed some minor thing
was causing the transmission not to
shift right. The engine and transmis-
sion looked like they were all there and
seemed to have the wiring connected to
the usual sensors. In most typical situa-
tions with multiple codes, the logic is to
solve the circuits which are setting the
lowest number code first.
One of the lowest codes present
related to the ECM power circuits.
This made sense, because someone had
forced the fuel pump relay to work all
the time. It should have taken only a
few minutes to verify the ECM fuel
pump relay control circuits were good.
At first I wasn’t too concerned that none
of the wiring diagrams matched the
car’s wiring. “No big deal,” I thought,
“it’s a Volkswagen.”
To my amazement, I couldn’t find
any wiring diagrams from any model or
year Volkswagen that matched this car!
To make a long story short, we finally
realized that the engine had come from
a 1995 Volkswagen. A few of the sen-
sors (TPS, IAC, Idle Switch, wiring,
etc.) were different between a 1995 and
a 1996 VW. Since the 18-pin engine
harness plugged right in the main wir-
ing harness near the distributor (figure
4), both friends assumed it was going to
work. It’s been over a year and, I as far
as I know, the owner still hasn’t decided
what to do.
I hope these examples help illus-
trate that when it seems electricity has
gone bad, fixing the problem may not
require advanced diagnostic strategies.
Sometimes you can make it right by
using simple logic and knowing what it
takes to make it good.
Figure 4: View of the 18-pin engine connector just below the radiator hose clamp.
When Electricity Goes Bad
Unless a code sets for
one of the sensors, a
lot of techs seem to
ignore the potential
problems a bad sensor
can create.






D19553-0
FPV DP 101736
FPAR-00293
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2010 Motorcraft Powertrain Ad
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4 1 09/08/10
Trim Sizes:
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B. 8.125” x 10.875” — Gears, Transmission Digest, Police Fleet Manager
C. 7.875” x 10.75” — Work Truck, Automotive Fleet, Business Fleet,
Government Fleet
D. 7.875" x 10.5" — Motor
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A higher level.
That’s what you get with Ford gas engines
and transmissions.
A higher build level means you’re getting engine and transmission assemblies built to the exacting specifications of
Ford Motor Company. So you not only get the quality build you expect in an assembly from Ford, but also one that’s built by
using parts that keep it specific to year, make and model as well as emissions calibrations.
Introducing the all-new 3-Year Unlimited-Mile Warranty – No Commercial Exceptions
Ford gasoline engines and transmissions are covered by a three-year/unlimited-mile warranty.* All warranties are backed by
Ford Motor Company. They’re also supported by more than 3,500 Ford and Lincoln Mercury Dealerships nationwide as well
as at their originating place of service.
Plus, unlike some competitors, the warranty is good for fleet vehicles. That means you get the same advantages
and coverage for commercial use, no exceptions.
For technical questions, contact the Powertrain Assistance Center at 1-800-392-7946 or visit FordParts.com.
*See dealer for limited-warranty details. Remanufactured diesel engines are covered by a two-year/unlimited-mileage warranty.
FPAR00293_D195530_R04.indd 1 9/8/10 5:28 PM
14 GEARS May/June 2011
F
ord’s 4R/5R55E and 5R55N/
W/S transmissions use a
hydraulic cooler bypass system
that can cause a system meltdown if the
thermal element or fluid cooler bypass
sleeve sticks.
If the sleeve sticks part way it’ll
restrict cooler flow and cause internal
component damage; meanwhile it may
not set any fluid temperature codes.
Very often the fluid will be burnt and
the overdrive planetary assembly com-
pletely destroyed.
Blocking the thermal valve sleeve
in the stroked position will prevent
this from happening. Some aftermar-
ket companies supply a block to keep
the fluid cooler bypass stroked in the
normal temperature position. Another
way to accomplish this is to move the
return spring to the opposite side of the
sleeve.
This same problem may also cause
intermittent lockup code P0741. The
accompanying hydraulic diagrams
show the function of the thermal ele-
ment and sleeve:
Figure 1 shows the thermal valve
at rest (4/5R55E; orange) in the cold
temperature position. In this position,
the valve directs oil through the fluid
cooler bypass sleeve (green), which
allows the oil to flow to the cooler
by Mike Souza
members.atra.com
www.atra.com
Figure 1 Figure 2
S t i c k i n g
Thermal Element
Can Cause Thermal Failure
4R / 5R55E / 5R55W / S/N 
Cooler Bypass System
GEARS May/June 2011 15
Figure 3
Figure 5
Figure 4
Figure 6
16 GEARS May/June 2011
through both cooler lines at the same time. Since there’s no
return, there’s no cooler flow. This helps the transmission
reach normal temperature faster in colder climates.
Figure 2 shows the transmission at normal temperature:
The thermal element moves the fluid cooler bypass sleeve
(extended pin), blocking off the oil being applied to the upper
cooler line fitting. In this position, oil flows to the cooler
through the lower cooler line and returns through the upper
cooler line. Figure 2 shows the lockup converter flow in the
released position at normal temperature.
Figure 3 again shows oil flow to the cooler at normal
temperature, but with the lockup converter flow in the applied
position. If the sleeve gets stuck — completely or part way
— it can restrict cooler flow in the converter clutch release
pressure circuit. This can set DTC P0741.
Placing the cooler bypass sleeve spring on the opposite
side of the sleeve locks the sleeve in the normal temperature
position, preventing a cooler flow problem.
The diagrams for the 5R55W/S (figures 4, 5, and 6) and
the 5R55N transmission (figures 7, 8, and 9) show cooler
flow working the same way. The only difference is the ther-
mal element, fluid cooler bypass sleeve, and converter clutch
control valve lineup aren’t in the same bore.
But blocking the fluid cooler bypass sleeve in the normal
temperature position, such as by relocating the spring to the
opposite side of the sleeve, will still keep the cooler flowing
properly and prevent overheating problems.
Sticking Thermal Element Can Cause Thermal Failure
Figure 8 Figure 9
Figure 7
C
M
Y
CM
MY
CY
CMY
K
GEARS_FINAL1.pdf 1 4/21/2011 10:09:08 PM
18 GEARS May/June 2011
GEARS May/June 2011 19
C
M
Y
CM
MY
CY
CMY
K
GEARS_FINAL1.pdf 1 4/21/2011 10:09:08 PM
C
M
Y
CM
MY
CY
CMY
K
GEARS_FINAL2.pdf 1 4/21/2011 10:15:14 PM
20 GEARS May/June 2011
GEARS May/June 2011 21
C
M
Y
CM
MY
CY
CMY
K
GEARS_FINAL2.pdf 1 4/21/2011 10:15:14 PM
22 GEARS May/June 2011
Which Is More Important: How It Works or What’s Wrong With It?
I
t’s Monday morning and as you’re
walking up to your bay you see
a late model GMC sitting there.
“There’s an Allison transmission in that
truck,” you might say to yourself. Then
the question: “I wonder what’s wrong
with it?” You find out later the com-
plaint is no power.
Before the test drive you perform a
quick inspection, check for codes, and
make sure the vehicle is ready to drive.
It has multiple codes; you record them
and clear them from memory. During
the test drive the vehicle goes in limp
mode. Back at the shop, five min-
utes later, you find the wiring harness
pinched (figure 1). Two hours later the
vehicle is fixed.
Quick fixes like these are always
great to learn about in seminars and
training classes. But understanding how
the transmission operates — and why
the quick fix worked in the first place
— is just as important. But sometimes
this transmission can fool you, like give
you a false Neutral. Let’s take a look at
how and why the Allison goes into fails
and what causes it.
Understanding a False
Neutral
If power is interrupted while the
transmission is operating in reverse
or neutral, the transmission defaults
to or continues neutral operation. At
that point you can turn the engine off
and start it again: The shift selector
will provide reverse, neutral, and drive
capability regardless of the range it was
in when the failure occurred.
In this state, pressure control sole-
noid 1 — PCS1 or trim A solenoid — is
de-energized, and allows the 3rd, 5th
and reverse clutches to apply. If you
move the selector valve into reverse,
Technically Speaking
Allison…
is that you?
Figure 1
Figure 2
by Lance Wiggins
members.atra.com
www.atra.com
24 GEARS May/June 2011
Which Is More Important: How It Works or What’s Wrong With It?
main pressure is routed to the low and
reverse clutch, allowing reverse opera-
tion.
If you move the selector valve
to drive, main pressure is routed to
the 1-2-3-4 clutch, allowing 3rd gear
operation. If the unit has no forward or
reverse, or won’t move at all, follow
these steps:
• Set the parking brake.
• Key off.
• Disconnect the case connector
at the transmission.
• Using a fused jumper wire, con-
nect terminal R (black/white)
of the automatic transmission
20-way connector to a known
good ground.
• Start the engine and move the
range selector to reverse —
the transmission should engage
reverse.
• Move the range selector
to drive — the transmission
should engage 3rd gear.
If reverse and 3rd gears are avail-
able in limp home mode, it may indi-
cate an electrical failure. If only one
or neither of the ranges work, it may
indicate an internal hydraulic failure
such as one of these conditions:
• Failed clutch
• Stuck valve
• Solenoid failure
• 1-2-3-4 clutch, 3rd, 5th and
reverse clutch, and the low and
reverse clutch
Erratic Operation after
Repair
If you’re experiencing erratic
transmission operation after a rebuild
or a battery disconnect, it’s important
to verify in which particular gears the
erratic operation is occurring.
Use a scan tool to determine these
shift sequences. If the shift timing
between two gears isn’t met, the TCM
will attempt to adapt the timing of that
shift within the program specifications.
The vehicle will need to be driven
more, specifically performing that shift.
Many times this will correct the condi-
tion.
It’s possible to reset individual
shifts without affecting the other shifts.
Monitor the adaptive cells on the scan
tool to determine if the adaptive strate-
gies have been met.
Always reset the TCM to base cali-
bration and fast adapt for all shifts. This
can be done in one step with fast learn.
If you miss this step, the TCM adaptive
values will be at their previous settings,
set to slow adaptive mode. Under these
conditions, it’ll take an unacceptably
long time for the adaptive values to
adjust for the new transmission.
Checking the Pressure for
Diagnostic Purposes
Checking mainline pressure helps
determine if a transmission failure is
due to a mechanical or an electrical
condition (figure 2).
Caution: Keep the brakes applied
at all times to prevent unexpected vehi-
cle motion. Personal injury may result
if the vehicle moves unexpectedly.
• Engine off.
• Remove the oil pressure tap
plug.
• Install the oil pressure gauge.
All transmission fluid level and
pressure checks must be made at
normal operating temperatures
71-93ºC (160-200ºF).
• Start the engine.
• Check the transmission fluid
level; adjust if necessary.
• Use the scan tool to check the
Figure 3
Figure 4
GEARS May/June 2011 25
engine RPM.
• With the brakes applied, record
the line pressure values with the
engine at 600 RPM, in neutral
and reverse. The transmission
will be in converter mode: torque
converter clutch not applied.
• With the brakes applied, record
the line pressure values with the
engine at 2100 RPM in neutral.
The transmission will be in con-
verter mode: torque converter
clutch not applied.
• With the brakes applied, use your
scan tool to check pressures in
first through fifth gear ranges at
600 RPM. The transmission will
be in converter mode: torque
converter clutch not applied.
• Compare the data recorded to
the line pressure specifications
(figures 3).
• Engine off.
• Disconnect the oil pressure
gauge.
• Install the oil pressure tap plug.
Problems and Fixes
We’ve covered the basics; now
let’s cover the problems and fixes.
Code P0842 (Transmission Fluid
Pressure (TFP) Switch 1 Solenoid
Circuit Low Voltage)
Code P0847 (Transmission Fluid
Pressure (TFP) Switch 2 Solenoid
Circuit Low Voltage) DTC
Code P0872 (Transmission Fluid
Pressure (TFP) Switch 3 Solenoid
Circuit Low Voltage)
These codes can be caused by a
fault in a clutch circuit, the valve body,
a shift solenoid, or a faulty pressure
switch circuit. These codes may be hard
faults or intermittent codes.
To verify whether a shift solenoid,
shift valve, or clutch is at fault, swap
shift solenoids C, D and E with one
another. If the problem remains the
same, look for a valve or clutch fault. If
it changes, suspect the solenoid.
With the valve body removed, you
can air check each clutch (figure 4).
Figure 5
A better way to test your light-duty automotive transmissions -
Mustang’s Universal Transmission Dyno - Smarter by Design.
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ID
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S
T
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R
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www.mustangae.com
CALL 888-468-7826
WIRELESS TRANSMISSION
CONTROL MODULES
V
A
LV
E
B
O
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Y

T
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T
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26 GEARS May/June 2011
Which Is More Important: How It Works or What’s Wrong With It?
Always service the spin-on oil fil-
ter at regular intervals. Make sure the
magnet is present at the top of the filter.
Always make sure the valve body
bolts are tightened evenly to 84-110
in-lbs. A burnishing tool is available
through the aftermarket to smooth out
any irregular marks in the bore for the E
shift valve. If the E shift valve sticks in
its bore, it usually affects 4th gear and
sets code P0872. After you clear the
code, the vehicle will shift normally:
1-2-3.
Gear ratio error in 5th (P0735
2001-2005), or 6th (P0736 2006-on)
before and after a rebuild can be caused
by a damaged range fork in the transfer
case, causing the transfer case to pop
out of gear at freeway speeds (figures 5
and 6). Units affected are 2001-current
K Series Chevy Silverado/GMC Sierra
2500HD/3500.
Four wheel drive vehicles equipped
with Allison transmissions use the vehi-
cle speed sensor on the transfer case as
an output speed sensor. When the trans-
fer case goes into neutral, the computer
sees the input RPM change as vehicle
speed remains constant, so it thinks
the transmission is slipping. One of the
main causes for this failure is a lack of
lubrication due to low fluid level.
Over time, the pump assembly can
wear a pinhole into the magnesium
case and produce a small leak. GM has
released an updated clip that resists
wear from the pump into the case
(figure 7). GM has also released an
updated range fork and hub assembly
to help with wear issues. Anaheim Gear
of Anaheim, California recommends
using GM Autotrak fluid for improved
durability.
• Autotrak Fluid P/N 12378508
• Range Fork P/N 12544310 (261
XHD) 12384964 (263 XHD)
We’ve also found the snap ring
groove in the rear case half for the
output bearing is wearing out (figure
8). The magnesium case is too soft and
the axial movement of the output shaft
causes the snap ring groove to widen
as much as 0.0200”. This excess clear-
ance causes the entire shaft to walk
back and forth, resulting in range fork
wear, which can cause the transmission
to shift into neutral at freeway speeds.
Figure 6
Figure 7
Figure 8
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New_Pkg_LipWizard_ad_final.indd 1 1/25/11 11:31 AM
28 GEARS May/June 2011
Which Is More Important: How It Works or What’s Wrong With It?
LCT 1000 applications may exhibit
late shifts, no shifts, or a lack of power.
This may be caused by the PTO switch
indicating that the PTO is being com-
manded on. It may act very similar to a
plugged fuel filter, and likely won’t set
a DTC. The TCM is being commanded
by the ECM to change the shift points
for the transmission. The engine speed
will typically be limited to 2000-3000
RPM (depending on calibration).
You can monitor the PTO switch
with a scan tool on most applications.
If the PTO switch is activated or if the
switch has failed, the ECM will limit
engine RPM at all throttle openings.
In addition, you may notice that turbo
boost pressure, MAF, and fuel delivery
commands indicate the engine isn’t
under full load.
When these conditions are met,
the ECM will command the TCM to
change the shift points, which can
lead to the complaint. If the switch is
off, check the switch and wiring with
your scan tool or multimeter. Repair
or replace the switch as necessary. The
PTO switch on the 2001-06 applica-
tions is located right of center on the
dash (figure 9).
Many customers are installing
PTO switches in vehicles that weren’t
originally equipped with a PTO from
the factory. Customers are using the
PTO input to force the engine to idle up
to speed after the engine warm up.
The factory harness is in place up
to connector C106, so the installation is
fairly simple. PTO switch kits are avail-
able from several sources. This means
this condition may occur even though
the vehicle isn’t equipped with a PTO.
LCT 1000 applications may exhib-
it any of these conditions:
• Transmission won’t move for-
ward or reverse (range inhib-
ited).
• Possible electrically related
shift solenoid, temperature sen-
sor, or PSM DTCs.
• Transmission will move for-
ward and reverse but won’t
shift.
These conditions may be intermit-
tent.
Inspect the main transmission har-
ness; it may be pinched where the
frame rail meets the body (at the body
mounts). If the harness is pinched,
repair the wiring and reroute it to pre-
vent it from becoming pinched again.
This problem is common on crew cab
applications.
Vehicles come and go. Knowing
what it takes to fix them is like having
the key to every room: all you have to
do is turn the key.
Until next time, remember:
Understanding how the transmission
operates is just as important as under-
standing why it’s acting up.
Figure 9
If it’s got wheels, chances are we have a transmission repair kit for it.
A box, no, but that doesn’t mean we aren’t thinking outside of it.
As a technological leader for over 30 years, we’re constantly striving to
improve ourselves and grow our product line to give you the world’s
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Just about the only vehicle we don’t make
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209-PRE-097 L: 7.375x10.125 T: 8.125x10.875 B: 8.375x11.125 4C
Gears Magazine..........May/June 2011
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Precision also offers outstanding technical assistance and support, including our
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209PRE-7.375x10.125-097:Layout 1 4/19/11 1:43 PM Page 1
30 GEARS May/June 2011
by Thom Tschetter
members.atra.com
www.atra.com
T
here are few things that bring
as much pleasure or sense of
accomplishment as crossing
something off your “To-Do” list. It
simply feels good to complete just
about any task that was worthy of your
list. In fact, it feels so good that it can
become addictive.
Most successful people use a
To-Do list in one form or another, and
they wouldn’t consider giving it up.
When you think about it, time man-
agement programs, day planners, and
schedulers are little more than To-Do
lists. Some are more sophisticated and
include things like prioritizing, prog-
ress tracking, and so on, but in the final
analysis they’re just a fancy way of
keeping track of the things you have
to do.
As usual, I’m up to challenging tra-
ditions and questioning what we might
call “conventional wisdom.” If you’ve
ever seen the musical Fiddler on the
Roof, you know how deep-rooted tradi-
tions can block change. But regardless
of how much we say we resist change,
let’s face it: For the most part, change
is good. In fact, we love change. We
rearrange furniture, modify colors, buy
new and improved products, update
our wardrobes, get new cars, and yes,
we even elect our leaders because they
promise change.
A To-Do list is generally all about
change; it’s a list of things you want to
fix or improve in your life. So how can
a To-Do list block change? Many of us
can become so focused on accomplish-
ing what’s on our To-Do lists that we
miss out on opportunities to improve
our businesses, our processes, and the
quality of our lives.
I’ve observed many shop own-
ers who are so busy working on their
To-Do lists that they don’t look up
long enough to consider new ideas or
opportunities, or to set time aside for
setting goals and developing plans for
accomplishing them. In short, marking
things off their To-Do lists becomes
their goal, and they get their sense
of accomplishment from crossing the
things off the list instead of improving
their businesses.
I believe there are some fundamen-
tal flaws in how we’ve traditionally
used To-Do lists. The lists themselves
can become so overwhelming that we
resist anything new because it’ll result
in adding to our already unmanageable
lists. So let’s take a look at how we
might improve things by changing how
we use To-Do lists.
First, let’s assume that your To-Do
list is only made up of things that are
truly important enough to justify being
on YOUR list. If you have no criteria
for determining what deserves to be
on YOUR list, add “create the criteria”
to YOUR list right now. You should
always consider whether something
deserves to be on YOUR list. For many
of you, this one step will shrink the size
of YOUR list and make it easier to take
the next steps.
Note the use of the word “YOUR”
in the previous paragraph. Implicit in
the word YOUR is the concept of
ownership. These are tasks that you
own, or, in other words, only you can
or should do.
What about all the things that don’t
meet the criteria to be on YOUR list,
but still need to get done? Chances
are those things can go on a new list.
Don’t Be Undone
By Your “To-Do” List
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32 GEARS May/June 2011
Let’s call the new list “Things to
Delegate.” Again, if you haven’t cre-
ated any criteria for determining what
you can delegate, add that to YOUR
list right now.
We don’t have the time or space to
deal completely with how to delegate
effectively, but Theodore Roosevelt put
it this way: “The best executive is the
one who has enough sense to pick good
people to do what he wants done, and
enough self-restraint to keep from med-
dling with them while they do it.”
Here is a simple “…ATE”-step
approach to help you delegate:
• StimulATE — Present what
you want them to do and why
to do it.
• EducATE — Explain how to
do it.
• DemonstrATE — Show them
how you want it done.
• SimulATE — Give them a
chance to try to do it.
• EvaluATE — Provide feedback
on how they did and correction
as needed.
• CongratulATE — Because what
gets rewarded gets repeated.
Many times, the things on the lists
are game changers. Once completed
and implemented, game changers fun-
damentally affect what is done or the
way things are done. They often elimi-
nate the need to continue doing certain
things, as well as clearly illuminating
the things that you need to start doing
and the things you need to keep doing.
This creates the need for another small
group of lists: the Stop-Doing list, the
Start-Doing list, and the Keep-Doing
list.
Here’s a simple example of how
this all works together. Let’s assume
you’ve decided to add brake repair to
your menu of services in your transmis-
sion shop. Here’s how you might use
these examples to manage the changes:
Create a comprehensive list of all
the things that need to be done to pre-
pare for and implement this new service
package. Examples would include:
• purchase equipment
• hire or train techs
• establish supplier relationships
• adjust how you schedule
appointments
…and more.
Determine which of the things on
this list must be done by you and put
them on YOUR To-Do list. Maybe
you’re the only one to make the equip-
ment purchases, but your manager will
take care of the staffing needs. You
might have the manager gather a list of
potential suppliers, but you’ll negotiate
the pricing and terms.
Determine who will do each of the
remaining steps using the “…ATE”-
step delegation process.
Decide what needs to go on the
Start-Doing list. One example would
be to start inspecting brakes as part of
every diagnostic service.
Decide what goes on the Keep-
Doing list. For instance, you’ll need to
keep using your established diagnostic
and sales procedures to make sure your
customers receive the same level of
satisfaction as they’ve come to expect
from you.
Your Stop-Doing list will cer-
tainly include, “stop referring brake
work to the brake specialist up the
street.” While this seems to go without
saying, don’t assume anything. I
know a shop owner who always had
one of his clean-up guys vacuum
customers’ cars and clean the win-
dows inside and out. When a new
car wash opened up across the street,
he decided to start having all the
customers’ cars washed. The car
wash did a great job, including vacu-
uming the cars and cleaning all the
windows inside and out. And, as
you most likely already guessed,
his clean up guy continued to vacuum
the cars and wash the windows.
The key point is that the tradi-
tional To-Do list can become both over-
whelming and addictive, yielding unin-
tended results and stunting creativity
and innovation. But by applying some
simple principles, you can manage the
process instead of doing it all yourself.
And by the way, share some of those
feelings of accomplishment with your
team… they’ll enjoy crossing things off
their lists, too.
Thom Tschetter has served our
industry for three decades as a man-
agement and sales educator. He owned
a chain of award-winning auto centers
in Washington State for over 25 years.
In 1996 his business was honored as
the No. 1 small business in the state,
and ranked in the top 10 nationally.
He also volunteers on the board
of directors for the Auto Repair Good
Guys Foundation, a non-profit founda-
tion, which provides consumer edu-
cation and guidance, charitable car
repairs, and scholarships to automotive
vo-techs in Arizona.
Thom is always eager to help our
industry. You can contact him by phone
at (480) 773-3131 or e-mail to coach-
thom@gmail.com.
Don’t Be Undone By Your “To-Do” List
Derived from a proven “force motor” design used
in millions of transmissions, BorgWarner’s EPC
replacement solenoid greatly reduces your risk of
stuck spool valve conditions associated with our
competitor’s “direct acting” design. The internal
moving parts of BorgWarner’s solenoid core are
made of hardened steel for incredible durability,
and the hydraulic section is made of precision
machined aluminum, anodized to resist wear and
contamination, with a filtered inlet and outlet for
added protection.
Over time, normal transmission wear adds con-
taminates to transmission fluid, which may cause
the spool valve movement of our competitor’s
OE design to become sluggish and output pres-
sures imprecise, resulting in poor shifts, slippage,
and high line pressure problems.
By contrast, BorgWarner’s larger internal spool
valve is moved with hydraulic force, developing
more than THREE TIMES THE FORCE of the OE
design to plow through debris to meter oil flow
properly. Calibrated to ensure smooth and durable
operation, and verified by extensive field testing,
BorgWarner’s EPC solenoid is the unbeatable
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2011BWA-50155v2:2010BorgWarner 4/15/11 9:05 AM Page 1
34 GEARS May/June 2011
by Steve Garrett
members.atra.com
www.atra.com
A Look at the New
MP Transfer Case
I
f you’ve had the opportunity to
look under a new 4WD truck
lately, you’ve probably noticed
something new: The transfer case looks
a little different than those you’ve
become used to working with for the
last decade or so.
Starting with the 2007 model year,
General Motors introduced a series of
new transfer case designs to replace
the New Venture Gear units they used
in the past. Built by Magna Powertrain
(MP), the new units are available in
three different models:
• Manual Shift (RPO NQG; models
1222/1225/1226)
• Electric Shift (RPO NQF; models
1625/1626)
• Auto (RPO NQH; models
3023/3024)
Several models are available
for each application, including the
1222/1225 and 1226 manually shifted
units, the 1625/1626 electrically shifted
units, and the 3023 and 3024 auto/
active transfer case models (figure 1).
All models use DEXRON VI fluid.
The models features are shown in the
accompanying chart. (Chart 1)
There are several differences
between the transfer cases beyond the
control system. Some are minor while
others will create major parts inter-
change problems if you try and install
the incorrect parts for the unit you’re
working on.
To identify the transfer case, check
the tag or stampings on the case (figure
2). As you can see from the chart, there
are nine different transfer cases just for
GM applications.
So what’s so different about these
units? Well, in a nutshell, the construc-
tion of the units is similar to the NV
design transfer cases you’ve worked on
for years, but the internal operation of
the shift mechanism is quite different.
The MP units use a new design
shift motor. In addition, this new design
shift motor requires a learn process
after replacement, for the control mod-
ule to learn its position properly.
MP T Case
Operation
First we’ll
look at how these
units operate:
• (RPO NQF)
MP 1625/MP
1626
• (RPO NQH)
MP 3023,
MP3024
Like other
electric shift GM
transfer cases,
the MP 1625 MP
1626, MP 3023 and MP 3024 use these
operational modes:
• 2 High
• 4 High
• Auto (MP 3023, MP 3024)
• 4 Low — 2.68:1
• Neutral
The MP series electronic transfer
Model RPO Trans
Input
Shaft
Splines
Output
Shaft
Splines
Chain
Size
Planet App
MP 1222
Light Duty
NQG 4L60E 27T 32T
7/16–
1.25
3 Pinion ½ Ton
MP 1222
Light Duty
NQG 6L80 32T 32T
7/16–
1.25
3 Pinion ½ Ton
MP 1225
Heavy Duty
NQG 6L90 29T 31T
7/16–
1.5
5 Pinion ¾ Ton
MP 1226
Super Duty
NQG
6L90
LCT
1000
29T 31T
7/16–
1.5
5 Pinion
¾ Ton
1 Ton
MP 1625
Heavy Duty
NQF 6L90 29T 31T
7/16–
1.5
5 Pinion ¾ Ton
MP 1626
Super Duty
NQF
6L90
LCT
1000
29T 31T
7/16–
1.5
5 Pinion
¾ Ton
1 Ton
MP 3023
Light Duty
NQH 4L60E 27T 32T
7/16–
1.25
3 Pinion ½ Ton
MP 3023
Light Duty
NQH 2ML70 32T 32T
7/16–
1.25
3 Pinion ½ Ton
MP 3024
Heavy Duty
NQH 6L90 29T 31T
7/16–
1.5
5 Pinion ¾ Ton
CHART 1
Figure 1
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36 GEARS May/June 2011
cases are “shift on the fly” units. To
select 2 High, Auto, or 4 High range,
simply rotate the switch to the desired
position.
The transfer case will only shift
into or out of 4WD Low under these
conditions:
• Key on
• A/T shifter in neutral
• VSS less than 3 MPH
(5 km/h)
• Move the switch into
(or out of) the 4 Low posi-
tion
To select neutral posi-
tion for towing purposes:
• Key on
• A/T shifter in neutral
• VSS less than 3 MPH
(5 km/h)
• Transfer case in 2
High position
• Rotate the switch
clockwise past the 4WD
Low position and hold it
in that position for 10 sec-
onds. The red neutral lamp
will light.
Auto Transfer
Case Operation
(RPO NQH) MP
3023, MP3024
The MP 3023 and
MP 3024 transfer cases
include these components:
• Transfer Case Shift
Control Switch
• Transfer Case 2WD, 4WD
Incremental Sensor
• Transfer Case Actuator Drive
Motor
• Transfer Case Shaft Position
Sensor
• Transfer Case Motor Lock
• Transfer Case Control Module
• Vehicle Speed Sensor
• Service 4X4 Indicator
• Transfer Case Shift Control
Switch
The rotary switch (located in the
dash) varies the voltage drop to the
Transfer Case Control Module (TCCM)
based on the switch’s position. The
TCCM provides a 5-volt reference sig-
nal to the switch.
As you rotate the switch, the resis-
tance varies within the switch input
circuit, creating different signal voltage
values at the TCCM. The TCCM moni-
tors the signal voltage to determine
which range to select.
Approximate TCCM voltage input
will read:
• 2WD — 2 Volts
• Auto — 4.4 Volts
• 4 High — 3.0 Volts
• 4 Low — 1.5 Volts
Transfer Case 2WD/4WD
Incremental Sensor
The incremental sensor is mounted
on the transfer case shift motor. The
sensor is a variable position, Hall Effect
sensor that creates a signal the TCCM
uses to determine the actual range posi-
tion the motor is moving toward.
The TCCM sends an 8-volt refer-
ence signal to the sensor (5-volt on
Dodge applications). The sensor indi-
cates the changing position for the
Figure 2
Figure 3
A Look at the New MP Transfer Case
GEARS May/June 2011 37
transfer case motor in degrees (0.15º
increments) of movement.
The sensor pulls the signal voltage
low (0.75 volts), or allows it to go high
(4.2 volts) as the motor rotates.
Sensor operation can be confus-
ing, because the transfer case position
doesn’t necessarily represent a specific
voltage value. You can monitor the sen-
sor voltage and degrees of movement
with your scan tool. Typical values will
be (chart 2):
* The motor direc-
tion will register CW
while shifting up in range:
2WD to Auto to 4 High
to 4 Low. Once the shift
is completed, the motor
position will read CCW.
** The impulse volt-
age will vary based on
sensor movement. It
isn’t uncommon to have
the voltage read 0.75V,
then change to 4.2V; or
the opposite may occur,
depending on the exact
position of the motor. In other words,
when shifting the transfer case, you’ll
see the value change without your
input. This is due to the linkage varying
just a fraction of a degree or so from the
last commanded shift into that range.
Transfer Case Shaft
Position Sensor (Rotational
Sensor)
The rotational sensor is mounted
into the back of the transfer case near the
motor assembly (figures 3 & 4). On
some applications, the sensor may be
described as the Transfer Case 2/4
Wheel Drive Actuator Position Sensor.
No matter the name, the operation is
the same:
The TCCM sends a 5-volt refer-
ence signal to the sensor. The TCCM
also provides the ground for the sensor.
As the shift shaft rotates, the sensor
sends a signal voltage to the TCCM
which varies with the position of the
shaft. This value represents the actual
position of the shift shaft. Typical scan
voltage values are (chart 3):
** Voltage varies with clutch com-
mand.
Transfer Case Motor
The transfer case motor is a per-
manent magnet, PWM, bidirectional
unit, currently manufactured by Bosch
(Daewoo on 2011 applications; figure
5). The TCCM controls the drivers for
the motor A and motor B circuits. The
motor current varies depending on the
command, and to meet the clutch slip
requirements in Auto Mode:
Command
Incremental
Sensor
Incremental
Sensor
Direction
Incremental
Sensor Voltage
Incremental
Sensor Impulse**
Incremental
Sensor
Direction
2WD 37º 0.75V 7.5V 0.75V or 4.2V CCW
Auto 102º 0.75V 7.5V
0.75V or
4.2V
CW*
4 High 127º 0.75V 7.5V
0.75V or
4.2V
CW*
4 Low –77º 4.20V 7.5V
0.75 or
4.2V
CW
Command
Sensor
Degrees
Sensor Signal
Voltage
2wd 37º 3.0V
Auto 102º 3.6V **
4 High 125º 4.0V
4 Low -77º 1.8V
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Figure 4
CHART 2
CHART 3
38 GEARS May/June 2011
• From 0-15 amps
• Current limited to 30 amps
• Motor resistance 14-20 ohms
Unlike the previous design NVG
transfer case motors, the new design
actually rotates the shift shaft either
clockwise (CW) or counterclockwise
(CCW). This moves the actuator cam
to apply or release the clutch.
As the actuator cam rotates, the
balls located between the levers are
forced up the ramps built into the
levers. This forces the levers to move
apart, applying pressure to the clutch.
Increasing the clutch apply pressure
reduces clutch slip, which, in turn,
increases the torque applied to the front
driveshaft (figures 6 and 7).
After replacing the transfer case
motor, you must perform a transfer case
motor learn process with a scan tool.
Transfer Case Motor
Brake
NQH applications use a brake
assembly to control the position of
the transfer case motor armature. The
brake is mounted within the transfer
case motor assembly, and is controlled
electronically by the TCCM.
The TCCM controls the ground for
the brake assembly. The brake is de-
energized (motor locked) during 2wd,
4 High and 4 Low ranges. In Auto
range, the brake is energized (motor
unlocked) if the motor requires move-
ment. Typical scan values will read
(chart 4):
** The voltage (current flow) for
the brake circuit will vary depending
on the commanded position. The 0.5
volts listed in the chart is based on the
vehicle being stationary with no wheel
slip. As the TCCM changes the clamp
load, you may see the voltage change.
The brake can cycle in as little as 20ms
from fully locked to fully unlocked.
This action balances the commanded
position for the motor with its actual
position, so the motor doesn’t need
to stay energized all the time in Auto
range.
Replacing and
Reprogramming the
TCCM
Both the NQH and NQF transfer
case applications will require program-
ming if the TCCM is replaced or if an
updated calibration is released. The
process is the same as for other GM
modules and carries the same proce-
dures and precautions as you’ve used in
the past with GM modules.
NQH, NQF Transfer Case
Clutch Reset Procedure
One additional service area is the
need for the TCCM to relearn the
transfer case clutch. You can perform
this process with a scan tool. If a scan
tool isn’t available, you can use the
vehicle’s electronics.
You must perform the clutch
relearn process after any of these situ-
ations:
• The transfer case was replaced.
• The TCCM was replaced or repro-
grammed.
• The transfer case was rebuilt or
internal repairs were performed.
Clutch reset with a scan tool:
• Key on, engine off.
• Access the Special Functions menu
with your scan tool.
• Select Clutch Reset Procedure
(Motor Learn Procedure).
When the Clutch Reset Procedure
is initiated, you should hear the motor
engage, indicating a successful learn
procedure.
Clutch reset without a scan tool:
• Key set to accessory.
• Switch into the 2 High mode.
• Turn the switch clockwise past
4 Low into the neutral request
mode and hold it for 30 seconds.
You should hear a noise from the
motor, indicating a successful learn
procedure.
As you can see, the new MP family
of transfer cases isn’t something you
should be afraid to tackle when one
comes your way. Next time we’ll look
at some of the common problems you
may see with these new units.
Until then, remember: The only
limits are, as always, those of vision.
Command
Motor Brake Voltage
Feedback
2 WD 7.5 Volts
Auto 0.5 V **
4 High 7.5 V
4 Low 7.5 V
A Look at the New MP Transfer Case
Figure 5
Figure 6
CHART 4

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ATRA’s Powertrain Expo
October 27 - 31
Las Vegas, NV Trade Show
co-hosted with
ATRA’s 2011 Powertrain Expo
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Why? Not only is ATRA hosting Expo in Vegas this year, but we will be teaming
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Learn the latest industry trends, network with tons of potential new partners
and do it in an exciting environment!
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Mention ATRA to get discounted
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Las Vegas Hilton
3000 Paradise Rd, Las Vegas, NV 89109
Phone: (800) 635-7711
ATRA’s 2011 Powertrain Expo
You need to be at ATRA’s 2011 Powertrain Expo.
Why? Not only is ATRA hosting Expo in Vegas this year, but we will be teaming
with APRA on the foor show to give you two tradeshows under one roof. You
get all the technical and management expertise that ATRA consistently pro-
vides, plus the showcasing of new parts from APRA members.
Learn the latest industry trends, network with tons of potential new partners
and do it in an exciting environment!
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October 30 - Nov 1: $169
Mention ATRA to get discounted
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Las Vegas Hilton
3000 Paradise Rd, Las Vegas, NV 89109
Phone: (800) 635-7711
ATRA’s 2011 Powertrain Expo
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thursday, october 27
2:00pm - 6:00pm Attendee Registration
Management Seminars
3:00pm - 6:00pm
The Importance of Processes & Procedures in a Crisis - Martin Brooks (Christschurch, New Zealand)
Transformational Thinking - Dennis Madden & Rodger Bland (ATRA)
Technical Seminars
3:00pm - 6:00pm
The Quick Fixes You Need Right Now - Lance Wiggins & Randall Schroeder (ATRA)
friday, october 28
8:00am - 3:00pm Attendee Registration
8:00am - 9:00am ATRA Member Meeting
Management Seminars
9:00am - 12:00pm
Yes You Can!™ - Bob Cooper (Elite Worldwide, Inc)
Technical Seminars
9:00am - 10:00am
A Shop’s Guide to Cost Savings, the Green & Safe Way - Carl Mustari (Chattahoochee Tech College)
Focusing on What You Need to Fix Transmissions TODAY - Dave Skora (Valve Body Pros)
Technical Seminars
10:00am - 11:00am
CAN BUS: A Simplistic But Intuitive View - Bill Henney (Bluereach Automation & Control Ltd)
Street Smart - Mike Brown (ATRA)
Technical Seminars
11:00am - 12:00pm
Diagnostic Breakdowns - Sean Boyle (Southern Illinois University)
Servicing & Repairing Chrysler Transmissions A to Z - Alan McAvory (Chrysler Midwest Business Center)
Management Seminars
1:00pm - 5:00pm
Success or Struggle? You Decide! - Maylan Newton (ESi)
The Four Gears in Online Marketing - Danny Sanchez (Autoshop Solutions)
Technical Seminars
1:00pm - 2:30pm
Electro-Hydraulic & Mechatronic Control - Bob Warnke (Sonnax)
LCT 1000 Problems & Updates - Steve Garrett (ATRA)
Technical Seminars
2:45pm - 4:15pm
What Are You Doing to Reduce Comebacks? - Bill Brayton (ATRA)
Vital Voltage Drop Tests You Should Know - Dan Marinucci (Communique)
Technical Seminars
4:30pm - 6:00pm
Is It The Torque Converter or the Transmission? - Joe Rivera (ProTorque)
Ford Powertrain-Fixing It Right the First Time - Stevie LaVallee (TEST Research)
saturday, october 29
8:00am - 3:00pm Attendee Registration
Management Seminars
9:00am - 12:00pm
Creating a Customer...For Free! - Scott Harris (Mustang Marketing)
Step Into the Thinking Room - Coach Ron Tunic (CRT Broadcasting)
Technical Seminars
9:00am - 10:30am
Real World Problems & Corrections - John Parmenter (Precision International)
Hybrid Service & Repair for Transmission Techs - Jack Rosebro (Perfect Sky)
Technical Seminars
10:30am - 12:00pm
4EAT, Phase II, 4AT or 5AT Which Is It? - Mike Souza (ATRA)
Chrysler CVT & Product Line Tests and Reviews - Randall Schroeder (ATRA)
1:00pm - 2:00pm ATRA Luncheon
2:00pm - 5:00pm Trade Show
5:00pm - 7:00pm Cocktail Reception
sunday, october 30
8:00am - 10:00am Supplier Meeting & 2012 Exhibitor Booth Drawing
9:00am - 2:00pm Attendee Registration
Management Seminars
9:00am - 12:00pm
Green Eggs & Ham Power Breakfast - Scott Johnson
Round Table Q&A - What’s Working Management Team
Technical Seminars
9:00am - 10:30am
Supplier Showcase: Sonnax
Supplier Showcase: Auto Research Design
Technical Seminars
10:30am - 12:00pm
Supplier Showcase: Mustang Dyno
12:00pm - 5:00pm Trade Show
monday, october 31
9:00am - 1:00pm Attendee Registration
9:00am - 2:00pm Trade Show
ATRA’s 2011 Powertrain Expo
You need to be at ATRA’s 2011 Powertrain Expo.
Why? Not only is ATRA hosting Expo in Vegas this year, but we will be teaming
with APRA on the foor show to give you two tradeshows under one roof. You
get all the technical and management expertise that ATRA consistently pro-
vides, plus the showcasing of new parts from APRA members.
Learn the latest industry trends, network with tons of potential new partners
and do it in an exciting environment!
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s
October 25-29: $105
October 30 - Nov 1: $169
Mention ATRA to get discounted
rate before October 6, 2011
Las Vegas Hilton
3000 Paradise Rd, Las Vegas, NV 89109
Phone: (800) 635-7711
thursday | seminars seminars | friday
thursday
october 27
2:00pm - 6:00pm
Attendee Registration
3:00pm - 6:00pm
Technical & Management Seminars
3:00pm - 6:00pm
Management Seminars
The Importance of Processes and Procedures in
a Crisis
Martin Brooks (Christschurch, New Zealand)
Last February, Martin’s two transmission shops were hit by
a major earthquake. He’ll explain how having well defned
processes and procedures helped with a quick recovery
while other businesses struggled. And, while you may never
experience a major earthquake, you’ll see how having clear
processes and procedures in place can be your lifeline
during times of crisis.
Creating a Customer...For Free!
Dennis Madden & Rodger Bland (ATRA)
ATRA’s Dennis Madden and Rodger Bland will help you
examine the different ways that your thought processes
can infuence your shop’s success or failure. You’ll see how
transforming your thinking to alter your attitude toward your
business can have a dramatic effect on how your custom-
ers view you and your shop.
Most importantly, you’ll discover the value of building your
customers’ trust, and how that trust can help eliminate the
stumbling blocks that so many shops face when dealing
with potential customers.
3:00pm - 6:00pm
Technical Seminars
The Quick Fixes to “Get the Customer Out the
Door ”
Lance Wiggins & Randall Schroeder (ATRA)
The latest fxes and quick tips to help you get the customer
out the door as soon as you get back to the shop. This
program will have the latest transmission failures and the
repairs based on the past year of ATRA HotLine calls.
Transformational Thinking:
A Look Back… A Look Ahead
It’s been 5 years since we first
started to examine what makes
one shop successful while others
struggle. Every step of the way
added a new piece to the puzzle,
until we got a clear view of the
picture. The difference, it seems, is
all in your head.
At this year’s Management
Seminar Program, we’ll focus on
you. We’ll look at how you view
your business, and the need to
transform your thought processes
to redefine what it takes to build
a successful transmission repair
business.
44 ATRA’s Powertrain Expo ATRA’s Powertrain Expo
ATRA’s 2011 Powertrain Expo
You need to be at ATRA’s 2011 Powertrain Expo.
Why? Not only is ATRA hosting Expo in Vegas this year, but we will be teaming
with APRA on the foor show to give you two tradeshows under one roof. You
get all the technical and management expertise that ATRA consistently pro-
vides, plus the showcasing of new parts from APRA members.
Learn the latest industry trends, network with tons of potential new partners
and do it in an exciting environment!
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October 25-29: $105
October 30 - Nov 1: $169
Mention ATRA to get discounted
rate before October 6, 2011
Las Vegas Hilton
3000 Paradise Rd, Las Vegas, NV 89109
Phone: (800) 635-7711
thursday | seminars seminars | friday
friday
october 28
8:00am - 3:00pm
Attendee Registration
8:00am - 9:00am
ATRA Member Meeting
9:00am - 12:00pm
Technical & Management Seminars
1:00pm - 5:00pm
Management Seminars
1:00pm - 6:00pm
Technical Seminars
3:00pm - 5:00pm
Management Seminars
The Four Gears in Online Marketing
Danny Sanchez (Autoshop Solutions)
There’s no question consumers are looking to the internet
for services. But when they Google phrases like transmission
repair, are they going to fnd your shop? And will they call
when they see your web site? Danny Sanchez, a 23-year
automotive veteran, AMI instructor, and president of Au-
toshop Solutions, will help you understand the Four Gears
of online marketing. From web site design, search engine
optimization (SEO), search engine marketing (SEM or PPC),
to social media marketing, Danny will detail the important
factors and key indicators to help you build a strong pres-
ence and draw more customers.
9:00am - 12:00pm
Management Seminars
Yes You Can!™
Bob Cooper (Elite Worldwide, Inc)
When it comes to building a more proftable, successful
shop, Bob Cooper says… “Yes you can!” He was one of
the frst to predict vehicle leasing programs, the trend in
auto maintenance, and the dealers aggressively target-
ing the service and repair business. He also accurately
predicted many shops would take on additional service
lines, and he’s brought many trend-setting marketing and
sales techniques to our industry. Join us, and not only will
Bob shares his vision of the future with you, but you will have
the rare opportunity during each Q&A session to fnd the
answers you have been looking for that will take you and
your shop right to the top.
This is what you will learn at this powerful, interactive session:
• What the future of the auto repair industry holds
for you
• What the new car dealers are doing and why
• How to fnd and hire the stars during these
changing times
• How to best market to today’s savvy consumer
• Benchmarks of the top shops in America
• How to drive up sales, profts and the value of
your shop
1:00pm - 3:00pm
Management Seminars
Success or Struggle? You Decide!
Maylan Newton (ESi)
How do you see the world? Believe it or not, how you
perceive your business has a lot to do with your success…
or lack of it.
In this seminar, Maylan defnes and categorizes some of the
most common personality types and attitudes in today’s
shop owners, and shows how those attitudes can shape
their business success, or, in some cases, sabotage their
career goals. And he discusses ways you can reinvent your
attitudes to help support yourself in the future.
ATRA’s Powertrain Expo ATRA’s Powertrain Expo 45
ATRA’s 2011 Powertrain Expo
You need to be at ATRA’s 2011 Powertrain Expo.
Why? Not only is ATRA hosting Expo in Vegas this year, but we will be teaming
with APRA on the foor show to give you two tradeshows under one roof. You
get all the technical and management expertise that ATRA consistently pro-
vides, plus the showcasing of new parts from APRA members.
Learn the latest industry trends, network with tons of potential new partners
and do it in an exciting environment!
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October 25-29: $105
October 30 - Nov 1: $169
Mention ATRA to get discounted
rate before October 6, 2011
Las Vegas Hilton
3000 Paradise Rd, Las Vegas, NV 89109
Phone: (800) 635-7711
friday | seminars seminars | friday
friday
october 28
(cont’d from pg 5)
8:00am - 3:00pm
Attendee Registration
8:00am - 9:00am
ATRA Member Meeting
9:00am - 12:00pm
Technical & Management Seminars
1:00pm - 5:00pm
Management Seminars
1:00pm - 6:00pm
Technical Seminars
friday | seminars (cont’d from pg 5) seminars | friday
ATRA will be providing
power extension cords in
designated rows in each
seminar room for those
attendees that plan on
bringing their laptops. These
spaces are limited so please
plan to arrive early.
9:00am - 10:00am
Technical Seminars
A Shop’s Guide to Cost Savings, the Green and
Safe Way
Carl Mustari (Chattahoochee Tech College)
In these lean times, Carl will present guidance to shop man-
agers on ways to reduce cost through effcient use of en-
ergy, waste oil heaters, shop lighting, recycling waste, flters,
batteries, etc. Also included is an overview of shop safety
with an emphasis on how shops can save their resources so
that their overhead can be reduced...the GREEN way.
Focusing on What You Need to Fix Transmissions
TODAY
Dave Skora (Valve Body Pros)
Dave understands the frustrations technicians face every-
day. If you want help solving problems quickly without a lot
of theory or time-wasting tests, this may be the seminar for
you.
10:00am - 11:00am
Technical Seminars
Street Smart: Is It Really a Transmission Problem?
Mike Brown (ATRA)
Before you make a decision to remove the transmission,
make sure it’s NOT the transmission.
CAN BUS: A Simplistic But Intuitive View
Bill Henney (Bluereach Automation &
Control Ltd)
A simple to understand look at why we need the CAN
system and how it affects us in the transmission industry. After
this session, you will be able to confdently work on CAN
enabled vehicles. We will also look at the principal of the
Lepellitier model.
46 ATRA’s Powertrain Expo
ATRA’s 2011 Powertrain Expo
You need to be at ATRA’s 2011 Powertrain Expo.
Why? Not only is ATRA hosting Expo in Vegas this year, but we will be teaming
with APRA on the foor show to give you two tradeshows under one roof. You
get all the technical and management expertise that ATRA consistently pro-
vides, plus the showcasing of new parts from APRA members.
Learn the latest industry trends, network with tons of potential new partners
and do it in an exciting environment!
L
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s
October 25-29: $105
October 30 - Nov 1: $169
Mention ATRA to get discounted
rate before October 6, 2011
Las Vegas Hilton
3000 Paradise Rd, Las Vegas, NV 89109
Phone: (800) 635-7711
friday | seminars seminars | friday
11:00am - 12:00pm
Technical Seminars
Diagnostic Breakdowns
Sean Boyle (Southern Illinois University)
Money and time aren’t the only things lost when a repair
comes back - customer confdence is lost as well.
• Learn effective diagnostic strategies
• Determine the root-cause of failures
• Learn how to approach no-code diagnostics
• Learn how to avoid diagnostic failures and
misdirection
Servicing & Repairing Chrysler Transmissions
A to Z
Alan McAvory (Chrysler Midwest
Business Center)
This presentation includes an update on current Chrysler
Automatic Transmission application, diagnostic, service and
repair procedures. An overview on how to access to Chr-
syler Service information, interpretation of Scan Tool data
and Flash Programing procedures:
• Application and Identifcation
• Service Information and Maintenance
• Accessing Chrysler Service & Parts Information
• Diagnosis & Repair
• Scan Tool Information
• DTC Event Data
• Flash Programming
• Electrical Connector Repairs
1:00pm - 2:30pm
Technical Seminars
Electro-Hydraulic & Mechatronic Control
Bob Warnke (Sonnax)
Common problems and methods for diagnosis:
•AISIN 6 speeds •AISIN 55-50/51 •ZF 6 HP/Ford 6R60
•722.6 / NAG1 / 722.9 •Chrysler 545RFE •Ford 6R140
•Ford 5R110 •GM 6L80E / 6T40E
LCT 1000 Problems & Updates
Steve Garrett (ATRA)
We will take a look at the problems you commonly face
with the LCT 1000. How do you diagnose them and how
do you repair them. In addition, we look at the “MAJOR”
product changes for the 2010-2011 model years and how
friday | seminars (cont’d from pg 5) seminars | friday
they impact your repairs on this unit. Parts interchangeability
is becoming an issue with this unit and we will explore the
interchange issues regarding the updated parts.
2:45pm - 4:15pm
Technical Seminars
What Are You Doing to Reduce Comebacks?
Bill Brayton (ATRA)
This seminar/discussion forum will bring techniques and
procedures used by top builders/owners in the industry to
reduce comebacks in their shops.
This seminar will look at late model transmission problem
areas and methods used to solve these problems whether
it is with a product or a procedure that the technicians cre-
ated to solve his/her particular issue.
Vital Voltage Drop Tests You Should Know
Dan Marinucci (Communiqué)
First, Dan covers the basics of voltage drop testing. Then
he applies that knowledge to solving some common elec-
trical problems technicians encounter. Both experienced
and inexperienced techs will appreciate the practical tips
presented here!
• Theory of voltage drop
• Practical applications of voltage drop
• Problem solving with voltage drop
• Typical voltage drop values
• Money-making tips on this technique
4:30pm - 6:00pm
Technical Seminars
Is It the Torque Converter or the Transmission?
Joe Rivera (ProTorque)
Joe takes you through a journey of problems that can easily
be fxed. This seminar will cover the most common problems
associated with the torque converter and how to repair it.
Ford Powertrain -- Fixing It Right The First Time
Stevie LaVallee (TEST Research)
Stevie will be covering late model Ford transmissions includ-
ing the newer six speeds and the increasingly popular CVT.
Learn the principles of operation, systematic diagnostic
routines, repair tips, and the importance of using fash
reprogramming strategy revisions in the repair process.
ATRA’s Powertrain Expo
ATRA’s 2011 Powertrain Expo
You need to be at ATRA’s 2011 Powertrain Expo.
Why? Not only is ATRA hosting Expo in Vegas this year, but we will be teaming
with APRA on the foor show to give you two tradeshows under one roof. You
get all the technical and management expertise that ATRA consistently pro-
vides, plus the showcasing of new parts from APRA members.
Learn the latest industry trends, network with tons of potential new partners
and do it in an exciting environment!
L
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A
c
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s
October 25-29: $105
October 30 - Nov 1: $169
Mention ATRA to get discounted
rate before October 6, 2011
Las Vegas Hilton
3000 Paradise Rd, Las Vegas, NV 89109
Phone: (800) 635-7711
saturday | seminars seminars | saturday
saturday
october 29
7:00am - 9:00am
Chapter President’s Meeting
8:00am - 3:00pm
Attendee Registration
9:00am - 12:00pm
Technical & Management Seminars
1:00pm - 2:00pm
ATRA Luncheon
2:00pm - 5:00pm
Trade Show Open
5:00pm - 7:00pm
Cocktail Reception
9:00am - 12:00pm
Management Seminars
Creating a Customer...For Free
Scott Harris (Mustang Marketing)
We’ve discovered through the What’s Working study that
one of the most successful ways of generating new custom-
ers is by increasing your shop’s involvement in the commu-
nity. Part of that means making sure the community knows
about that involvement!
Scott Harris, is the owner and president of Mustang Market-
ing a full service marketing company specializing in taking
their clients right to the top with proven marketing and
public relation strategies.
In fact, Mustang Marketing is the same company ATRA used
to brand the ATRA logo and website to the motoring pub-
lic. How’s that working? To date, ATRA is the most viewed
website in our entire industry!*
In this seminar attendees will learn how to create and dis-
tribute press releases that not only inform, but promote your
company’s true concern for the community it serves. Wheth-
er it’s an upcoming car care clinic, local fund raiser, or other
event supporting your community – getting the word out in
a targeted fashion is a win-win for both your shop and the
event it’s supporting – and the best part is, done right, most
if not all of the promotion is absolutely free! – So make sure
to pencil in this special bonus seminar at this year ’s expo.
Step Into The Thinking Room
Coach Ron Tunic (CRT Broadcasting)
Join Coach Ron for an inspiring session designed to help
you think like a leader, and more importantly, how to think for
yourself.
Learn to think the right way and you’ll make better choices.
Make better choices and you’ll see better opportunities.
Learn how to think and you will gain strength, self-conf-
dence and the ability to lead. If you’re ready to take the
leadership role in your own life, then you’re ready for the
Thinking Room!
Our Guarantee
To You:
We’re so confident of
your complete satisfaction
of our Technical &
Management seminars,
we’ll guarantee it in
writing: If, for any reason,
you aren’t 100% satisfied
with the information and
material you’ve received;
we will refund your entire
registration fees!
48 ATRA’s Powertrain Expo ATRA’s Powertrain Expo
ATRA’s 2011 Powertrain Expo
You need to be at ATRA’s 2011 Powertrain Expo.
Why? Not only is ATRA hosting Expo in Vegas this year, but we will be teaming
with APRA on the foor show to give you two tradeshows under one roof. You
get all the technical and management expertise that ATRA consistently pro-
vides, plus the showcasing of new parts from APRA members.
Learn the latest industry trends, network with tons of potential new partners
and do it in an exciting environment!
L
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A
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s
October 25-29: $105
October 30 - Nov 1: $169
Mention ATRA to get discounted
rate before October 6, 2011
Las Vegas Hilton
3000 Paradise Rd, Las Vegas, NV 89109
Phone: (800) 635-7711
saturday | seminars seminars | saturday
9:00am - 10:30am
Technical Seminars
Real World Problems & Corrections
John Parmenter (Precision International)
Get those cars fxed and back to the customer… fast!
That’s always your goal, and this class will help you do
just that. John will cover the fxes, R&R tips and tricks, as well
as pertinent items you never want to overlook during the
rebuilding process.
Hybrid Service & Repair for Transmission Techs
Jack Rosebro (Perfect Sky)
When servicing or repairing a hybrid transaxle or transmis-
sion, when do you need to disable a hybrid’s high-voltage
system, and how do you do it? How do you determine
that the system is safe to work on? How do you know that
a hybrid transaxle performance issue is not cause by the
vehicle’s battery pack or inverter? We’ll discuss those issues
as well as the more common hybrid transaxle faults that
technicians are seeing in the feld.
10:30am - 12:00pm
Technical Seminars
4EAT, Phase II, 4AT or 5AT Whis Is It?
Mike Souza (ATRA)
A look at the changes the 4 speed transmission has gone
through along with the introduction of the 5AT 5 speed.
The similarities between both the 4 speed and 5 speed
transmission.
Chrysler CVT & Product Line Tests and Reviews
Randall Schroeder (ATRA)
This class will delve into the Chrysler CVT: all the “things you
need to know” when repairing and testing these increas-
ingly common units. Along with the CVT information, you’ll
learn how to deal with problems and fxes for the TE/AE, RE
and RFE families of transmissions, followed by a question-
and-answer session.
ATRA’s Powertrain Expo ATRA’s Powertrain Expo 49
ATRA’s 2011 Powertrain Expo
You need to be at ATRA’s 2011 Powertrain Expo.
Why? Not only is ATRA hosting Expo in Vegas this year, but we will be teaming
with APRA on the foor show to give you two tradeshows under one roof. You
get all the technical and management expertise that ATRA consistently pro-
vides, plus the showcasing of new parts from APRA members.
Learn the latest industry trends, network with tons of potential new partners
and do it in an exciting environment!
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A
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s
October 25-29: $105
October 30 - Nov 1: $169
Mention ATRA to get discounted
rate before October 6, 2011
Las Vegas Hilton
3000 Paradise Rd, Las Vegas, NV 89109
Phone: (800) 635-7711
sunday | seminars
sunday
october 31
8:00am - 10:00am
Supplier Meeting &
Exhibitor Booth Drawing
9:00am - 2:00pm
Attendee Registration
9:00am - 12:00pm
Technical & Management Seminars
12:00pm - 5:00pm
Trade Show Open
4:00pm - 5:00pm
ATRA Longtimers’ Meeting
9:00am - 12:00pm
Management Seminars
Green Eggs & Ham Power Breakfast
with Scott Johnson
Whether your customers are on a train, in a plane, under a
box, or with a fox, you can bet they do not want to buy a
new transmission simply because that’s what you have to
sell.
In this early morning breakfast seminar, Scott will explain the
differences between a commodity-based business and a
service-oriented one. And you’ll learn how critical it is to
discover the needs of your customers, and how to address
those needs. Come in early and join us for breakfast; no
green eggs or ham… guaranteed!
Round Table Q&A
What’s Working Management Team
Immediately after the breakfast seminar, stick around for a
round table discussion covering the concepts we’ve been
discussing over the last few days. This Q&A will be hosted
by a few of our esteemed seminar trainers, and we’ll have
several shop owners on hand who’ve turned their busi-
nesses around by transforming their attitudes and rethinking
the way they approach their customers.
This is your chance to chime in and clarify the notions
you’ve been learning, and turn them into a new beginning
for your business… and your future. Don’t miss it!
9:00am - 10:30am
Technical Seminars
Supplier Showcase: Sonnax
Supplier Showcase: Auto Research & Design
10:30am - 12:00pm
Technical Seminars
Supplier Showcase: Mustang Dyno
A & Reds Transmission Parts
Adapt-A-Case
Alto Products Corporation
Amsoil Synthetic Lubricants
ATRA
Automotive Research & Design, LLC
Autoshop Solutions, Inc.
BorgWarner
Central Valve Bodies
Chrysler-Mopar
Dacco, Inc.
Demandforce, Inc.
Educational Seminars Institute (ESi)
Equipment Manufacturing Corp.
ETE Reman
EVT Parts
Exedy Friction Technics
Ford Customer Service Division
G Cor Automotive
Gandrud Parts Center
GEARS Magazine
General Motors
GFX Corp.
G-Tec Inc.
Hayden Automotive
HGM Electronics/PML Inc.
Jasper Engines & Transmissions
JDS Worldwide Corp.
KRS International
Kuhle
Lintex Auto Parts Co., LTD
Lubegard by International Lubricants, Inc.
A.I.M.
Auto Suppliers Limited
BPS Cores, Inc.
Car-Part.com
D&V Electronics Ltd.
D&W Diesel, Inc.
DCM Tech, Corp.
Dixie Electric Ltd
DS USA Ltd.
DuBois Marketing Inc.
Green Global Parts, Inc.
Guspro, Inc.
50 ATRA’s Powertrain Expo ATRA’s Powertrain Expo
sunday | seminars
exhibit
hours
2:00pm - 5:00pm
Saturday
12:00pm - 5:00pm
Sunday
9:00am - 2:00pm
Monday
co-hosted with
A & Reds Transmission Parts
Adapt-A-Case
Alto Products Corporation
Amsoil Synthetic Lubricants
ATRA
Automotive Research & Design, LLC
Autoshop Solutions, Inc.
BorgWarner
Central Valve Bodies
Chrysler-Mopar
Dacco, Inc.
Demandforce, Inc.
Educational Seminars Institute (ESi)
Equipment Manufacturing Corp.
ETE Reman
EVT Parts
Exedy Friction Technics
Ford Customer Service Division
G Cor Automotive
Gandrud Parts Center
GEARS Magazine
General Motors
GFX Corp.
G-Tec Inc.
Hayden Automotive
HGM Electronics/PML Inc.
Jasper Engines & Transmissions
JDS Worldwide Corp.
KRS International
Kuhle
Lintex Auto Parts Co., LTD
Lubegard by International Lubricants, Inc.
Management Feedback Systems, Inc.
Mustang Advanced Engineering
NATPRO
Northland Transmission Inc.
Oklahoma Transmission Supply, Inc. (OTS)
Omega Machine & Tool, Inc.
Power Pusher by Nu*Star, Inc.
Precision International
Precision of New Hampton/Hot Flush
ProftBoost Software, LLC
Raybestos Powertrain
Rostra Precision Controls, Inc.
Seal Aftermarket Products
Slauson Transmission Parts
Smart Blend Synthetics By Life Automotive
Products
Sonnax
STK Transmission Parts Co., LTD
SuperFlow Technologies Group
Superior Transmission Parts, Inc.
TRANSBRITE / Allen Woods & Assocates
Transmission Digest
Transmission Rebuilders Network Int’l (TRNi)
Transmission Rebuilders Network Worldwide
(TRNW)
Transmission Specialties, Inc.
Transtar Industries
TransTec by Corteco
Valeo Transmissions
Valve Body Pro
VBX-Valve Body Xpress
Whatever-It-Takes Transmission
A.I.M.
Auto Suppliers Limited
BPS Cores, Inc.
Car-Part.com
D&V Electronics Ltd.
D&W Diesel, Inc.
DCM Tech, Corp.
Dixie Electric Ltd
DS USA Ltd.
DuBois Marketing Inc.
Green Global Parts, Inc.
Guspro, Inc.
International Automotive Trading, Inc.
J&N Auto Electric
Knopf Automotive LLC
LR Miller Company, Inc.
Lewis Tool & Die, Inc.
LKQ Corporation
Lock-N-Stitch Inc.
Phoenix Automotive Cores
ProDiesel
Quality Equipment Sales
Rand Premium Electronics
RCP, Inc.
Rebuilders Automotive Supply Company
Regitar U.S.A., Inc.
Romaine Electric Corporation
Shenzhen Meridian Parts Company
STC Automotive, Inc.
Taditel U.S., Inc
The Recycler Core Company Inc.
Wagner Alternators & Supplies, Inc.
W Alglobal - Wetherill Associates Inc.
Xiamen Sunny General Machinery &
Electrical Co, Ltd
Zerust Corrosion Products
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ATRA’s Powertrain Expo ATRA’s Powertrain Expo 51
ATRA’s 2011 Powertrain Expo
You need to be at ATRA’s 2011 Powertrain Expo.
Why? Not only is ATRA hosting Expo in Vegas this year, but we will be teaming
with APRA on the foor show to give you two tradeshows under one roof. You
get all the technical and management expertise that ATRA consistently pro-
vides, plus the showcasing of new parts from APRA members.
Learn the latest industry trends, network with tons of potential new partners
and do it in an exciting environment!
L
a
s
V
e
g
a
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H
o
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A
c
c
o
m
m
o
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a
t
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o
n
s
October 25-29: $105
October 30 - Nov 1: $169
Mention ATRA to get discounted
rate before October 6, 2011
Las Vegas Hilton
3000 Paradise Rd, Las Vegas, NV 89109
Phone: (800) 635-7711
special events
friday, 10/28
8:00am - 9:00am
ATRA Member Meeting
You’ve heard it before: ATRA is your Association.
And the Member Meeting is your opportunity to
give voice to your opinions. This is the one time
every year that the ATRA Board and staff all meet
together in a forum with its Members to learn what
you want from ATRA. It’s your opportunity to help
shape ATRA’s future. Don’t miss out: Whether you’re
a Member or planning on becoming one, make
plans to join us at this year ’s Member Meeting.
saturday, 10/29
1:00pm - 2:00pm
ATRA Luncheon
After an intense morning of seminars, it’s time to sit
down to a sumptuous luncheon, courtesy of ATRA.
This is your frst real chance to rub elbows and
break bread with friends, old and new. Of course,
this is more than just a meal: It’s your chance to
enjoy entertainment, discuss what you’ve been
learning, and recharge your batteries as you
prepare to “shift gears” for an afternoon exploring
new products and services on the Expo show foor.
saturday, 10/29
5:00pm - 7:00pm
Cocktail Reception
For many, Expo doesn’t really kick into high gear
until the annual Cocktail Reception, as always,
hosted by Transtar Industries. Live music, an open
bar, and a wide selection of tasty hors d’oeuvres
are the backdrop for an evening of fun and
revelry, catching up with old friends, and meeting
new ones. It’s the industry networking event of the
year!
sunday, 10/30
8:00am - 9:00am
Industry Supplier Meeting
As a Supplier, your needs are different from those
of shop owners. You know it and so do we. That’s
why we’re holding our frst ever Industry Supplier
Meeting, right before the Exhibitor Booth Drawing.
We want to hear your thoughts and learn how we
can better serve the supply side of our industry.
Drop by, enjoy a continental breakfast on us, and
let’s discuss how we can address your needs.
sunday, 10/30
9:00am - 10:00am
2012 Exhibitor Booth Drawing
Immediately following the Industry Supplier Meeting,
stay for the Booth Drawing and reserve your spot
for the 2012 Expo to be held at Bally’s in Las
Vegas. Once again, sharing space with APRA and
leading into Industry Week.
What Works Best For You?
52 ATRA’s Powertrain Expo ATRA’s Powertrain Expo
ATRA’s 2011 Powertrain Expo
You need to be at ATRA’s 2011 Powertrain Expo.
Why? Not only is ATRA hosting Expo in Vegas this year, but we will be teaming
with APRA on the foor show to give you two tradeshows under one roof. You
get all the technical and management expertise that ATRA consistently pro-
vides, plus the showcasing of new parts from APRA members.
Learn the latest industry trends, network with tons of potential new partners
and do it in an exciting environment!
L
a
s
V
e
g
a
s
H
o
t
e
l


A
c
c
o
m
m
o
d
a
t
i
o
n
s
October 25-29: $105
October 30 - Nov 1: $169
Mention ATRA to get discounted
rate before October 6, 2011
Las Vegas Hilton
3000 Paradise Rd, Las Vegas, NV 89109
Phone: (800) 635-7711
special events
r
e
g
i
s
t
r
a
t
i
o
n

o
p
t
i
o
n
s
What Works Best For You?
Te
c
hnic
a
l o
r
M
a
na
g
e
m
e
nt C
o
nfe
re
nc
e
Thurs., O
c
t. 2
7
- S
un., O
c
t. 3
0
Attend either the Technical or M
anagement
seminars Thursday through Sunday, the Saturday
Luncheon & C
ocktail Reception, coffee breaks,
Saturday, Sunday & M
onday Trade Show
admission, and binders containing the Technical
Powerpoint printouts, Technical seminar program
C
D or M
anagement worksheet materials.
Trade Show Pass
Sat., Oct. 29 - Mon., Oct. 31
Your Trade Show Pass will give you access to
three full days in the exhibit hall and two shows
under one roof! ATRA & APRA have joined
forces once again to bring you more than 100
exhibitors!
Oct. 27 - 31
Las Vegas, NV
Las Vegas Hilton
Complete Conference
Thurs., Oct. 27 - Sun., Oct. 30
As a Complete Conference attendee you will
have access to all technical & management
seminars Thursday through Sunday, the Saturday
Luncheon & Cocktail Reception, coffee breaks,
Saturday, Sunday & Monday Trade Show
admission, binders containing the Technical
Powerpoint printouts, Technical seminar program
CD and Management worksheet materials,. Audio
CDs will be mailed to all Complete Conference
attendees after the Expo.
ATRA’s Powertrain Expo ATRA’s Powertrain Expo 53
ATRA’s 2011 Powertrain Expo
You need to be at ATRA’s 2011 Powertrain Expo.
Why? Not only is ATRA hosting Expo in Vegas this year, but we will be teaming
with APRA on the foor show to give you two tradeshows under one roof. You
get all the technical and management expertise that ATRA consistently pro-
vides, plus the showcasing of new parts from APRA members.
Learn the latest industry trends, network with tons of potential new partners
and do it in an exciting environment!
L
a
s
V
e
g
a
s
H
o
t
e
l


A
c
c
o
m
m
o
d
a
t
i
o
n
s
October 25-29: $105
October 30 - Nov 1: $169
Mention ATRA to get discounted
rate before October 6, 2011
Las Vegas Hilton
3000 Paradise Rd, Las Vegas, NV 89109
Phone: (800) 635-7711
can i register at the door?
Yes. The following are the dates and times for On-Site
Registration:
Thursday, October 27: 2pm - 6pm
Friday, October 28: 8am - 3pm
Saturday, October 29: 8am - 3pm
Sunday, October 30: 9am - 2pm
Monday, October 31: 9am - 1pm

what are the hotel rates?
ATRA has negotiated a $105 per night room rate for the
nights of October 25 - 29 and $169 per night for the nights of
October 30 - November 1. The cut-off dates for these special
rates is October 6. To make your reservations please call the
hotel directly at (800) 635-7711 and mention ATRA.
does ATRA make hotel reservations or is it included in
the cost of registration?
All attendees make their own hotel accommodations directly with
the Las Vegas Hilton by calling (800) 635-7711. Mention ATRA
to receive your discount room rate. Room reservations are not
included with your conference registration.
what are the registration cut-off dates for Expo?
The early registration cut-off date at the discount price is
9/16/11. The late registration cut-off date is 10/14/11. Any
registrations made after 10/14/11 will need to be done on-site
at the event.
did you receive my registration? am i registered?
Your confrmation will automatically be mailed to you immediately
after your registration is processed. Please contact ATRA at
(800) 428-8489 if you have not received your confrmation.
does my guest need to register?
Yes, everyone attending the seminars or trade show must have
an offcial badge and registration - except babies in strollers.
Spouses and children of conference registrants may be eligible
to receive free trade show access. Please call for details.
can i change one of my paid registrations from one
person to another?
Yes, you can switch the name on one or more of your
registrations up to 10 days before the event at no charge. Any
changes made within 10 days of the event will be charged $10
each. Call (800) 428-8489 with any changes you’d like to make.
frequently asked questions
what if i want to attend more than one seminar in a
session?
There will be audio tapes available for all of the seminar
sessions. All complete conference registrants will receive a free
audio CD which will be mailed at the end of the Expo.
4 Easy Ways to Register
Call: (800) 428-8489 or (805) 604-2000
Online: www.powertrainexpo.com
Send Reg form
by fax:
(805) 988-6761
Send Reg form
by mail:
ATRA Powertrain Expo Registration
2400 Latigo Ave
Oxnard, CA 93030
Registration Information
Enrollment is on a frst-come, frst-serve basis. Seating is limited by
room size. Seminars start promptly at their scheduled time. Arrive
early to be sure of good seating, and to meet with instructors
and other seminar attendees. Recording is not permitted.
What’s Included
Complete Conference: admission to all technical
& management seminars Thursday through Sunday, Saturday
Luncheon & Cocktail Reception, coffee breaks, Saturday,
Sunday & Monday Trade Show admission, binders containing
the Technical Powerpoint printouts, Technical seminar program
CD and Management worksheet materials. Audio CDs will be
mailed to all Complete Conference attendees after the Expo.
Technical or Management Conference: admission to
either the Technical or Management seminars Thursday through
Sunday, Saturday Luncheon & Cocktail Reception, coffee
breaks, Saturday, Sunday & Monday Trade Show admission, and
binders containing the Technical Powerpoint printouts, Technical
seminar program CD or Management worksheet materials.
Trade Show: admission to the trade show only
Cancellation Policy
All cancellation requests must be made in writing and mailed
to: ATRA’s Powertrain Expo Registration, 2400 Latigo Ave,
Oxnard, CA 93030 or FAX to (805) 988-6761. Cancellations
received before September 16, 2011 will be subject to a 5%
cancellation fee. Cancellations received between September
17, 2011 and October 14, 2011 will be subject to a 15%
cancellation fee. Cancellations received after October 14,
2011 will be subject to a 25% cancellation fee.
There will be no exceptions to this policy.
54 ATRA’s Powertrain Expo
ATRA’s 2011 Powertrain Expo
You need to be at ATRA’s 2011 Powertrain Expo.
Why? Not only is ATRA hosting Expo in Vegas this year, but we will be teaming
with APRA on the foor show to give you two tradeshows under one roof. You
get all the technical and management expertise that ATRA consistently pro-
vides, plus the showcasing of new parts from APRA members.
Learn the latest industry trends, network with tons of potential new partners
and do it in an exciting environment!
L
a
s
V
e
g
a
s
H
o
t
e
l


A
c
c
o
m
m
o
d
a
t
i
o
n
s
October 25-29: $105
October 30 - Nov 1: $169
Mention ATRA to get discounted
rate before October 6, 2011
Las Vegas Hilton
3000 Paradise Rd, Las Vegas, NV 89109
Phone: (800) 635-7711
frequently asked questions
Company Name ATRA Account Number
Contact Person: (will receive all correspondence)
Address
City State Zip
Country
Area Code Phone No. Fax No.
Email Address
( ) ( )
Registration Form
October 27
th
- 31
st
, 2011
Las Vegas, NV
TO REGISTER: Call toll free 1-800-428-8489 or FAX this completed form to 805-988-6761
Before Sept. 16
th
Sept. 17
th
- Oct. 14
th
ALL
REGISTRATION FEES Qty Member Non Mem Member Non Mem ON-SITE SUBTOTAL
Complete Conference Registrant* _____ $ 395 $ 495 $ 445 $ 545 $ 595 $____________
Technical or Management Conference* _____ 345 445 395 495 545 $____________
Trade Show _____ 10 10 10 10 30 $____________
Extra Luncheon Ticket _____ 45 45 45 45 65 $____________
(Included with Complete, Tech & Management Conferences)

TOTAL $____________
PAYMENT INFORMATION
* Check enclosed payable and mail to: ATRA, 2400 Latigo Avenue, Oxnard, CA 93030 Check # ___________________
Charge to: * MasterCard * Visa * AMEX * Discover
Card Number __________________________________________________________ Expiration Date Security Code
Print Name on Card ___________________________________________________________________ Signature _________________________________________________
Discount for current ATRA Members only. Join today and enjoy the member discount right away!
Badges will be issued from this list. Use a separate sheet for additional registrations.*
PLEASE PRINT CLEARLY

Complete Trade
Conference Technical Management Show Luncheon
NAME ______________________________________________________________________________ £ £ £ £ £
NAME ______________________________________________________________________________ £ £ £ £ £
NAME ______________________________________________________________________________ £ £ £ £ £
NAME ______________________________________________________________________________ £ £ £ £ £
NAME ______________________________________________________________________________ £ £ £ £ £
CONFERENCES
(Includes Luncheon and Trade Show)
I do not wish to receive any advertising or promotional material from Exhibitors.
*Conference Registrants may receive Trade Show Passes for spouse and/or children
by contacting ATRA Registration at 1-800-428-8489.
Other
Categories
ATRA’s Powertrain Expo
Every 5th Conference attendee is free!
Call ATRA for details
ATRA’s 2011 Powertrain Expo
You need to be at ATRA’s 2011 Powertrain Expo.
Why? Not only is ATRA hosting Expo in Vegas this year, but we will be teaming
with APRA on the foor show to give you two tradeshows under one roof. You
get all the technical and management expertise that ATRA consistently pro-
vides, plus the showcasing of new parts from APRA members.
Learn the latest industry trends, network with tons of potential new partners
and do it in an exciting environment!
L
a
s
V
e
g
a
s
H
o
t
e
l


A
c
c
o
m
m
o
d
a
t
i
o
n
s
October 25-29: $105
October 30 - Nov 1: $169
Mention ATRA to get discounted
rate before October 6, 2011
Las Vegas Hilton
3000 Paradise Rd, Las Vegas, NV 89109
Phone: (800) 635-7711
Together Again!
Powertrain Expo & Big R Show
Trade Show Dates
October 29 - 31
Las Vegas Hilton
Las Vegas, NV
O
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SUPPLIER
MEMBER
58 GEARS May/June 2011
I
was sitting at the kitchen counter
a few weeks ago, talking to my
brother about his 2004 F150. We
needed to replace the clutch fluid: His
truck has 260,000+ miles on it and the
fluid looked like chocolate milk.
As we were talking, my 16-year-
old daughter Paige was sitting with us.
Suddenly she started giggling hysteri-
cally. When I asked what was so funny,
she replied, “You guys are talking a
totally different language. I have no
idea what you’re saying.”
I chuckled, and explained what we
were talking about: What the clutch is,
how it works, what the fluid does, and
why it needed to be replaced. I found
myself explaining the repair in very
simple terms, and it worked. She under-
stood what we were going to do and it
made sense to her.
It’s All About
Communication
by Lance Wiggins
members.atra.com
www.atra.com
FROM THE TECH DIRECTOR
GEARS May/June 2011 59
Imagine how this would have
played out if the situation were
a little different: Instead of my
daughter listening to a conversa-
tion about my brother’s truck,
supposed she’d been a customer
asking about her car.
The customer’s already stressed
because her car has a problem. Add to
that the difficulty in asking a stranger
for help. And now she’s fighting to
understand an explanation laced with
jargon and tech-speak.
Some customers would head
straight for the door. And who could
blame them?
There’s a saying that goes, “If
you can’t dazzle them with brilliance,
baffle them with BS.” It’s a funny line,
and in some situations it might even be
a good strategy. But not when you’re
dealing with a customer who’s come
to your shop with a problem. There it’s
just bad business.
Remember, the customer’s con-
cerns go deeper than just “what’s
wrong,” or even whether you know
how to fix it. They’re also concerned
with whether you’re being honest with
them and giving them a fair price for
work they really need.
This can be especially true with
women who’ve never dealt with you or
your shop before. They’re often uneasy
about the reputation of auto mechanics:
One of the
services we’ve
been offering
lately at ATRA
has been to
answer consum-
er questions.
We get about
60 emails a
month through
the ATRA.com
web site.
Used, New
and Rebui l t
Hard Par t s
Sof t Par t s
El ect ri cal
Component s
& Fl ywheel s
The 2011
Sl auson Book
avai l abl e now
at Sl auson. com
… ask about custom
catalogs for your
business
Order Online 24/7 at www.slauson.com
Phone Hours: 7:00 am to 5:00 pm/ PST
Call (800) 421-5580 • Local (310) 768-2099
FAX ( 310) 768-8298 • Se habla Español!
Our Hard Parts Expertise saves you time, money and
headaches. We can do everything the BIG BOYS
can – and then some! Because, when it comes to
Hard Parts we literally Wrote the Book. In fact, you
probably have a Slauson Book in your shop right now
... and so do most other parts suppliers. Not only
that, but we were the frst to create a digital catalog
and ordering system, again setting the industry
standard for Hard Parts identifcation.

Slauson Transmission Parts
Making Hard Parts … Simple
60 GEARS May/June 2011
“They’ll sell you whatever they want
because they figure we won’t know the
difference.” By using big words and
industry jargon, you’re just reinforcing
their fears.
The key is learning to speak to
the customer; not at her… or him.
You have to reach out to her on her
level, and make sure she’s comfort-
able with your explanation. That
connection is essential for helping
develop the trust that’s a critical
part of the equation that defines
customer service.
One of the services we’ve
been offering lately at ATRA has
been to answer consumer ques-
tions. We get about 60 emails a
month through the ATRA.com web
site. Sometimes those questions
are very technical. But most of the
time, they’re asking us to verify
what they’ve been told, because
they’re experiencing a trust issue
with a shop or technician.
My job is to answer those ques-
tions as clearly as I can. Very often
that means breaking my explana-
tions down into simple terms and
concepts. Words and abbreviations
that we take for granted — like
TPS or EGR — have no real mean-
ing to the consumer. So I have to
explain those concepts in simpler
terms. And I have to relate those
systems to the problem they’re
having, so they know why it could
affect their car’s operation.
At the same time, I always
point them toward a nearby
ATRA Member shop to help them
through the specific conditions.
That way, if there’s additional ser-
vice necessary, we can help them
work through the problem and
come up with a solution that’ll
satisfy the consumer.
The object isn’t just to fix
their cars; it’s also to make sure
they’re comfortable with the solu-
tions. And most importantly, we
want to make sure they feel good
about having contacted ATRA and
brought their cars to an ATRA
Member shop.
Since we began offering this
program, I’ve received over 300
response emails from consumers
who’ve had their cars fixed, and
are planning to refer ATRA and the
ATRA Member shop to their friends.
It’s an important step toward build-
ing ATRA’s reputation as the name
to trust for transmission service and
repair. But it’s not something we can
do alone. You need to do your part by
remembering a key element of con-
sumer trust is all about communication.
It’s All About Communication
Milwaukee
Nashville
Los Angeles
Toronto
Bridgeport
Portland
Salt Lake City
Detroit
Vancouver
ATRA.com has become the most visited
Web site in the transmission industry.
Thousands of new customers have been using ATRA’s
Web site to fnd transmission repair shops in their area.
It can be. Being an ATRA member means ATRA
will place a link to your Web site on ATRA.com,
where customers can use the local search
feature to fnd shops in their area. This tool is
beginning to appear in top search results for
transmission repair on Google. This means
people looking for shops in search engines
are being directed to ATRA’s Web site and
ATRA members.
The page views have doubled since the launch
of ATRA’s local search feature. That’s potential
business you cannot even begin to gain strictly
from word-of-mouth referrals.
Your Web site is an essential tool to get
transmissions in need of repair into your shop.
Now it can be even more powerful. Join ATRA
today and start reaping the benefts of ATRA’s
Web presence.

Visit members.ATRA.com
or call 805-604-2000
AUTOMATIC TRANSMISSION
REBUILDERS ASSOCIATION
Cleveland
ATRA.com ATRA.com
Vancouver
Driving
CUstomers
Driving
CUstomers
Driving
CUstomers
to yoU
Driving
CUstomers
to yoU
is your shop one of them?
Milwaukee
Nashville
Los Angeles
Toronto
Bridgeport
Portland
Salt Lake City
Detroit
Vancouver
ATRA.com has become the most visited
Web site in the transmission industry.
Thousands of new customers have been using ATRA’s
Web site to fnd transmission repair shops in their area.
It can be. Being an ATRA member means ATRA
will place a link to your Web site on ATRA.com,
where customers can use the local search
feature to fnd shops in their area. This tool is
beginning to appear in top search results for
transmission repair on Google. This means
people looking for shops in search engines
are being directed to ATRA’s Web site and
ATRA members.
The page views have doubled since the launch
of ATRA’s local search feature. That’s potential
business you cannot even begin to gain strictly
from word-of-mouth referrals.
Your Web site is an essential tool to get
transmissions in need of repair into your shop.
Now it can be even more powerful. Join ATRA
today and start reaping the benefts of ATRA’s
Web presence.

Visit members.ATRA.com
or call 805-604-2000
AUTOMATIC TRANSMISSION
REBUILDERS ASSOCIATION
Cleveland
ATRA.com ATRA.com
Vancouver
Driving
CUstomers
Driving
CUstomers
Driving
CUstomers
to yoU
Driving
CUstomers
to yoU
is your shop one of them?
Milwaukee
Nashville
Los Angeles
Toronto
Bridgeport
Portland
Salt Lake City
Detroit
Vancouver
ATRA.com has become the most visited
Web site in the transmission industry.
Thousands of new customers have been using ATRA’s
Web site to fnd transmission repair shops in their area.
It can be. Being an ATRA member means ATRA
will place a link to your Web site on ATRA.com,
where customers can use the local search
feature to fnd shops in their area. This tool is
beginning to appear in top search results for
transmission repair on Google. This means
people looking for shops in search engines
are being directed to ATRA’s Web site and
ATRA members.
The page views have doubled since the launch
of ATRA’s local search feature. That’s potential
business you cannot even begin to gain strictly
from word-of-mouth referrals.
Your Web site is an essential tool to get
transmissions in need of repair into your shop.
Now it can be even more powerful. Join ATRA
today and start reaping the benefts of ATRA’s
Web presence.

Visit members.ATRA.com
or call 805-604-2000
AUTOMATIC TRANSMISSION
REBUILDERS ASSOCIATION
Cleveland
ATRA.com ATRA.com
Vancouver
Driving
CUstomers
Driving
CUstomers
Driving
CUstomers
to yoU
Driving
CUstomers
to yoU
is your shop one of them?
Milwaukee
Nashville
Los Angeles
Toronto
Bridgeport
Portland
Salt Lake City
Detroit
Vancouver
ATRA.com has become the most visited
Web site in the transmission industry.
Thousands of new customers have been using ATRA’s
Web site to fnd transmission repair shops in their area.
It can be. Being an ATRA member means ATRA
will place a link to your Web site on ATRA.com,
where customers can use the local search
feature to fnd shops in their area. This tool is
beginning to appear in top search results for
transmission repair on Google. This means
people looking for shops in search engines
are being directed to ATRA’s Web site and
ATRA members.
The page views have doubled since the launch
of ATRA’s local search feature. That’s potential
business you cannot even begin to gain strictly
from word-of-mouth referrals.
Your Web site is an essential tool to get
transmissions in need of repair into your shop.
Now it can be even more powerful. Join ATRA
today and start reaping the benefts of ATRA’s
Web presence.

Visit members.ATRA.com
or call 805-604-2000
AUTOMATIC TRANSMISSION
REBUILDERS ASSOCIATION
Cleveland
ATRA.com ATRA.com
Vancouver
Driving
CUstomers
Driving
CUstomers
Driving
CUstomers
to yoU
Driving
CUstomers
to yoU
is your shop one of them?
Milwaukee
Nashville
Los Angeles
Toronto
Bridgeport
Portland
Salt Lake City
Detroit
Vancouver
ATRA.com has become the most visited
Web site in the transmission industry.
Thousands of new customers have been using ATRA’s
Web site to fnd transmission repair shops in their area.
It can be. Being an ATRA member means ATRA
will place a link to your Web site on ATRA.com,
where customers can use the local search
feature to fnd shops in their area. This tool is
beginning to appear in top search results for
transmission repair on Google. This means
people looking for shops in search engines
are being directed to ATRA’s Web site and
ATRA members.
The page views have doubled since the launch
of ATRA’s local search feature. That’s potential
business you cannot even begin to gain strictly
from word-of-mouth referrals.
Your Web site is an essential tool to get
transmissions in need of repair into your shop.
Now it can be even more powerful. Join ATRA
today and start reaping the benefts of ATRA’s
Web presence.

Visit members.ATRA.com
or call 805-604-2000
AUTOMATIC TRANSMISSION
REBUILDERS ASSOCIATION
Cleveland
ATRA.com ATRA.com
Vancouver
Driving
CUstomers
Driving
CUstomers
Driving
CUstomers
to yoU
Driving
CUstomers
to yoU
is your shop one of them?
Milwaukee
Nashville
Los Angeles
Toronto
Bridgeport
Portland
Salt Lake City
Detroit
Vancouver
ATRA.com has become the most visited
Web site in the transmission industry.
Thousands of new customers have been using ATRA’s
Web site to fnd transmission repair shops in their area.
It can be. Being an ATRA member means ATRA
will place a link to your Web site on ATRA.com,
where customers can use the local search
feature to fnd shops in their area. This tool is
beginning to appear in top search results for
transmission repair on Google. This means
people looking for shops in search engines
are being directed to ATRA’s Web site and
ATRA members.
The page views have doubled since the launch
of ATRA’s local search feature. That’s potential
business you cannot even begin to gain strictly
from word-of-mouth referrals.
Your Web site is an essential tool to get
transmissions in need of repair into your shop.
Now it can be even more powerful. Join ATRA
today and start reaping the benefts of ATRA’s
Web presence.

Visit members.ATRA.com
or call 805-604-2000
AUTOMATIC TRANSMISSION
REBUILDERS ASSOCIATION
Cleveland
ATRA.com ATRA.com
Vancouver
Driving
CUstomers
Driving
CUstomers
Driving
CUstomers
to yoU
Driving
CUstomers
to yoU
is your shop one of them?
Milwaukee
Nashville
Los Angeles
Toronto
Bridgeport
Portland
Salt Lake City
Detroit
Vancouver
ATRA.com has become the most visited
Web site in the transmission industry.
Thousands of new customers have been using ATRA’s
Web site to fnd transmission repair shops in their area.
It can be. Being an ATRA member means ATRA
will place a link to your Web site on ATRA.com,
where customers can use the local search
feature to fnd shops in their area. This tool is
beginning to appear in top search results for
transmission repair on Google. This means
people looking for shops in search engines
are being directed to ATRA’s Web site and
ATRA members.
The page views have doubled since the launch
of ATRA’s local search feature. That’s potential
business you cannot even begin to gain strictly
from word-of-mouth referrals.
Your Web site is an essential tool to get
transmissions in need of repair into your shop.
Now it can be even more powerful. Join ATRA
today and start reaping the benefts of ATRA’s
Web presence.

Visit members.ATRA.com
or call 805-604-2000
AUTOMATIC TRANSMISSION
REBUILDERS ASSOCIATION
Cleveland
ATRA.com ATRA.com
Vancouver
Driving
CUstomers
Driving
CUstomers
Driving
CUstomers
to yoU
Driving
CUstomers
to yoU
is your shop one of them?
Milwaukee
Nashville
Los Angeles
Toronto
Bridgeport
Portland
Salt Lake City
Detroit
Vancouver
ATRA.com has become the most visited
Web site in the transmission industry.
Thousands of new customers have been using ATRA’s
Web site to fnd transmission repair shops in their area.
It can be. Being an ATRA member means ATRA
will place a link to your Web site on ATRA.com,
where customers can use the local search
feature to fnd shops in their area. This tool is
beginning to appear in top search results for
transmission repair on Google. This means
people looking for shops in search engines
are being directed to ATRA’s Web site and
ATRA members.
The page views have doubled since the launch
of ATRA’s local search feature. That’s potential
business you cannot even begin to gain strictly
from word-of-mouth referrals.
Your Web site is an essential tool to get
transmissions in need of repair into your shop.
Now it can be even more powerful. Join ATRA
today and start reaping the benefts of ATRA’s
Web presence.

Visit members.ATRA.com
or call 805-604-2000
AUTOMATIC TRANSMISSION
REBUILDERS ASSOCIATION
Cleveland
ATRA.com ATRA.com
Vancouver
Driving
CUstomers
Driving
CUstomers
Driving
CUstomers
to yoU
Driving
CUstomers
to yoU
is your shop one of them?
DRIVING Customers
TO YOU
62 GEARS May/June 2011
F
or years the answer was fairly
simple… and pretty much the
same in every transmission
shop across the country. If the trans-
mission is broken, you had one choice:
rebuild it. Simple, right?
Maybe not. In fact, today, a number
of shops are proving that the “rebuild
only” business model isn’t the only way
to run a successful transmission shop.
For years now, ATRA’s CEO
Dennis Madden has stressed the impor-
tance of discovering and addressing
your customers’ needs. It’s a legitimate
consideration, and one that’s easy to
forget about when confronted with the
dollar signs for a transmission rebuild.
Keep in mind that one of those
needs often involves cost. Sure, the cus-
tomer’s transmission is broken or worn
out; he has to get it fixed if he’s going
to put his car back on the road. But if he
can’t scrape together the $3500 to pay
for a full rebuild, nothing you can say
or do is going to change that.
The rebuild-only mentality began
in a different era. Back then a rebuild
would cost maybe $300 or $400 — a
lot of money in those days, but there
wasn’t much you could save and still
provide a respectable repair. Once you
had the transmission on the bench you
were committed to the bulk of the job.
The parts were only a few bucks, so
skipping a clutch pack wasn’t going to
save anything.
Used transmissions? They were
a crapshoot, because cars didn’t get
pieced out until they had a lot of miles
on them. And remans hadn’t become a
viable solution… yet.
Today a lot has changed in the
transmission business (seriously, is
there any way I can get paid for every
time I say that?) Today, $3000 for a
rebuild may mean the customer got
lucky!
But those changes have created
a number of viable options for you
and your customers… options that
make it possible for you to help meet
their financial needs, while still allow-
ing you to earn a reasonable profit.
Those options include remans, targeted
repairs, and even used units.
Think that’s just giving up? Or giv-
ing in? I talked to a couple shop own-
ers who are taking advantage of those
options and are enjoying record sales
because of them.
Six years ago, Glen Burnie
Transmissions in Maryland was just
scraping by, according to shop owner
Mark Schwartzman. They had over
50 employees, including nine rebuild-
ers. Then Mark transformed his way
of thinking: He started by becoming
a regional distributor for Certified
Transmission.
Today Glen Burnie has 18 employ-
ees and no rebuilders. And last year
they did nearly $6 million in business!
A fluke? This year he’s on track to
beat those sales by about 2%. Between
15-18% of those sales are “carryout”
units; transmissions bought by other
shops or individuals to install them-
selves.
The bulk of his business is sell-
ing remans and used transmissions.
He has a fulltime outside sales person,
Kimberly Hepburn, who introduces
other shops to their product line and
services.
Used transmissions? How can that
be profitable? Funny thing about that:
While our business was changing, so
was the insurance industry. And today,
many cars are totaled simply because
the airbags deployed. Which means
there are a lot of used transmissions
available with only 10 to 20 thousand
miles on them — just broken in.
What’s more, some of those trans-
missions are available for just a couple
hundred dollars. So Glen Burnie’s tech-
nicians can install a used unit for any-
where from $1200 to $1700 and still
make just as much as they would have
with a rebuild. And the customer saves
$1000 or more on the job.
As Mark explains, “I’ve already
spent the money for advertising to
bring the customers in the door. It
makes no sense to let them walk out
just because they can’t afford a $3000
repair… not when I can offer them a
lower-cost alternative, and still make a
good profit.”
The salvage yard offers Mark a
6-month, 6000-mile warranty on its
used units, and allows him to extend
the warranty for just a few bucks more.
Of course, not every transmis-
sion can be purchased used. Some are
known to have too many problems; oth-
ers cost too much to be profitable, when
they’re available at all.
And mileage matters: On one car,
20–30,000 miles is about the limit for
accepting a used transmission. On oth-
Sometimes a Rebuild
Isn’t the Only Answer
by Steve Bodofsky
members.atra.com
www.atra.com
GEARS May/June 2011 63
ers, 60–70,000 is still fine, as long as the oil looks clean and
the price is reasonable.
This is where experience comes in: You have to know
which transmissions are worth trying and which aren’t a good
risk. Take a look through your records for the last few years.
Does the unit tend to fail around 80,000 miles? Then you
won’t want to install anything with much more than 20,000
miles. But if the average mileage for a failure tends to be
closer to a quarter million miles, 60,000 miles is barely a drop
in the bucket.
Of course, Mark is an extreme case. He’s completely
transformed his business model from the standard transmis-
sion repair shop. But Glen Burnie Transmissions isn’t the only
shop that’s offering its customers alternatives to the high price
of rebuilds. Dave Riccio of Tri-City Transmission is doing it,
too (see the profile on Tri-City in the January/February 2011
issue of GEARS). And Dave has added another service alter-
native to the mix: targeted repair.
Sure, every transmission shop will replace a solenoid or
a valve body without selling a full rebuild. But once the unit
reaches the bench, most shops insist on going the rebuild
route.
This is where Dave differs. “We’ll sometimes install just
a torque converter in a car with 90,000 miles. Some shop
owners think I’m crazy for doing that. But if the converter
is the only problem and the customer really can’t afford a
rebuild, why not? We make a buck on the job and the cus-
tomer gets his car back on the road.”
Another place where Tri-City can sometimes save its
customers money is on front-wheel drive units, where the
differential is quiet and working okay. In that case they might
agree to leave the differential alone, and not run the case
through the parts washer. The customer saves a few hundred
dollars on the job, and still gets a transmission that works like
it just had a complete rebuild.
A big difference with today’s transmissions is parts cost.
Twenty years ago the clutches in a transmission might have
cost only five or ten bucks; there was no savings in rebuild-
ing one drum and not the others. But the clutches in today’s
transmissions can easily cost a few hundred dollars. So if the
customer’s up against it, and one or two clutch packs are okay,
there really may be a benefit in rebuilding just the drums that
are bad and leaving the rest alone.
Tri-City also offers used transmissions when they’re
available and are a reasonable alternative. But they go a step
further: They open the unit and check the clutches. Then they
replace the filter and the outside seals, and fill it with new oil.
That way they’re fairly confident that the used transmission
won’t leak, and will hold up for a reasonable amount of time.
One of the most critical considerations when offering the
customer a lower-cost alternative is communication. Dave
makes sure the customer understands that he isn’t getting a
rebuilt transmission, and that the job may involve a bit of risk.
And Dave offers to share that risk with the customer.
With used transmissions or targeted repairs, Dave offers a
limited, one-year, 12,000-mile warranty. The warranty is only
good at Tri-City: He doesn’t offer the Golden Rule Warranty,
and there’s no outside coverage, except in special cases.
And the warranty is 50-50: Both Dave and the customer
accept half the risk. If the job cost $1600, and the transmis-
sion fails while it’s under the warranty, Dave credits the cus-
tomer $800 toward the price of a rebuild.
As Dave sees it, he made money on the repair, so if he
has to cut into his profit on a rebuild to keep the customer
happy, it’s worth it. And since his rebuilders went through the
unit, he knows his risk is limited. How limited? Over the last
year, only one transmission had to come back for a warranty
rebuild after a targeted repair. Not a bad average.
In addition to explaining the process to the customer,
Dave has a special warranty form, which explains the service
that was performed and the limits of the warranty. So the cus-
tomer should be well informed about the repair he paid for,
and the coverage he’s receiving.
That’s important, because, left to their own devices, cus-
tomers will remember that their transmission got fixed and
that they paid $1600 for it — still a lot of money to them. The
nuances of the repair and the difference between a targeted
repair and a rebuild can slip away over time. That’s why
it’s critical to spend the time to explain the differences, and
clarify those differences on the repair order and the warranty.
Sure, it’s nice to sell a full rebuild. And in some cases a
custom rebuild is still the best option for the customer. But
sometimes the customers’ needs won’t allow it; they just don’t
have the money.
That’s okay; today’s changes in the market have created
the conditions to provide a new series of options to address
those needs… options that can still provide you with a sub-
stantial profit… if you’re willing to embrace them.

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Ondra Terry
8222b
64 GEARS May/June 2011
O
ur story begins with a call to
the ATRA Technical Hotline
from a technician named
Kyle. Kyle said he was working on “a
Lincoln with an attitude.”
The car in question was a 2003
Lincoln LS equipped with a 3.0L engine,
and a 5R55N transmission with harsh
shifts at times (Figure 1). According
to Kyle, the owner of the vehicle said
he’d been having drivability problems
for the past few months: erratic engine
idle, “Check Engine” light flashing
occasionally, engine surge while driv-
ing, and of course, harsh shifting.
The customer had taken his car
to a couple local shops to check the
driveability issues. After checking the
computer system and replacing several
sensors, such as the mass airflow sen-
sor, TPS, and MAP, he was referred to
Kyle to have the transmission operation
checked.
Harsh Shifts Verified
Kyle drove the car and immediate-
ly felt the harsh shifts. He returned to
the shop, connected his scan tool, and
checked for codes; there weren’t any.
Then Kyle installed his pressure gauge
on the line pressure tap for the PCA
and PCSB (pressure control solenoids
A and B) circuits and headed out for
another test drive.
During this test drive, PCS
pressure would climb to over 220
PSI at the same time the harsh shifts
were taking place. The Lincoln had
a pressure problem.
Checking PCS Solenoid
Command
The next step was to check voltage

at the PCS solenoid, to see whether
the computer was commanding high
pressure. Kyle connected his voltmeter
to the PCS circuit (figure 2), close to
the PCM (figure 3), and headed out for
another test drive.
During the test drive, PCS circuit
amperage would drop just before PCS
pressure started to rise to 220 PSI
(Figure 4). This indicated the computer
was actually commanding high line
pressure. With the computer command-
ing high PCS pressure, it was time to
take a look at the computer system.
Checking the Computer
System
Ford has issued several techni-
Keep Those Trannys rolling
A Lincoln with
an Attitude
by Pete Huscher
members.atra.com
www.atra.com
Kyle took the vehicle to his local Ford/Lincoln dealership where they
reprogrammed the PCM with the latest update. On the way back to the
shop the transmission continued to have the occasional harsh shift.
GEARS May/June 2011 65
cal bulletins related to programming
issues and updates to this PCM, to
correct pressure control issues. So I
recommended having the PCM repro-
grammed with the latest update before
spending hours checking PCM inputs,
and powers and grounds.
Kyle took the vehicle to his local
Ford/Lincoln dealership where they
reprogrammed the PCM with the latest
update. On the way back to the shop
the transmission continued to have the
occasional harsh shift. So, when he got
back to the shop, Kyle connected his
scan tool and started checking the PCM
inputs.
The scan tool showed the inputs
were all within specifications, which
suggested a faulty PCM. But, as I
explained to Kyle, the Lincoln PCM
Figure 1
Figure 3
Figure 2
66 GEARS May/June 2011
goes for about $1000; not something
you throw in without being sure. I rec-
ommended checking each individual
input and every power and ground to
the PCM before condemning it.
Kyle pulled out his meter and
started checking each input to the
PCM. All were within specifications.
Then he checked the PCM powers and
grounds; they were also within speci-
fication.
With the inputs, powers, and
grounds within specifications, Kyle
was fairly confident that he was deal-
ing with a faulty PCM, but he was still
hesitant to throw a $1000 PCM at the
vehicle. So I went over the inputs with
him. They were all within specifica-
tions. Then we took another look at the
PCM powers and grounds — also all
within specifications. All indications
pointed to a faulty PCM (Figure 5).
Replacing the Powertrain
Control Module
Kyle contacted his local Ford/
Lincoln dealership to order a new
PCM. They told him the PCM was on
backorder, and it would take about six
weeks to arrive. So he called me back
and asked me to try to help him find a
rebuilt PCM. I explained that there was
a reason the PCM was on backorder:
Ford was having problems with this
unit, and a used or rebuilt PCM may
come with the same problems. I rec-
ommended against installing a used or
rebuilt PCM, and suggested waiting for
the new PCM to arrive. Kyle agreed.
After the new PCM arrived, Kyle
installed it, and then took the vehicle
to his local Ford/Lincoln dealership
to have it programmed for the vehicle,
based on the VIN and security system
codes.
Figure 4
A Lincoln with an Attitude
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Shift points and pressure
adjustable, self calibrating
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Kit comes complete with
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manual for quick and
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GEARS May/June 2011 67
Figure 5
68 GEARS May/June 2011
Success is at Hand
With the freshly programmed PCM
in the vehicle, Kyle was ready to take
the car for a test drive to recheck trans-
mission operation. The transmission
operated perfectly. The shifts were on
time and smooth, each and every time.
Kyle has driven the vehicle several
times since replacing the PCM, and the
transmission always shifts perfectly.
In Closing
If you run in to a problem vehicle,
and you suspect a possible computer
problem (PCM/TCM/BCM, etc.), be
sure to take the time to check the inputs,
powers, and grounds to the computer
before replacing it. Remember, by per-
forming a thorough diagnosis, you, too,
can tame your vehicle’s attitude, and
keep those trannies rolling.
A Lincoln with an Attitude
The Crew at Seven Oaks Transmission L to R:
Lawrence Kruk, Garett DeGrave, Bob De Grave, Brian Fischer, Jim Doe, Maverick (Magic) Williams, Kyle DeGrave
FOR THE TRANSMISSION REBUILDING INDUSTRY
G
EARS
TM
GEARSMagazine.com
Where the Industry
Gathers
GEARSmagazine.com adds more past issues to site.
Tired of rummaging through past issues of GEARS for a certain article or
topic – can’t remember which issue it was in or if you even have it any-
more? We hear you!
• Now you can search past issues of GEARS (back to October 2008)
with more issues being added every month – it’s easy and Free
• Complete article search by author, keywords or publication date
Plus….
• Looking for parts or service? We’ve got you covered here too with the
all new GEARS Online Buyers Guide
• Search by specific category for quick website links to the suppliers of
our industry.
Coming Soon – Look for our new blog features and
iPowertrian News – updated and timely news and products that will keep
you and your shop on top of our ever changing industry.
GEARSMAGAZINE.com – The Industry’s Information Site
GEARS May/June 2011 69
You Made the Call and
ATRA Answered:
3-Year Golden Rule
Warranty for All Units
You hear it everywhere: It’s your
country… it’s your government… it’s
your planet. But when it comes down
to it, someone else always seems to be
calling the shots… and too often the
results aren’t what you’d hoped for.
Well, when we say ATRA is your
Association, we really mean it. In a
recent Membership Survey, we asked
what you’d like ATRA to do for you.
The results were overwhelming: extend
the 3-year Golden Rule Warranty to
cover all transmissions, regardless of
manufacturer or age. So that’s exactly
what we did.
ATRA already offered Members a
3-year warranty, but only for GM, Ford,
and Chrysler, and only on transmissions
that were less than 10 years old.
Effective immediately, ATRA
Members can now offer a full 3-year
Golden Rule Warranty on all make and
model transmissions, regardless of age.
The new 3-year warranty takes its place
along side ATRA’s already familiar 1-
and 2-year warranties. Which means
you can now complete toe-to-toe with
the warranties being offered by reman
companies.
“This is a terrific example of how
ATRA is supposed to work,” explains
ATRA CEO Dennis Madden. “When
there’s something that our Members
need — something that can help them
be more competitive and more profit-
able — it’s our job to make that hap-
pen. And that’s exactly what we’ve
done with the new, 3-year Golden Rule
Warranty.”
As with other Golden Rule
Warranties, the transmission must be
rebuilt to ATRA’s minimum require-
ment, and usage standards still apply.
To begin offering these new, 3-year
warranties, contact ATRA’s
Member Services and request
the new Golden Rule Warranty
forms. These forms no longer
limit the 3-year warranty to GM,
Ford, or Chrysler transmissions;
nor are they restricted to trans-
missions less than 10 years old.
For more details, visit ATRA’s
web site http://members.atra.
com.
The new 3-year Golden
Rule Warranty: One more way
that we’re proving every day that
ATRA really is your Association.
ATRA’s Ron Brattin
Brings SEO to ATRA
Members’ Web Sites
There’s little doubt that the internet
is quickly replacing the Yellow Pages
when consumers shop for services. So it
should come as no surprise that ATRA
is working to help its Members take full
advantage of internet marketing.
One of the most important con-
siderations for your internet presence
is SEO: Search Engine Optimization.
SEO determines your placement in
search engines, such as Google and
Yahoo: The higher your placement, the
more effective your internet marketing
will be.
ATRA’s Ron Brattin recently
earned his certificate in Search Engine
Optimization and Internet Marketing
through Web CEO: a leader in internet
marketing strategies.
“Ron put a lot of effort into this cer-
tification, and we’re really proud of the
work he’s accomplished,” says ATRA
CEO Dennis Madden. “The results
from his optimization techniques are
impressive: we’re seeing instant leaps
in search engine placement.”
Using exclusive analytical soft-
ware, Ron examines your site and
tweaks keywords and content to help
you achieve the highest ranking pos-
sible. Higher ranking is a lot like place-
ment in the Yellow Pages: That’s why
you’ll find so many companies with
names such as “AAAA Transmissions”;
not very creative, but it got them placed
ahead of everyone else. And higher
placement equals more calls.
Naturally ATRA’s SEO service
is available exclusively to ATRA
Members. If your site is hosted through
ATRA, Ron can make the tweaks
directly, to improve your site’s rank-
ing immediately. Not hosted through
ATRA? That’s okay: Ron can still eval-
uate your site and make recommenda-
tions.
To take advantage of ATRA’s SEO
service, call Ron at 1-805-604-2020.
Make sure you have your site URL and
passwords available for him to access
your site.
SEO is the next step to help you
market your shop, and it’s just one
more way that ATRA is here to help
make your shop more competitive…
and more profitable.
MEMBERSHIP MATTERS
You Made the Call and ATRA
Answered:
Ron Brattin
70 GEARS May/June 2011
Y
ou just acquired a few longtime
transmission shops in the area
and want to let the town know.
What do you do?
Well, if you’re Rapid Transmission
in the San Diego area, you throw a
Grand Reopening Bash, and invite the
whole town!
Rapid Transmissions has been in
operation for over 40 years. It was
recently acquired by Jim Alexander,
and he relocated two of its stores to
newer, larger accommodations. So they
wanted to reach out and introduce the
community to the new owner and new
stores with an open house get-together.
They called all their suppliers and
asked them to get involved: Transtar
supplied the food; Natpro set up a
booth with examples of old and new
technology; Southland Clutch brought
their performance clutches. The San
Diego Mustang Club was in attendance
and brought their show cars, along with
a local motorcycle club that brought
20-25 bikes.
Mark Raines, operations director
for Rapid Transmissions, explained: “It
gave us a chance to get together with a
lot of the people from the area and show
them who we are and what we have to
offer.”
Deon Olmos from ATRA’s Member
Services department came by with the
“ATRA Blimp,” lent a hand, and spoke
to folks about the benefits of dealing
with an ATRA Member shop. “Deon
was a huge help in making our event a
success,” claims Mike.
So how did things go? “The
response was fantastic,” says Mike.
“We planned for 150 people, and over
Rapid Transmissions Gets Its Party On!
by Dennis Madden
members.atra.com
www.atra.com
GEARS May/June 2011 71
200 showed up. Jim had to relight the grill and
cook up more food!”
We’ve been saying for years that the best way
to get your name out there is through community
involvement. And what a terrific way for Rapid
Trans to make its mark in the neighborhood.
Letter From a Consumer...
Dear Mr. Wiggins,
I want to express our deepest
gratitude for your help and the ser-
vices of ATRA. As you know from our
conversation, my wife and I were on
a long distance vacation with our
boat in tow when our transmission
when out in Placerville Ca. We had
never been to Placerville, let alone
know of anyone there to help us with
such a problem.
Thankfully, we found your com-
pany through a friend and with
one phone call had a referral to
one of your certified shops in close
distance to the hotel we landed at.
Once we made contact with J&C
Automotive, their professionalism
put us right at ease. They provided
safe storage for our boat and had
the ball rolling on the transmis-
sion right away. They are exactly
the people and the type of shop you
want to deal with at a time like that.
Although my wife and I had an
extended vacation in Placerville, we
were able to enjoy the area and not
stress about our vehicle or who was
working on it.
Thank you for your help, thanks
ATRA for the service, and thanks to
J&C Automotive for being part of
your group. Your phone numbers
will travel with us from now on!
Sincerely,
Stephen Doiron
Santa Barbara, CA
72 GEARS May/June 2011
POWER INDUSTRY NEWS
GM 6L80E, 6L90E
Kits with Pistons
from Precision
Precision International is pleased
to announce the availability of overhaul
kits with pistons (P/N KP33900J) for
two GM transmissions:
6L80E: (MYC) 2006-09 Cadillac
STS-V, XLR-V (4.4L), XLR (4.6L),
Escalade/ESV/EXT (6.2L), XLR
(4.6L), Corvette (6.0L,6.2L), GMC
Sierra Denali, Yukon Denali /XL Denali
(6.2L), Pontiac G8 GT (6.0L), Hummer
H2/SUT (6.2).
6L90E: (MYD) 2007-09 Chevy
Silverado HD, Suburban, GMC Sierra
HD, Yukon XL (6.0L).
Master and banner kits are also
available: PI# KP3300J series is sold
with and without pistons.
For more information, visit Precision
on line at www.TransmissionKits.com.
Dodge Takes the Win
with a Goerend Trans!
Congratulations to Aron Nick
and his team on winning the 1st
Superstock Quick 16 Diesel Drag Race
in Bradenton, Florida, February 26,
2011. Aron’s truck was equipped with
a Dodge 6.7L, and a 48RE Goerend
transmission. He registered a time of
10.90 seconds.
Also congratulations to Ashley
Black of Black’s Diesel of Adairsvill,
Georgia (www.blacksdiesel.com), with
a 5.9L Cummins diesel and a Goerend
48RE transmission, who scored a
4th place finish with a time of 11.47
seconds.
Both teams are proud to run
Goerend transmissions in their Dodge
trucks.
Visit Goerend’s web site at www.
goerend.com to view their extensive
testing equipment. Or call Goerend
Transmission at 563 778 2719. Shipping
worldwide.
Transtar Industries, Inc.
is the Premier Provider
of Honda and Acura
Units
Transtar Industries, Inc., the pre-
mier provider of world-class driveline
solutions, is also the leading supplier
of OE-quality Honda and Acura trans-
mission units to the automotive after-
market.
“Honda units may be difficult
to find in the Aftermarket today. At
Transtar, we have coverage of the vast
majority of the Honda and Acura total
offering,” said Jim Berry, Transtar’s
Vice President of Marketing. “Transtar’s
extensive inventory allows these units
to be shipped next day to virtually every
market in the United States. Whether
you rebuild, repair, or replace, Transtar
has solutions for every customer.”
“Uncommon units can be par-
ticularly challenging to transmis-
sion rebuilders,” says Mark Russell,
Director, Complete Transmission
Solutions at Transtar. “We offer solu-
tions for those hard-to-build units, like
Hondas and Acuras. We have what our
customers need, at a great value.”
Remanufactured in the U.S. to
the original OE specifications, every
Transtar Complete Transmission Unit is
fully tested using state-of-the-art equip-
ment and is backed by the Transtar Seal
of Quality. Units are updated with the
latest pieces and fittings and Transtar’s
36-month/100,000 mile premium war-
ranty.
Transtar’s representatives are very
dedicated to providing exceptional ser-
vice. For further details on Honda and
Acura units or any driveline kit or com-
ponent, customers should contact their
Transtar representative or call (855)
TRANSTAR.
Mazda FN4A-EL (4F27E)
and FS5A-EL (FNR5)
Reverse Bonded Piston
Mazda has revised the reverse
bonded piston for the FN4A-EL/FS5A-
EL transmission.
TransTec
®
item B81789 (OE FN11-
19-5H0A) was originally a notched
design on the clutch apply surface. The
apply surface is now a continuous, one-
piece surface.
This change produces a part that
is considered a window-frame design,
which creates more contact area with
the clutch plates, achieving a uniform
clamping load across the clutch plate
surface.
The new window frame design
will retrofit and can be used in place of
the previously notched design for both
applications.
When ordering part number
B81789 you will receive the new design
as stock is depleted on the old design.
For more, visit TransTec on line at
www.TransTec.com.
POWERTRAIN INDUSTRY NEWS
GEARS does not endorse new products but makes this new information available
to readers. If you have a new product, please email the press release information
with applicable digital photo or drawing to fpasley@atra.com or send by mail to
GEARS, 2400 Latigo Avenue, Oxnard, CA 93030.
© 2010 Freudenberg-NOK
11617 State Route 13 • Milan, Ohio 44846 • T: 419-499-2502 • F: 419-499-2804 • www.TransTec.com
11/8/10
Technical
Bulletin
A Division of Freudenberg-NOK
Mazda FN4A-EL (4F27E), FS5A-EL (FNR5)
Reverse Bonded Piston
Mazda has revised the reverse bonded piston for the FN4A-EL/FS5A-EL
transmission.
TransTec
®
item number B81789 (OE # FN11-19-5H0A) was originally a notched
design on the clutch apply surface. (Illustration 1) The apply surface is now a
continuous, one piece surface. (Illustration 2) This change produces a part that
is considered a window frame design which creates more contact area with
the clutch plates, achieving a uniform clamping load across the clutch plate
surface.
The new window frame design will retro ft and can be used in place of the
previously notched design for both applications.
When ordering part number B81789 you will receive the new design as stock
is depleted on the old design.
Illustration 1
Early Style B81789
Illustration 2
Late Style B81789
© 2010 Freudenberg-NOK
11617 State Route 13 • Milan, Ohio 44846 • T: 419-499-2502 • F: 419-499-2804 • www.TransTec.com
11/8/10
Technical
Bulletin
A Division of Freudenberg-NOK
Mazda FN4A-EL (4F27E), FS5A-EL (FNR5)
Reverse Bonded Piston
Mazda has revised the reverse bonded piston for the FN4A-EL/FS5A-EL
transmission.
TransTec
®
item number B81789 (OE # FN11-19-5H0A) was originally a notched
design on the clutch apply surface. (Illustration 1) The apply surface is now a
continuous, one piece surface. (Illustration 2) This change produces a part that
is considered a window frame design which creates more contact area with
the clutch plates, achieving a uniform clamping load across the clutch plate
surface.
The new window frame design will retro ft and can be used in place of the
previously notched design for both applications.
When ordering part number B81789 you will receive the new design as stock
is depleted on the old design.
Illustration 1
Early Style B81789
Illustration 2
Late Style B81789
GEARS May/June 2011 73
Mike Davidson Joins
Elite as Business
Development Coach
Elite Worldwide has announced
that Mike Davidson, an award-winning
shop owner, has joined the company as
its newest business development coach.
In his new role, Davidson will use
his years of experience as a shop owner
in Little Rock, Arkansas, and the infor-
mation he’s attained while serving on
numerous industry boards and panels,
to help shop owners throughout the
U.S. build more profitable businesses.
In addition to owning and operat-
ing one of the most successful auto
repair shops in the U.S., Davidson
is a graduate of the Automotive
Management Institute, was the recipi-
ent of Arkansas’s NAPA Technician of
the Year Award for seven consecutive
years, and is a winner of the coveted
Better Business Bureau Torch Award
for Marketplace Ethics.
Davidson has an affinity for help-
ing others, and currently does so by
providing viewers with car care tips in
local CBS segments.
“Elite is always looking for busi-
ness development coaches who not
only have a history of success as shop
owners, but who have a genuine com-
mitment to ethics as well. For an indi-
vidual like Mike Davidson to join our
team, who not only runs one of top
shops in the country, but who has
won the Torch Award for Marketplace
Ethics, is an absolute honor,” said Bob
Cooper, president of Elite Worldwide.
Visit Elite Worldwide on line at
www.EliteWorldwideStore.com, or
call, toll free, at 1-800-204-3548.
Superior’s New 4T65E
AFL Valve Fix
for Code P1811
Here’s what happens: Low pres-
sure from the AFL signal/balance oil
leaks from valve bore wear at the small
end of the balance side of the valve
bore in the channel plate casting. This
wear causes low AFL balance pressure,
which is becoming common in 4T65E
units and is the main cause for code
P1811.
When balance pressure leaks out
the end of the valve/bore it doesn’t keep
enough AFL balance oil against the
AFL valve’s spring load. This causes
the PCS to do one of two things:
1. Send more AFL feed pres-
sure to the balance side, resulting in
higher line pressures. This sets codes
and makes line pressure unstable when
trying to elevate AFL pressures. Or…
2. Leak so badly that it won’t
regulate anything, causing line pres-
sure to elevate to the point of damaging
components.
Either way, the leak creates a
vicious cycle as it tries to compensate
for itself.
To correct this, Superior offers
its K098 AFL valve fix. This newly
designed AFL valve-and-spring combo,
along with a simple cup plug, will
stop the leak. And since the valve’s
“Superior” design spreads the load
across the entire rear casting, it’s a long
term, Simple Solution™, sure to stop
wear and leaks in their tracks.
The valve kit is quick and easy to
install without purchasing extra tools,
reamers, or costly replacement valves
and sleeves.
For more information or to locate
your closest distributor, visit www.
superiortransmission.com.
Lockup Converter
for Non-Lockup
Transmissions, by Dacco
Alma Products and Dacco
have developed a drop-in lockup
torque converter for any non-lockup
transmission (THM-350 and 400,
Powerglide, 727, 904, C-4, C-6).
The unit requires no modifications
to hydraulics, hardware, or wiring.
Simply swap it the old non-lockup unit
to the new one. It’s available in a 10”
diameter, and stall speeds range from
1800-5000 RPM. Industrial testing
has yielded 15% improvement in fuel
economy.
In development for 3 years, it’s
perfect for oval track and street/strip
muscle cars. The result is better fuel
economy, more efficiency (more power
to the wheels), lower transmission
temperatures, and decreased crank
thrust.
In the past, a high stall torque
converter would have been too busy
for street applications. This new unit
allows a high stall for better acceleration
and 100% cruising efficiency with
lockup. It gives the car owner the
option of numerically increasing axle
ratio because of a locked converter,
which means better acceleration and
fuel economy.
Lockup is a feature that will give
automatic cars the same MPH in racing
as stick shift cars. The converter is fully
balanced and has bearings at every
interface.
Figure 1. Showing O.E. Design and
Common Leak Area. (sets Code 1811)
Figure 2. Showing Superior’s Innovative
Proprietary Design.
This is Why they set the Code 1811
Direct drive performance with the drivability
and ecency of a lock-up converter
• Applications for circle track, street performance, and
restoration.
• Patented lock-up converter for C6, THM
350/400, and Powerglide hydraulic transmissions.
• Improves torque and fuel efficiencies with multi-clutch
technology.
• Greater selection of available stall speeds.
• Lower inertia than stock converters.
• Improves transmission durability due to less slip and
lower transmission temperature. DROP IN!!
No transmission modifcations
or calibration required!
Make sure and
check out
in Booth #4115
74 GEARS May/June 2011
POWER INDUSTRY NEWS
The engineer that patented the
design (Pat #7770703) worked for
Chrysler Powertrain engineering for 18
years. Production starts June 1, 2011.
For more information contact
Dacco Transmission Parts 866-645-
1452, or visit www.daccoinc.com.
Lista International
Will Exhibit Its
Technician at Eastec 2011
Lista International Corporation
will feature its Technician Series tool-
boxes at EASTEC 2011, May 17-19 at
the Eastern States Exposition in West
Springfield, Massachusetts, booth 5423.
Lista International’s Technician
Series toolboxes are the largest capac-
ity, most durable boxes on the market,
at an affordable price. Proudly made in
the USA, they feature a rugged design
backed by a limited lifetime warranty.
They come in five gloss, powder-coated
colors, with two-tone color schemes
available.
All drawers are full extension with
a 440-pound capacity. Drawers come
standard with a mesh liner and include a
divider and bin tool organization starter
kit in the top drawer. Other drawers can
be equipped with a variety of divider
options.
Technician Series toolboxes are
available in a choice of four styles:
single bank, double bank, triple bank
and two-bay. This enormous selection
of footprints and drawer sizes means
there’s a toolbox configuration to meet
every need.
Worktops transform the toolbox
cabinet top into a productive work area.
Toolboxes come standard with protec-
tive ribbed rubber mat, and are avail-
able with optional tops of stainless steel
over wood core, stainless steel cover, or
butcher block.
The toolboxes feature base options
ranging from mobile casters, to fixed-
fork truck bases, to stationary raised
bases with leveling.
Visit Lista’s new web site devot-
ed to technician toolboxes at www.
ListaBox.com.
...Also from Lista International
Redesigned Workbench System
Lista International Corporation
announces its newly redesigned auto-
motive workbench system. Specially
designed for automotive service and
repair, Lista’s automotive storage and
workbench solutions can be easily con-
figured to suit specific needs without
custom cost.
Lista automotive service bay solu-
tions include storage cabinets, tool-
boxes, workbenches, and mobile carts.
Tough, industrial-grade construction
and materials are engineered to stand
up to hard use and still look great,
while giving technicians quick and easy
access to tools, parts, and supplies.
Rather than being limited to off-
the-shelf products, Lista offers versatile,
customized solutions that optimize the
efficiency and productivity of service
operations. The company customizes
high-density storage and timesaving
workspace solutions to bring consistent
appearance, efficiency, and space usage
to every cubic inch of available space in
a dealership.
For more information, visit Lista
on line at www.listaintl.com.
TCI
®
Max-Cool™
Deep Aluminum Pans
Premium cast,
high-quality Max-Cool™ deep alumi-
num pans from TCI turn the ordinary
into the extraordinary. A black powder-
coated finish and the ability to hold a
larger fluid supply increases heat dis-
sipation, dropping internal transmission
temperature by 20º to 30º, extending
transmission life.
These pans are built from aircraft-
quality aluminum and feature added
fins for improved cooling, while a mag-
netic drainplug keeps loose metal from
being circulated through the transmis-
sion.
A unique, O-ringed (where appli-
cable) sealing surface protects against
leaks. Pans include magnetic drain-
plugs, a 1/8” NPT port machined direct-
ly into the pan, new stainless steel
hardware, and Allen wrenches.
For more information on Max-
Cool™ pans or to see other great TCI
®

high performance drivetrain compo-
nents, visit www.tciauto.com, or call
toll free at 888-776-9824.
JDS Worldwide
of Miami to Open
in New Location!
After 20 years of experience and
knowledge of the industry gave way to
the creation of JDS Worldwide in 2004,
a surge of consumer loyalty and confi-
dence has allowed JDS Worldwide to
once again expand to meet the demands
that its customers have come to expect.
JDS Worldwide will be moving to
a new location in the heart of the com-
mercial district of Miami. With a new
warehouse providing more than twice
its previous capacity, JDS is poised to
provide better access to both its existing
customers and new clients.
“Our new location is an excel-
lent venue, which will allow for a
larger inventory, giving our customers
greater access to our products and our
company,” said Joe De Santino, presi-
dent of JDS Worldwide. “As both our
GEARS May/June 2011 75
international and domestic client bases
continue to grow, we found that, to
continue to deliver the level of quality
and performance our customers have
come to expect, this relocation was a
necessity.”
For more information please visit
www.jdsworlwide.com.
JASPER Offers
Remanufactured GM
6-Speed Transmissions
Jasper Engines & Transmissions,
the nation’s leader in remanufactured
products, has added the GM 6L80 and
6L90E 6-speed transmissions to its
remanufactured lineup, and are avail-
able for these 2007-2009 vehicles:
• Chevrolet Yukon Denali,
Avalanche and Suburban
• GMC Sierra Denali
• Cadillac Escalade
• Chevrolet/GMC C/K 1500-
3500 pickups
These transmissions are unique
in that the transmission control mod-
ule (TCM) is inside the transmission.
“These control modules are vehicle
identification number (VIN) specific
and must be reprogrammed accord-
ingly,” says James Corbin, JASPER
quality systems and new product devel-
opment manager. “JASPER will ship
these units already programmed per the
vehicle VIN from the factory.”
Every JASPER remanufactured
transmission is subjected to strict, high-
quality processes:
• Disassembly, meticulous
inspection, and cleaning of
components.
• All new and remanufactured
parts are carefully inspected
for correct tolerances to assure
dependability.
• JASPER’s research and product
development ensures inherent
OEM design problems are cor-
rected.
• Dynamometer testing of domes-
tic automatic transmissions
simulates in-vehicle operation
to assure trouble-free product
results.
• An available Premium Service
Plan offers customers even
greater value.
Each transmission is covered by
JASPER’s 3-year/100,000 mile nation-
wide transferable parts and labor war-
ranty. Full warranty disclosure is avail-
able on our web site or upon request.
For more information on the GM
6L80/90E and JASPER’s complete
line of remanufactured transmissions,
please call 800-827-7455, or log onto
www.jasperengines.com.
Precision Introduces
JF011E Overhaul Kit
Precision International has intro-
duced overhaul kits for JF011E trans-
missions.
This unit is a belt-driven CVT for
medium FWD vehicles, applicable for
up to 2.5 liter class vehicles. Part num-
ber 73900GX covers years 2007-2010
used in:
• Jeep Compass, Patriot
• Dodge Caliber
• Nissan Serena, Bluebird
Sylphy, Dualis
• Nissan Altima, Maxima,
Lafesta, X-Trail (2.5L)
• Nissan Rogue, Sentra
• Renault Koleos
• Suzuki Kizashi, Landy
• Mitsubishi Outlander, Delica
D5
• Mitsubishi Galant Fortis, RVR.
Master and Banner kits are also
available.
For more information, visit www.
transmissionkits.com.
Midwest Hard Parts
Now Selling Wholesale
Midwest Hard Parts, Inc. has pro-
vided top quality transmission hard
parts to transmission shops for over 10
years.
They’re proud to announce the
opening of a wholesale division. Their
goal is to offer the same top quality
parts to suppliers and transmission parts
stores at reduced prices, to allow for the
supplier and store to make a reasonable
markup and still be able to offer their
customers a fair market price.
Per customer request, MHPI offers
custom packing and labeling. They
guarantee 100% blind shipping using
plain boxes and going as far as to cut
their name off the shipping label.
Whether it’s foreign or domestic,
MHPI prides itself on stocking hard-
to-find parts. So leave the hard, greasy
work of teardown to them, and buy a
clean, ready-to-put-on-the-shelf part.
Contact Midwest Hard Parts at
1-877-799.4783 and request a copy of
their Frequently Sold Parts price sheet.
Mustang Introduces New
Universal Transmission
Dyno.
Mustang’s latest product innova-
tion for automotive transmission repair
and remanufacturing professionals is
MAE-LDU-40, a universal transmis-
sion dynamometer that represents the
most advanced, next-generation dyna-
mometer for testing light-duty automat-
ic passenger car and light truck inline
and transverse transmissions.
Mustang designed the new system
to specifically address the short-com-
76 GEARS May/June 2011
POWER INDUSTRY NEWS
ings of the standard transmission dynos
found in the market today. The result
is a transmission dynamometer that is
more easily adaptable, more accurate,
more user-friendly, with a more flexible
software and data acquisition package,
and most importantly, is more sensible
from an economic standpoint.
The new LDU-40 universal trans-
mission dynamometer is a quantum
leap forward from the outdated systems
that once upon a time were considered
state-of-the-art. Take your transmission
testing to an unprecedented level of
accuracy, efficiency and usability.
Forget the hassles of using custom
mounting plates and spacers to get a
torque converter fitted just right. Mount
and test transmissions faster and easier
than ever before with a universal sys-
tem so flexible, you can change setup
configurations in a matter of minutes,
with a single operator.
Universal Hardware
The MAE-LDU-40 dynamometer
is by far the most easily adaptable test
system on the market. Test a wide
variety domestic and foreign rear-
wheel transmissions without the need
to purchase countless custom mounting
plates.
Our patented Universal Adapter
Plate virtually eliminate the need to
have expensive custom plates for each
transmission you need to test – saving
you both time and money and simplify-
ing your testing operations.
Mustang’s system easily adjusts
to fit any torque converter without the
need for complicated spacers and bush-
ing combinations, making it easier to
center and mount more transmissions
faster.
Our rotating head stock also allows
you to easily adapt and configure the
test stand to test front wheel drive trans-
verse transmissions, including Honda
and Mitsubishi, and longitudinal 42LE
transmissions such as the Chrysler
A606.
Our use of U-joint drive shafts
simplifies set up and dramatically mini-
mizes the chance of damaging rear
seals due to misalignment issues.
More Accurate Test Results
The LDU-40 achieves the highest
level of accuracy in the industry thanks
to its high quality electronics package.
Cradle-mounted PAUs and preci-
sion strain-gauge-type load cells on
each output PAU provide continuous
feedback to the control loop, allowing
for more precise load control and more
accurate testing results.
A 30-tooth speed encoder ensures
a higher resolution speed signal, and
therefore a more accurate gear ratio
calculation.
The LDU-40 also includes
Mustang’s Transmission Control
Module, The MAE-TCM, standard
with every unit. The MAE-TCM gives
you the ability to test a transmission
using the correct frequency and duty
cycle, which ensures that the transmis-
sions are being tested exactly as they
perform in a vehicle.
All this results in a more accurate
dynamometer, so you can test with
more confidence.
TransTec Introduces
Pistons in Kits for
GM 6L45/50, 6L80, 6L90
Corteco now offers overhaul
kits with pistons for General Motors
6L45/50, 6L80 and 6L90 applications.
TransTec
®
brand kits 2509, 2565 and
2566 are on the shelf ready to be
shipped to you today.
The following pistons will be
included in the new kits:
ApplicAtion
1-2-3-4 clutch Bonded Balance piston
4-5-6 clutch Bonded Balance piston
4-5-6 clutch Bonded Apply piston
2-6 clutch Bonded Apply piston
low/Reverse Bonded Apply clutch piston
You can still order kits without pis-
tons. Those items are 2523 (6L45/50),
2508 (6L80) and 2530 (6L90).
Contact your customer service rep-
resentative to place an order today.
For more information, visit
TransTec on line at www.TransTec.
com.
TransTec Introduces
Aisin TR60-SN/VW O9D
TransTec is pleased to announce
the availability of TransTec
®
overhaul
kit 2554, which covers the rear wheel
drive, 6-speed Aisin Warner TR60-SN
transmission.
This unit is most commonly used
in the Volkswagen Touareg.
The kit includes genuine front and
rear NOK oil seals along with exclusive
Quantum™ brand teflon sealing rings
and premium TransTec
®
branded valve
body paper.
Featured
Components
part number Description
B33423 Molded rubber pan gasket
B37169 Front seal
B37170
Extension & adapter
housing seal
3542 Sealing ring kit
Kit number 2554 is in stock and avail-
able for immediate delivery.
For more information, visit
TransTec on line at www.TransTec.
com.
TransTec Introduces
Jatco JF011E /
Nissan RE0F10A Kits
TransTec is pleased to announce
the availability of TransTec
®
overhaul
kit 2557, which includes all neces-
sary sealing components to rebuild the
2006-up JF011E/RE0F10A transmis-
sion.
Featured
Components
p/n Description Year
2557 overhaul kit 06-up
B29002 Right axle seal 06-up
B29724 left axle seal 06-up
B37134 converter hub seal 06-up
B36523 Duraprene pan gasket 06-up
3544 Sealing ring kit 06-up
TransTec
®
kit 2557 is in stock and
available for immediate shipment.
For more information, visit
TransTec on line at www.TransTec.
com.
© 2011 Freudenberg-NOK
11617 State Route 13 • Milan, Ohio 44846 • T: 419-499-2502 • F: 419-499-2804 • www.TransTec.com
NPA 3/30/11
A Division of Freudenberg-NOK
New Product
Announcement
We are pleased to announce the availability of TransTec
®
overhaul kit 2554. Kit
2554 covers the rear wheel drive six speed Aisin Warner TR60-SN transmission.
This unit is most commonly used in the Volkswagen Touareg
This kit has genuine front and rear NOK oil seals along with exclusive Quantum™
brand tefon sealing rings and premium TransTec
®
branded valve body paper.
Aisin TR60-SN/ VW O9D
Kit number 2554 is in stock and available for immediate delivery
Featured Components
B33423 Molded rubber pan gasket
B37169 Front seal
B37170 Extension & adapter housing seal
3542 Sealing ring kit
Description
TransTec
®
Number
© 2011 Freudenberg-NOK
11617 State Route 13 • Milan, Ohio 44846 • T: 419-499-2502 • F: 419-499-2804 • www.TransTec.com
NPA 2/16/11
A Division of Freudenberg-NOK
New Product
Announcement
JATCO JF011E / NISSAN RE0F10A
TransTec
®
kit 2557 is in stock and available for immediate shipment.
Description Year
2557 Overhaul kit 06-UP
B29002 Right axle seal 06-UP
B29724 Left axle seal 06-UP
B37134 Converter hub seal 06-UP
B36523 Duraprene pan gasket 06-UP
3544 Sealing ring kit 06-UP
Featured Components
Item
Number
We are pleased to announce the availability of TransTec
®
overhaul kit 2557.
All necessary sealing components to rebuild the 2006-UP JF011E / RE0F10A
transmission are included.
GEARS May/June 2011 77
ERIKSSON INDUSTRIES
•1 YEAR UNLIMITED MILE WTY•
1-800-388-4418
Division of Wentworth Engineering
Authorized Parts Distributor
•Remanufactured Units * DYNO TESTED*
•5HP30, 5HP24, 5HP19, 5HP18, 4HP24, 4HP22,
4HP18, 4HP14
•Specializing in SAAB 900/9000 5SP,
as well as T-37 A/T
• Hard Parts: NEW / USED / REMANUFACTURED
Soft Parts / Friction Kits / Steel Kits / Repair Manuals
• Lifetime Fluids / Rebuild Kits / Valvebody Kits
1-800-388-4418
Fax: (860) 395-0047
www.erikssonindustries.com
146B Elm St., Old Saybrook, CT 06475
**COMPUTERS**
Transmission Control Module
E C M & T C M
Mitsubishi-Honda-Hyundai-GEO
Kia-Mazda-Nissan-Suzuki-Toyota
BOSCH ECM
GM - Ford - Chrysler - Dodge
Next Day Air Shipping Available
One Year Warranty
Best Customer Service!
Ford *GM * Chrysler off vehicle
ECM reprogramming available
8 8 8 - 2 1 7 - 4 0 7 2
Autocomp Technologies, Inc.
8515 N. Freeway, Houston, Texas
www.g-tec.com
www.g-tec.com
Heated Cooler
Line Flusher
Transmission
Dyno/CV
Tester
800-725-6499
417-725-6400
SHOPPER CLASSIFIED ADS
78 GEARS May/June 2011
SHOPPER CLASSIFIED ADS
GEARS Shopper advertising costs $325.00 for a one time insertion ad, (2 1/4 X 3) 2.25 X 3. Larger ads can be placed
elsewhere in the magazine and are charged at comparable rates. Check or money order must accompany all orders.
For information on Shopper advertising in GEARS, contact GEARS, 2400 Latigo Avenue, Oxnard, CA 93030, or call
(805) 604-2000.
BMW Mercedes-Benz Audi
Remanufactured to
Perfection
Hundreds of Transmissions in-stock.
Immediate installation available.
2 year unlimited warranty.
Dyno-tested.
Remanufactured torque converter included.
Toll free 800 - 372 - TRANS
1331 Rollins Road • Burlingame, CA 94010
tel 650 - 348 - 3990 fax 650 - 348 - 3019
Equipment Manufacturing Corp.
888-833-9000
www.equipmentmanufacturing.com
Valve Body Kits
RatioTek


RT-4L60E
Fix Code
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Adjust 1-2
shift firmness
without re-
moving VB.
RT-E4OD/4R
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Easy to Install - Low Cost - Great Results
3 High Tech
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Adjust shift firmness.
www.ratiotek.com 626-968-2754
-- Kits At Part Suppliers Now --
RT-4L60E-HD
RT-700R4
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RT-AX4S
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RT-A750E
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RT-A761E
RT-A761E-HD
RT-4ATAXLE
RT-4ATAXLE-HD
Also 5th Edition Ratiotek
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CORES
We’ve Got Yours!
CORES
We’ve Got Yours!
With over 150,000 transmission,
engine, and internal part cores on the shelf, we
have the cores you need – ready to ship today!
Find vintage cores on *Memory Lane*
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800.426.8771 800.826.7403
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702.649.6777 FAX 773.624.6660 FAX
AAEQ Gears Ad 1-4 pg 031209:1-17 AAEQ Gears Ad 3/12/09 2:31 PM Page 1
GEARS May/June 2011 79
INSTA-CLEAN
PARTS WASHERS
INSTA-CLEAN
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We Ship Anywhere
Our quality used hard parts are priced
to help you retain more profit
All parts are cleaned and inspected
O1d Ad O1d Ad O1d Ad O1d Ad
NLW Ad NLW Ad NLW Ad NLW Ad
WE HAVE WHAT YOU NEED
FOREIGN & DOMESTIC
Standard Transmissions
Transfer Cases
New & Used Parts
Rebuilt Units
*ONE CALL DOES IT ALL*
CALL
BRIAN OR ALBERT
866-571-GEAR
4 3 2 7
Northland Transmission Inc.
Phone: 715-458-2617 Fax: 715-458-2611
www.servobore.com
Fix it in less
than fifteen
minutes with
one of our
easy to use
kits.
No machine
shop required.

HARD PARTS FOR
Domestic and Foreign
AUTOMATIC TRANSMISSIONS
TORQUE CONVERTERS
TRANSFER CASES

WE HAVE OVER 500,000 PARTS IN STOCK
CALL 602-971-0477
getithardparts.com

WE SHIP UPS DAILY
NEED QUALITY
CONVERTERS?
Overhaul System!
Call for a free catalog
877-298-5003
www.atiracing.com
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EARS
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This could
be
your ad!
call
(805) 604-2000
and find out how!
For The Transmission rebuilding indusTry
80 GEARS May/June 2011
SHOPPER CLASSIFIED ADS
GEARS Shopper advertising costs $325.00 for a one time insertion ad, (2 1/4 X 3) 2.25 X 3. Larger ads can be placed
elsewhere in the magazine and are charged at comparable rates. Check or money order must accompany all orders.
For information on Shopper advertising in GEARS, contact GEARS, 2400 Latigo Avenue, Oxnard, CA 93030, or call
(805) 604-2000.
TrarsTccl
Arericar NaJe Nac|ires
P|.Z!JJ!IJJc&
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Contact us for details: 630.521.1700 phone 630.521.8890 fax
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CD4E Double Drum & ZF5HP24 "a" Drum
GEARS May/June 2011 81
USED, NEW
AND
REBUILT
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ONE CALL DOES IT ALL!




WE STOCK
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USED & REBUILT PARTS

We offer a complete machine shop
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800-461-5396
Rostra Performance
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Transmission.com
To find out more
visit:
82 GEARS May/June 2011
BUSINESS FOR SALE: Colorado
Springs Automotive/Transmission
Shop For Sale In business 25 plus
years. Large commercial referral base,
excellent reputation and name rec-
ognition. Well trained certifed staff in
place. Includes Real Estate. Owner re-
tiring. Adjusted Proft $84,000+ Char-
lie Jones, FBB, Ltd., 800-395-7653,
www.fbb.com.
BUSINESS FOR SALE: California –
You need to take a look at this one!
40 years of excellent business trans-
mission & general automotive service.
Same great location, central California,
this is not your ordinary shop. Large
building with latest equipment, owner
ready to retire. Contact (209) 602-
7250. ATRA Mbr
HELP WANTED: Experienced Tech-
nicians, Rebuilders, R &R, Diagnostic
Technicians and Service Writers. Mini-
mum of three years experience refer-
ences a must and work history and cer-
tifcations. Top pay, medical insurance,
paid vacation and a 5 day work week.
Located in the center of the Texas Hill
Country. Please e-mail resume to
a1m@classic.net or mail to Personnel
Dept., P. O. Box 2339, Kerrville, Tx.
78029-2339. ATRA Mbr
HELP WANTED: Technical Director
- Transmission remanufacturer is in
need of an experienced technical ex-
pert to lead its remanufacturing opera-
tions in remanufacturing standards and
quality control processes. This position
requires vast experience in late model
automatic transmissions, excellent
communication skills (verbal and writ-
ten), leadership abilities, and a drive
for high quality products in a produc-
tion environment. Excellent compen-
sation package, based on experience.
Full benefts and relocation allowance.
Please email your resume to b4ever-
real@aol.com.
HELP WANTED: Would you like to join
the team of a growing transmission
shop in Northern NJ? We are seeking
rebuilders, installers, and outside sales
help for a 5 day work week. Please for-
ward your work experience and history
along with salary requirements to fx-
intrannys@gmail.com. All replies kept
confdential. ATRA Mbr
HELP WANTED: Portland, OR –
Torque Converter Rebuilder – Must
have a minimum of three years ex-
perience in all phases of converter,
rebuilding, spline replacement, clutch
bonding, hub replacement, fnal as-
sembly and general machine skills.
Must be clean cut and have good refer-
ences. Pay DOE, benefts include va-
cation, holidays and medical. For more
information please call Dave at Port-
land Torque (800) 640-0970 or email:
dave@portlandtorque.com. ATRA Mbr
HELP WANTED: Regional Sales Peo-
ple – Large Midwest remanufacturer of
automatic transmission components
in need of aggressive sales people.
Sales Territory includes the North-
east, Southeast, Midwest, Central
and Southwest regions. Product lines
include remanufactured torque con-
verters, hard parts both used and re-
manufactured and new and complete
transmissions. Knowledge in our prod-
uct lines a must. All applicants held in
the strictest confdence. Send resume
to: jshawaluk@remanindustries.com.
ATRA Mbr
HELP WANTED: Transmission shop
looking for Sales Manger, Rebuilders
and R&R Techs. Contact: (805) 236-
1114.
SHOPPER CLASSIFIED
GEARS classified advertising cost $95.00 for up to 50 words for a one time insertion. ATRA members are eligible to receive up to three (3) FREE classified
advertisements in GEARS annually (per 9 issues). Members wishing to place ads once their three FREE ads have been placed may do so at the cost listed above.
Ads exceeding the maximum word count will cost $1.50 for each additional word (not including phone number and address).
May/June 2011
 
 
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SAVE TIME and Money
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TF80 (AF40‐6) 
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Call 1‐800‐582‐2760 * Fax 954‐364‐2401 
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Register:
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■ Transmission Sales
■ Transmission Shop Advertising
■ Transmission Shop Management
SALES
SEMINAR
SALES
SEMINAR
2011 ATRA Technical Seminars
GEARS May/June 2011 83
Name___________________________________________
Address_________________________________________
City_____________________________________________________
State_____________________________ Zip___________________
Phone___________________________________________________
Signature________________________________________________
X
Please enclose check or money order in U.S. funds and send to:
GEARS • 2400 LATIGO AVENUE • OXNARD, CALIFORNIA 93030
or call: (805)604-2000
U.S. $30 ~ Canada $45 ~ Other Areas $65
I want my very own subscription
to the next 9 issues of GEARS.
Subscribe Today!
Grab Your GEARS Now!
2011 ATRA Technical Seminars
5/14/11 Denver, CO
5/21/11 Des Moines, IA
6/4/11 Vancouver, BC
8/13/11 Albuquerque, NM
8/20/11 Cincinnati, OH
9/10/11 Atlanta, GA
9/17/11 Billings, MT
10/1/11 Chicago, IL
10/8/11 Portland, OR
11/5/11 Baltimore, MD
Check http://members.atra.com for more dates
and locations to come!
LOCATIONS
Registration Costs:
Prepaid, preregistered ATRA members $149
Prepaid, preregistered non-ATRA members $189
On-site registration $220
One free registration with every four paid.
800.428.8489 • http://members.atra.com
GM:
LCT 1000
4L60/65/70E
4T65E
4L30E
6L80
4L65E
4L80E
4T40/45E
CHRYSLER:
41TE
545RFE
45RFE
42RLE
42-46RE
IMPORT:
RE5R05A
All Hondas
AW55-50SN
FORD:
AWF 21B
6F50
AX4N
5R55N/W/S
TRANSMISSION OVERVIEW
Register
Today!
84 GEARS May/June 2011
2011
ADVERTISERS
Name Page Name Page
A.T.R.A. ......................................................................... 40, 61
http://members.atra.com
BorgWarner Automotive ...................................................... 33
www.borgwarner.com
Certified Transmission ......................................................... 31
www.certifiedtransmissions.com
Dacco Transmission Parts................................................... 11
www.daccoinc.com
ETE Reman ......................................................................... 17
www.enginetrans.com
EVT Parts ............................................................................ 57
www.evtparts.com
Florida Torque Converter Corp. ........................................... 67
www.floridatorqueconverters.com
Ford Customer Service Division .......................................... 13
www.fordparts.com
G-Cor Automotive Corp ....................................................... 35
www.g-corautomotive.com
GEARS Magazine .............................................................. 68
www.gearsmagazine.com
H G M Auto Electronics Inc. ................................................ 66
www.compushift.com
Jasper Engines & Transmissions ...................................... IBC
www.jasperengines.com
Kuhle ................................................................................... 66
www.kuhleus.com
Life Automotive Products Inc. ................................................ 7
www.smartblend.com
Lubegard
®
By International Lubricants, Inc. ................... OBC
www.lubegard.com
Mustang Advanced Engineering.......................................... 25
www.mustangdyne.com
Precision European Inc .............................................Rider, 83
www.PEIus.com
Precision International ......................................................... 29
www.transmissionkits.com
Raybestos Powertrain ........................................................... 3
www.raybestospowertrain.com
Seal Aftermarket Products................................................... 39
www.sealaftermarketproducts.com
Slauson Transmission Parts ................................................ 59
www.slauson.com
Sonnax Industries .............................................................. IFC
www.sonnax.com
SuperFlow Technologies Group .......................................... 67
www.superflow.com
Superior Transmission Parts ............................................... 23
www.superior-transmission.com
TCI Automotive .................................................................... 63
www.tciauto.com
Transmission Specialties ..................................................... 37
www.transmission-specialties.com
Transtar Industries, Inc. ......................................................... 9
www.transtar1.com
TransTec By CORTECO ...................................................... 27
www.transtec.com
VBX - ValveBody Xpress, Inc. ............................................. 36
www.valvebodyxpress.com
Whatever It Takes Transmission Parts, Inc. .......................... 5
www.wittrans.com
2
0
1
1
CALENDAR
ATRA Supplier Members
Reserve your free table top display for the
ATRA 2011 technical seminar series today!
Call (805) 604-2018
See ATRA Seminar Schedule page 83.
C
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CM
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