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HYDRA-MATIC

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4/5L40-E
CONTENTS
INTRODUCTION ..................................................................................... 3
HOW TO USE THIS BOOK ...................................................................... 4
UNDERSTANDING THE GRAPHICS ....................................................... 6
TRANSMISSION CUTAWAY VIEW (FOLDOUT) ....................................... 8
GENERAL DESCRIPTION ....................................................................... 9
PRINCIPLES OF OPERATION ............................................................... 9A
MAJOR MECHANICAL COMPONENTS (FOLDOUT) ...................... 10
RANGE REFERENCE CHART ......................................................... 11
TORQUE CONVERTER .................................................................. 12
APPLY COMPONENTS ................................................................. 15
PLANETARY GEAR SETS ............................................................. 29
HYDRAULIC CONTROL COMPONENTS ........................................ 32
ELECTRICAL COMPONENTS ........................................................ 45
POWER FLOW ...................................................................................... 53
COMPLETE HYDRAULIC CIRCUITS ..................................................... 85
LUBRICATION POINTS ....................................................................... 112
BUSHING AND BEARING LOCATIONS ............................................... 113
SEAL LOCATIONS .............................................................................. 114
ILLUSTRATED PARTS LIST ................................................................ 115
BASIC SPECIFICATIONS .................................................................... 136
PRODUCT DESIGNATION SYSTEM ................................................... 138
GLOSSARY ........................................................................................ 140
ABBREVIATIONS ............................................................................... 142
INDEX ................................................................................................ 143

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PREFACE
The Hydra-matic 4/5L40-E Technicians Guide is intended for automotive
technicians that are familiar with the operation of an automatic transaxle or
transmission. Technicians or other persons not having automatic transaxle
or transmission know-how may find this publication somewhat technically
complex if additional instruction is not provided. Since the intent of this
book is to explain the fundamental mechanical, hydraulic and electrical
operating principles, technical terms used herein are specific to the
transmission industry. However, words commonly associated with the
specific transaxle or transmission function have been defined in a Glossary
rather than within the text of this book.
The Hydra-matic 4/5L40-E Technicians Guide is also intended to assist
technicians during the service, diagnosis and repair of this transmission.
However, this book is not intended to be a substitute for other General
Motors service publications that are normally used on the job. Since there
is a wide range of repair procedures and technical specifications specific to
certain vehicles and transmission models, the proper service publication
must be referred to when servicing the Hydra-matic 4/5L40-E transmission.

COPYRIGHT 2001 POWERTRAIN GROUP


General Motors Corporation
ALL RIGHTS RESERVED

All information contained in this book is based on the latest data available
at the time of publication approval. The right is reserved to make product or
publication changes, at any time, without notice.
No part of any GM Powertrain publication may be reproduced, stored
in any retrieval system or transmitted in any form or by any means,
including but not limited to electronic, mechanical, photocopying,
recording or otherwise, without the prior written permission of
Powertrain Group of General Motors Corporation. This includes all
text, illustrations, tables and charts.

INTRODUCTION
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The Hydra-matic 4/5L40-E Technicians Guide is


another Powertrain publication from the Technicians
Guide series of books. The purpose of this
publication, as is the case with other Technicians
Guides, is to provide complete information on the
theoretical operating characteristics of this
transmission. Operational theories of the mechanical,
hydraulic and electrical components are presented in
a sequential and functional order to better explain
their operation as part of the system.
In the first section of this book entitled Principles
of Operation, detailed explanations of the major
components and their functions are presented. In
every situation possible, text describes component
operation during the apply and release cycle as well
as situations where it has no effect at all. The
descriptive text is then supported by numerous
graphic illustrations to further emphasize the
operational theories presented.
The second major section entitled Power Flow,
blends the information presented in the Principles of
Operation section into the complete transmission
assembly. The transfer of torque from the engine
through the transmission is graphically displayed on a
full page while a narrative description is provided on
a facing half page. The opposite side of the half page
contains the narrative description of the hydraulic fluid

as it applies components or shifts valves in the system.


Facing this partial page is a hydraulic schematic that
shows the position of valves, ball check valves, etc.,
as they function in a specific gear range.
The third major section of this book displays the
Complete Hydraulic Circuit for specific gear
ranges. Fold-out pages containing fluid flow
schematics and two dimensional illustrations of major
components graphically display hydraulic circuits.
This information is extremely useful when tracing
fluid circuits for learning or diagnosis purposes.
The Appendix section of this book provides
additional transmission information regarding
lubrication circuits, seal locations, illustrated parts
lists and more. Although this information is available
in current model year Service Manuals, its inclusion
provides for a quick reference guide that is useful to
the technician.
Production of the Hydra-matic 4/5L40-E Technicians
Guide was made possible through the combined
efforts of many staff areas within the General Motors
Powertrain Division. As a result, the Hydra-matic
4/5L40-E Technicians Guide was written to provide
the user with the most current, concise and usable
information available regarding this product.

HOW TO USE THIS BOOK


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First time users of this book may find the page layout
a little unusual or perhaps confusing. However, with
a minimal amount of exposure to this format its
usefulness becomes more obvious. If you are
unfamiliar with this publication, the following
guidelines are helpful in understanding the functional
intent for the various page layouts:

Read the following section, Understanding the


Graphics to know how the graphic illustrations
are used, particularly as they relate to the
mechanical power flow and hydraulic controls
(see Understanding the Graphics page 6).

Unfold the cutaway illustration of the Hydramatic 4/5L40-E (page 8) and refer to it as you
progress through each major section. This
cutaway provides a quick reference of component
location inside the transmission assembly and
their relationship to other components.

The Principles of Operation section (beginning on


page 9A) presents information regarding the major
apply components and hydraulic control
components used in this transmission. This section
describes how specific components work and
interfaces with the sections that follow.

The Power Flow section (beginning on page 53)


presents the mechanical and hydraulic functions
corresponding to specific gear ranges. This
section builds on the information presented in the
Principles of Operation section by showing

specific fluid circuits that enable the mechanical


components to operate. The mechanical power
flow is graphically displayed on a full size page
and is followed by a half page of descriptive text.
The opposite side of the half page contains the
narrative description of the hydraulic fluid as it
applies components or moves valves in the system.
Facing this partial page is a hydraulic schematic
which shows the position of valves, ball check
valves, etc., as they function in a specific gear
range. Also, located at the bottom of each half
page is a reference to the Complete Hydraulic
Circuit section that follows.

The Complete Hydraulic Circuits section


(beginning on page 85) details the entire hydraulic
system. This is accomplished by using a fold-out
circuit schematic with a facing page two
dimensional fold-out drawing of each component.
The circuit schematics and component drawings
display only the fluid passages for that specific
operating range.

Finally, the Appendix section contains a schematic


of the lubrication flow through the transmission,
disassembled view parts lists and transmission
specifications. This information has been included
to provide the user with convenient reference
information published in the appropriate vehicle
Service Manuals. Since component parts lists
and specifications may change over time, this
information should be verified with Service
Manual information.

HOW TO USE THIS BOOK


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LARGE CUTAWAY VIEW


OF TRANSMISSION
(FOLDOUT)

HALF PAGE TEXT FOR EASY


REFERENCE TO BOTH PAGES

RANGE REFERENCE CHART

RK )
PA nning

(En

FORWARD
CLUTCH
ASSEMBLY
(435451)

FORWARD
SPRAG
CLUTCH
ASSEMBLY
(461)

OVERDRIVE
CLUTCH
ASSEMBLY
(480487)

INTERMEDIATE INTERMEDIATE
SPRAG
CLUTCH
CLUTCH
ASSEMBLY
ASSEMBLY
(488497)
(473)

LOW /REVERSE LOW SPRAG SECOND


CLUTCH
COAST
CLUTCH
ASSEMBLY
CLUTCH
ASSEMBLY
(503)
ASSEMBLY
(510517)
(528535)

1
POWER FROM
TORQUE
CONVERTER
(1)

SECOND
CLUTCH
ASSEMBLY
(520527)

CONVERTER
PUMP
ASSEMBLY

NO POWER
TRANSMITTED
TO
DIFFERENTIAL
ASSEMBLY

REAR
INTERNAL
GEAR
(560)
HELD

PARK
(Engine Running)

su mp tra pu
Preses pu to the hen mand
ulat rdingents. Wthe defrom
accoirem ceeds, fluidr
requut ex sure lato
outp e presre regu
of linpressu
the

SECOND
SPRAG
CLUTCH
ASSEMBLY
(547)

STATOR
ROLLER
CLUTCH
ASSEMBLY

CONVERTER FEED
LINE

EX

DECREASE

DIRECT
CLUTCH
ACCUMULATOR

OVERDRIVE
CLUTCH
ACCUMULATOR

EX

EX

INTERMEDIATE
CLUTCH
ACCUMULATOR

SECOND
CLUTCH
ACCUMULATOR

EX

EX
ACCUM

LINE

1-2 SIGNAL

FEED LIMIT

FDL

FDL

2-3 SIGNAL

D432
SECOND CL
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REV CL

EX

SECOND CL
D432

EX

EX

EX

EX

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

(B)

OFF

EX

EX

EX

EX

2-3 SHIFT VALVE


345
2345

EX

10

FEED LIMIT

23 REGULATED

2345

EX

EX

LINE SAFETY MODE

23 REGULATED

29

EX

EX

OVERDRIVE CL FD 1

EX

4-5 SIGNAL

4-5 SHIFT VLV

COAST CLUTCH FEED

4-5 SHIFT
SOLENOID
VALVE
N/C

CNTRL

OFF

EX

EX

(C)

LINE SM

EX

EX

OVERDRIVE CL FD 2

11

FEED LIMIT

2c

LINE SM

LINE

R N D 4 3 2

LINE

32

D432

EX

REV

MANUAL VALVE

LINE

TCC SIGNAL

2345 OR REVERSE

REGULATED APPLY

REVERSE
REGULATED APPLY

EX

LINE

45

28

LINE

CO
MP
LE
PARK
TE
PAWL
HY
DR
ACTUATOR
ASSEMBLY 56
PA AULI
GE
B
(613)
C
86 CIR
CU
IT

LINE

LINE (from Pump)

Figure 53

Figure 52

56

COAST CLUTCH
123
123
123 BRAKING

EX

EX

EX

FEED LIMIT VALVE

TCC PWM
SOLENOID
VALVE
N/C

PARK
PAWL
(612)
ENGAGED

Figure 6

2b

FEED LIMIT

FORWARD AND COAST


CLUTCH HOUSING
ASSEMBLY
(433)

INPUT
SUN GEAR
SHAFT
(457)

CONTROL
VALVE BODY/
ACCUMULATOR
ASSEMBLY
(47)

TRANSMISSION
MANUAL SHIFT
SHAFT SWITCH
ASSEMBLY
(602)

MANUAL
VALVE
(377)

2-3 SIGNAL

FEED LIMIT

TRANSMISSION
FLUID
PAN
(62)

TCC PWM
SOLENOID
VALVE
(352)

OFF

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH

24

REVERSE CLUTCH
HOUSING ASSEMBLY
(401)

FORWARD/COAST
CLUTCH HOUSING
SHAFT
(433)
TRANSMISSION
FLUID
FILTER
(59)

(A)

2345

SECOND COAST CLUTCH

PARK PAWL
ACTUATOR
ASSEMBLY
(613)

CONVERTER
STATOR
ASSEMBLY

FEED LIMIT
1-2 SHIFT
SOLENOID
VALVE
N/C

1-2 SHIFT CONTROL VALVE

SAFETY MODE

TCC REGULATOR VALVE

CONVERTER
TURBINE
ASSEMBLY

2a

FEED LIMIT

1-2 SHIFT VALVE

FILTER
(312)

REAR
INTERNAL
GEAR
(560)
HELD

FRONT
INTERNAL
GEAR
(550)

PRESSURE
PLATE
ASSEMBLY

32
32 SAFETY MODE

THROTTLE SIGNAL
FILTERED FEED LIMIT

PRESSURE
CONTROL
SOLENOID
VALVE

REAR
INTERNAL
GEAR
(560)

TORQUE
CONVERTER
ASSEMBLY
(1)

MEMORY
FEED LIMIT
LINE
LINE SAFETY MODE

MEMORY PILOT

LINE
FEED LIMIT

PLANETARY
CARRIER
ASSEMBLY
(553)

MEMORY

MEMORY

TORQUE
CONVERTER
ASSEMBLY
(1)

FEED LIMIT

TORQUE
CONVERTER
HOUSING/PUMP
ASSEMBLY
(3)

LINE

LINE

FEED LIMIT

OUTPUT
SHAFT
(562)

SECOND CL

INTERMED CL

ACCUMULATOR

ACCUMULATOR
OVERDR CL FD 2

REVERSE CLUTCH

THROTTLE SIGNAL

ACCUMULATOR
DIRECT CL

BOOST VALVE

FEED LIMIT

REVERSE
CLUTCH
ASSEMBLY
(404420)

COAST
CLUTCH
ASSEMBLY
(437446)

eR

DIRECT
CLUTCH
ASSEMBLY
(405414)

TORQUE
CONVERTER
HOUSING/PUMP
ASSEMBLY
(3)

(Engine Running)

PRESS REG VALVE

HYDRA-MATIC 5L40-E

gin

(P)
Park l
the e oi
r in th
leve fromwing:
ctor sure follo
sele pres the
gthe line to 8): Re)
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po p is di lator (line prion
pum re Reguoutputnsmissmp

PARK

57

PAGE NUMBER
FOR REFERENCE TO
FLUID FLOW SCHEMATIC

FLUID FLOW SCHEMATIC


(FOLDOUT)

FLUID FLOW THROUGH


COMPONENTS (FOLDOUT)
RK g)
PA nnin
Ru

e
gin
(En

19

FEED LIMIT
32 SAFETY MODE
D432
32
2-3 SIGNAL

34

30

52
48

48

15
52

28
48

48
48

18
10

FORWARD CLUTCH

Figure 82

10
21

20
52

2
48

48

TOP CHANNEL PLATE (301)


(Bottom Channel Plate Side)

19

52

48

48

#10
10

Figure 83

FRONT

FRONT

48

13

10 42

28

45

34
27

43
28

48
10

#9

#8

BOTTOM CHANNEL PLATE (304)


(Control Valve Body Side)

10

22g/23
38b

19

18
43

BOTTOM CHANNEL PLATE (304)


(Top Channel Plate Side)

38d
38e

#6
48

30

54

47

36

52

47
10
2

52

40

42
43

39

38

52
54

48

48

FRONT CONTROL VALVE BODY (311)


(Bottom Channel Plate Side)

40d
54d
2c/54c

21

19h
15a

28

38c

24

20
18

21c/31 27
20c
2h 20d

17

22

14

19

24

38
52

31

30d

20b
26a

32

38

2m/54g

SPACER PLATE (307)


(Bottom Channel Plate Side)

52

13
15

19
2

10
48

44

34
33
17

52

52

52

30
28

33

21

35

22
30
33
54
25
25
17
30
44

26

42

35
22
35
39

20
20

22

36

52

35
19

52

40
2d/54e
25d
25e
17a 3
30c

22e
35b
44e
28b 52
39a
16
23 33e
52
2e
13b 33d
33c

21b/31
19c/21
44a 2
15e 33b 22
17b
19d/21
34a
15
21a
48a
27a 44b 10f
15f/18
17c/18
29 48b
44d
19b/21 19a 10i
43b
2f

43c/45
9
28a
11
42a
44c 10g
10
48
44f/45

48
10h

#7
(Spring)

48
30

19

15
14

25
26
25

35d
54f

30a
33a

22b
22d 22c
35a

52

22a

24c
36a

22f

48
48

30b

19f

14

35c
19e

25c
40a
32a

52
25

19i
25b
19

14a/23 26b

#5
21

15

34

27

10e
36f 26

8
19j
2b
36c 25
13a
37a
40c/41
40b
39c/41
36e
42b 52
36d 36b
43a
39b
38a
48 5
19g

25a

#4

19

52
17

44
18

48
10
42

28

15

13
21

48
48

TOP CHANNEL PLATE (301)


(Case Side)

REVERSE LOCKOUT
COAST CLUTCH

32

21
48

X-5

38

20

35
52

44
2

19
48

#3
38

52 26 32
33

28

#11

22

37

28

46
13

37
40

52

52

52

35

38

23

22
22
17

19
2

36

22 19
25
30

13
42 52

40
25

35

20 21

15

52 43

10
18

39

30

X-1

19
15

38

27
34

23a

20
19

36
36

52

FRONT

52

32
22

52

30

52

12

#2

48

19

28

52

FILTER
(308)

23
38

15

35

D432

123 REGULATED
123 BRAKING

REVERSE LOCKOUT
COAST CLUTCH

1-2 SIGNAL

FEED LIMIT

1-2 SIGNAL
123

TOP CHANNEL PLATE (301)


CASE (24)

13

52

41

35

52

19

47a

27c/46

52
12
48

27

23
37c

54b

43

20a

11
10

10
52

19

48

ONEN

24

X-3

41

27b

10d
23b

X-4

36
48

7b

48
37

48

11b
10c
12a
4
52
28c
48
47b 2a/54a

10
42

15b
11a/10b

13
36

48

37b
10a

2g

21

40

FRONT

2
41

19

15

7
2

13

24b
7a

24

FILTER
(312)

48

16a
23c

24a
48

FRONT

FRONT

48
43

48

23
48

48
37d
48

52

41

43

52

48
16

15c/16
7

48

23

15

36

42
27

48

15d/16
24

24

36
37

27
20

COMP

(36)
TRA TS
(40) NSMIS ( )
(203 TRANSMIS SION FLU
(213) CHECK VA SION FLU ID LEV
EL
(214) TRANSMISLVE RET ID PRE HOLE PLU
AIN SS
(230) BRASS OR SION FLU ER AN URE TES G
D
(232) TRANSMIS IFICE IN ID PUMP BALL AS T PLUG
SER
(233) ORIFICE SION VEN T SCREEN SEMBLY
SLE
ASSEM
(306) ORIFICE EVE T ASSEM
BLY
CONT CUP PLU
BLY
(#1 ROL G
(308) , 2, 3, VALVE BO
4, 5, DY
TCC
6,
(312) PWM 7, 8, BALL
PRESS SOLEN 9, 10, CHECK
11,
FIL URE CO OID VA 12 VALVE
86 TER ASSEMNTROL SOLVE FILTER
B
BLY LENOID ASSEM
VALVE BLY

FRONT

LINE

32

LINE
LINE SAFETY MODE
REVERSE LOCKOUT
D432

23 REGULATED

INTERMEDIATE CL

LOW AND REV CL OR RLO


REVERSE LOCKOUT
SECOND COAST CLUTCH

2-3 SIGNAL
D432
FEED LIMIT

1-2 SIGNAL
2-3 SIGNAL

LOW AND REV CL OR RLO

LINE

D432

2-3 SIGNAL

42

20
19

#12

ARE USED FOR

48
37
48

2
10

27

13

47

28

23

37

27

48

16
48

11

48

48

12

24
48

48

2-3 SIGNAL

LINE
123

REVERSE LOCKOUT
COAST CLUTCH

48
2

48
7

2345
2345
2345
32 SM
45
123
123
2345
21

21

20b

19

19d

19c

OVERDRIVE CL FD 2
OVERDRIVE CL FD 1
RLO

31

31

20c

20d

19b

42a

21a

19a

38

38e

22f

#6

21

21b

15

41

48

48
16

37
48
36

10

12
28

48
16

48

20

13

15f
15e

#5

32

15

48
21
27

10

35 15

#8
22e

17

21c

2f

2h

38d

38b

14a

22g

38c

#7

48
48

37

28
48

PASSAGES MARKED WITH


THE 5L40-E ONLY

X-2

48

10

43b

16

48

16

48

12

18

2345

#4

32

21

48
48

17b

45
123

X-5

23

27

16

48

24
2

48

24

17c

32 SM

32

D432

LINE

EX

REV

45

#3

30b

30a

X-1

28

1-2 SIGNAL

32
12

COAST CLUTCH
FORWARD CLUTCH

123 REGULATED
23 REGULATED

32 SM/FDL
2345
LOW AND REVERSE CL

EX

EX
EX

EX

COAST CLUTCH
123
123

FDL

EX

EX

2345

EX

EX

EX

345
2345
EX

REVERSE

45

EX

123 REGULATED
123 BRAKING
345

123 REGULATED

TCC SIGNAL
26b

19g

19i

25a

25b

36a

19j

24c

36b

15a

13a

38a

37b

37a

#2

32

48
16
37
7

FRONT

INTERMEDIATE CLUTCH
54g

2d
2e

35c

2m

54e

FDL

FDL

2-3 SIGNAL

SECOND CLUTCH
D432

EX

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED
EX

EX
EX

EX

EX

EX

345
45
DIRECT CLUTCH
345
45
LINE SAFETY MODE

345

REVERSE LOCKOUT
TCC SIGNAL
123 REGULATED
123 BRAKING
123 REGULATED
345

123
D432

LINE
36c

36d

13
22c

26a

32 SAFETY MODE

32
2-3 SIGNAL

EX
EX
EX

10i

18

(36)

CASE (24)
(Top Channel Plate Side)

EXHAUST FLUID NOT SHOWN


48

48

EX
EX

11
13b

32a

123
FEED LIMIT
32 SAFETY MODE

15

FORWARD CLUTCH
COAST CLUTCH

12

22

22b
39a

22

123 REGULATED
LINE
123 BRAKING
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2
45
OVERDRIVE CLUTCH FEED 1

LINE
1-2 SIGNAL

48b

#9

43

52

52

DUAL PURPOSE PASSAGES HAVE


CHANNEL PLATE SIDE NUMBERS LISTED FIRST

#1

33c
33b

2345

32

21

52

52

NON FUNCTIONAL HOLES HAVE BEEN


REMOVED FROM COMPONENT DRAWINGS
TO SIMPLIFY TRACING FLUID FLOW.

52

21

(203)
32
12 (203)

52
1

FLUID PUMP COVER (202)


(Case Side)

48

22e

GASKET (303)

LINE

EX

52
52

INDICATES BOLT HOLES

SUCTION

45

FLUID FILTER
ASSEMBLY
(59)

EX

OFF

COAST CLUTCH FEED


OVERDRIVE CLUTCH FEED 2
45

R N D 4 3 2

SPACER PLATE (307)


GASKET (305)
BOTTOM CHANNEL PLATE (304)

D432

OVERDRIVE CLUTCH FEED 1

FLUID
PAN
(62)

29

LINE SAFETY MODE

THROTTLE SIGNAL

(C)

2
16

(203)

TORQUE CONVERTER HOUSING (227)


(Fluid Pump Cover Side)

34a

4-5 SHIFT
SOLENOID
VALVE
N/C

CNTRL

52
16

40a

REAR CONTROL VALVE BODY (310)


GASKET (309)
19

345

37

48a

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
123
123

52
15

18

NOTE:

24

(203)

45

52

34

30

52

CASE (24)
(Fluid Pump Cover Side)
52

37

45

48

48

10h

#10

MANUAL VALVE

26

TCC SIGNAL
REVERSE LOCKOUT
LINE
REGULATED APPLY
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2

12
32

10

44f
43c

OFF

2345

6
7b

7a

36f

36e

23b

X-4

4-5 SHIFT VLV

52

52
21

48

8
52

22a

(B)

EX
SECOND COAST CLUTCH
OVERDRIVE CLUTCH FEED 1
2345
2345
23 REGULATED
4-5 SIGNAL

LOW PRESSURE

345

345
23a

2345 OR REVERSE

345

25

345

REVERSE CLUTCH

30d

ACCUM
OVERDRIVE CL FD 2 40d
32
32 SAFETY MODE

DIRECT CLUTCH

MEMORY
FEED LIMIT
LINE

EX

MEMORY

EX

EX

123
D432
345
DIRECT CLUTCH

EX

REGULATED APPLY

EX

EX

EX
EX

TCC SIGNAL

TCC SIGNAL

FILTER
(308)

23c

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

2345 OR REVERSE

15

REGULATED APPLY

TCC PWM
SOLENOID
VALVE
N/C

24b

345
345

32 SAFETY MODE

REVERSE CLUTCH

REGULATED APPLY

2345 OR REVERSE

REVERSE LOCKOUT

REVERSE CLUTCH

REVERSE LOCKOUT
LINE

OVERDRIVE CLUTCH FEED 1


OVERDRIVE CLUTCH FEED 2

16a

LINE

TCC REGULATOR VALVE

20a

OVERDRIVE CL FD 1
OVERDRIVE CL FD 2
345

FEED LIMIT
LINE

32
1-2 SIGNAL
32 SAFETY MODE
32
1-2 SIGNAL

RELEASE
TO COOLER

THROTTLE SIGNAL
FEED LIMIT
2-3 SIGNAL

CONVERTER FDL
CONVERTER FEED

TCC SIGNAL
REGULATED APPLY

LINE

SUCTION
2
21

LINE
COAST CLUTCH

FORWARD CLUTCH

PRESSURES
INTAKE & DECREASE (SUCTION)
CONVERTER & LUBE
MAINLINE
REGULATED LINE
SOLENOID SIGNAL
ACCUMULATOR
FEED LIMIT
THROTTLE SIGNAL

X-2

30c

54f

54d

54b
37c

DIRECT CL

OVERDRIVE CLUTCH

35d

APPLY
RELEASE
REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH
LUBE
APPLY

DIRECT CLUTCH

DIRECT CLUTCH

LINE

CASE (24)

COAST CLUTCH

DECREASE

CONVERTER FEED
DECREASE

FORWARD CLUTCH

LINE

COAST CLUTCH

PRESS REG VALVE


BOOST VALVE

LINE

16

24a

(214)

16

52

48

35

(40)

32
9
37 16 21

REVERSE CLUTCH

13

EX

FLUID PUMP
SCREEN
ASSEMBLY
(213)

FLUID
PUMP
COVER
(202)

FEED LIMIT VALVE

23
15b
15c

15d

52

21

CONVERTER
HOUSING
(224)

10c
10

#1

REV

16

37

32

28a

FDL 44 45
FDL 44c

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

30

EX

TCC
ENABLE
VALVE

FEED LIMIT
FEED LIMIT

#11

2345
INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH
23 REGULATED
2-3 SIGNAL
FEED LIMIT

REVERSE
LOCKOUT
VALVE

52

41

16

12

(213)
1

24

THROTTLE SIGNAL

APPLY

33d

2345

RLO

2-3 SHIFT VALVE

10a

23

FLUID PUMP COVER (202)


(Torque Converter Housing Side)

TCC
CONTROL
VALVE

1-2 SHIFT CONTROL VALVE

TCC SIGNAL

LINE SAFETY MODE

CNTRL 3-4 SHIFT

35b
33e

OFF

16
2/21

(214) 21
52

12

SAFETY MODE

1-2 SIGNAL
2-3 SIGNAL

(A)

32
48

16

PRESSURE
CONTROL
SOLENOID
VALVE

10b

1-2 SHIFT VALVE

35a

12

50

48

48

FILTER
(312)

28c

10d

10g

24

1-2 SHIFT
SOLENOID
VALVE
N/C

2
4

24
4
53
48
7
7

11b

11a

LINE
CONVERTER FEED

FD LIMIT

52

THROTTLE SIGNAL
FILTERED FEED LIMIT

44a
10f
27a
44b

37

PRESSURE
RELIEF
BALL
VALVE

DIRECT CLUTCH

44e

FDL

52
52

24
37

48

47b

27b

AIR
BLEED
(203)

86

MEMORY PILOT

12a

25d

17a
44d
28b

2-3 SIGNAL
FDL

24

52

EX

46

31

46

36

20
25c
25e

FDL
FEED LIMIT
1-2 SIGNAL

52

52

8
7

(233)

30

27c

D432

19e

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED

FEED LIMIT
MEMORY
MEMORY PILOT

52

37

21

8
7

48
24

16

4
53
48
7

48

52

48
53

D432

33a

SECOND CLUTCH
D432

LOW AND REVERSE CLUTCH


32

LINE

47a

AIR
BLEED
(233)

19h
19f

AIR
BLEED
(203)

D432

14

32 SAFETY MODE

2b

AIR
BLEED
(203)

ACCUM
SECOND CLUTCH

52

32

52
24

12

51
48

50

52

52

12

48

EX

OVERDRIVE CLUTCH FEED 1

42b

16
51

X-3

ACCUMULATOR
INTERMEDIATE CLUTCH

DIRECT CLUTCH

37d
43a

LINE
SECOND CLUTCH
21

53
8
6

32 5
21 9

19

OVERDRIVE CLUTCH FEED 2

40b

10e

48

39c

ACCUM

(232)
52

31

FLUID
PRESSURE
TEST PLUG
(40)

OVERDRIVE CLUTCH FEED 2

40c

39b

32

AIR
BLEED
(233)

ACCUMULATOR

41

COAST CLUTCH
DIRECT CLUTCH

LINE

54c

#12

TO COOLER
REVERSE CLUTCH
FORWARD CLUTCH

LUBE
AIR
BLEED
(203)

ACCUMULATOR

54a

5
2c

INTERMEDIATE CLUTCH

(231)
48

2a

EX

SECOND
CLUTCH
ACCUMULATOR

SPACER PLATE (307)

ACCUMULATOR HOUSING (333)

EX

INTERMEDIATE
CLUTCH
ACCUMULATOR

48
4
48

COOLER

ER
COOL

OVERDRIVE
CLUTCH
ACCUMULATOR

GASKET (309)
FRONT CONTROL VALVE BODY (311)

ACCUMULATOR HOUSING (328)

EX

DIRECT
CLUTCH
ACCUMULATOR

51

51

2
52

GASKET (303)
BOTTOM CHANNEL PLATE (304)
GASKET (305)

ACCUMULATOR HOUSING (323)

EX

(229)
(233)

TRANSMISSION
VENT
ASSEMBLY

ACCUMULATOR HOUSING (317)


CASE (24)
TOP CHANNEL PLATE (301)

SECOND CLUTCH
REVERSE LOCKOUT

OVERDRIVE CLUTCH

(Engine Running)

su mp tra pu
Preses pu to thWe hen mand
ulat rdingents. the defrom
accoirem ceeds, fluidr
requut ex sure lato
outp e presre regu
of linpressu
the

OVERDRIVE CLUTCH

LOW AND REV CL OR RLO


SECOND COAST CLUTCH

CENTER
SUPPORT
ASSEMBLY
(510535)

FORWARD CLUTCH
COAST CLUTCH
LUBE

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH
LUBE

TO

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

LUBE

(P)
Park l
the e oi
r in th
leve fromwing:
ctor sure follo
gsele pres the
the line ed to 218): Re)
re
ith
n,
W sitio rect Valve( essu
po p is di lator (line prion
pum re Reguoutputnsmissmp

PARK

TORQUE
CONVERTER
ASSEMBLY
(1)

NOTE:
PASSAGES AND
COMPONENTS
MARKED WITH
ARE USED FOR
THE 5L40-E ONLY

PARK

(Engine Running)

52
2

10
48

48

27

43

44
10

28
48
10

44

48

48

REAR CONTROL VALVE BODY (310)


(Bottom Channel Plate Side)

FOLDOUT 87

HALF PAGE TEXT AND LEGEND

COMPLETE ILLUSTRATED
PARTS LIST

Figure 1

UNDERSTANDING THE GRAPHICS


WWW.ALL-TRANS.BY

TORQUE
CONVERTER
ASSEMBLY
(1)

TORQUE
CONVERTER
HOUSING
(227)

CASE
ASSEMBLY
(24)

FLUID PUMP
COVER
ASSEMBLY
(202)

GASKET
(46)

CONTROL
VALVE BODY AND
ACCUMULATOR
ASSEMBLY
(47)

FLUID
FILTER
(59)

GASKET
(60)

FLUID
PAN
(62)

Figure 2

The flow of transmission fluid starts in the bottom


pan and is drawn through the filter, case assembly and
into the oil pump assembly. This is a basic concept of
fluid flow that can be understood by reviewing the
illustrations provided in Figure 2. However, fluid may
pass between the control valve body, spacer plate,
case and other components many times before reaching
a valve or applying a clutch. For this reason, the
graphics are designed to show the exact location where
fluid passes through a component and into other
passages for specific gear range operation.
To provide a better understanding of fluid flow in
the Hydra-matic 4/5L40-E transmission, the
components involved with hydraulic control and fluid
flow are illustrated in three major formats. Figure 3
provides an example of these formats which are:

A three dimensional line drawing of the component


for easier part identification.

A two dimensional line drawing of the component


to indicate fluid passages and orifices.

A graphic schematic representation that displays


valves, ball check valves, orifices and so forth,
required for the proper function of the transmission
in a specific gear range. In the schematic drawings,
fluid circuits are represented by straight lines and
orifices are represented by indentations in a circuit.
All circuits are labeled and color coded to provide
reference points between the schematic drawing
and the two dimensional line drawing of the
components.

Figure 4 (page 7B) provides an illustration of a


typical valve, bushing and valve train components.
A brief description of valve operation is also
provided to support the illustration.

Figure 5 (page 7B) provides a color coded chart


that references different fluid pressures used to
operate the hydraulic control systems. A brief
description of how fluid pressures affect valve
operation is also provided.

INTERMEDIATE CLUTCH

30b

LOW AND REV CL OR RLO


REVERSE LOCKOUT
SECOND COAST CLUTCH

23 REGULATED

INTERMEDIATE CL

LINE

2-3 SIGNAL
1-2 SIGNAL

34a
48b

22

EX
EX

33b

#9

EX
EX
EX

22b

OFF

11
10i
13b
43

13

18

2345

22c

22

X-1

28

LOW AND REV CL OR RLO

2-3 SIGNAL

EX

39a

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
123
123

THREE DIMENSIONAL

26a

45
32 SM

123 REGULATED
LINE
123 BRAKING
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2
45
OVERDRIVE CLUTCH FEED 1

D432

REVERSE LOCKOUT
COAST CLUTCH

D432

32

GASKET (303)

1-2 SIGNAL

21

21

LINE
123

FEED LIMIT

22f

#6
19

19d

15

19c

#5

21c

31

31

21a

42a

17
21b

20d

20c

#7

2-3 SIGNAL

22e
43b

16

19b

#4

19a

2f

2h

X-5

OVERDRIVE CL FD 2
OVERDRIVE CL FD 1
RLO

15e

123 REGULATED
123 BRAKING

123
123
2345

32

D432

LINE

18
15f

#8

2345
38

38e

17b
17c

45
123

38d

38c

27

LINE
1-2 SIGNAL

1-2 SIGNAL

123

TWO DIMENSIONAL
BOTTOM CHANNEL PLATE SIDE

32a

REV
38b

22g

14a

#3

REAR CONTROL
VALVE BODY
(310)

33c

LINE

(C)

EX

48a

EX

2345
2345
2345
32 SM

CNTRL

45

29

D432
FEED LIMIT

EX

48

4-5 SHIFT
SOLENOID
VALVE
N/C

45

LINE
1-2 SIGNAL

45

#10

LINE SAFETY MODE

D432

44f
43c

OFF

123 REGULATED
23 REGULATED

(B)

EX

COAST CLUTCH
123
123

45

EX

REVERSE

CNTRL

22e

EX
GASKET (305)
BOTTOM CHANNEL PLATE (304)

345

FDL
10h

23

26b

19i

19g

36a

25b

24c

25a

15a

36b

13a

38a

37b

37a

#2

SPACER PLATE (307)

BOTTOM CHANNEL PLATE SIDE

10

2-3 SHIFT
SOLENOID
VALVE
N/C

COAST CLUTCH FEED


OVERDRIVE CLUTCH FEED 2
45

R N D 4 3 2

TWO DIMENSIONAL

22a

EX

2345

EX

345
2345

EX

EX
EX

123 REGULATED
123 BRAKING
345

TCC SIGNAL
REVERSE LOCKOUT
TCC SIGNAL
123 REGULATED
123 BRAKING
123 REGULATED
345

345

DIRECT CLUTCH
345
45
LINE SAFETY MODE

REGULATED APPLY

4-5 SHIFT VLV

THREE DIMENSIONAL

28a

FDL 44 45
FDL 44c

32 SM/FDL
2345
LOW AND REVERSE CL

30d

FDL

FDL

EX

2-3 SIGNAL

EX

EX

#11

40a

123
D432

LINE
7b

30a

2e

30c
54e

2m

35c

2d

54g
54f

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED

SECOND CLUTCH
D432
EX

EX

23
33d

EX
SECOND COAST CLUTCH
OVERDRIVE CLUTCH FEED 1
2345
2345
23 REGULATED
4-5 SIGNAL

LOW PRESSURE

REAR CONTROL VALVE BODY (310)


GASKET (309)
19

TCC SIGNAL

LINE

FORWARD CLUTCH
COAST CLUTCH

123

TOP
CHANNEL PLATE
(301)

LINE SAFETY MODE


FEED LIMIT
32 SAFETY MODE

FEED LIMIT
32 SAFETY MODE

32 SAFETY MODE
REVERSE LOCKOUT
D432

32
15

32
2-3 SIGNAL
12

SUCTION

TORQUE CONVERTER
HOUSING
(227)

REV

123 REGULATED

EX

REGULATED APPLY
24b

26

OVERDRIVE CLUTCH FEED 1

FLUID
PAN
(62)

35a
35b
33e

OFF

2345

45

FLUID FILTER
ASSEMBLY
(59)

24

(A)

MANUAL VALVE

REVERSE LOCKOUT
LINE
REGULATED APPLY
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2

THROTTLE SIGNAL

10g

2345

345
45

EX

EX

EX

123
D432
345
DIRECT CLUTCH

EX

EX

EX
36f

345

EX

TCC SIGNAL

EX

REVERSE CLUTCH

2345 OR REVERSE
36c

36d

36e

23a

X-4

44b

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH
23 REGULATED

345

345
25

44a
10f
27a

2-3 SIGNAL
FEED LIMIT

REVERSE
LOCKOUT
VALVE

345

19j

THROTTLE SIGNAL

REVERSE LOCKOUT
LINE

2345 OR REVERSE

TCC SIGNAL

FILTER
(308)

345

REVERSE CLUTCH

PRESSURES
INTAKE & DECREASE (SUCTION)
CONVERTER & LUBE
MAINLINE
REGULATED LINE
SOLENOID SIGNAL
ACCUMULATOR
FEED LIMIT
THROTTLE SIGNAL

15

44e
44d
28b

21

COAST CLUTCH

FORWARD CLUTCH

16a

23c

LINE

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

(214)

X-2

TCC PWM
SOLENOID
VALVE
N/C

17a

RLO

LINE

TCC REGULATOR VALVE

23b

2
21

1
FLUID
PUMP
COVER
(202)

16

24a

32 SAFETY MODE

FLUID PUMP
SCREEN
ASSEMBLY
(213)

REGULATED APPLY

SUCTION

EX

LINE

16

#1

345

CONVERTER
HOUSING
(224)

13

REVERSE CLUTCH

REVERSE CLUTCH

TCC
ENABLE
VALVE

15b
15c
15d

OVERDRIVE CLUTCH FEED 1


OVERDRIVE CLUTCH FEED 2

TCC SIGNAL
REGULATED APPLY

LINE

CONVERTER FDL
CONVERTER FEED

COAST CLUTCH

APPLY

FEED LIMIT
FEED LIMIT

FEED LIMIT VALVE

23

25c
25e

FDL

2-3 SHIFT VALVE

10c
10

25d

FD LIMIT

2345

CNTRL 3-4 SHIFT

20

1-2 SHIFT
SOLENOID
VALVE
N/C

1-2 SHIFT CONTROL VALVE

D432

19e

LINE SAFETY MODE

10a

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

RELEASE
TO COOLER

7
10d

D432

33a

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REVERSE CLUTCH
FDL
2-3 SIGNAL
FDL
FEED LIMIT
1-2 SIGNAL

TCC SIGNAL

2-3 SIGNAL

28c

TCC
CONTROL
VALVE

REVERSE LOCKOUT

DECREASE

FORWARD CLUTCH

CONVERTER FEED
DECREASE

LINE
CONVERTER FEED

MEMORY
FEED LIMIT
LINE
EX

SAFETY MODE

1-2 SIGNAL

19h
19f

20b

PRESSURE
CONTROL
SOLENOID
VALVE

10b

DIRECT CLUTCH

MEMORY

EX

FILTER
(312)

11a

X-3
D432

14

1-2 SHIFT VALVE


DIRECT CLUTCH

MEMORY PILOT
THROTTLE SIGNAL
FILTERED FEED LIMIT

7a

PRESSURE
RELIEF
BALL
VALVE

32
32 SAFETY MODE

46

11b

EX

36

FEED LIMIT
MEMORY
MEMORY PILOT

20a

APPLY

46

12a

32
1-2 SIGNAL
32 SAFETY MODE

EX

27c

47b

OVERDRIVE CL FD 1
OVERDRIVE CL FD 2
345
FEED LIMIT
LINE

DIRECT CLUTCH

DIRECT CLUTCH

30

EX

AIR
BLEED
(203)

54d

32

47a

AIR
BLEED
(233)

21

SECOND CLUTCH

LINE

2b

ACCUM
SECOND CLUTCH

D432

32 SAFETY MODE

43a
42b

LINE
SECOND CLUTCH

19

DIRECT CLUTCH

37d

10e

AIR
BLEED
(203)

AIR
BLEED
(203)

OVERDRIVE CLUTCH FEED 2

40b

LINE

COAST CLUTCH

CASE (24)

37c

39b

27b

LINE

PRESS REG VALVE

OVERDRIVE CLUTCH FEED 1

INTERMEDIATE CLUTCH

ACCUM

ACCUMULATOR
INTERMEDIATE CLUTCH

31

BOOST VALVE

DIRECT CL

39c

32

THROTTLE SIGNAL

OVERDRIVE CLUTCH FEED 2

40c
41

COAST CLUTCH

EX

ACCUMULATOR

#12

DIRECT CLUTCH

FLUID
PRESSURE
TEST PLUG
(40)

54c

EX

SECOND
CLUTCH
ACCUMULATOR

FRONT CONTROL
VALVE BODY
ASSEMBLY
(311)

SECOND CLUTCH
REVERSE LOCKOUT

ACCUMULATOR HOUSING (333)

EX

INTERMEDIATE
CLUTCH
ACCUMULATOR

ACCUM
OVERDRIVE CL FD 2 40d

2c

LUBE
AIR
BLEED
(203)

ACCUMULATOR

54a

TO COOLER

AIR
BLEED
(233)

54b

SPACER PLATE (307)

2a

OVERDRIVE
CLUTCH
ACCUMULATOR

BOTTOM CHANNEL PLATE (304)


GASKET (305)

GASKET (309)
FRONT CONTROL VALVE BODY (311)

ACCUMULATOR HOUSING (328)

EX

DIRECT
CLUTCH
ACCUMULATOR

BOTTOM CHANNEL PLATE SIDE

LOW AND REV CL OR RLO


SECOND COAST CLUTCH

CENTER
SUPPORT
ASSEMBLY
(510535)

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (323)

EX

35d

APPLY
RELEASE

GASKET (303)

REVERSE CLUTCH
FORWARD CLUTCH

LINE

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (317)
CASE (24)
TOP CHANNEL PLATE (301)

2345 OR REVERSE

CO

COOLER

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

FORWARD CLUTCH
COAST CLUTCH
LUBE

LUBE

OVERDRIVE CLUTCH

TO

R
OLE

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH
LUBE

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

LUB

;;;
;;;
;;
;;;
;;;
;
;;;
;
;;
;
;;;
;
;;;
;
;;;
;;;
; ;;;
;;;
;
;;;
;;;

TORQUE
CONVERTER
ASSEMBLY
(1)

NOTE:
PASSAGES AND
COMPONENTS
MARKED WITH
ARE USED FOR
THE 5L40-E ONLY

WWW.ALL-TRANS.BY

UNDERSTANDING THE GRAPHICS

D432
32

2-3 SIGNAL

2-3 SIGNAL

TOP CHANNEL PLATE (301)


CASE (24)

REVERSE LOCKOUT
COAST CLUTCH

REVERSE LOCKOUT
COAST CLUTCH

COAST CLUTCH
FORWARD CLUTCH

FORWARD CLUTCH

THREE DIMENSIONAL

GRAPHIC
SCHEMATIC
REPRESENTATION

FLUID PUMP
COVER
ASSEMBLY
(202)

TWO DIMENSIONAL
CONTROL VALVE BODY SIDE

BOTTOM
CHANNEL
PLATE
(304)

CASE
ASSEMBLY
(24)

THREE DIMENSIONAL

TWO DIMENSIONAL
BOTTOM CHANNEL PLATE SIDE

SPACER
PLATE
(307)
THREE DIMENSIONAL

THREE DIMENSIONAL

THREE DIMENSIONAL

FLUID PUMP COVER SIDE

CONVERTER HOUSING SIDE

TOP CHANNEL PLATE SIDE

THREE DIMENSIONAL

TWO DIMENSIONAL
CONTROL VALVE BODY SIDE

ACCUMULATORS

TWO DIMENSIONAL

TWO DIMENSIONAL

TWO DIMENSIONAL

Figure 3

THREE DIMENSIONAL

FOLDOUT 7

TWO DIMENSIONAL

FOLDOUT 7A

UNDERSTANDING THE GRAPHICS

NOTE: NOT ALL VALVES ARE


USED WITH A BUSHING

BUSHING
SPRING
VALVE
BORE
PLUG

RESTRICTING
ORIFICE

SPACER
PLATE

RETAINING
PIN

BALL
CHECK
VALVE

VALVE
BODY

VALVE
BODY

BUSHING
TO APPLY
COMPONENT

SPACER
PLATE

APPLY
FLUID

SPRING
ASSIST
FLUID

SIGNAL
FLUID

APPLY FLUID SEATS


THE BALL CHECK VALVE
FORCING FLUID THROUGH
AN ORIFICE IN THE SPACER
PLATE, WHICH CREATES
A SLOWER APPLY.

SIGNAL
FLUID

SPRING
ASSIST
FLUID

APPLY
FLUID

BUSHING

BORE
PLUG

SPACER
PLATE

SPRING
VALVE

EXHAUST FROM THE


APPLY COMPONENT
UNSEATS THE
BALL CHECK VALVE,
THEREFORE CREATING
A QUICK RELEASE.

RETAINING
PIN

EX
WITH SIGNAL FLUID PRESSURE
EQUAL TO OR LESS THAN
SPRING AND SPRING ASSIST
FLUID PRESSURE THE VALVE
REMAINS IN CLOSED POSITION.

EX
WITH SIGNAL FLUID PRESSURE
GREATER THAN SPRING AND
SPRING ASSIST FLUID PRESSURE
THE VALVE MOVES OVER.

Figure 4

FLUID PRESSURES
INTAKE & INCREASE (SUCTION)
CONVERTER & LUBE
MAINLINE

SOLENOID SIGNAL

FEED LIMIT
THROTTLE SIGNAL

EXHAUST
DIRECTION OF FLOW

WITH EQUAL SURFACE AREAS


ON EACH END OF THE VALVE,
BUT FLUID PRESSURE "A"
BEING GREATER THAN FLUID
PRESSURE "B", THE VALVE
WILL MOVE TO THE RIGHT.

Figure 5

ACCUMULATOR

REGULATED LINE

WWW.ALL-TRANS.BY

TYPICAL BUSHING AND VALVE

WITH THE SAME FLUID PRESSURE


ACTING ON BOTH SURFACE "A"
AND SURFACE "B" THE VALVE
WILL MOVE TO THE LEFT. THIS
IS DUE TO THE LARGER SURFACE
AREA OF "A" THAN "B".

7B

WWW.ALL-TRANS.BY

HYDRA-MATIC 5L40-E
TORQUE
CONVERTER
HOUSING/PUMP
ASSEMBLY
(3)

DIRECT
CLUTCH
ASSEMBLY
(405414)

COAST
CLUTCH
ASSEMBLY
(437446)

REVERSE
CLUTCH
ASSEMBLY
(404420)

FORWARD
CLUTCH
ASSEMBLY
(435451)

FORWARD
SPRAG
CLUTCH
ASSEMBLY
(461)

OVERDRIVE
CLUTCH
ASSEMBLY
(480487)

INTERMEDIATE INTERMEDIATE
SPRAG
CLUTCH
CLUTCH
ASSEMBLY
ASSEMBLY
(488497)
(473)

LOW /REVERSE LOW SPRAG SECOND


CLUTCH
COAST
CLUTCH
ASSEMBLY
CLUTCH
ASSEMBLY
(503)
ASSEMBLY
(510517)
(528535)

CONVERTER
PUMP
ASSEMBLY

SECOND
CLUTCH
ASSEMBLY
(520527)
SECOND
SPRAG
CLUTCH
ASSEMBLY
(547)

STATOR
ROLLER
CLUTCH
ASSEMBLY

OUTPUT
SHAFT
(562)

PLANETARY
CARRIER
ASSEMBLY
(553)
REAR
INTERNAL
GEAR
(560)
FRONT
INTERNAL
GEAR
(550)
TORQUE
CONVERTER
ASSEMBLY
(1)

PARK PAWL
ACTUATOR
ASSEMBLY
(613)

FORWARD/COAST
CLUTCH HOUSING
SHAFT
(433)

PRESSURE
PLATE
ASSEMBLY

CONVERTER
TURBINE
ASSEMBLY

CONVERTER
STATOR
ASSEMBLY

TRANSMISSION
FLUID
FILTER
(59)

TCC PWM
SOLENOID
VALVE
(352)
Figure 6

TRANSMISSION
FLUID
PAN
(62)

MANUAL
VALVE
(377)

TRANSMISSION
MANUAL SHIFT
SHAFT SWITCH
ASSEMBLY
(602)

CONTROL
VALVE BODY/
ACCUMULATOR
ASSEMBLY
(47)

INPUT
SUN GEAR
SHAFT
(457)

WWW.ALL-TRANS.BY
Figure 7

HYDRA-MATIC 4/5L40-E
CROSS SECTIONAL DRAWING
A cross sectional line drawing is typically the standard
method for illustrating either an individual mechanical
component or a complete transmission assembly.
However, unless a person is familiar with all the
individual components of the transmission,
distinguishing components may be difficult in this type
of drawing. For this reason, a three dimensional
perspective illustration (shown on page 8) is the primary
drawing used throughout this book.
The purpose for this type of illustration is to provide a
more detailed graphic representation of each component
and to show their relationship to other components
within the transmission assembly. It is also useful for
8A

understanding the cross sectional line drawing by


comparing the same components from the three
dimensional perspective illustration. In this regard it
becomes an excellent teaching instrument.
Additionally, all the illustrations contained in this book
use a color scheme that is consistent throughout this
book. In other words, regardless of the type of
illustration or drawing, all components have an assigned
color and that color is used whenever that component
is illustrated. This consistency not only helps to provide
for easy component identification but it also enhances
the graphic and color continuity between sections.

GENERAL DESCRIPTION
WWW.ALL-TRANS.BY

The 4/5L40-E was designed to be a four or five speed


transmission. The same case and components are used
for both applications with the exclusion of the second
clutch and the second sprag clutch, and the use of a
smaller ravigneaux planetary carrier assembly in the
four speed version. This book will describe the five
speed model, however, the parts list will show the
differences in components between the four and five
speed. The function and operation of all components
and systems is the same for both the four and five speed
models, except that the four speed model uses third as
second gear, fourth as third gear and fifth as fourth gear.
The Hydra-matic 5L40-E is a fully automatic, five speed,
rear wheel drive, electronically controlled transmission.
It consists primarily of a four-element torque converter,
one planetary gear set, friction and mechanical clutches
and a hydraulic pressurization and control system.
The four-element torque converter contains a pump, a
turbine, a pressure plate splined to the turbine, and a
stator assembly. The torque converter acts as a fluid
coupling to smoothly transmit power from the engine
to the transmission. It also hydraulically provides
additional torque multiplication when required. The
pressure plate, when applied, provides a mechanical
direct drive coupling of the engine to the transmission.

The planetary gear set provides the five forward gear


ratios and reverse. Changing gear ratios is fully automatic
and is accomplished through the use of a Transmission
Control Module (TCM). The TCM receives and monitors
various electronic sensor inputs and uses this information
to shift the transmission at the optimum time.
The TCM commands shift solenoids, within the
transmission, on and off to control shift timing. The
TCM controls shift feel through the pressure control
solenoid. The TCM also controls the apply and release
of the torque converter clutch which allows the engine
to deliver the maximum fuel efficiency without
sacrificing vehicle performance.
The hydraulic system primarily consists of a vane type
pump, two control valve bodies, two channel plates,
converter housing and case. The pump maintains the
working pressures needed to stroke the clutch pistons
that apply or release the friction components. These
friction components (when applied or released) support
the automatic shifting qualities of the transmission.
The friction components used in this transmission consist
of nine multiple disc clutches. The multiple disc clutches
combine with four mechanical sprag clutches, to deliver
six different gear ratios through the gear set. The gear
set then transfers torque through the output shaft.

EXPLANATION OF GEAR RANGES

Figure 8

The transmission can be operated in any one of the


seven different positions shown on the shift quadrant
(Figure 8).
P Park position enables the engine to be started while
preventing the vehicle from rolling either forward or
backward. For safety reasons, the vehicles parking
brake should be used in addition to the transmission
Park position. Since the output shaft is mechanically
locked to the case through the parking pawl and rear
internal gear, Park position should not be selected until
the vehicle has come to a complete stop.
R Reverse enables the vehicle to be operated in a
rearward direction.
N Neutral position enables the engine to start and
operate without driving the vehicle. If necessary, this
position should be selected to restart the engine while
the vehicle is moving.

D Overdrive range should be used for all normal


driving conditions for maximum efficiency and fuel
economy. Overdrive range allows the transmission to
operate in each of the five forward gear ratios. Downshifts to a lower gear, or higher gear ratio are available
for safe passing by depressing the accelerator or by
manually selecting a lower gear with the shift selector.
4 Manual Fourth can be used for conditions where it
may be desirable to use only four gear ratios. These
conditions include towing a trailer and driving on hilly
terrain as described above. This range is also helpful
for engine braking when descending slight grades. Upshifts and downshifts are the same as in Overdrive
range for first, second, third and fourth gears except
that the transmission will not shift into fifth gear. Manual
Fourth can be selected at any vehicle speed but will
downshift into fourth gear only if vehicle speed is low
enough not to overrev the engine (calibratable in TCM).
3 Manual Third adds more performance for congested
traffic and hilly terrain. It has the same starting ratio
(first gear) as Manual Fourth but prevents the transmission from shifting above Third gear. Thus, Manual
Third can be used to retain third gear for acceleration
and engine braking as desired. Manual Third can be
selected at any vehicle speed but will downshift into
third gear only if vehicle speed is low enough not to
overrev the engine (calibratable in TCM).
FOLDOUT 9

WWW.ALL-TRANS.BY

2 Manual Second adds more performance for


congested traffic and hilly terrain. It has the same
starting ratio (first gear) as Manual Third but prevents the transmission from shifting above second
gear. Thus, Manual Second can be used to retain
second gear for acceleration and engine braking
as desired. Manual Second can be selected at any
vehicle speed but will downshift into second gear
only if vehicle speed is low enough not to overrev
the engine (calibratable in TCM).

When the vehicle speed slows down to a speed


low enough not to overrev the engine (calibratable
in TCM), the transmission will automatically shift
into first gear. This is particularly beneficial for
maintaining maximum engine braking when descending steep grades.

DRIVER SHIFT CONTROL GEAR RANGES


P

R
+

M/S

Figure 9

Some vehicles are equipped with a Driver Shift


Control (DSC) version of the selector system
(Figure 9). This configuration allows the driver

to manually shift between Park (P), Reverse (R),


Neutral (N) and Drive (D).
D In the Drive position, the transmission will
automatically upshift from first to fifth, and
downshift from fifth to first, according to the
Economy shift pattern programmed in the TCM.
M/S In the M/S position, the transmission will
either automatically upshift from first to fifth, and
downshift from fifth to first, according to the
Performance shift pattern programmed in the TCM
or, the driver may activate the manual function by
tapping the selector lever towards + or - to
cause an upshift or downshift. The transmission
will shift up or down depending on the request
that is made by tapping the selector. The TCM
will upshift automatically when maximum engine
speed is achieved and will protect from any
downshift which may overrev the engine.

PRINCIPLES OF OPERATION
An automatic transmission is the mechanical
component of a vehicle that transfers power
(torque) from the engine to the wheels. It
accomplishes this task by providing a number of
forward gear ratios that automatically change as
the speed of the vehicle increases. The reason
for changing forward gear ratios is to provide
the performance and economy expected from
vehicles manufactured today. On the performance
end, a gear ratio that develops a lot of torque
(through torque multiplication) is required in
order to initially start a vehicle moving. Once
the vehicle is in motion, less torque is required
in order to maintain the vehicle at a certain speed.
When the vehicle has reached a desired speed,
economy becomes the important factor and the
transmission will shift into overdrive. At this point
output speed is greater than input speed, and,
input torque is greater than output torque.
Another important function of the automatic
transmission is to allow the engine to be started

and run without transferring torque to the wheels.


This situation occurs whenever Park (P) or
Neutral (N) range has been selected. Also,
operating the vehicle in a rearward direction is
possible whenever Reverse (R) range has been
selected (accomplished by the gear sets).
The variety of gear ranges in an automatic
transmission are made possible through the
interaction of numerous mechanically,
hydraulically and electronically controlled
components inside the transmission. At the
appropriate time and sequence, these components
are either applied or released and operate the
gear set at a gear ratio consistent with the drivers
needs. The following pages describe the
theoretical operation of the mechanical, hydraulic
and electrical components found in the Hydramatic 4/5L40-E transmission. When an
understanding of these operating principles has
been attained, diagnosis of these transmission
systems is made easier.
9A

WWW.ALL-TRANS.BY

MAJOR MECHANICAL COMPONENTS


TORQUE
CONVERTER
ASSEMBLY
(1)

TORQUE CONVERTER
HOUSING/PUMP
ASSEMBLY
(3)

SPLINED
TOGETHER

DIRECT CLUTCH
INPUT AND
HUB
ASSEMBLY
(466)

FORWARD
CLUTCH SPRAG
OUTER RACE
(459)

INPUT SUN GEAR


SHAFT
ASSEMBLY
(457)

SPLINED TO
PLANETARY
CARRIER
ASSEMBLY

SPLINED
TOGETHER

DIRECT AND
REVERSE
CLUTCH
ASSEMBLY
(400-420)

SPLINED TO THE
REAR INPUT
SUN GEAR
IN THE
PLANETARY
CARRIER
ASSEMBLY

SECOND
CLUTCH SPRAG
ASSEMBLY
(547)

FORWARD
CLUTCH SPRAG
ASSEMBLY
(461)
INPUT SHAFT/
FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430-451)

INTERMEDIATE
CLUTCH SPRAG
OUTER RACE
(474)

PLANETARY
CARRIER
ASSEMBLY
(540-554)

LOW
CLUTCH SPRAG
INNER RACE
TRANSMISSION
(505)
CASE
(24)
REAR
INPUT
SUN
GEAR

SPLINED TO
PLANETARY
CARRIER
ASSEMBLY

INTERMEDIATE
CLUTCH SPRAG
ASSEMBLY
(473)

SPLINED TO THE
FRONT INPUT
SUN GEAR
IN THE
PLANETARY
CARRIER
ASSEMBLY

OVERDRIVE AND
REVERSE CLUTCH
HUB ASSEMBLY
(470)

10

SPLINED TO
TRANSMISSION
CASE (24)

Figure 10

FRONT
INPUT
SUN
GEAR

LOW
CLUTCH SPRAG
ASSEMBLY
LOW
(503)
CLUTCH SPRAG
OUTER RACE
(504)
OVERDRIVE AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480-497)

CENTER
SUPPORT
ASSEMBLY
(510-535)

SECOND
CLUTCH SPRAG
OUTER RACE
(545)

SECOND
CLUTCH SPRAG
INNER RACE
(549)

SPLINED TO
DIRECT
CLUTCH
INPUT
AND HUB
ASSEMBLY
(466)

REAR
INTERNAL GEAR
OUTPUT SHAFT
ASSEMBLY
(560-563)

WWW.ALL-TRANS.BY

COLOR LEGEND

RANGE REFERENCE CHART

COLOR LEGEND

MAJOR MECHANICAL COMPONENTS

APPLY COMPONENTS

The foldout graphic on page 10 contains a disassembled drawing


of the major components used in the Hydra-matic 4/5L40-E
transmission. This drawing, along with the cross sectional
illustrations on page 8 and 8A, show the major mechanical
components and their relationship to each other as a complete
assembly. Therefore, color has been used throughout this book
to help identify parts that are splined together, rotating at engine
speed, held stationary, and so forth. Color differentiation is
particularly helpful when using the Power Flow section for
understanding the transmission operation.

The Range Reference Chart on page 11, provides another


valuable source of information for explaining the overall function
of the Hydra-matic 4/5L40-E transmission. This chart highlights
the major apply components that function in a selected gear
range, and the specific gear operation within that gear range.

The color legend below provides the general guidelines that


were followed in assigning specific colors to the major
components. However, due to the complexity of this
transmission, some colors (such as grey) were used for artistic
purposes rather than based on the specific function or location
of that component.

HYDRA-MATIC 4L40-E - GEAR RATIOS

HYDRA-MATIC 5L40-E - GEAR RATIOS

FIRST
SECOND
THIRD

FIRST
SECOND
THIRD

2.82
1.54
1.00

FOURTH
REVERSE

0.70
2.38

3.42
2.21
1.60

FOURTH
FIFTH
REVERSE

1.00
0.75
3.03

Included as part of this chart is the same color reference to each


major component that was previously discussed. If a component
is active in a specific gear range, a word describing its activity
will be listed in the column below that component. The row
where the activity occurs corresponds to the appropriate
transmission range and gear operation. An abbreviated version
of this chart can also be found at the top of the half page of text
located in the Power Flow section. This provides for a quick
reference when reviewing the mechanical power flow information
contained in that section.

Components held stationary in the case or splined to


the case. Examples: the Fluid Pump Cover
Assembly (202), the Overdrive Clutch Housing
(493), and the Center Support (518). Also includes
the Clutch Sprag assemblies.
Components that rotate at engine speed. Examples:
the Torque Converter Assembly (1), the Fluid Pump
Rotor (223), and the Fluid Pump Vanes (222).
Components that rotate at turbine speed. Examples:
the Converter Turbine, the Forward Clutch and Input
Housing Assembly (433), and the Reverse Clutch
and Input Housing Assembly (401).
Components such as the Stator in the Torque
Converter Clutch Assembly (1).
Components such as the Input Sun Gear Shaft
Assembly (457).
RANGE

Components such as the Forward Clutch Sprag Outer


Race (459).
Components such as the Direct Clutch Input and
Hub Assembly (466), and the Input and Reaction
Carrier Assembly (553).
Components such as the Overdrive and Reverse
Clutch Hub Assembly (470).

GEAR

1-2 SHIFT 2-3 SHIFT 4-5 SHIFT


ENGINE
RATIO SOLENOID SOLENOID SOLENOID
BRAKING
VALVE
VALVE
VALVE

TCC
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT COAST REVERSE FORWARD
SECOND
SOLENOID
CLUTCH DRIVE CLUTCH MEDIATE CLUTCH REVERSE
CLUTCH COAST
CLUTCH CLUTCH CLUTCH CLUTCH
CLUTCH
VALVE
SPRAG CLUTCH SPRAG CLUTCH SPRAG CLUTCH
SPRAG CLUTCH

*NO

3.42

OFF

ON

OFF

OFF

APPLIED

APPLIED

LD

LD

YES

3.42

OFF

ON

ON

OFF

APPLIED

APPLIED

LD

LD

*NO

2.21

ON

ON

OFF

ON/OFF @

APPLIED

APPLIED

LD

APPLIED

LD

YES

2.21

ON

ON

ON

ON/OFF @

APPLIED

APPLIED

LD

APPLIED

LD

*NO

1.60

ON

OFF

OFF

ON/OFF @

APPLIED

APPLIED

LD

YES

1.60

ON

OFF

ON

ON/OFF @

APPLIED

APPLIED

LD

YES

1.00

OFF

OFF

ON

ON/OFF @ APPLIED APPLIED

APPLIED

LD

YES

0.75

OFF

OFF

OFF

ON/OFF @ APPLIED

APPLIED

@
ON/OFF

@
ON/OFF

APPLIED

APPLIED

D432

Components such as the Intermediate Clutch Sprag


Outer Race (474).
Components such as the Second Clutch Sprag Outer
Race (545).
Components such as the Second Clutch Sprag Inner
Race (549).
Components that rotate at transmission output speed.
Examples: the Output Shaft Assembly (562) and the
Input and Reaction Carrier Assembly (553).

NEUTRAL

@
ON/OFF

REVERSE

YES

3.03

@
ON/OFF

@
ON/OFF

@
ON/OFF

PARK

@
ON/OFF

@
ON/OFF

@
ON/OFF

OFF

APPLIED

APPLIED

APPLIED

LD

APPLIED

APPLIED

LD

APPLIED

APPLIED

APPLIED

APPLIED

APPLIED

APPLIED

APPLIED

Accumulators, Servos and Bands.


LD = LOCKED IN DRIVE
ON = SOLENOID ENERGIZED
OFF = SOLENOID DE-ENERGIZED

All bearings and bushings.

@ THE SOLENOID'S STATE FOLLOWS A SHIFT PATTERN WHICH DEPENDS UPON VEHICLE
SPEED AND THROTTLE POSITION. IT DOES NOT DEPEND UPON THE SELECTED GEAR.
ENGINE BRAKING IS ELECTRONICALLY CONTROLLED BY THE TCM, AND IS AVAILABLE AS
CALIBRATED FOR EACH MODEL AND APPLICATION.

All seals

10A

10B

Figure 11

11

MAJOR MECHANICAL COMPONENTS

WWW.ALL-TRANS.BY

COLOR LEGEND

RANGE REFERENCE CHART

COLOR LEGEND

APPLY COMPONENTS

The foldout graphic on page 10 contains a disassembled drawing


of the major components used in the Hydra-matic 4/5L40-E
transmission. This drawing, along with the cross sectional
illustrations on page 8 and 8A, show the major mechanical
components and their relationship to each other as a complete
assembly. Therefore, color has been used throughout this book
to help identify parts that are splined together, rotating at engine
speed, held stationary, and so forth. Color differentiation is
particularly helpful when using the Power Flow section for
understanding the transmission operation.
The color legend below provides the general guidelines that
were followed in assigning specific colors to the major
components. However, due to the complexity of this
transmission, some colors (such as grey) were used for artistic
purposes rather than based on the specific function or location
of that component.

The Range Reference Chart on page 11, provides another


valuable source of information for explaining the overall function
of the Hydra-matic 4/5L40-E transmission. This chart highlights
the major apply components that function in a selected gear
range, and the specific gear operation within that gear range.

HYDRA-MATIC 4L40-E - GEAR RATIOS

HYDRA-MATIC 5L40-E - GEAR RATIOS

FIRST
SECOND
THIRD

FIRST
SECOND
THIRD

2.82
1.54
1.00

FOURTH
REVERSE

0.70
2.38

3.42
2.21
1.60

FOURTH
FIFTH
REVERSE

1.00
0.75
3.03

Included as part of this chart is the same color reference to each


major component that was previously discussed. If a component
is active in a specific gear range, a word describing its activity
will be listed in the column below that component. The row
where the activity occurs corresponds to the appropriate
transmission range and gear operation. An abbreviated version
of this chart can also be found at the top of the half page of text
located in the Power Flow section. This provides for a quick
reference when reviewing the mechanical power flow information
contained in that section.

Components held stationary in the case or splined to


the case. Examples: the Fluid Pump Cover
Assembly (202), the Overdrive Clutch Housing
(493), and the Center Support (518). Also includes
the Clutch Sprag assemblies.
Components that rotate at engine speed. Examples:
the Torque Converter Assembly (1), the Fluid Pump
Rotor (223), and the Fluid Pump Vanes (222).
Components that rotate at turbine speed. Examples:
the Converter Turbine, the Forward Clutch and Input
Housing Assembly (433), and the Reverse Clutch
and Input Housing Assembly (401).
Components such as the Stator in the Torque
Converter Clutch Assembly (1).
Components such as the Input Sun Gear Shaft
Assembly (457).
RANGE

Components such as the Forward Clutch Sprag Outer


Race (459).
Components such as the Direct Clutch Input and
Hub Assembly (466), and the Input and Reaction
Carrier Assembly (553).
Components such as the Overdrive and Reverse
Clutch Hub Assembly (470).

GEAR

1-2 SHIFT 2-3 SHIFT 4-5 SHIFT


ENGINE
RATIO SOLENOID SOLENOID SOLENOID
BRAKING
VALVE
VALVE
VALVE

TCC
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT COAST REVERSE FORWARD
SECOND
SOLENOID
CLUTCH DRIVE CLUTCH MEDIATE CLUTCH REVERSE
CLUTCH COAST
CLUTCH CLUTCH CLUTCH CLUTCH
CLUTCH
VALVE
SPRAG CLUTCH SPRAG CLUTCH SPRAG CLUTCH
SPRAG CLUTCH

*NO

3.42

OFF

ON

OFF

OFF

APPLIED

APPLIED

LD

LD

YES

3.42

OFF

ON

ON

OFF

APPLIED

APPLIED

LD

LD

*NO

2.21

ON

ON

OFF

ON/OFF @

APPLIED

APPLIED

LD

APPLIED

LD

YES

2.21

ON

ON

ON

ON/OFF @

APPLIED

APPLIED

LD

APPLIED

LD

*NO

1.60

ON

OFF

OFF

ON/OFF @

APPLIED

APPLIED

LD

YES

1.60

ON

OFF

ON

ON/OFF @

APPLIED

APPLIED

LD

YES

1.00

OFF

OFF

ON

ON/OFF @ APPLIED APPLIED

APPLIED

LD

YES

0.75

OFF

OFF

OFF

ON/OFF @ APPLIED

APPLIED

@
ON/OFF

@
ON/OFF

APPLIED

APPLIED

D432

Components such as the Intermediate Clutch Sprag


Outer Race (474).
Components such as the Second Clutch Sprag Outer
Race (545).
Components such as the Second Clutch Sprag Inner
Race (549).
Components that rotate at transmission output speed.
Examples: the Output Shaft Assembly (562) and the
Input and Reaction Carrier Assembly (553).

NEUTRAL

@
ON/OFF

REVERSE

YES

3.03

@
ON/OFF

@
ON/OFF

@
ON/OFF

PARK

@
ON/OFF

@
ON/OFF

@
ON/OFF

OFF

APPLIED

APPLIED

APPLIED

LD

APPLIED

APPLIED

LD

APPLIED

APPLIED

APPLIED

APPLIED

APPLIED

APPLIED

APPLIED

Accumulators, Servos and Bands.


LD = LOCKED IN DRIVE
ON = SOLENOID ENERGIZED
OFF = SOLENOID DE-ENERGIZED

All bearings and bushings.

@ THE SOLENOID'S STATE FOLLOWS A SHIFT PATTERN WHICH DEPENDS UPON VEHICLE
SPEED AND THROTTLE POSITION. IT DOES NOT DEPEND UPON THE SELECTED GEAR.
ENGINE BRAKING IS ELECTRONICALLY CONTROLLED BY THE TCM, AND IS AVAILABLE AS
CALIBRATED FOR EACH MODEL AND APPLICATION.

All seals

10A

10B

Figure 11

11

COLOR LEGEND

MAJOR MECHANICAL COMPONENTS

APPLY COMPONENTS

The foldout graphic on page 10 contains a disassembled drawing


of the major components used in the Hydra-matic 4/5L40-E
transmission. This drawing, along with the cross sectional
illustrations on page 8 and 8A, show the major mechanical
components and their relationship to each other as a complete
assembly. Therefore, color has been used throughout this book
to help identify parts that are splined together, rotating at engine
speed, held stationary, and so forth. Color differentiation is
particularly helpful when using the Power Flow section for
understanding the transmission operation.

The Range Reference Chart on page 11, provides another


valuable source of information for explaining the overall function
of the Hydra-matic 4/5L40-E transmission. This chart highlights
the major apply components that function in a selected gear
range, and the specific gear operation within that gear range.

The color legend below provides the general guidelines that


were followed in assigning specific colors to the major
components. However, due to the complexity of this
transmission, some colors (such as grey) were used for artistic
purposes rather than based on the specific function or location
of that component.

Included as part of this chart is the same color reference to each


major component that was previously discussed. If a component
is active in a specific gear range, a word describing its activity
will be listed in the column below that component. The row
where the activity occurs corresponds to the appropriate
transmission range and gear operation. An abbreviated version
of this chart can also be found at the top of the half page of text
located in the Power Flow section. This provides for a quick
reference when reviewing the mechanical power flow information
contained in that section.

RANGE REFERENCE CHART

WWW.ALL-TRANS.BY

COLOR LEGEND

HYDRA-MATIC 4L40-E - GEAR RATIOS

HYDRA-MATIC 5L40-E - GEAR RATIOS

FIRST
SECOND
THIRD

FIRST
SECOND
THIRD

2.82
1.54
1.00

FOURTH
REVERSE

0.70
2.38

3.42
2.21
1.60

FOURTH
FIFTH
REVERSE

1.00
0.75
3.03

Components held stationary in the case or splined to


the case. Examples: the Fluid Pump Cover
Assembly (202), the Overdrive Clutch Housing
(493), and the Center Support (518). Also includes
the Clutch Sprag assemblies.
Components that rotate at engine speed. Examples:
the Torque Converter Assembly (1), the Fluid Pump
Rotor (223), and the Fluid Pump Vanes (222).
Components that rotate at turbine speed. Examples:
the Converter Turbine, the Forward Clutch and Input
Housing Assembly (433), and the Reverse Clutch
and Input Housing Assembly (401).
Components such as the Stator in the Torque
Converter Clutch Assembly (1).
Components such as the Input Sun Gear Shaft
Assembly (457).
RANGE

Components such as the Forward Clutch Sprag Outer


Race (459).
Components such as the Direct Clutch Input and
Hub Assembly (466), and the Input and Reaction
Carrier Assembly (553).
Components such as the Overdrive and Reverse
Clutch Hub Assembly (470).

GEAR

1-2 SHIFT 2-3 SHIFT 4-5 SHIFT


ENGINE
RATIO SOLENOID SOLENOID SOLENOID
BRAKING
VALVE
VALVE
VALVE

TCC
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT COAST REVERSE FORWARD
SECOND
SOLENOID
CLUTCH DRIVE CLUTCH MEDIATE CLUTCH REVERSE
CLUTCH COAST
CLUTCH CLUTCH CLUTCH CLUTCH
CLUTCH
VALVE
SPRAG CLUTCH SPRAG CLUTCH SPRAG CLUTCH
SPRAG CLUTCH

*NO

3.42

OFF

ON

OFF

OFF

APPLIED

APPLIED

LD

LD

YES

3.42

OFF

ON

ON

OFF

APPLIED

APPLIED

LD

LD

*NO

2.21

ON

ON

OFF

ON/OFF @

APPLIED

APPLIED

LD

APPLIED

LD

YES

2.21

ON

ON

ON

ON/OFF @

APPLIED

APPLIED

LD

APPLIED

LD

*NO

1.60

ON

OFF

OFF

ON/OFF @

APPLIED

APPLIED

LD

YES

1.60

ON

OFF

ON

ON/OFF @

APPLIED

APPLIED

LD

YES

1.00

OFF

OFF

ON

ON/OFF @ APPLIED APPLIED

APPLIED

LD

YES

0.75

OFF

OFF

OFF

ON/OFF @ APPLIED

APPLIED

@
ON/OFF

@
ON/OFF

APPLIED

APPLIED

D432

Components such as the Intermediate Clutch Sprag


Outer Race (474).
Components such as the Second Clutch Sprag Outer
Race (545).
Components such as the Second Clutch Sprag Inner
Race (549).
Components that rotate at transmission output speed.
Examples: the Output Shaft Assembly (562) and the
Input and Reaction Carrier Assembly (553).

NEUTRAL

@
ON/OFF

REVERSE

YES

3.03

@
ON/OFF

@
ON/OFF

@
ON/OFF

PARK

@
ON/OFF

@
ON/OFF

@
ON/OFF

OFF

APPLIED

APPLIED

APPLIED

LD

APPLIED

APPLIED

LD

APPLIED

APPLIED

APPLIED

APPLIED

APPLIED

APPLIED

APPLIED

Accumulators, Servos and Bands.


LD = LOCKED IN DRIVE
ON = SOLENOID ENERGIZED
OFF = SOLENOID DE-ENERGIZED

All bearings and bushings.

@ THE SOLENOID'S STATE FOLLOWS A SHIFT PATTERN WHICH DEPENDS UPON VEHICLE
SPEED AND THROTTLE POSITION. IT DOES NOT DEPEND UPON THE SELECTED GEAR.
ENGINE BRAKING IS ELECTRONICALLY CONTROLLED BY THE TCM, AND IS AVAILABLE AS
CALIBRATED FOR EACH MODEL AND APPLICATION.

All seals

10A

10B

Figure 11

11

TORQUE CONVERTER
WWW.ALL-TRANS.BY

THRUST
BEARING
ASSEMBLY
(E )

TURBINE
THRUST
SPACER
(B)

THRUST
BEARING
ASSEMBLY
(E)

DAMPER
ASSEMBLY
(D)
CONVERTER HOUSING
COVER ASSEMBLY
(A)

PRESSURE PLATE
ASSEMBLY
(C)

TURBINE
ASSEMBLY
(F)

STATOR
ASSEMBLY
(G)

CONVERTER PUMP
ASSEMBLY
(H)

TORQUE CONVERTER:

The torque converter (1) is the primary component for


transmittal of power between the engine and the
transmission. It is bolted to the engine flywheel (also known
as the flexplate) so that it will rotate at engine speed.
Some of the major functions of the torque converter are:
to provide for a smooth conversion of torque from the
engine to the mechanical components of the transmission.
to multiply torque from the engine that enables the
vehicle to achieve additional performance when required.
to mechanically operate the transmission fluid pump (3)
through the converter hub.
to provide a mechanical link, or direct drive, from the
engine to the transmission through the use of a torque
converter clutch (TCC).
The torque converter assembly is made up of the following
five main sub-assemblies:
a converter housing cover assembly (A) which is welded
to the converter pump assembly (H).
a converter pump assembly (H) which is the driving
member.
a turbine assembly (F) which is the driven or output
member.
a stator assembly (G) which is the reaction member
located between the converter pump and turbine
assemblies.
a pressure plate assembly (C) splined to the turbine
assembly to enable direct mechanical drive when
appropriate.

H
A

G
C
CONVERTER
HUB

STATOR
SHAFT
(202)

B
E

FORWARD
CLUTCH
AND INPUT
HOUSING
ASSEMBLY
(433)
(TURBINE
SHAFT)

CONVERTER PUMP ASSEMBLY AND TURBINE


ASSEMBLY

When the engine is running the converter pump assembly


acts as a centrifugal pump by picking up fluid at its center
and discharging it at its rim between the blades (see Figure
13). The force of this fluid then hits the turbine blades
and causes the turbine to rotate. As the engine and
converter pump increase in RPM, so does the turbine.
PRESSURE PLATE, DAMPER AND
CONVERTER HOUSING ASSEMBLIES

The pressure plate is splined to the turbine hub and applies


(engages) with the converter cover to provide a mechanical
coupling of the engine to the transmission. When the
pressure plate assembly is applied, the amount of slippage
that occurs through a fluid coupling is reduced (but not
necessarily eliminated), thereby providing a more efficient
transfer of engine torque to the drive wheels.

12

Torque converter failure


could cause loss of drive

and or loss of power.


To reduce torsional shock during the apply of the pressure plate to the
converter cover, a spring loaded damper assembly (D) is used. The
pressure plate is attached to the pivoting mechanism of the damper
assembly which allows the pressure plate to rotate independently of
the damper assembly up to approximately 45 degrees. During
engagement, the springs in the damper assembly cushion the pressure
plate engagement and also reduce irregular torque pulses from the
engine or road surface.
Figure 12

TORQUE CONVERTER
WWW.ALL-TRANS.BY

FLUID FLOW

STATOR
ASSEMBLY
(G)
TURBINE
ASSEMBLY
(F)

CONVERTER PUMP
ASSEMBLY
(H)

Figure 13
Stator roller clutch failure

roller clutch freewheels in both directions can


cause poor acceleration at low speed.

roller clutch locks up in both directions can


cause poor acceleration at high speed.

Overheated fluid.

STATOR ASSEMBLY
STATOR

STATOR HELD
FLUID FLOW REDIRECTED

CONVERTER
MULTIPLYING

FLUID FLOW
FROM TURBINE

CONVERTER AT
COUPLING SPEED
STATOR ROTATES
FREELY

The stator assembly is located between the


pump assembly and turbine assembly, and is
mounted on a one-way roller clutch. This oneway roller clutch allows the stator to rotate in
one direction and prevents (holds) the stator
from rotating in the other direction. The
function of the stator is to redirect fluid
returning from the turbine in order to assist the
engine in turning the converter pump assembly.
At low vehicle speeds, when greater torque is
needed, fluid from the turbine hits the front
side of the stator blades (the converter is
multiplying torque). At this time, the one-way
roller clutch prevents the stator from rotating
in the same direction as the fluid flow, thereby
redirecting fluid to assist the engine in turning
the converter pump. In this mode, fluid leaving
the converter pump has more force to turn the
turbine assembly and multiply engine torque.
As vehicle speed increases and less torque is
required, centrifugal force acting on the fluid
changes the direction of the fluid leaving the
turbine such that it hits the back side of the
stator blades (converter at coupling speed).
When this occurs, the roller clutch overruns
and allows the stator to rotate freely. Fluid is
no longer being redirected to the converter
pump and engine torque is not being multiplied.

Figure 14

13

TORQUE CONVERTER
WWW.ALL-TRANS.BY

RELEASE

APPLY

When the torque converter clutch is released, fluid is


fed into the torque converter by the pump into the
release fluid passage. The release fluid passage is
located between the stator shaft (202) and the turbine
shaft (433). Fluid travels between the shafts and enters
the release side of the pressure plate at the end of the
turbine shaft. The pressure plate is forced away from
the converter cover and allows the torque converter
turbine to rotate at speeds other than engine speed.

When the TCM determines that the vehicle is at the


proper speed for the torque converter clutch to apply
it sends a signal to the TCC PWM solenoid valve.
The TCC PWM solenoid valve then regulates line
fluid from the pump into the regulated apply passage.
The regulated apply fluid then feeds the apply fluid
passage and applies the torque converter. The apply
passage is located between the converter hub and the
stator shaft. The fluid flows between the shafts, then
passes into the torque converter on the apply side of
the pressure plate assembly. Release fluid is then
routed out of the torque converter between the turbine
shaft and the stator shaft.

The release fluid then flows between the friction


element on the pressure plate and the converter cover
to enter the apply side of the torque converter. The
fluid then exits the torque converter through the apply
passage, which is located between the torque
converter clutch hub and the stator shaft (202), and
enters the pump.

The TCC apply may occur in second, third, fourth


and fifth gear (depending on the shift pattern), and
should not apply until the transmission fluid and
engine coolant temperatures have reached a minimum
value (calibratable in TCM).

No TCC apply can be caused by:

Electrical connectors, wiring harness or solenoid damaged


Converter clutch valves stuck or assembled backwards
Pump to case gasket mispositioned
Solenoid O-ring seal cut or damaged
Turbine shaft O-ring seal cut or damaged
Control valve body TCC signal valve stuck
Solenoid screen blocked
TCC solenoid valve internal damage
Turbine speed sensor internal damage

For more information on TCC apply and release, see


Overdrive Range Fifth Gear TCC Released and
Applied, pages 7275.

FORWARD
CLUTCH
AND INPUT
HOUSING
ASSEMBLY
(433)
(TURBINE
SHAFT)

RELEASE
FLUID

Apply fluid pressure forces the pressure plate against


the torque converter cover to provide a mechanical
link between the engine and the turbine.

APPLY
FLUID

FORWARD
CLUTCH
AND INPUT
HOUSING
ASSEMBLY
(433)
(TURBINE
SHAFT)

APPLY
FLUID

RELEASE
FLUID

RELEASE
FLUID

PRESSURE
PLATE

TORQUE
CONVERTER
ASSEMBLY
(1)

APPLY
FLUID

PRESSURE
PLATE

TCC RELEASE
14

TORQUE
CONVERTER
ASSEMBLY
(1)

TCC APPLY
Figure 15

APPLY COMPONENTS
The sequence in which the components in this section
have been discussed coincides with their physical
arrangement inside the transmission. This order
closely parallels the disassembly sequence used in
the Hydra-matic 4/5L40-E Unit Repair Section
located in Section 7 of the appropriate Service
Manual. It also correlates with the components shown
on the Range Reference Charts that are used
throughout the Power Flow section of this book.
The correlation of information between the sections
of this book helps the user more clearly understand
the hydraulic and mechanical operating principles
for this transmission.

MATING
OR
RELATED
COMPONENTS

BRIEF
DESCRIPTION

APPLY COMPONENTS
REVERSE
CLUTCH
HOUSING
ASSEMBLY
(401)

APPLY COMPONENTS

During the exhaust of direct clutch fluid, the direct clutch housing ball
valve (405), located in the direct clutch piston (406), unseats. Cent
force, resulting from the rotation of the reverse clutch housing, forces re
direct clutch fluid to the outside of the housing and past the unseate
check valve. If this fluid did not completely exhaust from behind the p
there could be a partial apply, or drag, of the direct clutch plates.

DIRECT CLUTCH:

If inoperative the direct


clutch can cause no fourth
gear in D range or Manual
Fourth range; degraded
shifts from third to fourth
and from fourth to third.

DIRECT CLUTCH PISTON


BALL CHECK VALVE
(405)

REVERSE CLUTCH HOUSING


BALL CHECK VALVE
(403)

The reverse clutch assembly is located in


reverse clutch housing assembly (401).
external teeth on the reverse clutch plates (
are splined to the reverse clutch housing whil
internal teeth on the reverse clutch plate assem
(418) are splined to the overdrive and rev
clutch hub (470). The reverse clutch is app
only when the transmission is in reverse gea
provide a reverse gear ratio.

DIRECT CLUTCH APPLY:

To apply the direct clutch for Fourth and F


gears, direct clutch fluid is fed through the f
pump cover (202) and into the inner hub of
reverse clutch housing assembly (401). Feed h
in the inner hub allow direct clutch fluid to e
the housing between the reverse clutch piston (
and the direct clutch piston (406). Direct c
fluid pressure moves the piston to compress
direct and reverse clutch spring (407). As f
pressure increases, the piston compresses the c
plates until they are held against the direct c
backing plate (413). Also included in the asse
is a direct clutch apply (waved) plate (410
helps cushion the apply of the direct clutch.
When fully applied, the direct clutch plates (
direct clutch plate assemblies (412) and d
clutch apply plate (410) are locked toge
thereby holding the reverse clutch housing
direct clutch hub (466) together. This forces
direct clutch hub to rotate at the same speed
input/forward clutch housing assembly (433).

408

409

REVERSE CLUTCH RELEASE:

To release the reverse clutch, reverse clutch


exhausts through the reverse clutch fluid cir
allowing pressure at the reverse clutch piston (
to decrease. In the absence of fluid pressure, sp
force from the direct and reverse clutch sp
(407) moves the reverse clutch piston away
the clutch pack. This disengages the reverse c
plates (417) and reverse clutch plate assem
(418) from the backing plate (419).

DIRECT
DIRECT
DIRECT DIRECT CLUTCH
CLUTCH
CLUTCH
CLUTCH BACKING PLATE
APPLY PLATE
PLATE
PLATE
RETAINER RING
(WAVED)
ASSEMBLY
ASSEMBLY
(SELECTIVE)
(410)
(OUTER SPLINE) (INNER SPLINE)
(414)
(411)
(412)

410

412

411

413

402

414

404

RELEASED

APPLIED

DIRECT AND
REVERSE
CLUTCH SPRING
RETAINER
(408)

DIRECT AND
REVERSE
CLUTCH
SPRING
(407)

DIRECT AND
REVERSE
CLUTCH
SPRING
RETAINER
RING
(409)

DIRECT
CLUTCH
PISTON
(406)

REVERSE
CLUTCH
PISTON
INNER
SEAL
(402)

REVERSE
CLUTCH
APPLY
FLUID

REVERSE
CLUTCH
BACKING
PLATE
(419)
REVERSE
CLUTCH
BACKING
PLATE
RETAINER
RING
(SELECTIVE)
(420)

REVERSE
CLUTCH
PISTON
(404)

REVERSE
CLUTCH
HOUSING
ASSEMBLY
(401)

416

415

REVERSE
CLUTCH
SPACER
PLATE
(415)

REVERSE
REVERSE
REVERSE
CLUTCH
CLUTCH
CLUTCH
PLATE
PLATE
APPLY
ASSEMBLY
ASSEMBLY
PLATE
(OUTER SPLINE) (INNER SPLINE)
(416)
(417)
(418)

417

418

419

420

407

DIRECT
CLUTCH
BACKING
PLATE
(413)

REVERSE
CLUTCH
PISTON
(404)

To release the direct clutch, direct clutch


exhausts from the piston, through the inner hu
the reverse clutch housing and into the fluid p
cover (202). In the absence of fluid pressure, sp
force from the direct and reverse clutch spring (
moves the direct clutch piston away from the c
plates. This disengages the direct clutch plates (
direct clutch plate assemblies (412) and direct
apply plate (410) from the direct clutch bac
plate (413) and disconnects the reverse cl
housing from the direct clutch hub (466).
406

To apply the reverse clutch, reverse clutch flu


fed through the fluid pump cover (202) and be
the reverse clutch piston (404). Reverse cl
fluid pressure forces the piston against the d
clutch piston (406) and the direct and rev
clutch spring (407). As fluid pressure increa
the piston compresses the clutch plates tog
until they are held against the reverse cl
backing plate (419). Also included in the asse
is a reverse clutch spacer plate (415), and a re
clutch apply (waved) plate (416) that helps cu
the apply of the reverse clutch.
When fully applied, the reverse clutch plates
and reverse clutch plate assemblies (418) are l
together, thereby holding the reverse clutch hou
(401) and the overdrive and reverse clutch hub
together. This forces the overdrive and rev
clutch hub to rotate at the same speed as the for
clutch and input housing assembly (433).

DIRECT
CLUTCH
APPLY
FLUID

DIRECT CLUTCH RELEASE:

405

REVERSE CLUTCH APPLY:

DIRECT AND
REVERSE
CLUTCH
SPRING
RETAINER
RING
(409)

DIRECT
CLUTCH
PISTON
(406)

A plugged reverse clutch apply


passage, damaged clutch
plates, clutch spring or piston
seals can cause no reverse/
slips in reverse.

REVERSE CLUTCH:

DIRECT AND
DIRECT AND
REVERSE
REVERSE
CLUTCH
CLUTCH SPRING
SPRING
RETAINER
(407)
(408)

RELEASED

APPLIED

During the exhaust of reverse clutch fluid, the reverse clutch housin
check valve (403), located in the reverse clutch housing (401), u
Centrifugal force, resulting from the rotation of the reverse clutch ho
forces residual reverse fluid to the outside of the housing and past the un
ball check valve. If this fluid did not completely exhaust from behin
piston, there could be a partial apply, or drag, of the reverse clutch pla

REVERSE
CLUTCH
HOUSING
ASSEMBLY
(401)

The direct clutch assembly is located in the re


clutch piston (404), which is splined to the re
clutch housing assembly (401). The external
on the direct clutch plates (411) are splined t
reverse clutch piston while the internal teet
the direct clutch plate assemblies (412) are sp
to the direct clutch hub (466). The direct clut
applied when the transmission is in Fourth
Fifth gears.

FUNCTIONAL
DESCRIPTION

WWW.ALL-TRANS.BY

The Apply Components section is designed to explain


the function of the hydraulic and mechanical holding
devices used in the Hydra-matic 4/5L40-E
transmission. Some of these apply components, such
as clutches, are hydraulically applied and released
in order to provide automatic gear range shifting.
Other components, such as a sprag clutch, often react
to a hydraulically applied component by
mechanically holding or releasing another member
of the transmission. This interaction between the
hydraulically and mechanically applied components
is then explained in detail and supported with a graphic
illustration. In addition, this section shows the routing
of fluid pressure to the individual components and
their internal functions when it applies or releases.

16

Figure 17

Figure 18

CUTAWAY
VIEW

17

DISASSEMBLED
VIEW

Figure 16

15

APPLY COMPONENTS
WWW.ALL-TRANS.BY

REVERSE
CLUTCH
HOUSING
ASSEMBLY
(401)

During the exhaust of direct clutch fluid, the direct clutch housing ball check
valve (405), located in the direct clutch piston (406), unseats. Centrifugal
force, resulting from the rotation of the reverse clutch housing, forces residual
direct clutch fluid to the outside of the housing and past the unseated ball
check valve. If this fluid did not completely exhaust from behind the piston,
there could be a partial apply, or drag, of the direct clutch plates.
If inoperative the direct
clutch can cause no fourth
gear in D range or Manual
Fourth range; degraded
shifts from third to fourth
and from fourth to third.

DIRECT CLUTCH PISTON


BALL CHECK VALVE
(405)

DIRECT CLUTCH:

The direct clutch assembly is located in the reverse


clutch piston (404), which is splined to the reverse
clutch housing assembly (401). The external teeth
on the direct clutch plates (411) are splined to the
reverse clutch piston while the internal teeth on
the direct clutch plate assemblies (412) are splined
to the direct clutch hub (466). The direct clutch is
applied when the transmission is in Fourth and
Fifth gears.

DIRECT AND
DIRECT AND
REVERSE
REVERSE
CLUTCH
CLUTCH SPRING
SPRING
RETAINER
(407)
(408)

RELEASED

APPLIED

DIRECT CLUTCH APPLY:

To apply the direct clutch for Fourth and Fifth


gears, direct clutch fluid is fed through the fluid
pump cover (202) and into the inner hub of the
reverse clutch housing assembly (401). Feed holes
in the inner hub allow direct clutch fluid to enter
the housing between the reverse clutch piston (404)
and the direct clutch piston (406). Direct clutch
fluid pressure moves the piston to compress the
direct and reverse clutch spring (407). As fluid
pressure increases, the piston compresses the clutch
plates until they are held against the direct clutch
backing plate (413). Also included in the assembly
is a direct clutch apply (waved) plate (410) that
helps cushion the apply of the direct clutch.
When fully applied, the direct clutch plates (411),
direct clutch plate assemblies (412) and direct
clutch apply plate (410) are locked together,
thereby holding the reverse clutch housing and
direct clutch hub (466) together. This forces the
direct clutch hub to rotate at the same speed as the
input/forward clutch housing assembly (433).

DIRECT
CLUTCH
APPLY
FLUID

To release the direct clutch, direct clutch fluid


exhausts from the piston, through the inner hub of
the reverse clutch housing and into the fluid pump
cover (202). In the absence of fluid pressure, spring
force from the direct and reverse clutch spring (407)
moves the direct clutch piston away from the clutch
plates. This disengages the direct clutch plates (411),
direct clutch plate assemblies (412) and direct clutch
apply plate (410) from the direct clutch backing
plate (413) and disconnects the reverse clutch
housing from the direct clutch hub (466).

16

406

407

408

409

DIRECT
CLUTCH
BACKING
PLATE
(413)

REVERSE
CLUTCH
PISTON
(404)

DIRECT CLUTCH RELEASE:

405

DIRECT AND
REVERSE
CLUTCH
SPRING
RETAINER
RING
(409)

DIRECT
CLUTCH
PISTON
(406)

DIRECT
DIRECT
DIRECT DIRECT CLUTCH
CLUTCH
CLUTCH
CLUTCH BACKING PLATE
APPLY PLATE
PLATE
PLATE
RETAINER RING
(WAVED)
ASSEMBLY
ASSEMBLY
(SELECTIVE)
(410)
(OUTER SPLINE) (INNER SPLINE)
(414)
(411)
(412)

410

411

Figure 17

412

413

414

APPLY COMPONENTS
WWW.ALL-TRANS.BY

REVERSE
CLUTCH
HOUSING
ASSEMBLY
(401)

During the exhaust of reverse clutch fluid, the reverse clutch housing ball
check valve (403), located in the reverse clutch housing (401), unseats.
Centrifugal force, resulting from the rotation of the reverse clutch housing,
forces residual reverse fluid to the outside of the housing and past the unseated
ball check valve. If this fluid did not completely exhaust from behind the
piston, there could be a partial apply, or drag, of the reverse clutch plates.

REVERSE CLUTCH HOUSING


BALL CHECK VALVE
(403)

A plugged reverse clutch apply


passage, damaged clutch
plates, clutch spring or piston
seals can cause no reverse/
slips in reverse.

REVERSE CLUTCH:

The reverse clutch assembly is located in the


reverse clutch housing assembly (401). The
external teeth on the reverse clutch plates (417)
are splined to the reverse clutch housing while the
internal teeth on the reverse clutch plate assemblies
(418) are splined to the overdrive and reverse
clutch hub (470). The reverse clutch is applied
only when the transmission is in reverse gear to
provide a reverse gear ratio.
REVERSE CLUTCH APPLY:

To apply the reverse clutch, reverse clutch fluid is


fed through the fluid pump cover (202) and behind
the reverse clutch piston (404). Reverse clutch
fluid pressure forces the piston against the direct
clutch piston (406) and the direct and reverse
clutch spring (407). As fluid pressure increases,
the piston compresses the clutch plates together
until they are held against the reverse clutch
backing plate (419). Also included in the assembly
is a reverse clutch spacer plate (415), and a reverse
clutch apply (waved) plate (416) that helps cushion
the apply of the reverse clutch.
When fully applied, the reverse clutch plates (417)
and reverse clutch plate assemblies (418) are locked
together, thereby holding the reverse clutch housing
(401) and the overdrive and reverse clutch hub (470)
together. This forces the overdrive and reverse
clutch hub to rotate at the same speed as the forward
clutch and input housing assembly (433).
REVERSE CLUTCH RELEASE:

To release the reverse clutch, reverse clutch fluid


exhausts through the reverse clutch fluid circuit,
allowing pressure at the reverse clutch piston (404)
to decrease. In the absence of fluid pressure, spring
force from the direct and reverse clutch spring
(407) moves the reverse clutch piston away from
the clutch pack. This disengages the reverse clutch
plates (417) and reverse clutch plate assemblies
(418) from the backing plate (419).

402

404

415

REVERSE
CLUTCH
SPACER
PLATE
(415)

RELEASED

APPLIED

DIRECT AND
REVERSE
CLUTCH SPRING
RETAINER
(408)

DIRECT AND
REVERSE
CLUTCH
SPRING
(407)

DIRECT AND
REVERSE
CLUTCH
SPRING
RETAINER
RING
(409)

DIRECT
CLUTCH
PISTON
(406)

REVERSE
CLUTCH
PISTON
INNER
SEAL
(402)

REVERSE
CLUTCH
APPLY
FLUID

REVERSE
CLUTCH
BACKING
PLATE
(419)
REVERSE
CLUTCH
BACKING
PLATE
RETAINER
RING
(SELECTIVE)
(420)

REVERSE
CLUTCH
PISTON
(404)

REVERSE
CLUTCH
HOUSING
ASSEMBLY
(401)

416

Figure 18

REVERSE
REVERSE
REVERSE
CLUTCH
CLUTCH
CLUTCH
PLATE
PLATE
APPLY
ASSEMBLY
ASSEMBLY
PLATE
(OUTER SPLINE) (INNER SPLINE)
(416)
(417)
(418)

417

418

419

420

17

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apply plate (442) from the coast clutch backing plate (445) and
disconnects the forward clutch housing from the input sun gear
shaft assembly (457).
During the exhaust of coast clutch fluid, the coast clutch piston
ball check valve (437), located in the coast clutch piston (438),
unseats. Centrifugal force, resulting from the rotation of the
forward/coast clutch housing, forces residual coast clutch fluid to
the outside of the housing and past the unseated ball check valve.
If this fluid did not completely exhaust from behind the piston,
there could be a partial apply, or drag, of the coast clutch plates.

FORWARD CLUTCH
HOUSING ASSEMBLY
(433)

If inoperative the
coast clutch can
cause no engine
braking in first,
second, third and
fourth (all ranges),
and degraded shifts
from fourth to fifth.

COAST CLUTCH:

The coast clutch assembly is located in the coast clutch


housing (446), which is splined to the forward clutch housing
assembly (433). The external teeth on the coast clutch plates
(443) are splined to the coast clutch housing while the
internal teeth on the coast clutch plate assemblies (444) are
splined to the input sun gear shaft assembly (457). The
coast clutch is applied when the transmission is in all forward
gear ranges, except Fifth gear, to transfer engine coast torque
to the input and reaction planetary gear set.

COAST CLUTCH PISTON


BALL CHECK VALVE
(437)

COAST
FORWARD
CLUTCH AND COAST
HOUSING
CLUTCH
(446)
SPRING
(439)

COAST CLUTCH APPLY:

To apply the coast clutch, coast clutch fluid is fed through the
fluid pump cover (202), through the turbine shaft to the inner
hub of the forward clutch housing assembly (433). Feed holes in
the inner hub allow coast clutch fluid to enter the housing between
the forward clutch piston (436) and the coast clutch piston (438).
Coast clutch fluid pressure moves the piston to compress the
forward and coast clutch spring (439). As fluid pressure increases,
the piston compresses the clutch plates until they are held against
the coast clutch backing plate (445). Also included in the
assembly is a coast clutch spacer plate (441) and a coast clutch
apply (waved) plate (442)
that helps cushion
the apply of the
coast clutch.
When fully applied,
the coast clutch
plates (443), coast
clutch plate assemblies (444), coast clutch spacer plate (441)
and coast clutch apply plate (442) are locked together, thereby
holding the forward clutch housing and the input sun gear shaft
assembly (457) together. This forces the input sun gear shaft
assembly to rotate at the same speed as the input/forward clutch
housing assembly (433).

APPLIED

RELEASED

FORWARD
CLUTCH
HOUSING
ASSEMBLY
(433)

COAST
CLUTCH
PISTON
ASSEMBLY
(438)

LUBE
PASSAGE

FORWARD
AND COAST
CLUTCH
SPRING
RETAINER
RING
(440)
COAST
CLUTCH
APPLY
FLUID

COAST CLUTCH RELEASE:

To release the coast clutch, coast clutch fluid exhausts from the
piston, through the inner hub of the forward clutch housing and
into the fluid pump cover (202). In the absence of fluid pressure,
spring force from the forward and coast clutch spring (439)
moves the coast clutch piston away from the clutch plates. This
disengages the coast clutch plates (443), coast clutch plate
assemblies (444), coast clutch spacer plate (441) and coast clutch

437

18

438

439

440

441

442

COAST
CLUTCH
SPACER
PLATE
(SELECTIVE)
(441)
443 444

Figure 19

COAST
COAST
COAST
COAST
CLUTCH
CLUTCH
CLUTCH
CLUTCH
APPLY
PLATE
PLATE
BACKING
PLATE
ASSEMBLY
ASSEMBLY
PLATE
(442) (OUTER SPLINE) (INNER SPLINE) (445)
(443)
(444)
445

446

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During the exhaust of forward clutch fluid, the forward clutch


housing ball check valve, located in the forward clutch housing
assembly (434), unseats. Centrifugal force, resulting from the
rotation of the forward clutch housing assembly, forces residual
forward clutch fluid to the outside of the housing and past the
unseated ball check valve. If this fluid did not completely exhaust
from behind the piston, there could be a partial apply, or drag,
of the forward clutch plates.

FORWARD CLUTCH HOUSING


BALL CHECK VALVE
(434)

FORWARD CLUTCH
HOUSING ASSEMBLY
(433)

FORWARD CLUTCH:

The forward clutch assembly is located in the forward clutch


housing assembly (433). The external teeth on the forward
clutch plates (448) are splined to the forward clutch housing
while the internal teeth on the forward clutch plate
assemblies (449) are splined to the forward clutch sprag
outer race (459). The forward clutch is applied in all forward
gear ranges to transfer engine torque to the input and reaction
planetary gear set.

FORWARD CLUTCH HOUSING


BALL CHECK VALVE
(434)

FORWARD CLUTCH APPLY:

To apply the forward clutch, forward clutch fluid is fed through


the turbine shaft to the inner hub of the forward clutch housing.
Feed holes in the inner hub allow fluid to enter the housing
behind the forward clutch piston assembly (436). Forward clutch
fluid pressure moves the piston and compresses the forward and
coast clutch spring (439). As fluid pressure increases, the piston
moves the coast clutch housing (446) and compresses the clutch
plates until they are held against the forward clutch backing
plate (450). Also included in the clutch pack is a forward clutch
apply (waved) plate (447) that helps control the apply rate of the
forward clutch.
When fully applied,
the forward clutch
plates (448) and
forward clutch plate
assemblies (449)
are locked together,
thereby holding the
forward clutch housing
assembly and the forward clutch sprag outer race (459) together.
This forces the forward clutch sprag outer race to rotate at the
same speed as the forward clutch housing assembly.
FORWARD CLUTCH RELEASE:

To release the forward clutch, forward clutch fluid exhausts


from the piston, through the inner hub of the forward clutch
housing assembly and into the turbine shaft. In the absence of
fluid pressure, spring force from the forward and coast clutch
spring (439) moves the forward clutch piston assembly away
from the clutch plates. This disengages the forward clutch plates
(448), forward clutch plate assemblies (449) and forward clutch
apply (waved) plate (447) from the forward clutch backing plate
(450) and disconnects the forward clutch housing assembly from
the forward clutch sprag outer race (459).
436

439

440

447

448

APPLIED

RELEASED

If inoperative the
forward clutch can
cause forward
motion in Neutral,
loss of drive, and
harsh shifts from
D to R.

COAST
FORWARD
CLUTCH AND COAST
HOUSING
CLUTCH
(446)
SPRING
(439)

FORWARD
CLUTCH
HOUSING
ASSEMBLY
(433)
FORWARD
CLUTCH
PISTON
ASSEMBLY
(436)

LUBE
PASSAGE

FORWARD
AND COAST
CLUTCH
SPRING
RETAINER
RING
(440)

FORWARD
CLUTCH
BACKING
PLATE
(450)

FORWARD
CLUTCH
APPLY
FLUID

FORWARD
CLUTCH
APPLY
PLATE
(447)

449

Figure 20

FORWARD
FORWARD
FORWARD
CLUTCH
CLUTCH
CLUTCH
PLATE
PLATE
BACKING PLATE
ASSEMBLY
ASSEMBLY RETAINER RING
(INNER SPLINE) (INNER SPLINE) (SELECTIVE)
(448)
(449)
(451)

450

451

19

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FORWARD CLUTCH SPRAG RELEASED:

FORWARD
CLUTCH SPRAG
ASSEMBLY
(455-459)

The clutch sprag releases when the sprags pivot toward their
short diagonals. The length of the short diagonals (B) is less
than the distance between the inner and outer sprag races. This
occurs when power flow drives the input sun gear shaft assembly
(457) faster than the forward clutch drives the forward clutch
sprag outer race (459). During acceleration the clutch sprag is
overrun only in Fifth gear.
COAST CLUTCH APPLIED:

FORWARD CLUTCH SPRAG ASSEMBLY:

The forward clutch sprag assembly (461) is located between the


forward clutch sprag outer race (459) and the input sun gear
shaft assembly (457) (inner race). The input sun gear shaft
assembly is splined to the input sun gear in the input and reaction
carrier (553) while the forward clutch sprag outer race is splined
to the forward clutch plates. The clutch sprag is a type of oneway clutch that transfers engine torque from the forward clutch
to the input sun gear during acceleration in First, Second, Third
and Fourth gears in all ranges.

The coast clutch is applied in first, second, third and fourth gear
in all forward ranges. It holds the coast clutch housing (446)
and the input sun gear shaft assembly (457) together. These
components are then forced to rotate at the same speed as the
forward clutch housing assembly (433). This prevents the input
sun gear shaft assembly (457) from being driven faster than the
forward clutch sprag outer race (459) and, also allows engine
braking to occur in first, second, third or fourth gear if the
proper braking clutch is applied (refer to the range reference
chart on page 11), specific per customer application.

INPUT
SUN GEAR
SHAFT
ASSEMBLY
(457)

CLUTCH SPRAG HOLDING


OUTER RACE DRIVING THE INNER RACE

(A)
INNER
RACE
(457)

FORWARD
CLUTCH ROLLER
OUTER RACE WASHER
(458)

FORWARD
CLUTCH
SPRAG
ASSEMBLY
(461)
FORWARD
CLUTCH
ROLLER
INNER
BEARING
(456)

OUTER
RACE
(459)
DRIVING

LD
HE

SPRAG IS VIEWED FROM THIS DIRECTION


CLUTCH SPRAG RELEASED
INNER RACE OVERRUNNING THE OUTER RACE

(B)
INNER
RACE
(457)
DRIVING

FRE
E

OUTER
RACE
(459)
FORWARD
CLUTCH ROLLER
INNER RACE
THRUST RING
(455)

FORWARD CLUTCH SPRAG HOLDING:

When the forward clutch is applied, engine torque is transferred


to the forward clutch sprag outer race (459). The rotation of the
forward clutch sprag outer race pivots the sprags toward their
long diagonals. The length of the long diagonal (distance A) is
greater than the distance between the outer race and inner race
(457). This causes the sprags to lock between the inner and
outer races and transfer engine torque from the forward clutch
sprag outer race to the input sun gear shaft assembly (457).
455 456

20

457

FORWARD
CLUTCH SPRAG
ASSEMBLY
RETAINER RING
(460)

A damaged forward clutch sprag


assembly can cause loss of
drive, no first gear in overdrive
and manual ranges.

458

Figure 21

FORWARD
CLUTCH
SPRAG
OUTER RACE
(459)

459

460

461

460

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OVERDRIVE AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480-497)

If inoperative the overdrive clutch can cause:

No engine braking in third gear

No fifth gear - D

Degraded shifts from fourth to fifth and from


fifth to fourth.

OVERDRIVE CLUTCH:

The overdrive clutch assembly is located in the overdrive


clutch housing (493). The overdrive clutch housing is splined
to the transmission case (24). The external teeth on the
overdrive clutch plates (483) are splined to the overdrive
clutch housing while the internal teeth on the overdrive clutch
plate assemblies (482) are splined to the overdrive and reverse
clutch hub assembly (470). The overdrive clutch is applied
only when the transmission is in Overdrive range Fifth gear,
or in Third gear in D , manual fourth and manual third
ranges when engine braking is commanded ON.

OVERDRIVE
CLUTCH
BACKING
PLATE
(481)

OVERDRIVE
OVERDRIVE
CLUTCH
CLUTCH
PLATE
PLATE
ASSEMBLY
ASSEMBLY
(INNER SPLINE) (OUTER SPLINE)
(482)
(483)

OVERDRIVE
CLUTCH
SPACER
(484)

TRANSMISSION
CASE
(24)

OVERDRIVE
CLUTCH
HOUSING
(493)

OVERDRIVE CLUTCH APPLY:

To apply the overdrive clutch, overdrive clutch fluid is fed


through the transmission case (24) into the overdrive clutch
housing (493). A feed hole in the overdrive clutch housing
allows fluid to enter the housing behind the overdrive clutch
piston assembly (487). Overdrive clutch fluid pressure
moves the piston to compress the overdrive clutch spring
(486). As fluid pressure increases, the overdrive clutch
spacer plate (484) compresses the overdrive clutch plates
together until they are held against the overdrive clutch
backing plate (481).
When fully applied, the overdrive spacer (484), the overdrive
clutch plates (483) and the overdrive clutch plate assemblies
(482) are locked together, thereby holding the overdrive
clutch housing (493) and the overdrive and reverse clutch
hub assembly (470) together. This holds the overdrive and
reverse clutch hub assembly stationary to the transmission
case (24).

OVERDRIVE
CLUTCH
PISTON
ASSEMBLY
(487)

OVERDRIVE CLUTCH RELEASE:

To release the overdrive clutch, overdrive clutch fluid


exhausts through the overdrive clutch housing and into the
transmission case, allowing pressure at the overdrive clutch
piston (487) to decrease. In the absence of fluid pressure,
spring force from the overdrive clutch spring (486) moves
the overdrive clutch piston (487) away from the clutch
pack. This disengages the overdrive clutch plates (483) and
the overdrive clutch plate assemblies (482) from the backing
plate (481), thereby allowing the overdrive and reverse
clutch hub assembly to rotate freely.

480

481

482

OVERDRIVE
CLUTCH FLUID
OVERDRIVE CLUTCH OVERDRIVE OVERDRIVE
BACKING PLATE
CLUTCH
CLUTCH
RETAINER RING
SPRING
SPRING
(SELECTIVE)
RETAINER RING
(486)
(480)
(485)

483

484

Figure 22

485

486

487

21

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INTERMEDIATE CLUTCH SPRAG RELEASED:

INTERMEDIATE
CLUTCH SPRAG
ASSEMBLY
(470-477)

INTERMEDIATE CLUTCH SPRAG:

The intermediate clutch sprag assembly (473) is located between


the intermediate clutch sprag outer race (474) and the overdrive
and reverse clutch hub assembly (470) (inner race). The overdrive
and reverse clutch hub assembly is splined to the overdrive and
reverse sun gear in the input and reaction carrier (553) while the
intermediate clutch plate assemblies are splined to the intermediate
clutch sprag outer race (474). The intermediate clutch sprag is a
type of one-way clutch that, when effective, prevents the overdrive
and reverse clutch hub assembly from rotating in the direction
opposite of engine rotation. The clutch sprag is holding, and
effective, when the transmission is in Third Gear.

The intermediate clutch sprag releases when the sprags pivot


toward their short diagonals. The short diagonal (B) is smaller
than the distance between the inner race and outer race and the
outer race overruns the sprags. This action occurs in Fourth and
Fifth gears when the intermediate clutch is applied and power
flow drives the overdrive and reverse clutch hub assembly in the
direction of engine rotation.
Depending on model and application, the inner race may also
overrun the intermediate clutch sprag during coast conditions
(throttle released) in D , manual fourth and manual third ranges
Third Gear when vehicle speed is greater than engine speed
(refer to the Range Reference Chart on page 11). This causes
the transmission gear set to be driven by the vehicle drive shaft,
and not the engine, which drives the overdrive and reverse
clutch hub assembly in the direction of engine rotation,
overrunning the sprags.
INTERMEDIATE
CLUTCH SPRAG
RETAINER RING
(472)

INTERMEDIATE
CLUTCH SPRAG
ASSEMBLY
(473)

CLUTCH SPRAG HOLDING


OUTER RACE HOLDING THE INNER RACE

INTERMEDIATE
CLUTCH SPRAG
THRUST BEARING
ASSEMBLY
(476)

HE L D

(A)
INNER
RACE
(470)

INTERMEDIATE
CLUTCH SPRAG
OUTER RACE
(474)

OUTER
RACE
(474)

LD
HE

SPRAG IS VIEWED FROM THIS DIRECTION


CLUTCH SPRAG RELEASED
INNER RACE OVERRUNNING THE OUTER RACE
HEL D

(B)
INNER
RACE
(470)

FRE
E

OUTER
RACE
(474)

INTERMEDIATE CLUTCH SPRAG HOLDING:

In Third gear, power flow attempts to drive the overdrive and


reverse clutch hub assembly in the direction opposite of engine
rotation and pivots the sprags toward their long diagonals. The
long diagonal (A) of the sprag is greater than the distance between
the inner race and the outer race, causing the sprags to lock
against the intermediate clutch sprag outer race (474). However,
in Third gear the intermediate clutch is applied and the outer race
is held stationary to the transmission case (24). Therefore, the
sprag assembly, being locked between the outer race and
overdrive and reverse clutch hub assembly (inner race), holds the
overdrive and reverse clutch hub assembly (470) and the overdrive
and reverse sun gear (553) stationary to obtain a Third gear ratio
through the transmission gear set.
470

22

471

INTERMEDIATE
CLUTCH SPRAG
THRUST BEARING
ASSEMBLY
RETAINER
(477)
OVERDRIVE
AND REVERSE
CLUTCH HUB
ASSEMBLY (470)

INTERMEDIATE
CLUTCH SPRAG
THRUST WASHER
(471)

INTERMEDIATE
CLUTCH SPRAG
THRUST WASHER
(475)

A damaged intermediate clutch sprag can cause no third gear


or, no torque in third gear, in overdrive range, manual fourth,
or manual third.

472

Figure 23

473

472

474

475

476

477

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OVERDRIVE AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480-497)

intermediate clutch sprag outer race from the overdrive clutch housing/
transmission case. Therefore, the intermediate clutch sprag is no
longer effective the outer race will rotate with the overdrive and
reverse clutch hub assembly when the sprags engage.
If inoperative the intermediate clutch can cause:
No third gear in overdrive range, manual fourth or
manual third

Degraded shifts from second to third and from third


to second

INTERMEDIATE CLUTCH:

The intermediate clutch assembly is located between the


intermediate clutch housing (496) and the overdrive clutch
housing (493). The overdrive clutch housing is splined to
the transmission case (24). The external teeth on the
intermediate clutch plates (491) are splined to the overdrive
clutch housing (493) while the internal teeth on the
intermediate clutch plate assemblies (490) are splined to
the intermediate clutch sprag outer race (474). The
intermediate clutch is applied when the transmission is in
Third, Fourth, and Fifth gears.

INTERMEDIATE INTERMEDIATE INTERMEDIATE INTERMEDIATE


CLUTCH
CLUTCH
CLUTCH
CLUTCH
BACKING PLATE
PLATE
PLATE
APPLY
(489)
ASSEMBLY
PLATE
ASSEMBLY
(INNER SPLINE) (OUTER SPLINE)
(492)
(490)
(491)

TRANSMISSION
CASE
(24)

OVERDRIVE
CLUTCH
HOUSING
(493)

INTERMEDIATE CLUTCH APPLY:

To apply the intermediate clutch, intermediate clutch apply


fluid is fed from the transmission case (24) into the
intermediate clutch housing (496). A feed hole in the
intermediate clutch housing allows fluid to enter the housing
behind the intermediate clutch piston assembly (495).
Intermediate clutch fluid pressure moves the piston to
compress the intermediate clutch spring (494). As fluid
pressure increases, the piston compresses the intermediate
clutch plates until they are held against the intermediate clutch
backing plate (489). Also included in the intermediate clutch
pack is an intermediate clutch apply (waved) plate (492) that
helps control the apply rate of the intermediate clutch.
When fully applied, the intermediate clutch plates (491)
and intermediate clutch plate assemblies (490) are locked
together, thereby holding the intermediate clutch sprag outer
race (474) stationary to the transmission case. This allows
the intermediate clutch sprag (473) to become effective and
hold when the overdrive and reverse clutch hub assembly
(470) attempts to rotate in the direction opposite of engine
rotation. Remember that the inner race of the intermediate
clutch sprag is part of the overdrive and reverse clutch hub
assembly (470).

INTERMEDIATE
CLUTCH
HOUSING
(496)

INTERMEDIATE
CLUTCH
SPRING
(494)

INTERMEDIATE CLUTCH RELEASE:

To release the intermediate clutch, intermediate clutch fluid


exhausts from the piston, through the intermediate clutch
housing and into the transmission case. In the absence of
fluid pressure, spring force from the intermediate clutch
spring (494) moves the piston away from the clutch plates.
This disengages the intermediate clutch plates (491) and
intermediate clutch plate assemblies (490) from the
intermediate clutch backing plate (489) and disconnects the
488

489

490

491

INTERMEDIATE
CLUTCH FLUID
INTERMEDIATE INTERMEDIATE INTERMEDIATE
CLUTCH
CLUTCH
CLUTCH
BACKING PLATE
HOUSING
PISTON
RETAINER RING RETAINER RING
ASSEMBLY
(SELECTIVE)
(497)
(495)
(488)

492

Figure 24

494

495

496

497

23

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LOW CLUTCH SPRAG RELEASED:

LOW
CLUTCH
SPRAG
ASSEMBLY
(500-505)

LOW CLUTCH SPRAG:

The low clutch sprag assembly (503) is located between the low
clutch sprag outer race (504) and the low clutch sprag inner race
(505). The low clutch sprag outer race is splined to the
transmission case (24) through the intermediate clutch housing
assembly (496) and the overdrive clutch housing (493). The low
clutch sprag inner race is splined to the input and reaction carrier
(553). The low clutch sprag assembly is a type of one-way
clutch that prevents the input and reaction carrier from rotating
in the direction opposite of engine rotation. The low clutch sprag
is holding, and effective, when the vehicle is in First Gear.

The low clutch sprag releases when the sprags pivot toward their
short diagonals. The length of the short diagonals (B) is less than
the distance between the inner race and the outer race. This
causes the inner race to overrun the sprags. This action occurs in
Second, Third, Fourth and Fifth gears when power flow drives
the input and reaction carrier in the direction of engine rotation.
Depending on model and application, the input and reaction
carrier may also overrun the low clutch sprag during coast
conditions (throttle released) in D , manual fourth, manual third
and manual second ranges First Gear when vehicle speed is
greater than engine speed. This causes the transmission gear set
to be driven by the vehicle drive shaft, and not the engine,
which drives the input and reaction carrier in the direction of
engine rotation, overrunning the sprags.

CLUTCH SPRAG HOLDING


OUTER RACE HOLDING THE INNER RACE

HEL D

(A)

LOW
CLUTCH
SPRAG
INNER RACE
(505)

LOW
CLUTCH
ROLLER
THRUST
WASHER
(501)

OUTER
RACE
(504)

LD
HE

INNER
RACE
(505)

LOW
CLUTCH
SPRAG
OUTER RACE
(504)

LOW
CLUTCH
SPRAG
ASSEMBLY
RETAINER
RING
(502)

SPRAG IS VIEWED FROM THIS DIRECTION


CLUTCH SPRAG RELEASED
INNER RACE OVERRUNNING THE OUTER RACE

HEL D
OUTER
RACE
(504)

(B)

FRE
E

INNER
RACE
(505)

LOW
CLUTCH
ROLLER
RETAINER
(500)
LOW
CLUTCH
SPRAG
ASSEMBLY
(503)

LOW CLUTCH SPRAG HOLDING:

In First gear, power flow attempts to drive the input and reaction
carrier in the direction opposite of engine rotation and pivots the
sprags toward their long diagonals. The long diagonal (A) of
the sprag is greater than the distance between the inner race and
the outer race, causing the sprags to lock between the inner
and outer races. This action holds the input and reaction carrier
stationary to the transmission case (24) to obtain a First gear
ratio through the transmission gear set.
500

24

501

502

503

502

Figure 25

A damaged low clutch sprag can cause loss of drive/no first


gear in overdrive range and all manual ranges.

504

501

505

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If inoperative the low and reverse clutch can cause:


No first gear engine braking in overdrive range,
manual fourth, manual third, manual second, or
manual first
No reverse/slips in reverse

CENTER
SUPPORT
ASSEMBLY
(510-535)

LOW AND
REVERSE
CLUTCH
BACKING
PLATE
(511)

LOW AND REVERSE CLUTCH:

LOW AND
The low and reverse clutch assembly is located in the center
REVERSE
support (518). The center support is splined to the transmission
CLUTCH
case (24). The external teeth on the low and reverse clutch
PLATE
RETAINER
plates (513) are splined to the center support (518) while the
RING
internal teeth on the low and reverse clutch plate assemblies
(SELECTIVE)
(512) are splined to the low clutch sprag inner race (505). The
(510)
low and reverse clutch is applied when the transmission is in
First gear in all forward ranges when engine braking is
CENTER
commanded ON, and in Reverse.
SUPPORT

LOW AND
REVERSE
CLUTCH
PLATE
ASSEMBLY
(OUTER SPLINE)
(513)
LOW AND
LOW AND
REVERSE
REVERSE
CLUTCH
CLUTCH
PLATE
APPLY
ASSEMBLY
PLATE
(INNER SPLINE)
(514)
(512)

(518)

LOW AND REVERSE CLUTCH APPLY:

To apply the low and reverse clutch, low and reverse clutch or
reverse lockout (RLO) apply fluid is fed from the transmission
case (24) into the center support (518). A feed hole in the center
support allows fluid to enter behind the low and reverse clutch
piston assembly (517). Low and reverse clutch or reverse lockout
(RLO) fluid pressure moves the piston to compress the low and
reverse clutch spring (516). As fluid pressure increases, the
piston compresses the low and reverse clutch plates until they
are held against the low and reverse clutch backing plate (511).
Also included in the clutch pack is a low and reverse clutch
apply (waved) plate (514) that helps control the apply rate of the
low and reverse clutch.
When fully applied, the low and reverse clutch plates (513) and
low and reverse clutch plate assemblies (512) are locked together,
thereby holding the low clutch sprag inner race (505) stationary
to the transmission case (24). The low clutch sprag inner race
(505) is splined to the input and reaction carrier (553), causing
the input and reaction carrier to be held stationary also.
LOW AND REVERSE CLUTCH RELEASE:

To release the low and reverse clutch, low and reverse clutch or
reverse lockout (RLO) fluid exhausts from the piston, through
the center support and into the transmission case. In the absence
of fluid pressure, spring force from the low and reverse clutch
spring (516) moves the piston away from the clutch plates. This
disengages the low and reverse clutch plates (513) and low and
reverse clutch plate assemblies (512) from the low and reverse
clutch backing plate (511) and disconnects the low clutch sprag
inner race from the center support/transmission case. Therefore,
the low clutch sprag inner race (505) and the input and reaction
carrier (553) are free to rotate in the direction of engine rotation.

510

511

512

LOW AND
REVERSE
CLUTCH
SPRING
RETAINER
RING
(515)

513

LOW AND
REVERSE
CLUTCH
SPRING
(516)

514

Figure 26

LOW AND
REVERSE
CLUTCH
PISTON
(517)

515

LOW AND
REVERSE
CLUTCH
OR RLO
FLUID

516

REVERSE
LOCKOUT
FLUID

517

25

APPLY COMPONENTS
WWW.ALL-TRANS.BY

CENTER
SUPPORT
ASSEMBLY
(510-535)

If inoperative the second clutch can cause:


No second gear in overdrive range, manual fourth,
manual third, or manual second

Degraded shifts from first to second and from


second to first

SECOND SECOND
SECOND SECOND
CLUTCH CLUTCH
CLUTCH
CLUTCH
APPLY
PLATE
PLATE
BACKING
PLATE ASSEMBLY ASSEMBLY PLATE
(523)
(OUTER
(INNER
(526)
SPLINE)
SPLINE)
(524)
(525)

SECOND CLUTCH:

The second clutch assembly is located in the center support


(518). The center support is splined to the transmission case
(24). The external teeth on the second clutch plates (524) are
splined to the center support (518) while the internal teeth on
the second clutch plate assemblies (525) are splined to the second
clutch sprag outer race (545). The second clutch is applied
when the transmission is in Second, Third, Fourth or Fifth gears.

SECOND
CLUTCH
BACKING
PLATE
RETAINER
RING
(SELECTIVE)
(527)

SECOND CLUTCH APPLY:

To apply the second clutch, second clutch apply fluid is fed from
the transmission case (24) into the center support (518). A feed
hole in the center support allows fluid to enter behind the second
clutch piston (520). Second clutch fluid pressure moves the
piston to compress the second clutch spring (521) to cushion the
apply. As fluid pressure increases, the piston compresses the
second clutch plates until they are held against the second clutch
backing plate (526). Also included in the clutch pack is a second
clutch apply (waved) plate (523) that, in addition to the second
clutch spring, helps control the apply rate of the second clutch.
When fully applied, the second clutch plates (524) and second
clutch plate assemblies (525) are locked together, thereby holding
the second clutch sprag outer race (545) stationary to the
transmission case (24). This allows the second clutch sprag
assembly (547) to become effective and hold when the second
clutch sprag inner race (549) attempts to rotate in the direction
opposite of engine rotation.
SECOND CLUTCH RELEASE:

To release the second clutch, second clutch fluid exhausts from


the piston, through the center support and into the transmission
case. In the absence of fluid pressure, spring force from the
second clutch spring (521) moves the piston away from the
clutch plates. This disengages the second clutch plates (524)
and second clutch plate assemblies (525) from the second clutch
backing plate (526) and disconnects the second clutch sprag
outer race (545) from the second clutch sprag inner race (549).
Therefore, the second clutch sprag is no longer effective the
inner race is free to rotate.
CENTER
SUPPORT
(518)

520

26

521

522

523

524

525

Figure 27

SECOND
CLUTCH
PISTON
(520)

SECOND
CLUTCH
SPRING
(521)

SECOND
CLUTCH
FLUID

526

SECOND
CLUTCH
SPRING
RETAINER
RING
(522)

527

APPLY COMPONENTS
WWW.ALL-TRANS.BY

SECOND CLUTCH SPRAG RELEASED:

SECOND
CLUTCH
SPRAG
ASSEMBLY
(540-549)

SECOND CLUTCH SPRAG:

The second clutch sprag assembly (547) is located between the


second clutch sprag outer race (545) and the second clutch sprag
inner race (549). The second clutch sprag outer race is splined to
the second clutch plate assemblies (525). The second clutch sprag
inner race is splined to the reaction internal gear (550). The second
clutch sprag assembly is a type of one-way clutch that prevents the
reaction internal gear (550) from rotating in the direction opposite
of engine rotation and affects the output gear ratio of the input and
reaction carrier (553). The second clutch sprag is holding, and
effective, when the vehicle is in Second Gear.

The second clutch sprag releases when the sprags pivot toward
their short diagonals. The length of the short diagonals (B) is
less than the distance between the inner race and the outer race.
This causes the inner race to overrun the sprags. This action
occurs in Third, Fourth and Fifth gears when power flow drives
the reaction internal gear (550) in the direction of engine rotation.
Depending on model and application, the reaction internal gear
(550) may also overrun the second clutch sprag during coast
conditions (throttle released) in D , manual fourth, manual
third, and manual second ranges Second Gear when vehicle
speed is greater than engine speed (refer to the Range Reference
Chart on page 11). This causes the transmission gear set to be
driven by the vehicle drive shaft, and not the engine, which
drives the reaction internal gear in the direction of engine rotation,
overrunning the sprags.
INPUT AND
REACTION
BEARING
ASSEMBLY
(541)

CLUTCH SPRAG HOLDING


OUTER RACE HOLDING THE INNER RACE

OUTER
RACE
(545)

LD
HE

INNER
RACE
(549)

SECOND
CLUTCH
SPRAG
INNER
RACE
(549)

SECOND
CLUTCH
ROLLER
OUTER
RACE
WASHER
(544)

SECOND
CLUTCH
SPRAG
ASSEMBLY
RETAINER
(546)

HEL D

(A)

SECOND
CLUTCH
ROLLER
INNER
RACE
BEARING
ASSEMBLY
(542)

SPRAG IS VIEWED FROM THIS DIRECTION


CLUTCH SPRAG RELEASED
INNER RACE OVERRUNNING THE OUTER RACE
INPUT AND
REACTION
CARRIER
OUTER
RING
(540)

HEL D

OUTER
RACE
(545)

(B)

FRE
E

INNER
RACE
(549)

SECOND CLUTCH SPRAG HOLDING:

In Second gear, power flow attempts to drive the reaction internal


gear (550) in the direction opposite of engine rotation and pivots
the sprags toward their long diagonals. The long diagonal (A) of
the sprag is greater than the distance between the inner race and the
outer race, causing the sprags to lock between the inner and outer
races. Because the second clutch is also applied, this action holds
the reaction internal gear (550) stationary to the transmission case
(24) to obtain a Second gear ratio through the transmission gear set.
540

541

542

543

544

545

SECOND
CLUTCH
SPRAG
RETAINER
(543)

546

Figure 28

SECOND
CLUTCH
SPRAG
OUTER
RACE
(545)

SECOND
CLUTCH
SPRAG
ASSEMBLY
(547)

REACTION
INTERNAL
GEAR
(550)

A damaged second clutch sprag can cause no second gear in


overdrive range, manual fourth, manual third and manual
second.

547

546

544

548

549

27

APPLY COMPONENTS
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CENTER
SUPPORT
ASSEMBLY
(510-535)

If inoperative the second coast clutch can cause:


No second gear engine braking in overdrive range,
manual fourth, manual third, or manual second

SECOND COAST CLUTCH:

The second coast clutch assembly is located in the center support


(518). The center support is splined to the transmission case
(24). The external teeth on the second coast clutch plates (532)
are splined to the center support (518) while the internal teeth
on the second coast clutch plate assemblies (533) are splined to
the second clutch sprag inner race (549). The second coast
clutch is applied when the transmission is in Second gear in all
forward ranges when engine braking is commanded ON.

SECOND
COAST
CLUTCH
SPACER
(531)

SECOND
SECOND
SECOND
SECOND
COAST
COAST
COAST
COAST
CLUTCH
CLUTCH
CLUTCH
CLUTCH
PLATE
BACKING
BACKING
PLATE
ASSEMBLY ASSEMBLY
PLATE
PLATE
(INNER
(534)
RETAINER
(OUTER
SPLINE)
SPLINE)
RING
(533)
(SELECTIVE)
(532)
(535)

SECOND COAST CLUTCH APPLY:

To apply the second coast clutch, second coast clutch apply fluid
is fed from the transmission case (24) into the center support
(518). A feed hole in the center support allows fluid to enter
behind the second coast clutch piston assembly (528). Second
coast clutch fluid pressure moves the piston to compress the
second coast clutch spring (529) to cushion the apply. As fluid
pressure increases, the piston compresses the second coast clutch
plates until they are held against the second coast clutch backing
plate (534). Also included in the clutch pack is a second coast
clutch spacer (531).
When fully applied, the second coast clutch plates (532) and
second coast clutch plate assemblies (533) are locked together,
thereby holding the second clutch sprag inner race (549)
stationary to the transmission case (24). This allows the second
clutch sprag assembly (547) to become effective and hold when
the second clutch sprag inner race (549) attempts to rotate.
SECOND COAST CLUTCH RELEASE:

To release the second coast clutch, second coast clutch fluid


exhausts from the piston, through the center support and into the
transmission case. In the absence of fluid pressure, spring force
from the second coast clutch spring (529) moves the piston
away from the clutch plates. This disengages the second coast
clutch plates (532) and second coast clutch plate assemblies
(533) from the second coast clutch backing plate (534) and
disconnects from the second clutch sprag inner race (549).
Therefore, the second clutch sprag is no longer effective the
inner race is free to rotate.

528

28

529

530

531

CENTER
SUPPORT
(518)

532

Figure 29

533

SECOND
COAST
CLUTCH
PISTON
(528)

SECOND
COAST
CLUTCH
FLUID

SECOND
COAST
CLUTCH
SPRING
(529)

534

SECOND
COAST
CLUTCH
SPRING
RETAINER
RING
(530)
535

PLANETARY GEAR SETS


WWW.ALL-TRANS.BY

PLANETARY GEAR SETS

Planetary gear sets are commonly used in automatic transmissions


as the primary method of multiplying the torque, or twisting force,
of the engine (reduction). Planetary gear sets are also used to reverse
the direction of rotation, function as a coupling for direct drive, and
provide an overdrive gear ratio.
Planetary gear sets are so named because of their physical arrangement.
All planetary gear sets contain at least three main components:
a sun gear at the center of the gear set,
a carrier assembly with planet pinion gears that rotate around
the sun gear and,
an internal (ring) gear that encompasses the entire gear set.
The gears are designed such that several gear teeth are always in
contact, or mesh, at the same time. This design distributes the
energy forces over several gear teeth for greater strength and
eliminates potential clash that is a common occurrence in manual
transmissions when gear teeth go in and out of mesh. Another
benefit of planetary gear sets is that shafts are generally used for
input and output components and can be arranged on the same axis,
thus providing a very compact unit.
The Hydra-matic 4/5L40-E transmission uses one planetary gear
set, the Ravigneaux gear set. Figures 30, 31 and 32 show this gear
set and it's respective components. These figures also graphically
explain how the planetary gear set is used to achieve each of the
transmission's five forward gear ratios and Reverse.
Ravigneaux Planetary Gear Set

The Ravigneaux planetary gear set is unique in that it resembles a


combination of two gear sets. This gear set consists of three sets of
pinion gears (one long and two short) in one planetary carrier (553),
two sun gears front input and rear input, and two internal gears
reaction (550) and rear (560). The front input sun gear is in constant
mesh with the long pinion gears. The rear input sun gear is in

constant mesh with the rear short pinion gears. The long pinion
gears are in constant mesh with both the front and the rear short
pinion gears, and the rear internal gear (560). The front short pinion
gears are in constant mesh with the reaction internal gear (550) in
addition to the long pinion gears. Also, the output shaft (562) is
splined to the rear internal gear (560) which acts as a part of the
Ravigneaux planetary gear set.
Torque

When engine torque is transferred through a gear set the output


torque from the gear set can either increase, decrease, or remain the
same. The output torque achieved depends on:
which member of the gear set provides the input torque,
which member of the gear set (if any) is held stationary, and,
which member of the gear set provides the output torque.
If output torque is greater than input torque the gear set is operating
in reduction (First, Second, Third and Reverse gears). If output
torque is less than input torque, then the gear set is operating in
overdrive (Fifth gear). When output torque equals input torque the
gear set is operating in direct drive (Fourth gear) and all gear set
components are rotating at the same speed.
Torque vs. Speed

One transmission operating condition directly affected by input and


output torque through a gear set is the relationship of torque with
output speed. As the transmission shifts from First to Second to
Third to Fourth to Fifth gear, the overall output torque to the wheels
decreases as the speed of the vehicle increases (when input speed
and input torque are held constant). Higher output torque is needed
at low vehicle speed (First, Second and Third gears) to provide the
power to move the vehicle from a standstill. However, once the
vehicle is moving and the speed of the vehicle increases (Fourth
and Fifth gears), less output torque is required to maintain that
speed. This provides for a more efficient operation of the powertrain.
Gear set failure can cause noise and loss of drive.

INPUT AND
REACTION
CARRIER
(553)

REACTION
INTERNAL
GEAR
(550)

INPUT AND
REACTION
CARRIER
(553)

FRONT
INPUT
SUN
GEAR

Figure 30

REAR
INTERNAL
GEAR
(560)

REAR
INPUR
SUN
GEAR

29

WWW.ALL-TRANS.BY

PLANETARY GEAR SETS


REACTION
INTERNAL
GEAR
(550)
DRIVEN
FRONT INPUT
SUN GEAR
DRIVEN

REDUCTION
FIRST GEAR
INPUT
SUN GEAR
SHAFT
ASSEMBLY
(457)
DRIVING

INPUT AND
REACTION
CARRIER
(553)
HELD

REAR
INTERNAL
GEAR
(560)
DRIVEN
REAR INPUT
SUN GEAR
DRIVING
REACTION
INTERNAL
GEAR
(550)
HELD
FRONT INPUT
SUN GEAR
DRIVEN

REAR INPUT
SUN GEAR
DRIVING
REACTION
INTERNAL
GEAR
(550)
DRIVEN
FRONT INPUT
SUN GEAR
HELD

REAR INPUT
SUN GEAR
DRIVING

30

REAR
INTERNAL GEAR
(560)
DRIVEN

FRONT INPUT
SUN GEAR
DRIVEN

REDUCTION
SECOND GEAR
INPUT
SUN GEAR
SHAFT
ASSEMBLY
(457)
DRIVING

REACTION
INTERNAL GEAR
(550)
DRIVEN

OVERDRIVE AND
REVERSE CLUTCH
HUB ASSEMBLY
(470)
DRIVEN

REAR
INTERNAL GEAR
(560)
DRIVEN

INPUT AND
REACTION
CARRIER
(553)
DRIVEN

REDUCTION
THIRD GEAR
INPUT
SUN GEAR
SHAFT
ASSEMBLY
(457)
DRIVING

REACTION
INTERNAL GEAR
(550)
HELD

OVERDRIVE AND
REVERSE CLUTCH
HUB ASSEMBLY
(470)
HELD

REAR INPUT
SUN GEAR
DRIVING
INPUT AND
REACTION
CARRIER
(553)
DRIVEN
FRONT INPUT
SUN GEAR
HELD

Figure 31

FIRST GEAR

SECOND GEAR

REAR INPUT
SUN GEAR
DRIVING

FRONT INPUT
SUN GEAR
DRIVEN

Increasing the output torque is known as operating in reduction


because there is a decrease in the speed of the output member
proportional to the increase in output torque. Therefore, with a
constant input speed, the output torque increases when the
transmission is in a lower gear, or higher gear ratio. Reduction
occurs in First, Second, Third and Reverse gears through the
Ravigneaux gear set.

In First gear, torque input to the Ravigneaux gear set is provided


by the rear input sun gear in the direction of engine rotation.
The rear input sun gear drives the rear short pinion gears in the
direction opposite of engine rotation. The rear short pinion
gears then drive the long pinion gears in the direction of engine
rotation. The long pinion gears drive the front short pinion
gears which in turn drive the reaction internal gear (550) in the
direction opposite of engine rotation. The front short pinion
gears also attempt to drive the input and reaction carrier (553) in
the direction opposite of engine rotation but, the low clutch
sprag prevents this from occurring and the carrier is held
stationary. This action forces the long pinion gears to drive the
rear internal gear (560) and output shaft assembly in an reduction
gear ratio of approximately 3.42:1.

INPUT AND
REACTION
CARRIER
(553)
HELD

INPUT AND
REACTION
CARRIER
(553)
DRIVEN

REAR
INTERNAL
GEAR
(560)
DRIVEN

REDUCTION

OVERDRIVE AND
REVERSE CLUTCH
HUB ASSEMBLY
(470)
DRIVEN

REAR INPUT
SUN GEAR
DRIVING

INPUT AND
REACTION
CARRIER
(553)
DRIVEN

REAR
INTERNAL
GEAR
(560)
DRIVEN

PLANETARY GEAR SETS

REACTION
INTERNAL GEAR
(550)
DRIVEN

In Second gear, the torque input to the Ravigneaux gear set is


provided by the rear input sun gear in the direction of engine
rotation. The rear input sun gear drives the rear short pinion
gears in the direction opposite of engine rotation. The rear short
pinion gears then drive the long pinion gears in the direction of
engine rotation. The long pinion gears drive the front short
pinion gears, and the front short pinion gears then attempt to
drive the reaction internal gear (550) in the direction opposite of
engine rotation but, because the second clutch is applied, the
second clutch sprag prevents this from occurring and the rear
internal gear is held stationary. The front short pinion gears are
forced to walk around the stationary reaction internal gear and
drive the input and reaction carrier (553) in the direction of
engine rotation. This action forces the long pinion gears to
drive the rear internal gear (560) and output shaft assembly in a
reduction gear ratio of approximately 2.21:1.

THIRD GEAR

REAR
INTERNAL GEAR
(560)
DRIVEN

In Third gear, the torque input to the Ravigneaux gear set is


provided by the rear input sun gear in the direction of engine
rotation. The rear input sun gear drives the rear short pinion
gears in the direction opposite of engine rotation. The rear
short pinion gears then drive the long pinion gears in the direction
of engine rotation. The long pinion gears drive the front short
pinion gears, and the front short pinion gears then attempt to
drive the front input sun gear in the direction opposite of engine
rotation. However, the intermediate clutch is applied, holding
the front input sun gear stationary and forcing the long pinion
gears to walk around the stationary front input sun gear, driving
the input and reaction carrier (553) in the direction of engine
rotation. This action forces the long pinion gears to drive the
rear internal gear (560) and output shaft assembly in a reduction
gear ratio of approximately 1.60:1.

30A

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PLANETARY GEAR SETS

DIRECT DRIVE

Direct drive through a planetary gear set is obtained when any


two members of the gear set rotate in the same direction at the
same speed. This forces the third member of the gear set to
rotate at the same speed. Therefore, in direct drive the output
speed of the transmission is the same as the input speed from the
converter turbine. Output speed will equal engine speed when
the torque converter clutch is applied (see Torque Converter
pages 12-14).
FOURTH GEAR

Direct drive occurs in Fourth gear when input torque to the


Ravigneaux gear set is provided by both the rear input sun gear
and the direct clutch input and hub assembly (466). The direct
clutch input and hub assembly (466) is splined directly to the
input and reaction carrier (553) and drives the carrier in the
direction of engine rotation at input speed. The rear input sun
gear attempts to drive the long pinion gears in the direction of
engine rotation at input speed through the rear short pinion
gears but, because the carrier is rotating at the same speed, the
long pinion gears are prevented from rotating on their pins and
they force the rear internal gear (560) to rotate at the same
speed. Therefore, the Ravigneaux carrier (553) and the output
shaft assembly (562) are driven at the same speed for a direct
drive 1:1 gear ratio.

PLANETARY GEAR SETS


REACTION
INTERNAL
GEAR
(550)
DRIVEN
FRONT INPUT
SUN GEAR
DRIVEN

INPUT AND
REACTION
CARRIER
(553)
DRIVING

REAR
INTERNAL
GEAR
(560)
DRIVEN
REAR INPUT
SUN GEAR
DRIVING
REACTION
INTERNAL
GEAR
(550)
DRIVEN
FRONT INPUT
SUN GEAR
HELD

DIRECT DRIVE
FOURTH GEAR
INPUT SUN GEAR
SHAFT ASSEMBLY
(457)
DRIVING

DIRECT CLUTCH
INPUT AND HUB
ASSEMBLY
(466)
DRIVING

REAR
INTERNAL GEAR
(560)
DRIVEN

INPUT AND REACTION


CARRIER
(553)
DRIVING

OVERDRIVE AND
REVERSE CLUTCH
HUB ASSEMBLY
(470)
DRIVEN

OVERDRIVE
FIFTH GEAR
INPUT SUN GEAR
SHAFT ASSEMBLY
(457)
DRIVEN

FRONT INPUT
SUN GEAR
DRIVEN

REACTION
INTERNAL GEAR
(550)
DRIVEN

DIRECT CLUTCH
INPUT AND HUB
ASSEMBLY
(466)
DRIVING

REAR
INTERNAL GEAR
(560)
DRIVEN

OVERDRIVE

Operating the transmission in Overdrive allows the output speed


of the transmission to be greater than the input speed from the
engine. This mode of operation allows the vehicle to maintain a
given road speed with reduced engine speed for increased fuel
economy.

INPUT AND
REACTION
CARRIER
(553)
DRIVING

FIFTH GEAR

Overdrive is achieved through the Ravigneaux gear set and only


occurs in Overdrive Range Fifth Gear. The overdrive clutch
holds the overdrive and reverse clutch hub (470) and the front
input sun gear stationary to the transmission case. Therefore,
when input torque drives the input and reaction carrier (553) in
the direction of engine rotation, the long pinion gears walk in
the direction of engine rotation around the stationary front input
sun gear. These pinion gears then drive the rear internal gear
(560) in the direction of engine rotation in an overdrive gear
ratio of approximately 0.75:1.

REAR
INTERNAL
GEAR
(560)
DRIVEN
REAR INPUT
SUN GEAR
DRIVEN
REACTION
INTERNAL
GEAR
(550)
DRIVEN
FRONT INPUT
SUN GEAR
DRIVING

REAR INPUT
SUN GEAR
DRIVING

INPUT AND REACTION


CARRIER
(553)
DRIVING

OVERDRIVE AND
REVERSE CLUTCH
HUB ASSEMBLY
(470)
HELD

FRONT INPUT
SUN GEAR
HELD

REACTION
INTERNAL GEAR
(550)
DRIVEN

REAR INPUT
SUN GEAR
DRIVEN

REVERSE
INPUT
SUN GEAR
SHAFT
ASSEMBLY
(457)
DRIVEN

OVERDRIVE AND
REVERSE CLUTCH
HUB ASSEMBLY
(470)
DRIVING

REVERSE

The Ravigneaux planetary gear set reverses the direction of power


flow rotation when the reverse clutch and the low and reverse
clutch are applied. Input torque to the Ravigneaux gear set is
provided through the reverse clutch to the front input sun gear in
the direction of engine rotation, while the input and reaction
carrier (553) is held stationary by the low and reverse clutch.
The front input sun gear drives the long pinion gears in the
direction opposite of engine rotation. With the input and reaction
carrier (553) held, the long pinion gears drive the rear internal
gear (560) and output shaft (562) assembly in the direction
opposite of engine rotation (reverse), in a reduction gear ratio of
approximately 3.03:1.

INPUT AND
REACTION
CARRIER
(553)
HELD

REAR
INTERNAL
GEAR
(560)
DRIVEN
REAR INPUT
SUN GEAR
DRIVEN

30B

REAR INPUT
SUN GEAR
DRIVEN

REAR
INTERNAL GEAR
(560)
DRIVEN

INPUT AND
REACTION
CARRIER
(553)
HELD
FRONT INPUT
SUN GEAR
DRIVING

Figure 32

REACTION
INTERNAL GEAR
(550)
DRIVEN

31

HYDRAULIC CONTROL COMPONENTS


WWW.ALL-TRANS.BY

The previous sections of this book were used to


describe some of the mechanical component
operations of the Hydra-matic 4/5L40-E. In the
Hydraulic Control Components section a detailed

FLUID PUMP
ASSEMBLY
(200-241)

DIRECT
CLUTCH
ACCUMULATOR

description of individual components used in the


hydraulic system will be presented. These hydraulic
control components apply and release the clutch packs
to provide automatic shifting of the transmission.

OVERDRIVE
CLUTCH
ACCUMULATOR

FRONT
CONTROL
VALVE BODY
(311)

32

Figure 33

INTERMEDIATE
CLUTCH
ACCUMULATOR

SECOND
CLUTCH
ACCUMULATOR

REAR
CONTROL
VALVE BODY
(310)

HYDRAULIC CONTROL COMPONENTS


WWW.ALL-TRANS.BY

FLUID PUMP ASSEMBLY


TORQUE
CONVERTER
HOUSING
(227)

PUMP
COVER
ASSEMBLY
(202)

VANE
RING
(225)

SLIDE
PIN
VANE SLIDE SLIDE SLIDE ASSEMBLY
RING RING O-RING (216)
(231)
SEAL
(221) (220)
(242)

ROTOR
GUIDE
(224)

ROTOR
(223)

31

AIR
BLEED
(233)

SLIDE
SEAL
(218)

SLIDE
SEAL
SUPPORT
(217)

FLUID PUMP ASSEMBLY

The fluid pump assembly contains a variable displacement, vane


type pump, located in the torque converter housing (227). When
the engine is cranking, the torque converter pump hub, which is
keyed to the fluid pump rotor (223), turns the rotor at cranking
speed. As the fluid pump rotor and the fluid pump vanes (222)
begin to rotate, the volume of fluid between the vanes is at its
maximum, creating a vacuum at the pump intake port. The
vacuum allows atmospheric pressure, acting on the fluid in the
bottom pan, to prime the pump quickly and pressurize the
hydraulic system when the engine is running.

LINE

PRESSURE
RELIEF
BALL
VALVE
LINE

DECREASE

SLIDE
SPRING
(219)

30

EX

DECREASE

SLIDE
(216)

FLUID
PUMP
SCREEN
ASSEMBLY
(213)
LINE

VANE
RING
(221)
SUCTION

ROTOR
(223)
FLUID
PUMP
ASSEMBLY

VANE
(222)

FLUID
PAN
(62)

Fluid from the transmission bottom pan (62) is drawn through


the fluid filter assembly (59) and into the fluid pump intake
(suction) fluid circuit. This fluid is then forced to rotate around
the fluid pump slide (216) to the pump outlet port where the
clearance between the fluid pump slide and the fluid pump rotor
decreases. Decreasing the volume pressurizes the fluid and
forces the fluid into the line pressure fluid circuit. This fluid is
directed to the pressure regulator valve and becomes the main
supply of fluid to the various components and hydraulic circuits
in the transmission.
The events described above occur when the pump is operating
at maximum output. Since most normal driving conditions do
not require maximum output, the pressure regulator valve will
move far enough against spring force to allow excess line pressure
fluid to enter the decrease fluid circuit. Decrease pressure is
applied to the backside of the fluid pump slide, and moves the
slide against pump slide spring (219) pressure to lower the
output of the pump. The result is a control of the pump's
delivery rate of fluid to the hydraulic system.

Pump Related Diagnostic Tips

FLUID FILTER
ASSEMBLY
(59)

Figure 34

Transmission Overheating
Loss of drive
High or low line pressure
Slipping clutch or harsh apply

33

HYDRAULIC CONTROL COMPONENTS

- throttle signal fluid pressure routed from the pressure control


(PC) solenoid valve (this fluid pressure is proportional to
engine torque see page 51). Throttle signal fluid pressure
moves the line boost valve (207) against the line boost valve
spring (208) which acts against the pressure regulator valve.
- pressure regulator valve spring force.
- line pressure acting on the end of the pressure regulator
valve.
- reverse clutch fluid pressure acting on the line boost valve
in Reverse.

Pressure Regulation

The PC solenoid valve regulates throttle signal fluid pressure as


a function of engine torque (minimum signal pressure at low
torque, maximum signal pressure at high torque). Line pressure,
acting on the end of the pressure regulator valve, moves the
valve against spring force and throttle signal fluid pressure to a
point where line pressure enters both the converter feed and the
decrease fluid circuits. Decrease fluid pressure moves the pump
slide (216) against spring force and toward the center of the
pump cavity, causing the slide to partially cover the pump intake
port and increase the concentricity between the pump slide and
the rotor which, as a consequence, decreases the pump output
capacity. Decrease pressure and the position of the pump slide
constantly varies depending on driving conditions and the amount
of fluid pressure and volume needed to operate the transmission.

The pressure regulator valve routes line pressure into both the
converter feed and the decrease fluid circuits. Converter feed
fluid is routed through the TCC control valve to the torque
converter apply and release, and the cooler fluid circuits.
Decrease fluid pressure moves the fluid pump slide against the
force of the pump slide spring (219).

Pressure Regulator Related


Diagnostic Tips
A stuck or damaged pressure regulator valve could cause:

High or low line pressure

Slipping clutches or harsh apply

Transmission overheating

Low or no cooler/lube flow

AIR
BLEED
(233)

AIR
BLEED
(233)

30

EX

31

30

EX

31

LINE

PRESSURE
RELIEF
BALL
VALVE
LINE

LINE

FLUID
PUMP
ASSEMBLY

LINE

THROTTLE SIGNAL

THROTTLE SIGNAL
FILTERED FEED LIMIT
EX

EX

FLUID
PUMP
SCREEN
ASSEMBLY
(213)

LINE

FILTERED FEED LIMIT


LINE (To Manual Valve)

PRESSURE
CONTROL
SOLENOID
VALVE

PRESSURE
CONTROL
SOLENOID
VALVE

MINIMUM PUMP OUTPUT

34

SUCTION

REVERSE CLUTCH

BOOST VALVE

FLUID
PUMP
SCREEN
ASSEMBLY
(213)

THROTTLE SIGNAL

SUCTION

REVERSE CLUTCH

THROTTLE SIGNAL

FLUID
PUMP
ASSEMBLY

BOOST VALVE

LINE

EX

PRESS REG VALVE

LINE

LINE

DECREASE

CONVERTER FEED
DECREASE

LINE

PRESSURE
RELIEF
BALL
VALVE

DECREASE

CONVERTER FEED
DECREASE
PRESS REG VALVE

EX

AIR
BLEED
(233)

AIR
BLEED
(233)

LINE

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PRESSURE REGULATION
The main components that control line pressure are the pressure
control solenoid valve and the pressure regulator valve. The
fluid pressure required to apply the clutches varies in relation to
throttle position and engine torque. At the pressure regulator
valve, line pressure is regulated in response to the following:

MAXIMUM PUMP OUTPUT

Figure 35

LINE (To Manual Valve)

HYDRAULIC CONTROL COMPONENTS


Pressure Relief Ball Valve (239)

Regulates line pressure in relation to vehicle operating conditions


(see page 34 on Pressure Regulation). The pressure regulator
valve is biased by throttle signal fluid pressure, pressure regulator
spring (209) force, line pressure routed to the end of the valve,
and reverse clutch fluid pressure acting on the line boost valve
in Reverse. Line pressure is routed through the valve and into
both the converter feed and decrease fluid circuits.
A stuck pressure regulator valve could cause high or low
fluid pressure.
Line Boost Valve (207)

A pressure relief ball not seated or damaged could cause


high or low fluid pressure.
Torque Converter Clutch (TCC) Control Valve (235)

Controlled by the TCC PWM solenoid valve state and TCC


signal fluid pressure, it directs converter feed fluid pressure to
the release side of the converter clutch and into the cooler fluid
circuit. The TCC control valve also directs regulated apply
fluid to the apply side of the converter clutch. The valve is held
in the release position (as shown) by spring force when the TCC
PWM solenoid valve is OFF. With the TCC PWM solenoid
valve ON, TCC signal fluid pressure increases and moves the
valve into the apply position against spring force.
If stuck, missing or binding, the TCC control valve or
spring may cause:
Incorrect TCC apply or release
Inadequate lubrication

AIR
BLEED
(233)

Torque Converter Clutch (TCC)


Enable Valve (237):

DIRECT CLUTCH

EX
DIRECT CLUTCH

PRESSURE
RELIEF
BALL
VALVE

FLUID
PUMP
ASSEMBLY

DECREASE

LINE

CONVERTER
HOUSING
(224)

EX

SUCTION

REVERSE CLUTCH

EX

TCC
ENABLE
VALVE

FLUID PUMP
SCREEN
ASSEMBLY
(213)

LINE

APPLY
TCC SIGNAL
REGULATED APPLY

LINE

CONVERTER FDL
CONVERTER FEED

TCC
CONTROL
VALVE

When the TCC is released, converter feed


fluid passes through the valve and enters
the converter feed limit fluid circuit to
go on stand by at the TCC control valve.
If for any reason the TCC control valve
is stuck ON when the TCC is commanded
OFF, converter feed limit pressure will
enter the release side of the converter
preventing overheating of the TCC.
When the TCC applies, TCC signal fluid
moves the valve against spring force and
allows regulated apply pressure to be
directed to the TCC control valve and
then to the apply side of the TCC.
If stuck, missing or binding, the
TCC enable valve or spring may
cause incorrect TCC apply or
release.

REGULATED APPLY

CONVERTER FEED

RELEASE
TO COOLER

DIRECT CLUTCH

COAST CLUTCH

LINE

FORWARD CLUTCH

CONVERTER FEED
DECREASE
PRESS REG VALVE
BOOST VALVE

The pressure relief ball valve and spring (238) prevent line pressure
from exceeding approximately 2240 to 2520 kPa (320 to 360 psi).
Above this pressure, line fluid pressure moves the ball against
spring force and exhausts until line pressure decreases sufficiently.

30

31

EX

AIR
BLEED
(203)

AIR
BLEED
(203)

LINE

AIR
BLEED
(233)

AIR
BLEED
(203)

COAST CLUTCH

LINE
REVERSE CLUTCH
FORWARD CLUTCH

Throttle signal fluid pressure moves the line boost valve against
the line boost valve spring (208). The line boost valve spring
then transfers the force from throttle signal fluid pressure to the
pressure regulator valve. Therefore, line pressure increases as
throttle position and engine torque increase. Also, reverse clutch
fluid pressure acting on the line boost valve increases the operating
range of line pressure when the transmission is in Reverse.

THROTTLE SIGNAL

(214)

SUCTION

AIR
BLEED
(203)

COAST CLUTCH

FLUID
PUMP
COVER
(202)

FORWARD CL

21

REVERSE CL

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VALVES LOCATED IN THE FLUID PUMP COVER ASSEMBLY


PRESSURE REGULATOR VALVE TRAIN (204-210)
Pressure Regulator Valve (210)

LINE

Brass Orifice Insert (214)

The brass orifice insert is located in the fluid pump cover (202).
It is a restriction, between the line and forward clutch fluid
circuits, that provides a constant feed to the forward clutch in
order to reduce garage shift response time.

Check Valve Retainer and Ball Assemblies (203)

These four assemblies are located in the reverse clutch, forward


clutch, direct clutch and coast clutch fluid circuits. When the
clutch releases the ball unseats and allows air into the circuit to
displace the exhausting fluid.

Orifice Cup Plugs (233)

Orifice cup plugs are located in the fluid pump cover (202).
They allow air to escape from the fluid circuits and prevent
pressure oscillations.

Figure 36

35

HYDRAULIC CONTROL COMPONENTS


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VALVES LOCATED IN THE FRONT CONTROL VALVE BODY

Pressure Control (PC) Solenoid Valve Assembly (357):

Controlled by the TCM, it provides controlled throttle signal fluid


pressure to the line boost valve (207). (See the Electrical
Components Section for additional information.)
A leaking/damaged o-ring or bad electrical connection can
cause high or low line pressure.

Feed Limit Valve (353):

The PC solenoid valve and the shift solenoid valves can not support
more than a given fluid pressure. In order not to overload these
solenoids, the feed limit valve regulates line fluid pressure into
feed limit fluid pressure given by the solenoid design. Force from
the feed limit valve spring (354) and orificed feed limit fluid
pressure acting on the end of the valve regulate line pressure as it
passes through the valve and enters the feed limit circuit. Feed
limit pressures will normally equal line pressure when line pressure
is below the calibrated limiting values.
If stuck in the exhaust position, the feed limit valve or
spring could cause 5th gear only and low line pressure.

3-4 SHIFT VALVE TRAIN (343-346)


3-4 Shift Valve (345):

Responds to 2-3 signal fluid pressure acting on the 3-4 shift control
valve, 1-2 signal fluid pressure and force from the 3-4 shift valve
spring (344). Depending on the transmission gear range operation
and the shift solenoid valve states, the valve directs D432 fluid
into the 123 fluid circuit to apply the coast clutch, or it directs 345
fluid into the direct clutch and the 45 fluid circuits to apply the
direct and overdrive clutches. When in the released position, the
valve opens 123 fluid to an exhaust.
3-4 shift valve stuck in the applied position could cause no 4th
or slips in 4th gear, and no 5th or slips in 5th gear.
3-4 shift valve stuck in the released position could cause no
engine braking in 1st, 2nd and 3rd gear.

3-4 Shift Control Valve (346):

Responds to 2-3 signal fluid pressure and force from the 3-4 shift
valve spring (344). Depending on the transmission gear range
operation and the 2-3 shift solenoid valve state, the valve allows
D432 fluid to be directed into the 123 fluid circuit to apply the
coast clutch. When in the released position, the valve allows 123
clutch fluid to exhaust.
3-4 shift control valve stuck in the applied position could
cause no 4th or slips in 4th gear, and no 5th or slips in 5th gear.

TCC REGULATOR VALVE TRAIN (347-352)


Torque Converter Clutch Pulse Width Modulated (TCC PWM)
Solenoid Valve Assembly (352):

Voltage supply is through the ignition switch while the TCM


provides the ground to energize the solenoid. The solenoid regulates
2345 or reverse fluid into TCC signal fluid pressure (according to
TCC PWM duty cycle) that is routed to the TCC control valve
(235), the TCC enable valve (237), the reverse lockout (RLO)
valve (385), and to the TCC regulator apply valve (348). (See the
Electrical Components Section for additional information.)
Stuck on, exhaust plugged, would cause no TCC release in
2nd, 3rd, 4th or fifth gear, and no reverse.
Stuck off, leaking o-ring, no voltage, would cause no TCC/
slip or soft apply.

Torque Converter Clutch (TCC) Regulator Apply Valve (348):

It is controlled by TCC signal fluid pressure on one side of the


valve and spring force from the TCC regulator apply valve spring
(347) and orificed regulated apply pressure at the other end. When
the TCC PWM solenoid valve assembly is energized and TCC
signal fluid pressure is present, it regulates line fluid pressure into
the regulated apply fluid passage.
Stuck in the release position would cause no TCC/slip or
soft apply.
Stuck in the maximum pressure position would cause harsh
TCC apply.

36

3-4 shift control valve stuck in the released position could


cause no engine braking in 1st gear.

HYDRAULIC CONTROL COMPONENTS


Safety Mode Valve (341):

Responds to memory pilot (1-2 signal) fluid pressure and force


from the safety mode valve spring (342). Under normal
transmission operation, when the first 1-2 shift occurs, the valve is
shifted to the applied position by memory pilot fluid. If there is no
TCM signal to the shift solenoid valves, the transmission will
operate in fifth gear. When the engine is switched off, the valve
shifts to the released position and directs (when the engine is
restarted) line pressure into the line safety mode fluid circuit
allowing the transmission to operate in fourth gear.
If stuck in the applied position, the transmission could be
limited to fifth gear only in Safety Mode.

32
32 SAFETY MODE

MEMORY
MEMORY PILOT

EX

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

MEMORY
FEED LIMIT
LINE

MEMORY PILOT

PRESSURE
CONTROL
SOLENOID
VALVE

EX

EX

SAFETY MODE

LINE SAFETY MODE

1-2 SIGNAL
2-3 SIGNAL

EX

EX

345
45

LINE

REGULATED APPLY
LINE

TCC SIGNAL

TCC PWM
SOLENOID
VALVE
N/C

REGULATED APPLY

EX

TCC REGULATOR VALVE

2345 OR REVERSE

345
45

EX

EX

EX

EX

FEED LIMIT VALVE

123
D432
345
DIRECT CLUTCH

FEED LIMIT
FEED LIMIT

123
D432
345

EX

CNTRL 3-4 SHIFT

EX

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VALVES LOCATED IN THE FRONT CONTROL VALVE BODY

FRONT
CONTROL
VALVE BODY

Figure 37

37

HYDRAULIC CONTROL COMPONENTS


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VALVES LOCATED IN THE REAR CONTROL VALVE BODY

Reverse Lockout (RLO) Valve (385):

1-2 Shift Control Valve (366):

Responds to TCC signal fluid pressure and force from the reverse
lockout valve spring (386). In reverse gear the valve directs
reverse fluid into the reverse lockout (RLO) fluid circuit to apply
the reverse clutch and the low and reverse clutch. When the TCC
PWM solenoid valve provides TCC signal fluid pressure, the RLO
valve is applied to block reverse fluid from entering the reverse
lockout fluid circuit, thereby preventing reverse clutch or low and
reverse clutch apply while the vehicle is moving forward at a
speed greater than a value calibratable in the TCM, even if the
manual valve is in reverse position.

Responds to 1-2 signal fluid pressure, 2-3 signal fluid pressure, and
force from the 1-2 shift control valve spring (367). Depending on
the transmission gear range operation, 1-2 shift solenoid valve and
2-3 shift solenoid valve operating states, the valve directs feed limit
fluid into the FDL fluid circuit in order to apply the 1-2 shift valve.
When released, the valve opens FDL fluid to exhaust.

Reverse lockout valve stuck in the applied position could


cause no reverse gear.
Reverse lockout valve stuck in the released position could
allow the reverse clutch and the low and reverse clutch to
apply, if reverse gear is selected while the vehicle is moving
forward at any speed, causing transmission damage.

1-2 shift control valve stuck in the applied position could


cause 1st gear only.
1-2 shift control valve stuck in the released position could
cause no 1st gear.

1-2 Shift Valve (387):

Responds to FDL fluid pressure and force from the 1-2 shift valve
spring (388). Depending on the transmission gear range operation,
1-2 shift solenoid valve and 2-3 shift solenoid valve operating
states, the valve directs 123 regulated fluid into the low and reverse
clutch fluid circuit in order to provide engine braking. When
released, the valve directs D432 fluid into the 2345 fluid circuit
and the second clutch fluid circuit.

Low Pressure Control Valve (383):

In first, second and third gear coast conditions, when engine braking
is desired, 123 braking fluid pressure is regulated through the
valve into the 123 regulated fluid circuit by orificed 123 regulated
fluid pressure and force from the low pressure control valve spring
(382). Depending on the transmission gear and the shift solenoid
valve operating states, 123 regulated fluid is directed to provide
engine braking through a controlled apply of the low and reverse
clutch, the second coast clutch or the overdrive clutch.
A missing, stuck or incorrectly assembled low pressure
control valve could cause harsh or no engine braking in 1st,
2nd, or third gear.

1-2 shift valve stuck in the applied position could cause no


2nd, 3rd, 4th or 5th gear.
1-2 shift valve stuck in the released position could cause no
1st gear.

2-3 SHIFT VALVE TRAIN (349-351, 369-372)


2-3 Shift Solenoid (SS) Valve Assembly (369):

1-2 SHIFT VALVE TRAIN (343, 349-351, 366-368, 387-388)


1-2 Shift Solenoid (SS) Valve Assembly (368):

The 1-2 SS valve assembly is a normally closed, 3-port, ON/OFF


type solenoid controlled by the TCM. When energized (ON) in
Second and Third Gear, the 1-2 SS valve assembly fluid inlet port
opens allowing feed limit fluid to pressurize the 1-2 signal fluid
circuit. 1-2 signal fluid pressure acts on the 1-2 shift control valve
and the 3-4 shift valve to control the shift valve positioning for the
appropriate gear range. 1-2 signal (memory pilot) fluid pressure
also acts on the safety mode valve to provide safe transmission
operation if there is no TCM signal to the shift solenoid valves.
When de-energized (OFF), the solenoid inlet port is closed and 12 signal fluid is exhausted through the solenoid exhaust port. (See
the Electrical Components Section for more detail.)
1-2 SS valve stuck off or leaking could cause a 1st, 4th and
5th gear only condition.
1-2 SS valve stuck on could cause 2nd and 3rd gears only.

The 2-3 SS valve assembly is a normally closed, 3-port, ON/OFF


type solenoid controlled by the TCM. When energized (ON) in
First and Second Gear, the 2-3 SS valve assembly fluid inlet port
opens allowing feed limit fluid to pressurize the 2-3 signal fluid
circuit. 2-3 signal fluid pressure acts on the 2-3 shift control
valve, the 1-2 shift control valve, and the 3-4 shift control valve to
control the shift valve positioning for the appropriate gear range.
When de-energized (OFF), the solenoid inlet port is closed and 23 signal fluid is exhausted through the solenoid exhaust port. (See
the Electrical Components Section for more detail.)
2-3 SS valve stuck off or leaking could cause no 1st or
2nd gear.
2-3 SS valve stuck on could cause 1st and 2nd gears only.

2-3 Shift Control Valve (370) and 2-3 Shift Valve (371):

The 2-3 shift valve train responds to 2-3 signal fluid pressure and
force from the 2-3 shift valve spring (372). Depending on the
transmission gear range operation and the 2-3 shift solenoid valve
state, the valve train controls the routing and exhausting of various
fluids to obtain the appropriate gear range as determined by the
TCM or gear selector lever.
2-3 shift valve stuck in the applied position could cause 1st
or 2nd gear only.
2-3 shift valve stuck in the released position could cause no
3rd, 4th or 5th gears.

38

HYDRAULIC CONTROL COMPONENTS


4-5 SHIFT VALVE TRAIN (349-351, 373-376)

4-5 shift valve stuck in the applied position could cause no


5th gear.

4-5 Shift Solenoid (SS) Valve Assembly (376):

The 4-5 SS valve assembly is a normally closed, 3-port, ON/OFF


type solenoid controlled by the TCM. When energized (ON) in
Fourth Gear, the 4-5 SS valve assembly fluid inlet port opens
allowing feed limit fluid to pressurize the 4-5 signal fluid circuit.
4-5 signal fluid pressure acts on the 4-5 shift control valve to help
control the 4-5 shift valve positioning for the appropriate gear
range. When de-energized (OFF), the solenoid inlet port is closed
and 4-5 signal fluid is exhausted through the solenoid exhaust
port. (See the Electrical Components Section for more detail.)

4-5 shift valve stuck in the released position could cause no


4th gear and no engine braking in 1st, 2nd or 3rd gears.

Manual Valve (377):

The manual valve is fed by line pressure from the fluid pump assembly
and is mechanically linked to the gear selector lever. When a gear
range is selected, the manual valve directs line pressure into the
various circuits by opening and closing feed passages. The circuits
that are fed by the manual valve are: Reverse, D432, and 32.

4-5 SS valve stuck off or leaking could cause no 4th gear


and no engine braking in 1st, 2nd or 3rd gears.
4-5 SS valve stuck on could cause no 5th gear.

FDL
FEED LIMIT

FDL

EX

SECOND CL
D432

D432
SECOND CL
23 REG
123 REG
123 REG
LOW AND REV CL

The 4-5 shift valve train responds to 4-5 signal fluid pressure and
force from the 4-5 shift valve spring (373). Depending on the
transmission gear range operation and the 4-5 shift solenoid valve
state, the valve train controls the routing and exhausting of various
fluids to obtain the appropriate gear range as determined by the
TCM or gear selector lever.

Stuck, misaligned or damaged, the manual valve and linkage


could cause:
No Park
No reverse or slips in reverse
Drives in Neutral
No Drive
No gear selections
Shift indicator indicates wrong gear selection

2-3 SIGNAL

4-5 Shift Control Valve (375) and 4-5 Shift Valve (374):

1-2 SIGNAL
FD LIMIT
1-2 SHIFT
SOLENOID
VALVE
N/C

2345

(A)

EX

1-2 SHIFT CONTROL VALVE

EX

EX

EX

1-2 SHIFT VALVE

2345
INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH
23 REGULATED

TCC SIGNAL

2-3 SIGNAL
FEED LIMIT

RLO

REV

EX
4-5 SHIFT
SOLENOID
VALVE
N/C

(C)

EX

EX

COAST CLUTCH
123
123

45

EX

4-5 SHIFT VLV CNTRL

REVERSE

EX

(B)

EX
SECOND COAST CLUTCH
OVERDRIVE CLUTCH FEED 1
2345
2345
23 REGULATED
4-5 SIGNAL

LOW PRESSURE

123 REGULATED
123 BRAKING
345

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

EX

EX

2345

REVERSE
LOCKOUT
VALVE

345
2345

EX

EX

2-3 SHIFT VALVE

123 REGULATED

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
123
123

COAST CLUTCH FEED


OVERDRIVE CLUTCH FEED 2
45

MANUAL VALVE

R N D 4 3 2

Figure 38

32

D432

LINE

REV

EX

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VALVES LOCATED IN THE REAR CONTROL VALVE BODY

REAR
CONTROL
VALVE BODY

39

HYDRAULIC CONTROL COMPONENTS


In the Hydra-matic 4/5L40-E, accumulators are used to control
shift feel for the apply of the second clutch (2nd), the intermediate
clutch (3rd), the direct clutch (4th), and the overdrive clutch (5th).
All four of these accumulators function identically.

CLUTCH
ACCUMULATOR

An accumulator is a fluid pressure operated component that


absorbs a certain amount of clutch apply fluid pressure to cushion
the clutch engagement.

EX
LINE

WWW.ALL-TRANS.BY

ACCUMULATORS

Clutch apply fluid pressure, directed to an accumulator piston


and helped by a spring force, opposes an accumulator fluid
pressure to create an action similar to a shock absorber.

ACCUMULATOR

Upshift Control:

CLUTCH APPLY

UPSHIFT CONTROL
CLUTCH APPLIED
ACCUMULATOR ABSORBS
EXCESS APPLY PRESSURE

CLUTCH
ACCUMULATOR
LINE

EX

During the clutch apply, clutch apply fluid pressure moves the
clutch piston against the clutch piston spring and clutch plates.
After the clearance between the clutch plates is taken up by the
clutch piston travel and the clutch plates begin to hold, fluid
pressure in the circuit builds up rapidly. This clutch apply fluid
pressure is also directed to an accumulator assembly. As clutch
apply fluid pressure increases, the accumulator piston moves to an
intermediate position determined by the equilibrium between
accumulator fluid pressure and clutch apply fluid pressure, assisted
by the accumulator spring force. The movement of the accumulator
piston delays the pressure buildup in the circuit and allows for a
more gradual clutch apply. Without an accumulator in the circuit,
this rapid buildup of clutch apply fluid pressure would cause the
clutch to grab very quickly and create a harsh shift.
The force of the accumulator fluid pressure controls the rate at
which the clutch is applied. Because accumulator fluid pressure
is supplied by line fluid pressure, it is affected by engine throttle
position. At minimum or light throttle, engine torque is at a
minimum and the clutch requires less apply force. At heavy
throttle, the engine develops a large amount of torque which
requires a greater apply pressure to hold the clutch. To
accommodate these various conditions, the pressure regulator
valve (210) regulates line fluid pressure, and therefore accumulator
fluid pressure, in order to control shift feel in the transmission. At
greater throttle positions, accumulator fluid pressure increases,
thereby creating less cushion for the clutch apply fluid during an
upshift. Remember that throttle signal fluid acting on the pressure
regulator valve (210) is regulated according to engine torque by
the pressure control (PC) solenoid valve (357).

ACCUMULATOR

Downshift Control:

During a downshift, the clutch apply fluid pressure is exhausted


from the accumulator assembly by the shift valve. Accumulator
fluid pressure, supplied by orificed line fluid pressure from the
fluid pump, fills the accumulator with fluid and returns the
piston to its initial position in preparation for another upshift.
Orificing line fluid pressure helps control the rate at which
accumulator fluid pressure fills the accumulator and the rate at
which clutch apply fluid exhausts. If clutch apply fluid exhausts
too quickly, pressure could build up in the clutch apply circuit.
This would cause the clutch to release too slowly and possibly
drag and damage the clutch.

CLUTCH APPLY

DOWNSHIFT CONTROL
CLUTCH RELEASED
ACCUMULATOR
READY FOR UPSHIFT

40

Figure 39

HYDRAULIC CONTROL COMPONENTS


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DIRECT CLUTCH ACCUMULATOR ASSEMBLY:

The direct clutch accumulator assembly is located in an


accumulator housing bolted to the front control valve body and
consists of the direct clutch accumulator piston (315) and the
direct clutch accumulator piston spring (313). The direct clutch
accumulator assembly is the primary component for controlling
the shift feel of a 3-4 shift.

DIRECT
CLUTCH
ACCUMULATOR
ASSEMBLY
318

OVERDRIVE
CLUTCH
ACCUMULATOR
ASSEMBLY

318

317

323

A leak at the accumulator piston seal or porosity in the


accumulator housing could cause slipping during a 3-4 shift.
322

A stuck accumulator piston would cause harsh 3-4 shifts.


316

321

315

320

OVERDRIVE CLUTCH ACCUMULATOR ASSEMBLY:

The overdrive clutch accumulator assembly is located in an


accumulator housing bolted to the front control valve body and
consists of the overdrive clutch accumulator piston (321) and
the overdrive clutch accumulator piston spring (319). The
overdrive clutch accumulator assembly is the primary component
for controlling the shift feel of a 4-5 shift.

314
319
313

A leak at the accumulator piston seal or porosity in the


accumulator housing could cause slipping during a 4-5 shift.

311

A stuck accumulator piston would cause harsh 4-5 shifts.


FRONT
CONTROL
VALVE
BODY

INTERMEDIATE CLUTCH ACCUMULATOR ASSEMBLY:

The intermediate clutch accumulator assembly is located in an


accumulator housing bolted to the rear control valve body and
consists of the intermediate clutch accumulator piston (326) and
the intermediate clutch accumulator piston spring (324). The
intermediate clutch accumulator assembly is the primary
component for controlling the shift feel of a 2-3 shift.

INTERMEDIATE
CLUTCH
ACCUMULATOR
ASSEMBLY

318

SECOND
CLUTCH
ACCUMULATOR
ASSEMBLY

318
328

333

A leak at the accumulator piston seal or porosity in the


accumulator housing could cause slipping during a 2-3 shift.
332

A stuck accumulator piston would cause harsh 2-3 shifts.

331
327
326
330

SECOND CLUTCH ACCUMULATOR ASSEMBLY

*: in an
The second clutch accumulator assembly is located
accumulator housing bolted to the rear control valve body and
consists of the second clutch accumulator piston (331) and the
second clutch accumulator piston spring (329). The second
clutch accumulator assembly is the primary component for
controlling the shift feel of a 1-2 shift.

325

329

324
310

A leak at the accumulator piston seal or porosity in the


accumulator housing could cause slipping during a 1-2 shift.
A stuck accumulator piston would cause harsh 1-2 shifts.

Note: The second clutch accumulator assembly is used for


the 5L40-E only.

REAR
CONTROL
VALVE
BODY

Figure 40

41

HYDRAULIC CONTROL COMPONENTS


WWW.ALL-TRANS.BY

BALL CHECK VALVES LOCATION AND FUNCTION


#1 REVERSE CLUTCH:

#8 LOW AND REVERSE CLUTCH OR RLO:

Located in the bottom channel plate, it seats to force reverse


lockout fluid through orifice 13 on the spacer plate and into the
reverse clutch fluid circuit. This helps control the apply rate of
the reverse clutch. When the reverse clutch releases, exhausting
reverse clutch fluid unseats, and flows past, the #1 ball check
valve and into the reverse lockout fluid circuit. This allows for
a faster exhaust of reverse clutch fluid and a quick release of the
reverse clutch.

Located in the bottom channel plate, it allows either low and


reverse clutch fluid (in a First gear coast condition) or reverse
lockout (RLO) fluid (in Reverse) to enter the low and reverse
clutch or RLO fluid circuit while blocking the other fluid circuit.
Low and reverse clutch or RLO fluid is used to apply the low
and reverse clutch.

#9 23 REGULATED/OVERDRIVE CLUTCH FEED 1:


#2 REVERSE/2345:

Located in the bottom channel plate, it allows either reverse


fluid (in Reverse) or 2345 fluid (in Second, Third, Fourth and
Fifth) to enter the 2345 or reverse fluid circuit while blocking
the other fluid circuit.

#3 45:

Located in the bottom channel plate, it seats to force 45 fluid


through orifice 27 to help control the apply rate of the overdrive
clutch. When the clutch releases, exhausting 45 fluid unseats,
and flows past, the #3 ball check valve. This allows for a
faster exhaust of 45 fluid and a quick release of the overdrive
clutch assembly.

Located in the bottom channel plate, it seats to force 23 regulated


fluid through orifice 22 before entering the overdrive clutch
feed 1 circuit. This helps control the apply rate of the overdrive
clutch in a Third gear coast condition. When the overdrive
clutch releases, exhausting 23 regulated fluid unseats, and flows
past, the #9 ball check valve. This allows for a faster exhaust of
23 regulated fluid and a quick release of the overdrive clutch.

#10 32 SAFETY MODE/FDL:

Located in the bottom channel plate, it allows either 32 safety


mode fluid (in Safety Mode operation only) or FDL fluid (in
First gear) to enter the 32 safety mode or FDL fluid circuit while
blocking the other fluid circuit.

#11 23 REGULATED/SECOND COAST CLUTCH


(Used Only On 5L40-E Models):
#4 123:

Located in the bottom channel plate, it seats to force 123 fluid


through orifice 16 to help control the apply rate of the coast
clutch. When the coast clutch releases, exhausting 123 fluid
unseats, and flows past, the #4 ball check valve. This allows
for a faster exhaust of 123 fluid and a quick release of the
coast clutch.

#5 COAST CLUTCH:

Located in the bottom channel plate, it seats to force forward


clutch fluid through orifice 17 before entering the coast clutch
feed circuit. This helps control the apply rate of the coast
clutch. When the coast clutch releases, exhausting coast clutch
feed fluid unseats, and flows past, the #5 ball check valve. This
allows for a faster exhaust of coast clutch feed fluid and a quick
release of the coast clutch.

Located in the bottom channel plate, it seats to force 23 regulated


fluid through orifice 23 before entering the second coast clutch
circuit. This helps control the apply rate of the second coast
clutch in a Second gear coast condition. When the second
coast clutch releases, exhausting 23 regulated fluid unseats,
and flows past, the #11 ball check valve. This allows for a
faster exhaust of 23 regulated fluid and a quick release of the
second coast clutch.

#12 OVERDRIVE CLUTCH FEED:

Located in the bottom channel plate, it allows either overdrive


clutch feed 1 fluid (in a Third gear coast condition) or overdrive
clutch feed 2 fluid (in Fifth gear) to enter the overdrive clutch
fluid circuit while blocking the other fluid circuit. Overdrive
clutch fluid is used to apply the overdrive clutch.

Ball Check Valves Related Diagnostic Tips


#6 D432/FORWARD CLUTCH:

Located in the bottom channel plate, it seats to force D432 fluid


through orifice 15 before entering the forward clutch circuit.
This helps control the apply rate of the forward clutch. When
the forward clutch releases, exhausting D432 feed fluid unseats,
and flows past, the #6 ball check valve. This allows for a faster
exhaust of D432 fluid and a quick release of the forward clutch.

Understanding the design principle of each


ball check valve will help in the diagnosis of
hydraulic related conditions. For example:
A harsh shift complaint could be caused by a stuck or
missing ball check valve.
Slow reverse or disengagement could be caused by a
stuck #1 ball check valve.

#7 FORWARD CLUTCH/COAST CLUTCH:

Located in the bottom channel plate, it is seated by a calibrated


spring and provides extra D432 fluid flow into the forward clutch
and coast clutch circuits to reduce garage shift response time.

42

No engine compression braking in manual first could


be caused by a missing or stuck #8 ball check valve.

11

23

48

13

19

23
36

15

36

40

41

23

48
19

#2

X-4

36

#11

REVERSE
2345
22g

20

37

33d

23

23 REGULATED

27

43

23 REGULATED

10

#12

33e

16

15d

#1
24

27

42

16

48

37

48

47

48
37

14a

10

16

15

2
12
28

15c

REVERSE CLUTCH

48

39c

23

13

48
48

41

X-2

FRONT

40c

#1

REVERSE LOCKOUT

BALL CHECK VALVES LOCATION AND FUNCTION

OVERDRIVE CL FEED 2
OVERDRIVE CL FEED 1

#12

38

X-3

2345 OR REVERSE

19

19

15

35

#2
39

30

25

25

22
22

28

#11

2
17

27

#6
48

23 REGULATED

44

#10

19

18
43

23 REGULATED

21

15

34

10

X-5

27

#5

52

44
2

#3

38d

35

#4

45
2

#7
(Spring)

48
10 42

13

28

123

48
10

#9

#4

#8

20d

#10

20

19

38

17
45

38

33

20c

43c

32
26

30

45
X-5
38e

44f
45

#3
38

38b

45

23

36

22 19

38c

FDL

40

45

X-1

32 SAFETY MODE

16

BOTTOM CHANNEL PLATE (304)


(Control Valve Body Side)

33c
33b

D432

#8

21

15f

D432

Figure 41

31

#5

21c

31
21b

17

FORWARD CLUTCH

FORWARD CLUTCH
D432

#6

19c

15

21

FORWARD CLUTCH
21

19b

#7

18

REVERSE LOCKOUT

123

COAST CLUTCH FEED

19d

17c

19a

LOW AND REV CL OR RLO

123

#9

LOW AND REVERSE CL

WWW.ALL-TRANS.BY

OVERDRIVE CLUTCH

HYDRAULIC CONTROL COMPONENTS

FORWARD CLUTCH

43

HYDRAULIC CONTROL
NOTES COMPONENTS
WWW.ALL-TRANS.BY

44

ELECTRICAL COMPONENTS
WWW.ALL-TRANS.BY

Safety Mode operating state of the solenoids forces


the transmission to operate in Fifth gear regardless of
other vehicle operating conditions when the gear selector
is in a forward drive range. Also, in Safety Mode the
PC solenoid valve is turned off which increases line
pressure to a maximum and the TCC PWM solenoid
valve cannot apply the TCC. This allows the vehicle to
be operated safely, despite the disabled electronic
controls, until the condition can be corrected.

The Hydra-matic 4/5L40-E transmission incorporates


electronic controls that utilize the transmission control
module (TCM) (see Note below) to control shift points
(through shift solenoid valves), torque converter clutch
(TCC) apply and release [through the torque converter
clutch pulse width modulated (TCC PWM) solenoid] and
line pressure [through the pressure control (PC) solenoid
valve]. Electrical signals from various sensors provide
information to the TCM about vehicle speed, throttle
position, engine coolant temperature, transmission fluid
temperature, gear range selector position, engine speed,
converter turbine speed, engine load braking and operating
mode. The TCM uses this information to determine the
precise moment to upshift or downshift, apply or release
the TCC and what fluid pressure is needed to apply the
clutches. This type of control provides consistent and
precise shift points and shift quality based on the operating
conditions of the vehicle.

Another feature of the Hydra-matic 4/5L40-E is the


electronic control of engine braking. In Overdrive Range,
Manual Fourth, Manual Third, and Manual Second, engine
braking in first, second and third gear can be obtained if
desired by activation of the 4-5 shift solenoid valve.
Note: Some models utilize a Powertrain Control Module
(PCM) instead of a TCM. The PCM functions similar
to the TCM but does incorporate some different controls.
However, throughout this publication only the TCM is
referenced for simplicity. Refer to the appropriate
General Motors Service Manual for a description of
PCM controls.

If for any reason the entire electronic control system of


the transmission becomes disabled, all three of the shift
solenoid valves will be de-energized (turned OFF). This
A

ECM

SERIAL DATA

DLC

INPUTS
INFORMATION SENSORS
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.

THROTTLE POSITION (TP) SENSOR


MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
ENGINE SPEED SENSOR
MANIFOLD AIR TEMPERATURE (MAT) SENSOR
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
TRANSMISSION INPUT SPEED SENSOR (A/T ISS)
TRANSMISSION OUTPUT SPEED SENSOR (A/T OSS)
TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR
TRANSMISSION MANUAL SHIFT
SHAFT SWITCH ASSEMBLY
ACCELERATOR PEDAL POSITION (APP) SENSOR
TCC BRAKE SWITCH
DRIVER SHIFT CONTROL (DSC) SWITCHES
OPERATING MODE SELECTION SWITCHES

TCM

CAN BUS

BCM

OUTPUTS
ELECTRONIC CONTROLLERS


TRANSMISSION CONTROL
MODULE (TCM) OR
POWERTRAIN CONTROL
MODULE (PCM) (SEE NOTE ABOVE)

ENGINE CONTROL MODULE (ECM)

BODY CONTROL MODULE (BCM)

ELECTRONIC BRAKE AND TRACTION


CONTROL MODULE (EBTCM)
(NOT SHOWN)

DIAGNOSTIC LINK CONNECTOR


(DLC)

Figure 42

ELECTRONICALLY CONTROLLED
TRANSMISSION COMPONENTS
1. PRESSURE CONTROL (PC)
SOLENOID VALVE
2. TORQUE CONVERTER CLUTCH
PULSE WIDTH MODULATION
(TCC PWM) SOLENOID
3. 1-2 SHIFT SOLENOID (SS) VALVE
4. 2-3 SHIFT SOLENOID (SS) VALVE
5. 4-5 SHIFT SOLENOID (SS) VALVE

45

ELECTRICAL COMPONENTS
WWW.ALL-TRANS.BY

TRANSMISSION MANUAL SHIFT SHAFT


SWITCH ASSEMBLY (602):

The transmission manual shift shaft switch assembly (602) is a


sliding contact switch attached to the manual shift shaft inside
the transmission case. The five inputs to the TCM from the
transmission manual shift shaft switch assembly indicate which
position is selected by the transmission selector lever. This
information is used for engine controls as well as determining
the transmission shift patterns. The state of each input is available
for display on the scan tool. The five input parameters
represented are Mode A, Mode B, Mode C, Mode P (Parity) and
Mode N (P/N Start).

N
P
B
A
C

TRANSMISSION MANUAL SHIFT


SHAFT SWITCH ASSEMBLY
(602)

C
A
B
P

If the TCM detects an improper signal from the transmission


manual shift shaft switch assembly, a DTC will be activated.
The DTC strategy may be different depending on the
customer/application (refer to the appropriate Service
Information).

N
P
2
R

RANGE
INDICATOR

CIRCUIT
A

P/N

Park

Reverse

Neutral

Overdrive

Manual Fourth

Manual Third

Manual Second

1 = Closed (Resistance <50 ohms)


0 = Open (Resistance >50k ohms)

46

Figure 43

ELECTRICAL COMPONENTS
WWW.ALL-TRANS.BY

TRANSMISSION SPEED SENSORS


Automatic Transmission Output (Shaft) Speed
(A/T OSS) Sensor (42):

The A/T OSS sensor is a variable reluctance magnetic pickup


located in the rear of the transmission case. This sensor is
mounted in the case opposite the rear internal gear (560). The
rear internal gear is splined to the output shaft assembly (562).
The sensor consists of a permanent magnet surrounded by a coil
of wire. As the output shaft and rear internal gear rotate, an
alternating current (AC) is induced in the coil by the teeth on
the rear internal gear as they pass by the magnetic pickup.
Therefore, whenever the vehicle is moving, the A/T OSS sensor
produces an AC voltage signal proportional to vehicle speed.

MAGNETIC
PICKUP
REAR
INTERNAL
GEAR
(560)

At the TCM, the AC signal is electronically conditioned to a 5


volt square wave form (see Figure A). The square wave form
can then be interpreted as transmission output speed by the
TCM through the frequency of square waves in a given time
frame. The square waves can be thought of as a representation
of the rear internal gear teeth. Therefore, the more teeth (or
waves) that pass by the magnetic pickup in a given time frame,
the faster the vehicle is moving. The square wave form is
compared to a fixed clock signal within the TCM to determine
transmission output speed.

ELECTRICAL
CONNECTOR
OUTPUT SPEED SENSOR

LOW SPEED

HIGH SPEED

OUTPUT VOLTS

5.0

If the TCM detects an improper signal from the transmission


input or output speed sensors, a DTC will be activated.

TIME

The DTC strategy may be different depending on the


customer/application (refer to the appropriate Service
Information).

FIGURE A: CONDITIONED SIGNAL

Sensor resistance should measure between 325 and 485


ohms at 20C (68F). Output voltage will vary from a
minimum of 0.5 V peak to peak at 100 RPM, to 600 V
peak to peak at 8500 RPM.
Automatic Transmission Input (Shaft) Speed
(A/T ISS) Sensor (44):

MAGNETIC
PICKUP

REVERSE
CLUTCH
INPUT
HOUSING
ASSEMBLY
(401)

The A/T ISS sensor operates identically to the A/T OSS sensor
except that it uses the stamped teeth on the reverse clutch input
housing assembly (401) as the rotor (reluctor). Remember that
the reverse clutch input housing assembly is driven at converter
turbine speed. The A/T ISS sensor square wave form is also
compared to a fixed clock signal within the TCM to determine
actual converter turbine speed. The TCM uses transmission
input and output speeds to help determine line pressure,
transmission shift patterns, TCC apply pressure, gear ratios, and
TCC slippage for diagnostic purposes.

ELECTRICAL
CONNECTOR
INPUT SPEED SENSOR

Figure 44

47

ELECTRICAL COMPONENTS
WWW.ALL-TRANS.BY

Automatic Transmission Fluid Temperature (TFT) Sensor:

WIRE

The TFT sensor is part of the transmission wiring harness


assembly (55). The TFT sensor is a resistor, or thermistor,
which changes value based on temperature (see chart). The
sensor has a negative-temperature coefficient. This means that
as the temperature increases, the resistance decreases, and as the
temperature decreases the resistance increases. The TCM
supplies a 5-volt reference signal to the sensor and measures the
voltage drop in the circuit. When the transmission fluid is cold
the sensor resistance is high and the TCM detects high signal
voltage. As the fluid temperature warms to a normal operating
temperature, the resistance becomes less and the signal voltage
decreases. The TCM uses this information to maintain shift
quality and torque converter clutch apply quality over operating
temperature range.

WIRE

If transmission fluid temperatures become excessively high


[above approximately 140C (284F) (calibratable in the TCM)],
the TCM will disable ECCC function and command lock up
mode. Applying the TCC serves to reduce transmission fluid
temperatures created by the fluid coupling in the torque converter
with the TCC released.
RESISTOR
(THERMISTOR)

Above approximately 149C (300F) (calibratable in the TCM),


the TCM will set a transmission fluid temperature code. This
causes the TCM to use a fixed value of 135C (275F)
(calibratable in the TCM) as the transmission fluid temperature
input signal.

If the TCM detects an improper signal from the transmission


fluid temperature sensor, a DTC will be activated.
The DTC strategy may be different depending on the
customer/application (refer to the appropriate Service
Information).

TRANSMISSION FLUID TEMPERATURE SENSOR

Temperature

Resistance

R% (+/-)

+/-C

-40
-30
-20

100000
51400
27610

10.5
9.69
9.02

1.51
1.52
1.49

-10
0
10
20
30
40

15450
8972
5391
3342
2132
1397

8.35
7.74
7.16
6.64
6.19
5.73

1.49
1.43
1.42
1.42
1.41
1.39

50
60
70
80
90
100

938
645
453
324
237
176

5.32
4.92
4.55
4.19
3.89
3.59

1.38
1.35
1.30
1.27
1.25
1.22

110
120
130
140
150

132
101
79
62
49

3.25
2.96
2.66
2.58
2.83

1.16
1.13
1.07
1.09
1.26

TFT SENSOR RESISTANCE (OHMS)

16,000

133
-10

110
TEMPERATURE ( C)

TFT SENSOR RESISTANCE VS. TEMPERATURE

48

Figure 45

ELECTRICAL COMPONENTS

FEED
LIMIT
FLUID
SOLENOID
SIGNAL
FLUID

PLUNGER

When the 2-3 SS valve is de-energized (OFF), feed limit fluid is


blocked from feeding the 2-3 signal fluid circuit, and any existing
2-3 signal fluid pressure exhausts through the solenoid.
4-5 Shift Solenoid (SS) Valve (376):

The 4-5 SS valve functions similar to the 1-2 SS valve and the
2-3 SS valve in that the TCM controls the path to ground for the
electrical circuit to turn the solenoid ON or OFF. Feed limit
fluid feeds the 4-5 signal fluid circuit at the 4-5 shift control
valve (375). When the 4-5 SS valve is energized (ON), feed
limit fluid is allowed to pass through the solenoid, thereby
creating 4-5 signal fluid pressure (see Second Gear Coast example
below). 4-5 signal fluid pressure acts on the 4-5 shift control
valve (375) and the 4-5 shift valve (374) (against spring force)
to move it into the upshifted position.
When the 4-5 SS valve is de-energized (OFF), feed limit fluid is
blocked from feeding the 4-5 signal fluid circuit, and any existing
4-5 signal fluid exhausts through the solenoid.
2-3 SIGNAL

FDL

FDL

FEED LIMIT
EX

FD LIMIT
9

1-2 SHIFT
SOLENOID
VALVE
N/C

1-2 SIGNAL

When the 1-2 SS valve is de-energized (OFF), feed limit fluid is


blocked from feeding the 1-2 signal fluid circuit, and any existing
1-2 signal fluid pressure exhausts through the solenoid.

(A)

ON

EX

EX

EX

1-2 SHIFT VALVE


1-2 SHIFT CONTROL VALVE

1-2 SIGNAL
2-3 SIGNAL
INTERMEDIATE CLUTCH

23 REG

INTERMEDIATE CL

OVERDRIVE CL FD 1

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

(B)

EX

EX

2-3 SHIFT VALVE

10

FEED LIMIT

ON

EX

1-2 Shift Solenoid (SS) Valve (368):

Feed limit fluid feeds the 1-2 signal fluid circuit at the 1-2 shift
control valve (366). When the 1-2 SS valve is energized (ON),
feed limit fluid is allowed to pass through the solenoid, thereby
creating 1-2 signal fluid pressure (see Second Gear Coast example
below). 1-2 signal fluid pressure acts together with spring force
on the 1-2 shift control valve (366) to keep it in the downshifted
position when 2-3 signal fluid pressure is present. 1-2 signal
fluid pressure also acts on the 3-4 shift valve (345) and the
safety mode valve (341).

METERING
BALL

2345

Shift solenoid valve resistance should measure between 15


and 17 ohms when measured at 20C (68F). The resistance
should measure approximately 24 ohms at 150 C (302F).

2-3 signal fluid pressure also acts on the 1-2 shift control valve
(366) and the 3-4 shift control valve (346).

EX

The shift solenoid valves are de-energized (turned OFF) when


the TCM opens the path to ground for the solenoids electrical
circuit. With the solenoid OFF, solenoid spring force moves the
metering ball and plunger away from the exhaust seat. This
blocks feed limit fluid from entering the signal fluid circuit and
allows any existing signal fluid pressure to flow past the metering
ball and exhaust out of the solenoid as shown in the illustration.

O-RING

1-2, 2-3 OR 4-5 SHIFT SOLENOID VALVE

345
2345

When the TCM provides a path to ground for the electrical


circuit to energize (turn ON) the solenoid, current flows through
the coil assembly in the solenoid and creates a magnetic field.
The magnetic field moves the plunger to the left (with respect to
the illustration) and feed limit fluid seats the metering ball against
the exhaust seat, thereby blocking the exhaust passage and
creating signal fluid pressure.

FLUID
SCREEN

CONNECTOR

2345
D432
SECOND CL
23 REG
123 REG
123 REG
LOW AND REV CL

ON/OFF

SPRING

SECOND CL
D432

OFF
ON
OFF
ON
OFF
ON
ON
OFF

EX

ON
ON
ON
ON
OFF
OFF
OFF
OFF

1-2 SIGNAL

OFF
OFF
ON
ON
ON
ON
OFF
OFF

COIL
ASSEMBLY

2-3 SIGNAL

NO
YES
NO
YES
NO
YES
YES
YES

YES

4-5 SS
VALVE

Neutral
Reverse
Park

1
1
2
2
3
3
4
5

2-3 SS
VALVE

ARMATURE

D432

GEAR

ENGINE 1-2 SS
BRAKING VALVE

EXHAUST
SEAT
EXHAUST
O-RING

RANGE

DIAPHRAGM

HOUSING

The Hydra-matic 4/5L40-E uses three electromagnetic shift


solenoid valves (1-2, 2-3 and 4-5) to control upshifts and
downshifts in all forward gear ranges. The shift solenoid valves
are all identical, normally closed, 3-port, ON/OFF type solenoids
controlled by the TCM. These shift solenoid valves work together
in a combination of ON and OFF sequences to control the
various shift valves. The TCM uses numerous inputs (as shown
in Figure 42) to determine which solenoid state combination the
transmission should be in. The following table shows the
solenoid state combination required for each gear range:

EX
SECOND COAST CLUTCH
23 REGULATED

Figure 46

EX

COAST CL FD

EX

COAST CL
123
123

45

OVERDRIVE CL FD 2

4-5 SHIFT
SOLENOID
VALVE
N/C

(C)

EX

EX

345
45

4-5 SIGNAL

4-5 SHIFT VLV CNTRL


EX

The 2-3 SS valve functions similar to the 1-2 SS valve in that the
TCM controls the path to ground for the electrical circuit to turn
the solenoid ON or OFF. Feed limit fluid feeds the 2-3 signal
fluid circuit at the 2-3 shift control valve (370). When the 2-3
SS valve is energized (ON), feed limit fluid is allowed to pass
through the solenoid, thereby creating 2-3 signal fluid pressure
(see Second Gear Coast example below). 2-3 signal fluid pressure
acts on the 2-3 shift control valve (370) and the 2-3 shift valve
(371) (against spring force) to move it into the upshifted position.

EX

CNTRL 3-4 SHIFT

2-3 Shift Solenoid (SS) Valve (369):

123
D432
345
DIRECT CL

WWW.ALL-TRANS.BY

SHIFT SOLENOID VALVES

FEED LIMIT
LINE SAFETY MODE
123 BRAKING

ON
11

FEED LIMIT

SECOND GEAR COAST

49

ELECTRICAL COMPONENTS
DIAPHRAGM

EXHAUST

INTERNAL
O-RING

O-RING

INLET
COIL
ASSEMBLY SEAT
STAINLESS STEEL
SHIM

ARMATURE

Torque Converter Clutch Pulse Width Modulation (TCC PWM)


Solenoid Valve (352):

EXHAUST
SEAT

The TCC PWM solenoid valve is a normally closed, pulse


width modulated (PWM) solenoid used to control the apply and
release of the converter clutch. The TCM operates the solenoid
with a negative duty cycle, at a fixed frequency of 32 Hz, to
control the rate of TCC apply/release. The solenoids ability to
ramp the TCC apply and release pressures results in a smoother
TCC operation.

WWW.ALL-TRANS.BY

HOUSING

2345 OR
REVERSE
FLUID

TCC
SIGNAL
FLUID

METERING
BALL

CONNECTOR

When vehicle operating conditions are appropriate to apply the


TCC, the TCM increases the duty cycle to allow the TCC PWM
solenoid valve to command TCC signal fluid pressure at a level
sufficient to move the TCC enable valve and the TCC control
valve to the apply position. Release pressure is directed to
exhaust, and regulated apply fluid is directed to the apply side of
the converter pressure plate/damper assembly. The TCM then
increases the duty cycle to control a slippage of 2080 RPM
between the pressure plate/damper assembly and the converter
cover. This provides for improved filtration of engine vibrations
and allows the TCC to apply at low engine speeds in 2nd, 3rd,
4th and 5th gear. At high speed, lock up mode is set by activating
the TCC PWM solenoid valve at maximum duty cycle.
Release of the TCC is achieved by decreasing the duty cycle to
a level low enough to allow spring force to move the TCC
enable valve and the TCC control valve to the release position.
Apply fluid is directed to exhaust and converter feed fluid is
directed into the release circuit to the release side of the pressure
plate/damper assembly.

TCC PWM SOLENOID VALVE

There are also some operating conditions that may prevent or


enable TCC apply under various conditions (engine temperature,
transmission temperature, brake switch activation) depending
on vehicle application.
If the TCM detects that the TCC system is stuck ON or
stuck OFF, a DTC will be activated.

TCC PWM solenoid valve resistance should measure


between 10.0 and 11.5 ohms when measured at 20C
(68F). The resistance should measure approximately 16
ohms at 150C (300F).

The DTC strategy may be different depending on the


customer/application (refer to the appropriate Service
Information).

Torque Converter Clutch Pulse Width Modulation (TCC PWM)


Solenoid Valve Operation:

50

APPLY

EX

Figure 47

REGULATED APPLY

EX

REGULATED APPLY

REGULATED APPLY

2345 OR REVERSE

REGULATED APPLY

EX

APPLY

TCC SIGNAL

CONVERTER FDL
CONVERTER FEED

EX

TCC PWM
SOLENOID
VALVE
N/C

TCC SIGNAL

TO COOLER

CONVERTER FEED

TCC
ENABLE
VALVE

LINE

TCC REGULATOR VALVE

RELEASE

TCC
CONTROL
VALVE

APPLY

;;;
;;;
;
;;;
;;;;
;;;
;;;;
;
;;;
;;
;;;
;;;
;;
;;;
;;;
;;
;;;
;;;
;;
;;;
;;;
;;;

RELEASE

TORQUE
CONVERTER
ASSEMBLY
(1)

The TCC PWM solenoid valve is the electronic control component


of the TCC apply and release system. The other components are
all hydraulic control or regulating valves. The illustration below
shows all the valves and the TCC PWM solenoid valve that
make up the TCC control system. (For more information on
system operation see pages 7475 in the Power Flow section).

ELECTRICAL COMPONENTS
The pressure control (PC) solenoid valve is a precision electronic
pressure regulator that controls transmission line pressure based
on current flow through its coil windings. As current flow is
increased, the magnetic field produced by the coil moves the
solenoids plunger further away from the exhaust port. Opening
the exhaust port decreases the output fluid pressure regulated by
the PC solenoid valve, which ultimately decreases line pressure.
The TCM controls the PC solenoid valve based on various
inputs including throttle position, transmission fluid temperature
and gear state.

PRESSURE
CONTROL
(THROTTLE
SIGNAL)

PRESSURE
SUPPLY
(FILTERED
FEED LIMIT)

O-RING

COIL
CONNECTOR
ASSEMBLY
HOUSING

EXHAUST

Duty Cycle, Frequency and Current Flow:

A duty cycle may be defined as the percentage of time current


is flowing through a solenoid coil during each cycle. The number
of cycles that occur within a specified amount of time, usually
measured in seconds, is called frequency. Typically, the
operation of an electronically controlled pulse width modulated
solenoid is explained in terms of duty cycle and frequency.

CALIBRATION
FLUID
VARIABLE
SCREW
SCREENS RESTRICTION DIAPHRAGM SPRING
PRESSURE CONTROL SOLENOID VALVE

The TCM controls the PC solenoid valve on a positive duty


cycle at a fixed frequency of 292.5 Hz (cycles per second). A
higher duty cycle provides a greater current flow through the
solenoid. The high (positive) side of the PC solenoid valve
electrical circuit at the TCM controls the PC solenoid valve
operation. The TCM provides a ground path for the circuit,
monitors average current and continuously varies the PC solenoid
valve duty cycle to maintain the correct average current flowing
through the PC solenoid valve.
Duty Cycle

Current

Line Pressure

Minimum

0.1 Amps

Maximum

Maximum

1.1 Amps

Minimum

175
(Nom)
LINE PRESSURE

WWW.ALL-TRANS.BY

Pressure Control (PC) Solenoid Valve (357):

50
(Nom) 0

1.1
CURRENT (AMPS)

Pressure control solenoid valve resistance should measure


between 3.5 and 4.6 ohms when measured at 20C (68F),
and approximately 6 ohms at 150C (302F).

The duty cycle and current flow to the PC solenoid valve are
mainly affected by throttle position (engine torque) and they are
inversely proportional to throttle angle (engine torque). In other
words, as the throttle angle (engine torque) increases, the duty
cycle is decreased by the TCM which decreases current flow to
the PC solenoid valve. Current flow to the PC solenoid valve
creates a magnetic field that moves the solenoid armature against
spring force.

If the TCM detects a pressure control solenoid valve


electrical malfunction, a DTC will be activated.
The DTC strategy may be different depending on the
customer/application (refer to the appropriate Service
Information).

Transmission Adapt Function:

Programming within the TCM also allows for automatic


adjustments in shift pressure that are based on the changing
characteristics of the transmission components. As the apply
components within the transmission wear, shift time (the time
required to apply a clutch) increases. In order to compensate for
this wear, the TCM adjusts trim pressure by controlling the PC
solenoid valve in order to maintain the originally calibrated shift
timing. The automatic adjusting process is referred to as
adaptive learning and it is used to assure consistent shift feel
plus increase transmission durability. The TCM monitors the
A/T ISS and the A/T OSS during commanded shifts to determine
if a shift is occurring too fast (harsh) or too slow (soft) and
adjusts the PC solenoid valve signal to maintain a set shift feel.

Transmission adapts must be reset whenever the transmission


is overhauled or replaced (see appropriate service manual).

Figure 48

51

ELECTRICAL COMPONENTS
WWW.ALL-TRANS.BY

COMPONENTS EXTERNAL TO THE TRANSMISSION


Throttle Position (TP) Sensor: The ECM monitors the variable
voltage signal from the TP sensor to calculate throttle position
(angle). These input signals are then transmitted over the CAN
bus to the TCM, in addition to other vehicle and transmission
sensor inputs, in order to determine the appropriate line pressure,
shift pattern and TCC apply and release for the transmission. In
general, with greater throttle angle, upshift speeds and line pressure
both increase.

Engine Speed Sensor: Monitored by the ECM through the ignition


module, information from this sensor is transmitted over the CAN
bus to the TCM and used to help determine shift patterns and TCC
apply and release.

Manifold Absolute Pressure (MAP) Sensor: The MAP sensor


measures changes relative to intake manifold pressure which results
from changes in engine load and speed. These changes are
converted to a voltage output which is monitored by the ECM and
transmitted over the CAN bus to the TCM in order to adjust line
pressure and shift timing.

Engine Coolant Temperature (ECT) Sensor: The ECM monitors


the variable resistance signal from this sensor to determine engine
coolant temperature. When the engine is cold, resistance is high,
and when the engine is hot, resistance through the sensor is low.
The ECM then transmits this information over the CAN bus to the
TCM where it is used to prevent the TCC from applying when
engine temperature is below approximately 20C (68F) (calibratable).

TCC Brake Switch: This switch causes the TCM to command


TCC release. When the brake pedal is depressed, the TCM opens
the path to ground for the TCC electrical circuit which releases the
torque converter clutch.

Driver Shift Control (DSC) Switches: These switches are located


either on the steering wheel or on a secondary gate within the
console shift lever mechanism. The TCM uses the switch inputs
to provide manual shift control to the driver. When a switch is
depressed, the TCM opens a path to ground causing the transmission
to shift up or down.

Operating Mode Selection Switches: Depending on the customer/


application, vehicles may be equipped with switches allowing the
driver to select various automatic operating modes (Economy,
Performance, Winter), or manual mode (Driver Shift Control) to
allow manual shifting by bumping the selector lever up and down.

Diagnostic Link Connector (DLC): The DLC is a multi-terminal


connector that is located under the vehicle dashboard. The DLC is
connected by serial data wires to the various control modules
located throughout the vehicle. The DLC can be used to diagnose
conditions in the vehicle's electrical system, TCM or PCM, and
various transmission components. Refer to the appropriate Service
Manual for specific electrical diagnosis information.

Controller Area Network (CAN) Bus: The CAN bus consists of


two wires that connect the various vehicle control modules together,
allowing them to exchange information about vehicle conditions.
Manifold Air Temperature (MAT) Sensor: The ECM monitors
the variable resistance signal from the MAT sensor to determine
manifold air temperature. When the air is cold, resistance is high,
and when the air is hot, resistance through the sensor is low. The
ECM then transmits this information over the CAN bus to the TCM
where it is used to prevent the TCC from applying when manifold
air temperature is below approximately 20C (68F) (calibratable).

Accelerator Pedal Position (APP) Sensor: The APP sensor is


monitored by the ECM in order to determine accelerator pedal
position. The ECM uses this signal to open and close the throttle
in response to the driver's commands. It also signals the TCM
when the accelerator pedal is fully depressed, allowing forced
downshifts and maximum performance.

52

Note: These are typical inputs to the controllers. The


combination and usage of these inputs may vary depending on
model and application.

WWW.ALL-TRANS.BY

POWER FLOW

This section of the book describes how torque from


the engine is transferred through the Hydra-matic
4/5L40-E transmission allowing the vehicle to move
either in a forward or reverse direction. The
information that follows details the specific mechanical
operation, electrical, hydraulic and apply components
that are required to achieve a gear operating range.

The full size, right hand pages contain a simplified


version of the Complete Hydraulic Circuit that is
involved for that range and gear. Facing this full page
is a half page insert containing text and a detailed
explanation of what is occurring hydraulically in that
range and gear. A page number located at the bottom
of the half page of text provides a ready reference to
the complete Hydraulic Circuits section of this book
if more detailed information is desired.

The full size, left hand pages throughout this section


contain drawings of the mechanical components used
in a specific range and gear. Facing this full page is a
half page insert containing a color coded range
reference chart at the top. This chart is one of the key
items used to understand the mechanical operation of
the transmission in each range and gear. The text
below this chart provides a detailed explanation of
what is occurring mechanically in that range and gear.

It is the intent of this section to provide an overall


simplified explanation of the mechanical, hydraulic
and electrical operation of the Hydra-matic 4/5L40-E
transmission. If the operating principle of a clutch, or
valve is unclear, refer to the previous sections of this
book for individual component descriptions.

RK g)
PA nnin
Ru
e
gin
(En

)
k (P
Pa r
the he oil
er finrom ting:
v
or le re ow
lect essu e foll
e se e pr o th ): Regh th lin d t
18 )
Witsition, irecte Valve(2ressure
d
po p is lator (line psion
u t
pum Reg tpu mis

(Engine Running)
1
POWER FROM
TORQUE
CONVERTER
(1)

NO POWER
TRANSMITTED
TO
DIFFERENTIAL
ASSEMBLY

REAR
INTERNAL
GEAR
(560)
HELD

PARK
(Engine Running)

re ou ns p
ssu mp tra pum
Pretes pu to the hen emand
ulaordingents. Wthe dfrom
accuirem ceeds, fluidr
req ut ex ssure ulato
outpne preure reg
of lipress
the

CONVERTER FEED
LINE
PRESS REG VALVE

PARK

EX

DECREASE

DIRECT
CLUTCH
ACCUMULATOR

OVERDRIVE
CLUTCH
ACCUMULATOR

EX

EX

INTERMEDIATE
CLUTCH
ACCUMULATOR

SECOND
CLUTCH
ACCUMULATOR

EX

EX

LINE

1-2 SIGNAL

FEED LIMIT

FDL

FDL

2-3 SIGNAL

EX

SECOND CL
D432

FEED LIMIT
1-2 SHIFT
SOLENOID
VALVE
N/C

(A)

OFF

EX

EX

EX

1-2 SHIFT CONTROL VALVE


2345

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH

24

LINE SAFETY MODE

2-3 SIGNAL

23 REGULATED

10

FEED LIMIT

23 REGULATED

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL
29

EX

OFF

EX

(B)

EX

2345

EX

FILTER
(312)

345
2345

2-3 SHIFT VALVE


EX

EX

SAFETY MODE
EX

2a

FEED LIMIT

1-2 SHIFT VALVE


EX

MEMORY

EX

LINE
FEED LIMIT

PRESSURE
CONTROL
SOLENOID
VALVE

32
32 SAFETY MODE

MEMORY PILOT

MEMORY
FEED LIMIT
LINE
LINE SAFETY MODE

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

D432
SECOND CL
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REV CL

FEED LIMIT

TORQUE
CONVERTER
HOUSING/PUMP
ASSEMBLY
(3)

LINE

LINE

FEED LIMIT

TORQUE
CONVERTER
ASSEMBLY
(1)

SECOND CL

INTERMED CL

ACCUMULATOR

ACCUMULATOR
OVERDR CL FD 2

THROTTLE SIGNAL

ACCUMULATOR
DIRECT CL

REVERSE CLUTCH

BOOST VALVE

ACCUM

EX

2b

FEED LIMIT
FEED LIMIT
EX

4-5 SIGNAL

EX

TCC PWM
SOLENOID
VALVE
N/C

MP

LE

56

TE

EX

EX

11

2c

32

D432

R N D 4 3 2

LINE

EX

REV

REGULATED APPLY

REGULATED APPLY

MANUAL VALVE

LINE

CO

OFF

REVERSE
TCC SIGNAL

EX

PARK
PAWL
(612)
ENGAGED

PARK
PAWL
ACTUATOR
ASSEMBLY
(613)

COAST CLUTCH FEED

(C)

FEED LIMIT

LINE SM
2345 OR REVERSE

LINE

REVERSE CLUTCH
HOUSING ASSEMBLY
(401)

OVERDRIVE CL FD 2

4-5 SHIFT
SOLENOID
VALVE
N/C

CNTRL
LINE SM

28

LINE

TCC REGULATOR VALVE

45

EX

EX

EX

EX

FEED LIMIT VALVE

FORWARD AND COAST


CLUTCH HOUSING
ASSEMBLY
(433)

COAST CLUTCH
123
123
123 BRAKING

4-5 SHIFT VLV

FEED LIMIT

SECOND COAST CLUTCH


OVERDRIVE CL FD 1

REAR
INTERNAL
GEAR
(560)
HELD

HY

DR
PA AUL
GE IC
86 CIR
C

UIT

LINE

LINE

LINE (from Pump)

56

Figure 53

Figure 52

Figure 49

57

53

WWW.ALL-TRANS.BY

MECHANICAL POWERFLOW FROM THE TORQUE CONVERTER


TO THE TURBINE SHAFT
2a
(Engine Running)

1
POWER FROM
THE ENGINE

2
POWER TO
DRIVE FLUID PUMP

FLUID PUMP
ROTOR (223)
DRIVEN

MECHANICAL POWERFLOW FROM


THE TORQUE CONVERTER TO
THE TURBINE SHAFT
(Engine Running)
The mechanical power flow in the Hydra-matic 4/5L40-E
transmission begins at the point of connection between the
torque converter and the engine flywheel. When the engine is
running, the torque converter cover (pump) is forced to rotate
at engine speed. As the torque converter rotates it multiplies
engine torque and transmits it to the turbine shaft (433). The
turbine shaft provides the primary link to the mechanical
operation of the transmission.
The Hydra-matic 4/5L40-E automatic transmission requires a
constant supply of pressurized fluid to cool and lubricate all
of the components throughout the unit. It also requires a
holding force to be applied to the clutches during the various
gear range operations. The torque converter housing/pump
assembly (3) and the control valve body accumulator assembly
(47) provide for the pressurization and distribution of fluid
throughout the transmission.
1 Power from the Engine

Torque from the engine is transferred to the transmission through


the engine flywheel which is bolted to the engine crankshaft.
2 Power to Drive the Fluid Pump
3
FLUID COUPLING
DRIVES THE TURBINE

The fluid pump rotor (223) is keyed to the torque converter hub.
Therefore, the fluid pump rotor also rotates at engine speed.
3 Fluid Coupling Drives the Turbine

Transmission fluid inside the torque converter (1) creates a fluid


coupling which in turn drives the torque converter turbine.
4 Turbine Shaft Driven

As the torque converter turbine rotates, the turbine shaft (433),


which is splined to the torque converter turbine, is also forced to
rotate at turbine speed.

4
TURBINE
SHAFT DRIVEN

TORQUE CONVERTER
ASSEMBLY
(1)

NOTE: To minimize the amount of repetitive text, the


remaining mechanical power flow descriptions will begin
with the turbine shaft (433). The transfer of torque from the
engine through the torque converter to the turbine shaft is
identical in all gear ranges except when the torque converter
clutch is applied (see pages 74A and 74B for complete
explanation of torque converter apply.

SPLINED TO
TORQUE CONVERTER
STATOR ASSEMBLY

SPLINED TO
TORQUE CONVERTER
TURBINE ASSEMBLY

FORWARD CLUTCH
AND INPUT HOUSING
ASSEMBLY (433)
(TURBINE SHAFT)

KEYED TO
FLUID PUMP
ROTOR

54

Figure 50

TORQUE CONVERTER
HOUSING/PUMP ASSEMBLY
(3)

54A

3 TORQUE

1 PRESSURE

CONVERTER

AIR
BLEED
(233)

TORQUE
CONVERTER
ASSEMBLY
(1)

CONVERTER FEED

1a
CONVERTER FEED

3d
APPLY

EX

3b TCC Regulator Valve:

TCC
ENABLE
VALVE

Spring force holds the valve in the release position, thereby


blocking line pressure from entering the regulated apply
fluid circuit.

SUCTION
LINE

54B

1c

EX

2 SHIFT ACCUMULATION
2a

FEED LIMIT

EX

LINE
ACCUMULATOR

4 SAFETY MODE

4-5 SIGNAL

LINE

INTERMEDIATE CLUTCH

32

MEMORY PILOT

4a
LINE

11

4b

LINE
4

OFF

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
COAST CLUTCH
COAST CLUTCH FEED
OVERDRIVE CLUTCH FEED 2

ACCUMULATOR

OVERDRIVE CLUTCH FEED 2

(C)

EX

123
123

SECOND CLUTCH

4-5 SHIFT
SOLENOID
VALVE
N/C

4-5 SHIFT VLV CNTRL


EX

ACCUMULATOR

ACCUMULATOR

LINE

DIRECT CLUTCH

FEED LIMIT VALVE


EX

EX

1b

EX

EX

SECOND
CLUTCH
ACCUMULATOR

32 SAFETY MODE

SAFETY MODE

LINE
MEMORY

EX

EX

INTERMEDIATE
CLUTCH
ACCUMULATOR

EX

OVERDRIVE
CLUTCH
ACCUMULATOR

EX

DIRECT
CLUTCH
ACCUMULATOR

FEED LIMIT

EX

FEED LIMIT

EX

Line safety mode fluid forces the 4-5 shift valve to downshift
to the fourth gear position allowing (after the engine has
been switched OFF) a fourth gear start (instead of fifth) in
the event of safety mode.

FILTER
(312)
PRESSURE
CONTROL
SOLENOID
VALVE

4a Safety Mode Valve:

4b 4-5 Shift Valve and 4-5 Shift Control Valve:

FILTERED FEED LIMIT

3c

4 SAFETY MODE

When the first 1-2 shift occurs, the safety mode valve shifts
from the released position to the applied position and remains
there until the engine is switched OFF. If safety mode
occurs (no TCM signal to the shift solenoid valves), the
transmission will shift to safety (fifth) gear. If the engine is
then switched OFF and ON, still with no TCM signal, the
safety mode valve will return to, and remain in, the released
position. Line pressure fluid will pass through the safety
mode valve into the line safety mode fluid circuit. Line
safety mode fluid is routed to the 4-5 shift valve train.

LINE

EX

REGULATED APPLY

EX

THROTTLE SIGNAL
TCC SIGNAL

Spring force holds the valve in the release position allowing


converter feed fluid to enter the release circuit.
Release fluid pressure is routed to the torque converter to keep
the TCC released. Fluid leaves the converter in the apply fluid
circuit and returns to the cooler through the TCC control valve.

FLUID
PAN
(62)

REGULATED APPLY

EX

3d TCC Control Valve:

3e Torque Converter:

LINE (to manual valve)

FLUID FILTER
ASSEMBLY
(59)

45

Converter feed fluid is routed through the TCC enable valve


and into the converter FDL circuit. Converter FDL fluid is
routed to the TCC control valve.

3b

FORWARD CLUTCH

LINE

REGULATED APPLY

Line pressure is routed through the pressure regulator valve


and into the converter feed fluid circuit. Converter feed fluid is
routed to the TCC control valve and to the TCC enable valve.

TCC PWM
SOLENOID
VALVE
N/C

TCC SIGNAL

3a Pressure Regulator Valve:

(214)

APPLY

TCC SIGNAL

3 TORQUE CONVERTER (RELEASED POSITION ONLY)

FLUID PUMP
SCREEN
ASSEMBLY
(213)

LINE

LINE

TCC REGULATOR VALVE

2345 OR REVERSE

CONVERTER FDL
CONVERTER FEED

Accumulator fluid is routed to each of the accumulator


assemblies in preparation for upshifts and downshifts.

3c TCC Enable Valve:

RELEASE

TCC
CONTROL
VALVE

FLUID
PUMP
ASSEMBLY

TO COOLER

2 SHIFT ACCUMULATION
2a Direct, Overdrive, Intermediate, and Second Clutch
Accumulator Assemblies:

THROTTLE SIGNAL

RELEASE

REGULATED APPLY

Controlled by the TCM, the PC solenoid valve regulates


filtered feed limit fluid pressure into the throttle signal
fluid circuit.

BOOST VALVE

EX

Line pressure is routed through the valve and into the feed
limit fluid circuit. The valve limits feed limit fluid pressure
to a maximum pressure. Feed limit fluid is routed to the
pressure control solenoid valve, the safety mode valve, the
1-2 control valve, and also feeds the 1-2 signal, the 2-3
signal, and the 4-5 signal fluid circuits.

SUCTION

1b Feed Limit Valve:

LINE

LINE

3e

PRESSURE
RELIEF
BALL
VALVE

DECREASE

APPLY

Regulates pump output (line pressure) in response to throttle


signal fluid pressure acting on the line boost valve, spring
force, and line pressure acting on the end of the valve. Line
pressure is directed to the manual valve, the TCC regulator
valve, feed limit valve, and the safety mode valve. Line
pressure also feeds the converter feed circuit through the
pressure regulator valve, and the accumulator fluid circuits.

CONVERTER FEED
DECREASE

3a

EX

LINE

31

1a Pressure Regulator Valve:

30

FLUID
PRESSURE
TEST PLUG
(40)

REVERSE CLUTCH

1 PRESSURE REGULATION

1c Pressure Control (PC) Solenoid Valve:

AIR
BLEED
(233)

LINE

FEED LIMIT (to 1-2 and 2-3 SS valves)

When the gear selector lever is in the Park (P) position and the
engine is running, fluid is drawn into the oil pump and line
pressure is directed to the pressure regulator valve.

REGULATION

PRESS REG VALVE

(Engine Running)

COMMON HYDRAULIC FUNCTIONS FOR ALL RANGES

RELEASE

WWW.ALL-TRANS.BY

HYDRAULIC POWERFLOW COMMON


FUNCTIONS FOR ALL RANGES

LINE SAFETY MODE

NOTE: PASSAGES AND COMPONENTS MARKED


WITH ARE USED FOR THE 5L40-E ONLY

MEMORY

Figure 51

FEED LIMIT

55

PARK

WWW.ALL-TRANS.BY

PARK

(Engine Running)

(Engine Running)
REAR
INTERNAL
GEAR
(560)
HELD

1
POWER FROM
TORQUE
CONVERTER
(1)

2
NO POWER
TRANSMITTED
TO
DIFFERENTIAL
ASSEMBLY

OFF OFF OFF


LD = LOCKED IN DRIVE

The manual shift shaft (606) and the manual valve (377) are
in the Park position. The parking pawl actuator assembly
(613) engages the parking pawl (612) with the lugs on the
rear internal gear (560).
The rear internal gear is held stationary by the parking pawl.
The output shaft (562), which is splined to the rear internal
gear is also held stationary preventing the vehicle from
moving.

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

Power from Torque Converter

The input shaft forward and coast clutch assembly (433)


and the reverse clutch housing assembly (401) are driven by
the turbine shaft, which is splined to the converter turbine.
2

Power Flow Terminated

The input shaft forward and coast clutch assembly rotates


freely without any clutches applied or sprag clutches holding
and power flow is terminated.

TORQUE
CONVERTER
ASSEMBLY
(1)

Note: The vehicle should be completely stopped before selecting


Park range or internal damage to the transmission could occur.
Also, the manual linkage must be adjusted properly so the
indicator quadrants in the vehicle correspond with the manual
shaft detent lever (600) in the transmission. If not adjusted
properly, an internal leak between fluid passages at the manual
valve may cause a clutch to slip or cause the transmission to not
hold in park.
Refer to the appropriate General Motors Service Manual for the
proper manual linkage adjustment procedures.

TORQUE
CONVERTER
HOUSING/PUMP
ASSEMBLY
(3)

REAR
INTERNAL
GEAR
(560)
HELD
FORWARD AND COAST
CLUTCH HOUSING
ASSEMBLY
(433)
REVERSE CLUTCH
HOUSING ASSEMBLY
(401)
PARK
PAWL
(612)
ENGAGED

PARK
PAWL
ACTUATOR
ASSEMBLY
(613)

56

Figure 52

56A

PARK

(Engine Running)

SOLENOID

FORWARD OVER- INTERM. INTER- LOW LOW AND


SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF OFF OFF

LD = LOCKED IN DRIVE

FLUID PRESSURE DIRECTED IN PREPARATION FOR A SHIFT


Manual Valve:

CONVERTER FEED

Mechanically controlled by the gear selector lever, the manual


valve is in the Park (P) position and prevents line pressure
from the pressure regulator valve from entering the reverse,
D432 and 32 fluid circuits.

LINE

EX

2a 1-2 Shift Solenoid (SS) Valve and


1-2 Shift Control Valve:

DECREASE

DIRECT
CLUTCH
ACCUMULATOR

OVERDRIVE
CLUTCH
ACCUMULATOR

EX

EX

INTERMEDIATE
CLUTCH
ACCUMULATOR

SECOND
CLUTCH
ACCUMULATOR

EX

EX

BOOST VALVE

ACCUM

LINE

Feed limit fluid from the feed limit valve is routed to the 4-5
SS valve in preparation for a shift.

FEED LIMIT

FEED LIMIT

1-2 SIGNAL
FDL

FDL

2-3 SIGNAL

EX

FEED LIMIT
1-2 SHIFT
SOLENOID
VALVE
N/C

(A)

OFF

EX

EX

EX

1-2 SHIFT CONTROL VALVE


2345

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH

24

LINE SAFETY MODE

SAFETY MODE

2-3 SIGNAL

23 REGULATED

10

FEED LIMIT

23 REGULATED

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL
29

EX

OFF

EX

(B)

EX

EX

FILTER
(312)

345
2345

2-3 SHIFT VALVE


EX

EX

FEED LIMIT

2345

PRESSURE
CONTROL
SOLENOID
VALVE

2a

1-2 SHIFT VALVE

EX

LINE
FEED LIMIT

EX

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

32
32 SAFETY MODE

MEMORY PILOT

MEMORY
FEED LIMIT
LINE
LINE SAFETY MODE

MEMORY

EX

Line fluid fills the accumulator circuits and accumulator


assemblies in preparation for an upshift.

SECOND CL
D432

Direct Clutch, Overdrive Clutch, Intermediate Clutch,


and Second Clutch Accumulators:

D432
SECOND CL
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REV CL

Note: Refer to Shift Solenoid Valves on page 49 for a description


of solenoid and shift valve operation.
3

LINE

LINE

FEED LIMIT

2c 4-5 Shift Solenoid (SS) Valve:

SECOND CL

Feed limit fluid from the feed limit valve is routed to the
2-3 SS valve in preparation for a shift.

ACCUMULATOR

THROTTLE SIGNAL

2b 2-3 Shift Solenoid (SS) Valve:

INTERMED CL

REVERSE CLUTCH

ACCUMULATOR
OVERDR CL FD 2

Feed limit fluid from the feed limit valve is routed to the
1-2 SS valve and to the 1-2 shift control valve in
preparation for a shift.

ACCUMULATOR
DIRECT CL

PRESS REG VALVE

WWW.ALL-TRANS.BY

PARK

(Engine Running)

EX

2b

FEED LIMIT
FEED LIMIT
EX

4-5 SIGNAL

LINE
TCC PWM
SOLENOID
VALVE
N/C

COAST CLUTCH FEED

EX

EX

11

FEED LIMIT

2c

REGULATED APPLY

32

D432

R N D 4 3 2

LINE

EX

REV

REGULATED APPLY

MANUAL VALVE

LINE

56B

OFF

REVERSE

TCC SIGNAL

2345 OR REVERSE
LINE

COMPLETE HYDRAULIC CIRCUIT


Page 86

(C)

LINE SM

EX

LINE

OVERDRIVE CL FD 2

EX

TCC REGULATOR VALVE

4-5 SHIFT
SOLENOID
VALVE
N/C

CNTRL
LINE SM

28

COAST CLUTCH
123
123
123 BRAKING

EX

EX

EX

EX

FEED LIMIT VALVE

45

4-5 SHIFT VLV

FEED LIMIT

SECOND COAST CLUTCH


OVERDRIVE CL FD 1

LINE

LINE (from Pump)

Figure 53

57

REVERSE

1
POWER FROM
TORQUE
CONVERTER
(1)

2
REVERSE
CLUTCH
APPLIED

5
INPUT AND
REACTION
CARRIER
(553)
HELD

4
LOW AND
REVERSE
CLUTCH
APPLIED

3
FRONT
INPUT SUN
GEAR
DRIVING

6
REAR
INTERNAL
GEAR
(560)
DRIVEN

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF OFF OFF

APPLIED

APPLIED

LD = LOCKED IN DRIVE

In Reverse (R), torque from the engine is multiplied through the


torque converter and transmission gear set to the vehicles drive
shaft and rear axle. The planetary gear set operates in reduction
and also reverses the direction of input torque for a reverse gear
ratio of approximately 3.03:1.
The manual shift shaft (606) and the manual valve (377) are
in the Reverse position.
1

POWER TO
DIFFERENTIAL
ASSEMBLY

WWW.ALL-TRANS.BY

REVERSE

Power from Torque Converter

The input shaft forward and coast clutch assembly (433) is


driven by the converter turbine.
2

Reverse Clutch Applied

The reverse clutch plates (415-419) are applied and allow


the overdrive and reverse clutch hub assembly (470), to
drive the front input sun gear.
3

Front Input Sun Gear Driving

Engine torque is transferred from the reverse clutch housing,


through the front input sun gear and to the long pinion
gears. The long pinion gears are in mesh with and drive the
rear internal gear (560).
4

REVERSE
CLUTCH
HOUSING
ASSEMBLY
(401)

OVERDRIVE AND
REVERSE CLUTCH
HUB ASSEMBLY
(470)

FOWARD AND
COAST CLUTCH
HOUSING
ASSEMBLY
(433)

REVERSE
CLUTCH
APPLIED

Low and Reverse Clutch Applied

The low and reverse clutch is applied and holds the low
clutch sprag inner race which is splined to the input and
reaction carrier.
5

Input and Reaction Carrier Assembly Held

With the low and reverse clutch holding the input and reaction
carrier assembly, the reaction long pinion gears drive the
rear internal gear (560) in a reverse direction.
6

Rear Internal Gear Driven

The rear internal gear (560) is splined to the output shaft


assembly (562), thus the output shaft is also driven in a
reverse direction.

When the throttle is released in Reverse, power from the


vehicle (output shaft) drives through the reverse clutch to the
input shaft faster than engine speed is driving the input shaft.
The engine then works as a brake, slowing the transmission
down to input speed. This is referred to as engine braking.

LOW AND
REVERSE
CLUTCH
APPLIED

INPUT AND
REACTION
CARRIER
(553)
HELD

FRONT
INPUT SUN
GEAR
DRIVING

REAR
INTERNAL
GEAR
(560)
DRIVEN

LOW CLUTCH
SPRAG
ASSEMBLY

58

Figure 54

58A

REVERSE
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

CONVERTER FEED

With the manual valve in the reverse position, line pressure


is directed into the reverse fluid circuit.

DIRECT
CLUTCH
ACCUMULATOR

AIR
BLEED
(203)

1b Reverse Lockout Valve:

EX

EX

1c

Reverse fluid is routed through the reverse lockout valve


into the reverse lockout fluid circuit.

EX

2a

REVERSE LOCKOUT

LOW AND REVERSE CL

12

LINE

SECOND CL

ACCUMULATOR

INTERMED CL

LINE
REVERSE LOCKOUT

FEED LIMIT

FEED LIMIT
REVERSE LOCKOUT

#1
1-2 SIGNAL

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH

10

FEED LIMIT

23 REGULATED

1b
TCC SIGNAL

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

(B)

EX

EX

345
2345

EX

2-3 SHIFT VALVE

29

EX

OFF

EX

SECOND COAST CLUTCH

RLO

OVERDRIVE CL FD 1

FEED LIMIT
FEED LIMIT

4-5 SIGNAL

4-5 SHIFT
SOLENOID
VALVE
N/C

COAST CLUTCH FEED

CNTRL
LINE SM

EX

EX

(C)

OFF
11

FEED LIMIT

LINE SM

4b

FILTER
(308)

R N D 4 3 2

32

LINE

D432

REV

MANUAL VALVE
EX

REGULATED APPLY

REVERSE
TCC SIGNAL

2345 OR REVERSE

EX

LINE

OVERDRIVE CL FD 2

EX

TCC PWM
SOLENOID
VALVE
N/C

COAST CLUTCH
123
123
123 BRAKING

28

LINE

TCC REGULATOR VALVE

45

EX

EX

EX

FEED LIMIT VALVE

4 FLUID PRESSURE DIRECTED IN PREPARATION


FOR TCC APPLY
4a #2 Ball Check Valve:

4-5 SHIFT VLV


EX

REVERSE
LOCKOUT
VALVE

REVERSE

Reverse clutch fluid enters the reverse clutch housing and acts
on the reverse clutch piston to apply the reverse clutch plates.

EX

EX

3b Reverse Clutch:

FEED LIMIT

LINE SAFETY MODE

2-3 SIGNAL

23 REGULATED

FILTER
(312)

FEED LIMIT

FDL

EX

OFF

2345
24

EX

(A)

EX

1-2 SHIFT CONTROL VALVE

SAFETY MODE
EX

FEED LIMIT
1-2 SHIFT
SOLENOID
VALVE
N/C

2345

EX

LINE
FEED LIMIT

PRESSURE
CONTROL
SOLENOID
VALVE

FEED LIMIT

1-2 SHIFT VALVE


EX

THROTTLE SIGNAL
FILTERED FEED LIMIT

EX

MEMORY PILOT

32
32 SAFETY MODE

3a

REVERSE LOCKOUT

MEMORY

2-3 SIGNAL

REVERSE LOCKOUT

FDL

SECOND CL
D432

REVERSE CLUTCH

EX

D432
SECOND CL
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REV CL

13

EX

X-2

Note: Remember that the function of an orifice is to control the


flow rate of fluid and rate of apply or release of a clutch.

The TCC PWM solenoid valve remains de-energized (OFF).


2345 or reverse fluid is prevented from entering the TCC
signal fluid circuit. Under normal circumstances the TCC
PWM solenoid valve is not energized. In the event the TCC
PWM solenoid valve is energized (when engaging Reverse
while driving in Forward above a certain speed), TCC signal
fluid will shift the reverse lockout valve to block reverse
fluid from entering the reverse lockout circuit and the reverse
clutch and the low and reverse clutch will release to prevent
damage to the transmission.

EX

LINE

Located in the bottom channel plate, reverse lockout fluid


seats the #1 ball check valve and is forced through orifice
#13 in the control valve body spacer plate into the reverse
clutch fluid passage.

4b Torque Converter Clutch Pulse Width Modulation


(TCC PWM) Solenoid Valve:

SECOND
CLUTCH
ACCUMULATOR

2b Low and Reverse Clutch:

Located in the bottom channel plate, reverse fluid seats the


#2 ball check valve against the 2345 fluid passage and directs
fluid into the 2345 or reverse fluid passage.

EX

INTERMEDIATE
CLUTCH
ACCUMULATOR

ACCUMULATOR
OVERDR CL FD 2

ACCUMULATOR
DIRECT CL

REVERSE CLUTCH

THROTTLE SIGNAL

Located in the bottom channel plate, reverse lockout fluid


seats the #8 ball check valve against the low and reverse
clutch fluid passage and directs fluid into the low and reverse
clutch or reverse lockout fluid passage. Reverse lockout
fluid pressure is also orificed, through orifice #12, to provide
a controlled apply of the low and reverse clutch.

3 REVERSE CLUTCH APPLIES


3a #1 Ball Check Valve:

OVERDRIVE
CLUTCH
ACCUMULATOR

ACCUM

REVERSE CLUTCH

2 LOW AND REVERSE CLUTCH APPLIES


2a #8 Ball Check Valve and Orifice #12:

Low and reverse clutch or reverse lockout fluid pressure


enters the outer area of the low and reverse clutch piston
and moves the piston against spring force to apply the low
and reverse clutch plates. In addition, reverse lockout fluid
pressure is orificed into the inner area of the low and reverse
clutch piston and provides additional force to apply the low
and reverse clutch plates.

DECREASE

#8

1c Pressure Regulator and Line Boost Valves:

Reverse clutch fluid at the line boost valve boosts line


pressure for the additional torque requirements in Reverse.
Throttle signal fluid pressure from the pressure control (PC)
solenoid acting on the line boost valve also helps determine
line pressure in Reverse depending on throttle position and
other TCM input signals.

LINE

DIRECT CLUTCH

REVERSE LOCKOUT
SECOND CLUTCH

REVERSE CLUTCH

PRESS REG VALVE

1 PRESSURE REGULATION
1a Manual Valve:

SECOND COAST CL
LOW AND REV CL OR RLO

2b

3b

BOOST VALVE

When the gear selector lever is moved to the Reverse (R)


position (from the Park position) the following changes occur
in the transmissions hydraulic and electrical systems.

CENTER
SUPPORT
ASSEMBLY
(510535)

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

MEMORY
FEED LIMIT
LINE
LINE SAFETY MODE

APPLIED

MEMORY

APPLIED

REGULATED APPLY

OFF OFF OFF


LD = LOCKED IN DRIVE

1a

LINE

WWW.ALL-TRANS.BY

REVERSE

SOLENOID

2345

4a

#2

2345 OR REVERSE
LINE

LINE
2345 OR REVERSE

COMPLETE HYDRAULIC CIRCUIT


Page 88

58B

LINE (from Pump)

Figure 55

59

NEUTRAL

WWW.ALL-TRANS.BY

NEUTRAL

(Engine Running)

(Engine Running)
1
POWER FROM
TORQUE
CONVERTER
(1)

2
NO POWER
TRANSMITTED
TO
DIFFERENTIAL
ASSEMBLY

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF OFF OFF
LD = LOCKED IN DRIVE

When the gear selector lever is placed in the Neutral (N) position,
mechanical power flow is identical to Park (P) range, except
that the park lock actuator assembly (613) is disengaged. The
park pawl spring (611) releases the park pawl (612) from the
lugs on the rear internal gear (560). With the park pawl
disengaged, the output shaft is free to rotate allowing the vehicle
to roll.
The manual shift shaft (606) and the manual valve (377) are
in the Neutral position.

Power from Torque Converter

The input shaft forward and coast clutch housing assembly


is splined to and driven by the converter turbine.
2

Powerflow Terminated

Without any clutches applied, or sprag clutches holding, the


input shaft forward and coast clutch housing assembly rotates
freely and power flow is terminated.

Neutral range may be selected for starting the engine when


the vehicle is standing still or moving down the road.
TORQUE
CONVERTER
HOUSING/PUMP
ASSEMBLY
(3)

TORQUE
CONVERTER
ASSEMBLY
(1)

REVERSE
CLUTCH
HOUSING
ASSEMBLY
(401)

FORWARD AND
COAST CLUTCH
HOUSING
ASSEMBLY
(433)

REAR
INTERNAL
GEAR
(560)

PARK
PAWL
(612)
DISENGAGED

PARK
PAWL
ACTUATOR
ASSEMBLY
(613)

60

Figure 56

60A

NEUTRAL

CONVERTER FEED

DIRECT
CLUTCH
ACCUMULATOR

AIR
BLEED
(203)

EX

EX

1e

1a Manual Valve:

The manual valve is moved to the Neutral position and


blocks line pressure from entering the reverse fluid circuit.
The reverse fluid circuit is opened to an exhaust at the
manual valve.

EX

EX

2b

REVERSE LOCKOUT

LOW AND REVERSE CL

12

LINE

SECOND CL

ACCUMULATOR

INTERMED CL

LINE

LINE
REVERSE LOCKOUT

FEED LIMIT

FEED LIMIT
REVERSE LOCKOUT

#1
1-2 SIGNAL

EX

2-3 SIGNAL

23 REGULATED

10

FEED LIMIT

23 REGULATED

1d
TCC SIGNAL

EX

EX

2-3 SHIFT VALVE

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

(B)
29

EX

OFF

EX

SECOND COAST CLUTCH

RLO

OVERDRIVE CL FD 1

FEED LIMIT
FEED LIMIT

4-5 SIGNAL

COAST CLUTCH FEED

CNTRL

EX

EX

(C)

LINE SM

OVERDRIVE CL FD 2

EX

TCC PWM
SOLENOID
VALVE
N/C

COAST CLUTCH
123
123
123 BRAKING

28

LINE

TCC REGULATOR VALVE

45

EX

4-5 SHIFT VLV

EX

EX

EX

REVERSE

REVERSE
LOCKOUT
VALVE

FEED LIMIT VALVE

OFF
11

FEED LIMIT

LINE SM

REGULATED APPLY

R N D 4 3 2

FILTER
(308)

32

LINE

D432

REV

EX

MANUAL VALVE

1a

LINE

REGULATED APPLY

REVERSE

TCC SIGNAL

2345 OR REVERSE

EX

LINE

4-5 SHIFT
SOLENOID
VALVE
N/C

EX

EX

Note: Allowing fluid to bypass an orifice when exhausting


ensures a quick release of the clutch. This prevents the friction
material from dragging and creating excess fluid
temperatures or damaging the clutch.

FEED LIMIT

FDL
EX

OFF

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH

24

EX

(A)

2345

FEED LIMIT

Low and reverse clutch or reverse lockout fluid seats the #8


ball check valve against the low and reverse clutch fluid
circuit and enters the reverse lockout fluid circuit where it
exhausts along with reverse clutch fluid past the manual valve.

1-2 SHIFT CONTROL VALVE

SAFETY MODE

FILTER
(312)

2b #8 Ball Check Valve:

1-2 SHIFT
SOLENOID
VALVE
N/C

EX

PRESSURE
CONTROL
SOLENOID
VALVE

FEED LIMIT

1-2 SHIFT VALVE

345
2345

LINE
FEED LIMIT

EX

2 LOW AND REVERSE CLUTCH RELEASES

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

FEED LIMIT

2345

MEMORY PILOT

EX

1c

EX

MEMORY

REVERSE LOCKOUT

Reverse clutch fluid exhausts from the line boost valve,


allowing line pressure to return to the normal operating
range as in Park, Neutral and Overdrive gear ranges.

2-3 SIGNAL

REVERSE LOCKOUT

1e Line Boost Valve:

FDL

SECOND CL
D432

REVERSE CLUTCH

EX

D432
SECOND CL
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REV CL

13

EX

X-2

Reverse lockout fluid passes through the reverse lockout


valve and into the reverse fluid circuit and on to the manual
valve where it exhausts.

Note: In Park, Reverse and Neutral the shift solenoid valves


are shown de-energized. This is the normal operating state
when the vehicle is stationary or at low vehicle speeds. However,
the TCM will change the shift solenoid valve states depending
on vehicle speed. For example, if Neutral range is selected
when the vehicle is operating in Second gear, the shift solenoid
valves will remain in a Second gear state. But with the manual
valve in Neutral, line pressure is blocked, D432 fluid exhausts
and the transmission will shift into Neutral.

SECOND
CLUTCH
ACCUMULATOR

1d Reverse Lockout Valve:

Low and reverse clutch or reverse lockout fluid exhausts


from the outer area of the low and reverse clutch piston to
the #8 ball check valve. Reverse lockout fluid also exhausts
from the inner area of the low and reverse clutch piston
through orifice #12. The exhaust of these fluids allows the
low and reverse clutch to release.

INTERMEDIATE
CLUTCH
ACCUMULATOR

ACCUMULATOR
OVERDR CL FD 2

THROTTLE SIGNAL

Reverse clutch fluid unseats the #1 ball check valve and


enters the reverse lockout fluid circuit. Reverse lockout
fluid then flows to the reverse lockout valve where it enters
the reverse fluid circuit.

2a Low and Reverse Clutch:

EX

LINE SAFETY MODE

1c #1 Ball Check Valve:

OVERDRIVE
CLUTCH
ACCUMULATOR

ACCUM

REVERSE CLUTCH

ACCUMULATOR
DIRECT CL

Reverse clutch fluid exhausts from the reverse clutch to the


#1 ball check valve allowing the reverse clutch to release.

DECREASE

#8

REVERSE CLUTCH

1b Reverse Clutch:

LINE

DIRECT CLUTCH

REVERSE LOCKOUT
SECOND CLUTCH

REVERSE CLUTCH

1 REVERSE CLUTCH RELEASES

SECOND COAST CL
LOW AND REV CL OR RLO

2a

1b

EX

When the gear selector lever is moved to the Neutral (N)


position, the hydraulic and electrical system operation is
identical to Park (P) range. However, if Neutral is selected
after the vehicle was operating in Reverse (R), the following
changes would occur in the hydraulic system:

CENTER
SUPPORT
ASSEMBLY
(510535)

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

32
32 SAFETY MODE

OFF OFF OFF


LD = LOCKED IN DRIVE

(Engine Running)

PRESS REG VALVE

FORWARD OVER- INTERM. INTER- LOW LOW AND


SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

BOOST VALVE

SOLENOID

MEMORY
FEED LIMIT
LINE
LINE SAFETY MODE

WWW.ALL-TRANS.BY

NEUTRAL

(Engine Running)

2345

#2
2345 OR REVERSE
LINE

LINE
2345 OR REVERSE

COMPLETE HYDRAULIC CIRCUIT


Page 90

60B

LINE (from Pump)

Figure 57

61

OVERDRIVE RANGE FIRST GEAR


(before the first 1-2 shift has occurred)

(before the first 1-2 shift has occurred)


1
POWER FROM
TORQUE
CONVERTER
(1)

2a
COAST
CLUTCH
APPLIED

2
FORWARD
CLUTCH
APPLIED

3
FORWARD
CLUTCH
SPRAG
(461)
HOLDING

6
LOW
CLUTCH
SPRAG
(503)
HOLDING

7
LOW AND
REVERSE
CLUTCH
APPLIED

6a
INPUT AND
REACTION
CARRIER
(553)
HELD

5
LONG
PLANETARY
PINION
GEAR
DRIVING

8
REAR
INTERNAL
GEAR
(560)
DRIVEN

4
REAR
INPUT SUN
GEAR
DRIVING
POWER TO
DIFFERENTIAL
ASSEMBLY

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF ON OFF

APPLIED APPLIED

LD

LD

APPLIED

LD = LOCKED IN DRIVE

In Overdrive Range D First Gear, torque from the engine is


multiplied through the torque converter and transmission gear set
to the vehicles drive shaft. The planetary gears operate in reduction
to achieve a First gear starting ratio of approximately 3.42:1.
The manual shift shaft (606) and the manual valve (377) are
in the Overdrive D position.
1

WWW.ALL-TRANS.BY

OVERDRIVE RANGE FIRST GEAR

Power from Torque Converter

The input shaft forward and coast clutch housing assembly


(433) is splined to and driven by the converter turbine.

Forward and Coast Clutches Applied

The forward clutch, which is located within the input shaft


forward and coast clutch housing assembly (433), is applied
and holds the forward clutch sprag outer race (459). The
coast clutch is also located in the input shaft forward and
coast clutch housing assembly (433) and is also applied.
3
4a
REAR SHORT
PINION GEAR
DRIVING

The forward clutch sprag (461) holds and power is


transmitted to the input sun gear shaft assembly (457).
4

FORWARD
CLUTCH
APPLIED

COAST
CLUTCH
APPLIED

REVERSE
CLUTCH
HOUSING
ASSEMBLY
(401)

Forward Clutch Sprag Holding

Rear Input Sun Gear Driving

The input sun gear shaft assembly (457) is splined to the


rear input sun gear. The rear input sun gear drives the rear
short planetary pinions.

FORWARD
CLUTCH
SPRAG
(461)
HOLDING

Long Planetary Pinion Gears Driving

The rear short planetary pinions drive the long planetary


pinions. The long pinions are in mesh with the front input
sun gear, the front short pinions and the rear internal gear.
6

Low Clutch Sprag Holding

The power transferred to the input and reaction carrier (553)


by the long planetary pinions attempts to rotate the carrier but,
the carrier is held stationary by the low clutch sprag (503).
7

Low and Reverse Clutch Applied

The low and reverse clutch, which is located within the


center support (518), is applied and holds the low clutch
sprag inner race (505). This assists the low clutch sprag in
holding the input and reaction carrier (553) stationary.
8

LOW
CLUTCH
SPRAG
(503)
HOLDING

LOW AND
REVERSE
CLUTCH
APPLIED

INPUT AND
REACTION
CARRIER
(553)
HELD

REAR
INPUT
SUN GEAR
DRIVING

With the input and reaction carrier (553) held, the long
pinions drive the rear internal gear (560) to achieve the first
gear starting ratio of approximately 3.42:1

LONG
PLANETARY
PINION
GEAR
DRIVING

When the throttle is released in Overdrive Range First Gear


before the first 1-2 shift has occurred, power from the vehicle
wheels attempts to drive the transmission components faster
than engine torque is driving them. Because the low and
reverse clutch is applied and holds the input and reaction carrier
assembly stationary, the low clutch sprag (503) is prevented
from overrunning and engine braking slows the vehicle.
As vehicle speed increases, less torque multiplication is needed
for maximum efficiency. Therefore, it is desirable to shift the
transmission to a lower gear ratio, or Second gear.

REAR SHORT
PINION GEAR
DRIVING

62

Rear Internal Gear Driven

Figure 58

REAR
INTERNAL
GEAR
(560)
DRIVEN

Note: the above description of mechanical power flow occurs


before the first 1-2 shift has occurred.

62A

OVERDRIVE RANGE FIRST GEAR

(before the first 1-2 shift has occurred)

LD = LOCKED IN DRIVE

When the gear selector lever is moved to the Overdrive Range D


position from the Neutral (N) position, before the first 1-2 shift has
occurred, the following changes occur to shift the transmission into
Overdrive Range First Gear.

62B

COMPLETE HYDRAULIC CIRCUIT


Page 92

CENTER
SUPPORT
ASSEMBLY
(510535)

2b

FORWARD CLUTCH
COAST CL
LUBE

AIR
BLEED
(203)

4h

AIR
BLEED
(203)

DIRECT
CLUTCH
ACCUMULATOR

OVERDRIVE
CLUTCH
ACCUMULATOR

EX

EX

INTERMEDIATE
CLUTCH
ACCUMULATOR

SECOND
CLUTCH
ACCUMULATOR

EX

EX
ACCUM

#8

LINE

REVERSE LOCKOUT

LOW AND REVERSE CL

4g

LINE

SECOND CLUTCH

ACCUMULATOR

INTERMEDIATE CL

ACCUMULATOR
OVERDRIVE CL FD 2

ACCUMULATOR
DIRECT CL

COAST CLUTCH

FORWARD CLUTCH

LINE
FEED LIMIT

FEED LIMIT
D432
2-3 SIGNAL

FDL

1-2 SIGNAL

2-3 SIGNAL

FDL

(B)

ON

EX

EX

EX

SECOND COAST CLUTCH


OVERDRIVE CL FD 1

FEED LIMIT

EX

2345

EX

EX

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

EX
29

EX

32 SM/FDL

4-5 SIGNAL

#10

4-5 SHIFT VLV

4-5 SHIFT
SOLENOID
VALVE
N/C

CNTRL

OVERDRIVE CL FD 2
123 BRAKING
LINE SAFETY MODE

OFF

EX

EX

(C)

LINE SM

28

CST CL
123
123
123 BRK

EX

32 SM

4d

11

FEED LIMIT

3c
123
123

D432

COAST CLUTCH FEED

32

123

2a

123

4c
LINE

LINE

R N D 4 3 2

D432

REV

EX

MANUAL VALVE

LINE

REGULATED APPLY

D432

EX

EX

EX

EX

2-3 SHIFT VALVE

REVERSE

TCC SIGNAL

2345 OR REVERSE

FEED LIMIT

SECOND CL
D432

2-3 SIGNAL

FDL

10

FEED LIMIT

COAST CLUTCH

EX

OFF

4a

23 REGULATED

LOW PRESSURE

EX

TCC PWM
SOLENOID
VALVE
N/C

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH

24

19

LINE

TCC REGULATOR VALVE

(A)

23 REGULATED

EX

EX

EX

FEED LIMIT VALVE

FEED LIMIT

2-3 SIGNAL

FDL

EX

FEED LIMIT

5a

4e

DIRECT CLUTCH

FEED LIMIT

26

2345

45

FEED LIMIT

1-2 SHIFT VALVE

EX

123
D432
345

4b

EX

CNTRL 3-4 SHIFT


EX

FILTER
(312)

COAST CLUTCH

1-2 SIGNAL
2-3 SIGNAL

LINE SAFETY MODE

EX

EX

SAFETY MODE

4f

1-2 SHIFT
SOLENOID
VALVE
N/C

1-2 SHIFT CONTROL VALVE

345
2345

PRESSURE
CONTROL
SOLENOID
VALVE

32
32 SAFETY MODE

EX

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

123 REGULATED

2-3 SIGNAL

MEMORY PILOT

LINE
FEED LIMIT

FORWARD CLUTCH

3b

MEMORY

X-3

EX

D432
SECOND CL
23 REGULATED
123 REG
123 REGULATED

20
14

LOW AND REV CL

FDL

LINE

1 MANUAL VALVE
In the Overdrive position the manual valve routes line pressure into the
D432 fluid circuit. D432 fluid is routed to the 1-2 shift valve and to
the 3-4 shift valve.
2 FORWARD CLUTCH APPLIES
2a #6 and #7 Ball Check Valves:
D432 fluid seats the #6 ball check valve and passes through
orifice #15 into the forward clutch fluid circuit. D432 fluid also
passes by the spring loaded #7 ball check valve to feed the forward
clutch circuit as necessary to help control forward clutch apply.
2b Forward Clutch Assembly:
Forward clutch fluid is routed to the forward clutch piston to
apply the forward clutch plates.
3 COAST CLUTCH APPLIES
3a #5 Ball Check Valve:
Forward clutch fluid seats the #5 ball check valve and passes
through orifice #17 into the coast clutch feed circuit. This orifice
helps to control coast clutch apply.
3b Safety Mode Valve
Before the first 1-2 shift has occurred, the safety mode valve
(341) remains in the released position, allowing line fluid pressure
to enter the line safety mode fluid circuit.
3c 4-5 Shift Valve:
Line safety mode fluid applies the 4-5 shift valve (374) against 45 shift valve spring (373) force. This allows coast clutch feed
fluid to enter the coast clutch fluid circuit.
3d Coast Clutch Assembly:
Coast clutch fluid is routed to the coast clutch piston to apply the
coast clutch plates.
4 LOW AND REVERSE CLUTCH APPLIES
4a 2-3 Shift Solenoid (SS) Valve:
The 2-3 SS valve is energized, allowing feed limit fluid to enter
the 2-3 signal fluid circuit. 2-3 signal fluid overcomes spring
force and applies the 2-3 shift valve (371).
4b 3-4 Shift Control Valve and 3-4 Shift Valve:
2-3 signal fluid is routed to the 3-4 shift control valve (346) and
applies the valve against spring force. This allows D432 fluid to
enter the 123 fluid circuit.
4c #4 Ball Check Valve:
123 fluid seats the #4 ball check valve and passes through orifice
#16. This orifice helps to control low and reverse clutch apply.
4d 4-5 Shift Valve:
Orificed 123 fluid is routed to the 4-5 shift valve (374) where it
passes into the 123 braking fluid circuit.
4e Low Pressure Control Valve:
123 braking fluid is routed to the low pressure control valve (383).
This valve regulates 123 braking fluid into the 123 regulated fluid
circuit against spring force and orificed 123 regulated fluid pressure.
4f 1-2 Shift Control Valve and 1-2 Shift Valve:
2-3 signal fluid is also routed to the 1-2 shift control valve (366)
and applies the valve against spring force. This allows feed limit
fluid to enter the FDL fluid circuit. FDL fluid is routed to the 1-2
shift valve (387) and applies the valve against spring force. 123
regulated fluid is routed through orifice #20 to the 1-2 shift valve
where it passes into the low and reverse clutch fluid circuit.
4g #8 Ball Check Valve:
Low and reverse clutch fluid seats the #8 ball check valve against
the reverse lockout fluid passage and enters the low and reverse
clutch or reverse lockout fluid passage.
4h Low and Reverse Clutch:
Low and reverse clutch or reverse lockout fluid pressure enters the
outer area of the low and reverse clutch piston and moves the piston
against spring force to apply the low and reverse clutch plates.
5 FLUID PRESSURE DIRECTED IN PREPARATION
FOR A SHIFT TO SECOND GEAR
5a 1-2 Shift Valve:
D432 fluid is routed to the 1-2 shift valve (387) where it is
blocked by the valve in preparation for an upshift to second gear.

3d

SECOND COAST CL
LOW AND REV CL OR RLO

APPLIED

345
45

LD

MEMORY
FEED LIMIT
LINE
LINE SAFETY MODE

LD

123
D432

APPLIED APPLIED

REGULATED APPLY

OFF ON OFF

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

REVERSE LOCKOUT
SECOND CLUTCH

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

FORWARD CLUTCH

WWW.ALL-TRANS.BY

OVERDRIVE RANGE FIRST GEAR

(before the first 1-2 shift has occurred)

LINE
D432

#4

16

#7

17

FORWARD CLUTCH

#6

D432

FORWARD CLUTCH

Figure 59

15

123

123

LINE (from Pump)

#5

3a

63

OVERDRIVE RANGE FIRST GEAR


(after the first 1-2 shift has occurred)

(after the first 1-2 shift has occurred)


1
POWER FROM
TORQUE
CONVERTER
(1)

2a
COAST
CLUTCH
APPLIED

2
FORWARD
CLUTCH
APPLIED

3
FORWARD
CLUTCH
SPRAG
(461)
HOLDING

6
LOW
CLUTCH
SPRAG
(503)
HOLDING

6a
INPUT AND
REACTION
CARRIER
(553)
HELD

5
LONG
PLANETARY
PINION
GEAR
DRIVING

7
REAR
INTERNAL
GEAR
(560)
DRIVEN

4
REAR
INPUT SUN
GEAR
DRIVING
POWER TO
DIFFERENTIAL
ASSEMBLY

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF ON OFF

APPLIED APPLIED

LD

LD

LD = LOCKED IN DRIVE

In Overdrive Range D First Gear, torque from the engine is


multiplied through the torque converter and transmission gear set
to the vehicles drive shaft. The planetary gears operate in reduction
to achieve a First gear starting ratio of approximately 3.42:1.
The manual shift shaft (606) and the manual valve (377) are
in the Overdrive D position.
1

WWW.ALL-TRANS.BY

OVERDRIVE RANGE FIRST GEAR

Power from Torque Converter

The input shaft forward and coast clutch housing assembly


(433) is splined to and driven by the converter turbine.

Forward and Coast Clutches Applied

The forward clutch, which is located within the input shaft


forward and coast clutch housing assembly (433), is applied
and holds the forward clutch sprag outer race (459). The
coast clutch is also located in the input shaft forward and
coast clutch housing assembly (433) and is also applied.
3
4a
REAR SHORT
PINION GEAR
DRIVING

The forward clutch sprag (461) holds and power is


transmitted to the input sun gear shaft assembly (457).
4

COAST
CLUTCH
APPLIED

REVERSE
CLUTCH
HOUSING
ASSEMBLY
(401)

FORWARD
CLUTCH
APPLIED

FORWARD
CLUTCH
SPRAG
(461)
HOLDING

Forward Clutch Sprag Holding

Rear Input Sun Gear Driving

The input sun gear shaft assembly (457) is splined to the


rear input sun gear. The rear input sun gear drives the rear
short planetary pinions.
5

Long Planetary Pinion Gears Driving

The rear short planetary pinions drive the long planetary


pinions. The long pinions are in mesh with the front input
sun gear, the front short pinions and the rear internal gear.
6

Low Clutch Sprag Holding

The power transferred to the input and reaction carrier (553)


by the long planetary pinions attempts to rotate the carrier but,
the carrier is held stationary by the low clutch sprag (503).
7

Rear Internal Gear Driven

With the input and reaction carrier (553) held, the long
pinions drive the rear internal gear (560) to achieve the first
gear starting ratio of approximately 3.42:1

When the throttle is released in Overdrive Range First


Gear, power from the vehicle wheels drives the transmission
components faster than engine torque is driving them. This
causes the low clutch sprag (503) to overrun and allows the
vehicle to coast freely without engine braking.

LOW
CLUTCH
SPRAG
(503)
HOLDING

INPUT AND
REACTION
CARRIER
(553)
HELD

REAR
INPUT
SUN GEAR
DRIVING

In order to achieve engine braking, the low and reverse clutch


can be applied to hold the input and reaction carrier assembly.
See Manual Second First Gear (page 82A) for a description
of power flow during coast conditions.

LONG
PLANETARY
PINION
GEAR
DRIVING

As vehicle speed increases, less torque multiplication is needed


for maximum efficiency. Therefore, it is desirable to shift the
transmission to a lower gear ratio, or Second gear.
Note: the above description of mechanical power flow occurs
after the first 1-2 shift has occurred.

REAR SHORT
PINION GEAR
DRIVING

64

Figure 60

REAR
INTERNAL
GEAR
(560)
DRIVEN

64A

OVERDRIVE RANGE FIRST GEAR

OVERDRIVE RANGE FIRST GEAR

(after the first 1-2 shift has occurred)

SOLENOID

FORWARD OVER- INTERM. INTER- LOW LOW AND


SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
LD

LD = LOCKED IN DRIVE

FORWARD CLUTCH
COAST CL
LUBE

When the gear selector lever is moved to the Overdrive


Range D position from the Neutral (N) position, after the
first 1-2 shift has occurred, the following changes occur to
shift the transmission into Overdrive Range First Gear.
DIRECT
CLUTCH
ACCUMULATOR

1 MANUAL VALVE

In the Overdrive position the manual valve routes line pressure


into the D432 fluid circuit. D432 fluid is routed to the 1-2 shift
valve and to the 3-4 shift valve.

AIR
BLEED
(203)

EX

AIR
BLEED
(203)

OVERDRIVE
CLUTCH
ACCUMULATOR

3f

EX

INTERMEDIATE
CLUTCH
ACCUMULATOR

SECOND
CLUTCH
ACCUMULATOR

EX

EX
ACCUM

2 FORWARD CLUTCH APPLIES


2a #6 and #7 Ball Check Valves:

LINE

2b #5 Ball Check Valve:

SECOND CLUTCH

FORWARD CLUTCH

LINE

ACCUMULATOR
DIRECT CL

D432 fluid seats the #6 ball check valve and passes through
orifice #15 into the forward clutch fluid circuit. D432 fluid
also passes by the spring loaded #7 ball check valve to feed
the forward clutch circuit as necessary to help control forward
clutch apply.

2c

ACCUMULATOR

LD

INTERMEDIATE CL

APPLIED APPLIED

ACCUMULATOR
OVERDRIVE CL FD 2

OFF ON OFF

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

COAST CLUTCH

WWW.ALL-TRANS.BY

(after the first 1-2 shift has occurred)

LINE
FEED LIMIT

Forward clutch fluid seats the #5 ball check valve and passes
through orifice #17 into the coast clutch feed circuit.

FEED LIMIT
D432

2c Forward Clutch Assembly:

Forward clutch fluid is routed to the forward clutch piston


to apply the forward clutch plates.

2-3 SIGNAL

1-2 SIGNAL
FDL

EX

EX

EX

EX

FEED LIMIT

FDL

2-3 SIGNAL

SECOND CL
D432

2-3 SIGNAL
FDL

D432
ON

EX

EX

EX

SECOND COAST CLUTCH


OVERDRIVE CL FD 1

FEED LIMIT

EX

2345

EX

345
2345

(B)

29

EX
4-5 SIGNAL

4-5 SHIFT
SOLENOID
VALVE
N/C

#10

OVERDRIVE CL FD 2
LINE SAFETY MODE

OFF

EX

EX

(C)

LINE SM

28

CST CL
123
123
123 BRK

EX

32 SM

45

4-5 SHIFT VLV CNTRL

11

FEED LIMIT

3e
123
123

D432

REGULATED APPLY

REVERSE

123
D432

32

123

2a

123

3d
LINE

LINE

R N D 4 3 2

D432

REV

EX

MANUAL VALVE

LINE

REGULATED APPLY

2345 OR REVERSE

EX

COAST CLUTCH FEED

D432 fluid is routed to the 1-2 shift valve (387) where it


is blocked by the valve in preparation for an upshift to
second gear.
LINE
D432

#4

16

#7

17

FORWARD CLUTCH

15

#6

D432

FORWARD CLUTCH

Figure 61

#5

123

123

LINE (from Pump)

64B

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

COAST CLUTCH

4 FLUID PRESSURE DIRECTED IN PREPARATION


FOR A SHIFT TO SECOND GEAR
4a 1-2 Shift Valve:

COMPLETE HYDRAULIC CIRCUIT


Page 92

10

FEED LIMIT

2-3 SHIFT VALVE

32 SM/FDL

EX

TCC PWM
SOLENOID
VALVE
N/C

LINE

FORWARD CLUTCH

TCC REGULATOR VALVE

OFF

3a

23 REGULATED

EX

LINE

3e 4-5 Shift Valve:

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH

24

EX

EX

EX

FEED LIMIT VALVE

123 fluid seats the #4 ball check valve and passes through
orifice #16. This orifice helps to control coast clutch apply.

(A)

23 REGULATED

FDL

EX

FEED LIMIT

FEED LIMIT

2-3 SIGNAL

DIRECT CLUTCH

FEED LIMIT

26

4a

EX

EX

123
D432
345

3c

FEED LIMIT

1-2 SHIFT
SOLENOID
VALVE
N/C

1-2 SHIFT CONTROL VALVE

345
45

EX

CNTRL 3-4 SHIFT

3b

1-2 SHIFT VALVE

COAST CLUTCH

1-2 SIGNAL

LINE SAFETY MODE

EX

EX

SAFETY MODE

FILTER
(312)

X-3

2345

2-3 SIGNAL

3d #4 Ball Check Valve:

Coast clutch fluid is routed to the coast clutch piston to


apply the coast clutch plates.

32
32 SAFETY MODE

EX
PRESSURE
CONTROL
SOLENOID
VALVE

2-3 signal fluid is also routed to the 3-4 shift control valve
(346) and moves the valve against 3-4 shift valve spring
(344) force to the applied position. This allows D432 fluid
to enter the 123 fluid circuit at the 3-4 shift valve (345).

3f Coast Clutch Assembly:

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

3c 3-4 Shift Control Valve and 3-4 Shift Valve:

Orificed 123 fluid is routed to the 4-5 shift valve (374)


where it passes into the coast clutch fluid circuit.

MEMORY
FEED LIMIT
LINE
LINE SAFETY MODE

MEMORY PILOT

TCC SIGNAL

2-3 signal fluid is routed to the 1-2 shift control valve (366)
and moves the valve against 1-2 shift control valve spring
(367) force to the applied position. This allows feed limit
fluid to enter the FDL fluid circuit. FDL fluid is routed to
the 1-2 shift valve (387) and moves the valve against 1-2
shift valve spring (388) force to the applied position to
block D432 fluid at the valve.

FORWARD CLUTCH

3b 1-2 Shift Control Valve and 1-2 Shift Valve:

MEMORY

LINE
FEED LIMIT

The 2-3 SS valve is energized, allowing feed limit fluid to


enter the 2-3 signal fluid circuit. 2-3 signal fluid overcomes
2-3 shift valve spring (372) force and moves the 2-3 shift
valve (371) to the applied position.

2-3 SIGNAL

3 COAST CLUTCH APPLIES


3a 2-3 Shift Solenoid (SS) Valve:

EX

D432
SECOND CL
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REV CL

FDL
14

2b

65

OVERDRIVE RANGE SECOND GEAR

3
FORWARD
CLUTCH
SPRAG
(461)
HOLDING

2
FORWARD
CLUTCH
APPLIED

2a
COAST
CLUTCH
APPLIED

1
POWER FROM
TORQUE
CONVERTER
(1)

6
SECOND
CLUTCH
APPLIED

7
SECOND
CLUTCH
SPRAG
(547)
HOLDING

7a
REACTION
INTERNAL
GEAR
(550)
HELD

8
INPUT AND
REACTION
CARRIER
(553)
DRIVEN

9
REAR
INTERNAL
GEAR
(560)
DRIVEN

5
LONG
PINION GEAR
DRIVING
4
REAR INPUT
SUN GEAR
DRIVING

WWW.ALL-TRANS.BY

OVERDRIVE RANGE SECOND GEAR

POWER TO
DIFFERENTIAL
ASSEMBLY

4a
REAR SHORT
PINION
GEAR
DRIVING
8a
FRONT SHORT
PINION
GEAR
DRIVING

COAST
CLUTCH
APPLIED

REVERSE
CLUTCH
HOUSING
ASSEMBLY
(401)

FORWARD
CLUTCH
SPRAG
(461)
HOLDING

FORWARD
CLUTCH
APPLIED

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
ON ON OFF

APPLIED APPLIED

LD

APPLIED

LD

LD = LOCKED IN DRIVE

As vehicle speed increases, input signals from the transmission


speed sensors (input and output), throttle position (To) sensor,
and other vehicle sensors are sent to the transmission control
module (TCM). The TCM processes this information to
determine the precise moment to shift the transmission. In
Second gear, the planetary gear set continues to operate in
reduction at a gear ratio of approximately 2.21:1.
1

Power from Torque Converter

The input shaft forward and coast clutch housing assembly


(433) is splined to and driven by the converter turbine.
2

Forward and Coast Clutches Applied

The forward clutch, which is located within the input shaft


forward and coast clutch housing assembly (433), is applied
and holds the forward clutch sprag outer race (459). The
coast clutch is also located in the input shaft forward and
coast clutch housing assembly (433) and is also applied.
3

Forward Clutch Sprag Holding

The forward clutch sprag (461) holds and power is


transmitted to the input sun gear shaft assembly (457).
4

Rear Input Sun Gear Driving

The input sun gear shaft assembly (457) is splined to the


rear input sun gear. The rear input sun gear drives the rear
short planetary pinions.
5

Long Planetary Pinion Gears Driving

The rear short planetary pinions drive the long planetary


pinions. The long pinions are in mesh with the front input
sun gear, the front short pinions and the rear internal gear.
6

Second Clutch Applied

The second clutch, which is located within the center support


(518), is applied and holds the second clutch sprag outer
race (545).
7

Second Clutch Sprag Holding

The power transferred to the front short pinions by the long


planetary pinions attempts to rotate the reaction internal
gear (550) but, the reaction internal gear is held stationary
by the second clutch sprag (547).
8

SECOND
CLUTCH
SPRAG
(547)
HOLDING
SECOND
CLUTCH
APPLIED

Figure 62

LONG
PINION
GEAR
DRIVING

Rear Internal Gear Driven

The long pinions drive the rear internal gear (560) to achieve
the second gear ratio of approximately 2.21:1

REAR SHORT
PINION GEAR
DRIVING

REAR
INPUT
SUN GEAR
DRIVING

66

The front short pinions are driven around the stationary


reaction internal gear (550), driving the input and reaction
carrier (553).

REACTION
INTERNAL
GEAR
(550)
HELD

INPUT AND
REACTION
CARRIER
(553)
DRIVEN

Input and Reaction Carrier Driven

When the throttle is released in Overdrive Range Second


Gear, power from the vehicle wheels drives the transmission
components faster than engine torque is driving them. This
causes the second clutch sprag (547) to overrun and allows
the vehicle to coast freely without engine braking.

REAR
INTERNAL
GEAR
(560)
DRIVEN

In order to achieve engine braking, the second coast clutch


can be applied to hold the reaction internal gear. See Manual
Second Second Gear (page 80A) for a description of power
flow during coast conditions.
As vehicle speed increases, less torque multiplication is needed
to move the vehicle efficiently. Therefore, it is desirable to shift
the transmission to a lower gear ratio, or Third gear.

66A

OVERDRIVE RANGE SECOND GEAR

SOLENOID

FORWARD OVER- INTERM. INTER- LOW LOW AND


SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

DIRECT
CLUTCH
ACCUMULATOR

AIR
BLEED
(203)

EX

The 1-2 SS valve is energized, allowing feed limit fluid to


enter the 1-2 signal fluid circuit. 1-2 signal fluid, together
with 1-2 shift control valve spring (367) force, overcomes
2-3 signal fluid pressure and moves the 1-2 shift control
valve (366) to the released position. This blocks feed limit
fluid from entering the FDL fluid circuit.

OVERDRIVE
CLUTCH
ACCUMULATOR

AIR
BLEED
(203)

EX

EX

EX

1c

#8

2a

REVERSE LOCKOUT

LOW AND REVERSE CL

LINE

LINE

ACCUMULATOR

SECOND CLUTCH

INTERMEDIATE CL

ACCUMULATOR
OVERDRIVE CL FD 2

ACCUMULATOR
DIRECT CL

LINE
FEED LIMIT

FEED LIMIT

D432

1c Second Clutch:

1-2 SIGNAL
2-3 SIGNAL

Second clutch fluid is directed to the second clutch piston to


apply the second clutch plates and achieve Second gear.

1-2 SIGNAL
FDL

EX

EX

D432
2345
2-3 SHIFT
SOLENOID
VALVE
N/C

(B)

EX

SECOND COAST CLUTCH


OVERDRIVE CL FD 1
2345
2345

3a
EX

18

4-5 SIGNAL

4-5 SHIFT
SOLENOID
VALVE
N/C

28

OVERDRIVE CL FD 2
123 BRAKING
LINE SAFETY MODE

123
123

R N D 4 3 2

123

32

D432

LINE

REV

EX

123
D432

D432

COAST CLUTCH FEED

2345

REGULATED APPLY

11

FEED LIMIT

MANUAL VALVE

LINE

REGULATED APPLY

FILTER
(308)

OFF

EX

EX

(C)

LINE SM

#10

CST CL
123
123
123 BRK

4-5 SHIFT VLV CNTRL

32 SM

EX

29

EX

32 SM/FDL

ON

EX

EX

EX

CNTRL

FEED LIMIT

EX

X-1

2345

LOW PRESSURE

REVERSE

TCC SIGNAL

2345 OR REVERSE

4b

FEED LIMIT

FDL

2-3 SIGNAL

EX

D432
SECOND CL
23 REGULATED
123 REG
123 REG

SECOND CL
D432

EX

EX

2-3 SHIFT VALVE

EX

EX

10

FEED LIMIT

COAST CLUTCH

EX

LINE

FORWARD CLUTCH

TCC PWM
SOLENOID
VALVE
N/C

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH

19

LINE

TCC REGULATOR VALVE

ON

2-3 SIGNAL

FDL

EX
EX

FEED LIMIT VALVE

(A)

23 REGULATED

DIRECT CLUTCH

FEED LIMIT
FEED LIMIT

4b TCC PWM Solenoid Valve:

26

FEED LIMIT

23 REGULATED

45

24

EX

123
D432
345

EX

2345 fluid seats the ball check valve against the reverse
passage and enters the 2345 or reverse fluid circuit.

EX

CNTRL 3-4 SHIFT

FILTER
(312)

1b

345
45

4 TORQUE CONVERTER CLUTCH RELEASED


4a #2 Ball Check valve:

FEED LIMIT

2345

EX

1-2 SIGNAL
2-3 SIGNAL

1a

1-2 SHIFT
SOLENOID
VALVE
N/C

1-2 SHIFT CONTROL VALVE

345
2345

SAFETY MODE

20

X-3

EX

PRESSURE
CONTROL
SOLENOID
VALVE

14

1-2 SHIFT VALVE

FDL
123 REGULATED

EX

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

2-3 SIGNAL

MEMORY
FEED LIMIT
LINE
LINE SAFETY MODE

MEMORY PILOT

EX

2345 fluid is routed to the 2-3 shift valve (371) where it is


blocked by the valve in preparation for an upshift to third gear.

MEMORY

LINE
FEED LIMIT

FORWARD CLUTCH

1-2 SIGNAL
2-3 SIGNAL

21

LOW AND REV CL

FDL

2 SHIFT ACCUMULATION
2a Second Clutch Accumulator:

2345 or reverse fluid is directed through the TCC PWM


solenoid valve filter to the TCC PWM solenoid valve.
However, depending on the shift pattern, the TCM keeps
the pulse width modulated (PWM) solenoid de-energized
blocking filtered 2345 or reverse fluid from entering the
TCC signal fluid circuit, thereby keeping the torque converter
clutch released.

SECOND
CLUTCH
ACCUMULATOR

ACCUM

1b 1-2 Shift Valve:

3 FLUID PRESSURE DIRECTED IN PREPARATION


FOR A SHIFT TO THIRD GEAR
3a 2-3 Shift Valve:

INTERMEDIATE
CLUTCH
ACCUMULATOR

REVERSE LOCKOUT
SECOND CLUTCH

FORWARD CLUTCH
COAST CL
LUBE

1 SECOND CLUTCH APPLIES


1a 1-2 Shift Solenoid (SS) Valve:

Second clutch fluid is also sent to the second clutch


accumulator assembly. Second clutch fluid, together with
accumulator spring force, moves the second clutch
accumulator piston against accumulator fluid pressure to
cushion the apply of the second clutch.

SECOND COAST CL
LOW AND REV CL OR RLO

As vehicle speed increases, the transmission control module


(TCM) receives input signals from both the input and output
speed sensors, the throttle position (To) sensor and other vehicle
sensors to determine the precise moment to energize or turn
ON the 1-2 shift solenoid (SS) valve.

FDL fluid is exhausted from the 1-2 shift valve (387) and
1-2 shift valve spring (388) force moves the valve to the
released position to allow D432 fluid to enter the second
clutch and 2345 fluid circuits.

CENTER
SUPPORT
ASSEMBLY
(510535)

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

LD

COAST CLUTCH

APPLIED

LINE SAFETY MODE

LD

EX

APPLIED APPLIED

32
32 SAFETY MODE

ON ON OFF
LD = LOCKED IN DRIVE

FORWARD CLUTCH
COAST CLUTCH

WWW.ALL-TRANS.BY

OVERDRIVE RANGE SECOND GEAR

123
2345

4a

#2

#4

16

#7

17

#5

15

#6

2345 OR REVERSE
LINE

LINE
D432

123
D432

2345 OR REVERSE

COMPLETE HYDRAULIC CIRCUIT


Page 94

66B

123

LINE (from Pump)


FORWARD CLUTCH

FORWARD CLUTCH

Figure 63

67

OVERDRIVE RANGE THIRD GEAR

1
POWER FROM
TORQUE
CONVERTER
(1)

2a
COAST
CLUTCH
APPLIED

2
3
7
6
FORWARD
FORWARD
INTERMEDIATE INTERMEDIATE
CLUTCH CLUTCH SPRAG
CLUTCH
CLUTCH
APPLIED
(461)
SPRAG
APPLIED
HOLDING
(473)
HOLDING

9
SECOND
CLUTCH
APPLIED

10
SECOND
CLUTCH
SPRAG
(547)
OVERRUNNING

7a
FRONT
INPUT
SUN
GEAR
HELD

11
8
REAR
INPUT AND
INTERNAL REACTION
GEAR
CARRIER
(560)
(553)
DRIVEN
DRIVEN
11a
LONG
PINION
GEAR
DRIVING

POWER TO
DIFFERENTIAL
ASSEMBLY

WWW.ALL-TRANS.BY

OVERDRIVE RANGE THIRD GEAR

4
REAR
INPUT
SUN GEAR
DRIVING
5
REAR SHORT
PINION
GEAR
DRIVING

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
ON OFF OFF

REVERSE
CLUTCH
HOUSING
ASSEMBLY
(401)

COAST
CLUTCH
APPLIED

LD

APPLIED

APPLIED

Power from Torque Converter

The input shaft forward and coast clutch housing assembly


(433) is splined to and driven by the converter turbine.
2

Forward and Coast Clutches Applied

The forward clutch, which is located within the input shaft


forward and coast clutch housing assembly (433), is applied
and holds the forward clutch sprag outer race (459). The
coast clutch is also located in the input shaft forward and
coast clutch housing assembly (433) and is also applied.
3

Forward Clutch Sprag Holding

The forward clutch sprag (461) holds and power is


transmitted to the input sun gear shaft assembly (457).
4

Rear Input Sun Gear Driving

The input sun gear shaft assembly (457) is splined to the


rear input sun gear. The rear input sun gear drives the rear
short planetary pinions.
5

FORWARD
CLUTCH
APPLIED

LD

As vehicle speed continues to increase, input signals from the


transmission speed sensors (input and output), throttle position
(To) sensor, and other vehicle sensors are sent to the TCM. The
TCM uses this information to determine the precise moment to
shift the transmission into Third gear. In Third gear, the planetary
gear set continues to operate in reduction at a gear ratio of
approximately 1.60:1.

Long Planetary Pinion Gears Driving

The rear short planetary pinions drive the long planetary


pinions. The long pinions are in mesh with the front input
sun gear, the front short pinions and the rear internal gear.

INTERMEDIATE
CLUTCH SPRAG
(473)
HOLDING

FORWARD
CLUTCH
SPRAG
(461)
HOLDING

APPLIED APPLIED

LD = LOCKED IN DRIVE

Intermediate Clutch Applied

The intermediate clutch, which is located within the overdrive


and intermediate clutch assembly (15), is applied and holds
the intermediate clutch sprag outer race (474).
7

Intermediate Clutch Sprag Holding

The power transferred to the front short pinions by the long


planetary pinions attempts to drive the front input sun gear
but, the front input sun gear is held stationary by the
intermediate clutch sprag (473).
8

Input and Reaction Carrier Driven

The long planetary pinions are forced to walk around the


stationary front input sun gear, driving the input and reaction
carrier (553).
9

Second Clutch Applied

The second clutch, which is located within the center support


(518), is applied and holds the second clutch sprag outer
race (545).

SECOND
CLUTCH
APPLIED

SECOND
CLUTCH
SPRAG
(547)
OVERRUNNING

FRONT INPUT
SUN GEAR
HELD

10 Second Clutch Sprag Overrunning

The power transferred to the front short pinions by the long


planetary pinions drives the reaction internal gear (550) in
the opposite direction of the input and reaction carrier (553)
and the second clutch sprag (547) overruns.

REAR
SHORT
PINION
GEAR
DRIVING

11 Rear Internal Gear Driven

The long pinions drive the rear internal gear (560) to achieve
the second gear ratio of approximately 1.60:1

INTERMEDIATE
CLUTCH
APPLIED

INPUT AND
REACTION
CARRIER
(553)
DRIVEN

68

Figure 64

REAR INPUT
SUN GEAR
DRIVING

LONG
PINION
GEAR
DRIVING

REAR
INTERNAL
GEAR
(560)
DRIVEN

When the throttle is released in Overdrive Range Third


Gear, power from the vehicle wheels drives the transmission
components faster than engine torque is driving them. This
causes the intermediate clutch sprag (473) to overrun and
allows the vehicle to coast freely without engine braking.
In order to achieve engine braking, the overdrive clutch can
be applied to hold the front input sun gear. See Manual
Third Third Gear (page 78A) for a description of power
flow during coast conditions.
As vehicle speed increases, less torque multiplication is required
to move the vehicle efficiently. Therefore, it is desirable to shift
the transmission to a lower gear ratio, or Fourth gear.

68A

OVERDRIVE RANGE THIRD GEAR

SOLENOID

FORWARD OVER- INTERM. INTER- LOW LOW AND


SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

DIRECT
CLUTCH
ACCUMULATOR

AIR
BLEED
(203)

EX

OVERDRIVE
CLUTCH
ACCUMULATOR

AIR
BLEED
(203)

EX

SECOND
CLUTCH
ACCUMULATOR

EX

EX

LINE

LINE

ACCUMULATOR

2a

SECOND CLUTCH

INTERMEDIATE CL

ACCUMULATOR
OVERDRIVE CL FD 2

ACCUMULATOR
DIRECT CL

1c Intermediate Clutch:

LINE
INTERMEDIATE CLUTCH

Intermediate clutch fluid is directed to the intermediate clutch


piston to apply the intermediate clutch plates and achieve
Third gear.

FEED LIMIT

FEED LIMIT
D432
SECOND CLUTCH

1-2 SIGNAL
FDL

FEED LIMIT

FDL

2-3 SIGNAL

EX

EX

D432
2345
(B)
29

EX
EX
SECOND COAST CLUTCH

1a
FEED LIMIT

2345
2345

345

18

OVERDRIVE CL FD 1

4c

4-5 SIGNAL

4-5 SHIFT
SOLENOID
VALVE
N/C

28

(C)

EX

CST CL
123
123
123 BRAKING

EX

4-5 SHIFT VLV CNTRL

EX

OFF

EX

EX

EX

345
2345

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

OFF
11

FEED LIMIT
LINE SAFETY MODE
123
123

OVERDRIVE CL FD 2
COAST CLUTCH
COAST CLUTCH FEED

R N D 4 3 2

D432

123

32

D432

LINE

EX

REV

345
123
D432

123
2345

345
25

2345

345

REGULATED APPLY

MANUAL VALVE

LINE

4b

REGULATED APPLY

3a
FILTER
(308)

REVERSE
TCC SIGNAL

2345 OR REVERSE

EX

LINE

FORWARD CLUTCH

TCC PWM
SOLENOID
VALVE
N/C

X-1

4a

LINE

TCC REGULATOR VALVE

EX

SECOND CL
D432

EX

2-3 SHIFT VALVE

EX

DIRECT CLUTCH

26

10

FEED LIMIT

1b

EX

EX

EX

FEED LIMIT VALVE

345 fluid is routed through the X-4 ball check valve pocket.
In some transmission models there is a ball check valve
present which would force 345 fluid through orifice #25.

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH

23 REGULATED

EX
EX

123
D432
345

EX

4b X-4 Ball Check Valve:

ON

2-3 SIGNAL

EX

FEED LIMIT
FEED LIMIT

(A)

23 REGULATED

3-4 SHIFT

2345 fluid is routed through the 2-3 shift valve (371) into
the 345 fluid circuit.

1-2 SHIFT CONTROL VALVE

24

1-2 SIGNAL

4 FLUID PRESSURE DIRECTED IN PREPARATION


FOR A SHIFT TO FOURTH GEAR
4a 2-3 Shift Valve:

1-2 SHIFT
SOLENOID
VALVE
N/C

2345

2-3 SIGNAL

CNTRL

FEED LIMIT

1-2 SHIFT VALVE

SAFETY MODE

FILTER
(312)

FEED LIMIT

2345

PRESSURE
CONTROL
SOLENOID
VALVE

X-3

45

EX

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

14

EX

MEMORY PILOT

2-3 SIGNAL

MEMORY
FEED LIMIT
LINE
LINE SAFETY MODE

MEMORY

EX

Filtered 2345 or reverse fluid is still available at the TCC


PWM solenoid valve. However, depending on the shift
pattern, the TCM keeps the pulse width modulated (PWM)
solenoid de-energized blocking filtered 2345 or reverse fluid
from entering the TCC signal fluid circuit, thereby keeping
the torque converter clutch released.

LINE
FEED LIMIT

FORWARD CLUTCH

1-2 SIGNAL
2-3 SIGNAL

21

D432
SECOND CL
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REV CL

1-2 SIGNAL
2-3 SIGNAL

2 SHIFT ACCUMULATION
2a Intermediate Clutch Accumulator:

345 fluid is routed to the 3-4 shift valve (345) where it is


blocked by the valve in preparation for an upshift to fourth gear.

INTERMEDIATE
CLUTCH
ACCUMULATOR

ACCUM

1b 2-3 Shift Valve:

4c 3-4 Shift Valve:

SECOND COAST CL
LOW AND REV CL OR RLO

OVERDRIVE CLUTCH

The 2-3 SS valve is de-energized, blocking feed limit fluid


from entering the 2-3 signal fluid circuit. 2-3 signal fluid
pressure exhausts through the 2-3 SS valve and 2-3 shift
valve spring (372) force moves the 2-3 shift valve (371) to
the released position.

3 TORQUE CONVERTER CLUTCH RELEASED


3a TCC PWM Solenoid Valve:

1c
REVERSE LOCKOUT
SECOND CLUTCH

FORWARD CLUTCH
COAST CL
LUBE

1 INTERMEDIATE CLUTCH APPLIES


1a 2-3 Shift Solenoid (SS) Valve:

Intermediate clutch fluid is also sent to the intermediate


clutch accumulator assembly. Intermediate clutch fluid,
together with accumulator spring force, moves the
intermediate clutch accumulator piston against accumulator
fluid pressure to cushion the apply of the intermediate clutch.

CENTER
SUPPORT
ASSEMBLY
(510535)

INTERMEDIATE CLUTCH

As vehicle speed increases, the TCM receives input signals


from both speed sensors, the To sensor and other vehicle sensors
to determine the precise moment to de-energize or turn OFF
the 2-3 shift solenoid (SS) valve. The 2-3 solenoid is OFF when
the TCM removes the path to ground for that electrical circuit.
This allows 2-3 signal fluid to exhaust at the 2-3 SS valve.

2345 fluid is routed through the 2-3 shift valve and enters
the intermediate clutch circuit.

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

APPLIED

COAST CLUTCH

APPLIED

EX

LD

EX

LD

32
32 SAFETY MODE

APPLIED APPLIED

345
45

ON OFF OFF
LD = LOCKED IN DRIVE

FORWARD CLUTCH
COAST CLUTCH

WWW.ALL-TRANS.BY

OVERDRIVE RANGE THIRD GEAR

#2

X-4
345

LINE

#4

16

#7

17

#5

15

#6

2345 OR REVERSE
LINE
D432

123
D432

2345 OR REVERSE

COMPLETE HYDRAULIC CIRCUIT


Page 96

68B

123

LINE (from Pump)


FORWARD CLUTCH

FORWARD CLUTCH

Figure 65

69

OVERDRIVE RANGE FOURTH GEAR

2
FORWARD
CLUTCH
APPLIED

7
INPUT AND
REACTION
CARRIER
(553)
DRIVING

3
8
6
10
11
9
12
FORWARD INTERMEDIATE INTERMEDIATE DIRECT CLUTCH SECOND SECOND
REAR
CLUTCH
INTERNAL
INPUT AND HUB CLUTCH CLUTCH
CLUTCH
CLUTCH
SPRAG
GEAR
ASSEMBLY
SPRAG
APPLIED SPRAG
APPLIED
(461)
(560)
(466)
(473)
(547)
HOLDING OVERRUNNING
DRIVEN
DRIVING
OVERRUNNING

2a
1
5
POWER FROM DIRECT COAST
TORQUE
CLUTCH CLUTCH
CONVERTER APPLIED APPLIED
(1)

WWW.ALL-TRANS.BY

OVERDRIVE RANGE FOURTH GEAR

POWER TO
DIFFERENTIAL
ASSEMBLY

4
REAR
INPUT
SUN
GEAR
DRIVING

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF OFF ON APPLIED

COAST
CLUTCH
APPLIED

FORWARD
CLUTCH
APPLIED

FORWARD
CLUTCH
SPRAG
(461)
HOLDING

LD

APPLIED

APPLIED

As vehicle speed increases further, input signals from both


transmission speed sensors (input and output), throttle position
(To) sensor, and other vehicle sensors are sent to the TCM. The
TCM uses this information to determine the precise moment to
shift the transmission into Fourth Gear. In Fourth gear, the
planetary gear set rotates as a unit, providing a 1:1 direct drive
gear ratio between the converter turbine and output shaft.
1

Power from Torque Converter

The input shaft forward and coast clutch housing assembly


(433) is splined to and driven by the converter turbine.
2

Forward and Coast Clutches Applied

The forward clutch, which is located within the input shaft


forward and coast clutch housing assembly (433), is applied
and holds the forward clutch sprag outer race (459). The
coast clutch is also located in the input shaft forward and
coast clutch housing assembly (433) and is also applied.
3

Forward Clutch Sprag Holding

The forward clutch sprag (461) holds and power is


transmitted to the input sun gear shaft assembly (457).
4

Rear Input Sun Gear Driving

The input sun gear shaft assembly (457) is splined to the


rear input sun gear. The rear input sun gear attempts to drive
the long planetary pinion gears through the rear short
planetary pinions.
5

DIRECT CLUTCH
INPUT AND HUB
ASSEMBLY
(466)
DRIVING

APPLIED APPLIED

LD = LOCKED IN DRIVE

Direct Clutch Applied

The direct clutch, which is located within the reverse clutch


housing assembly (401), is applied and engine torque is
transferred to the direct clutch input and hub assembly (466).
6

Direct Clutch Input and Hub Assembly Driving

The direct clutch input and hub assembly (466) is splined to


and drives the input and reaction carrier (553).
7

Input and Reaction Carrier Driving

With the rear input sun gear and the input and reaction
carrier both turning at converter turbine speed, the carrier
pinion gears are locked together as an assembly and drive
the rear internal gear (560).

DIRECT
CLUTCH
APPLIED

Rear Internal Gear Driven

The input and reaction carrier (553) drives the rear internal
gear (560) at converter turbine speed to obtain a 1:1 direct
drive gear ratio through the transmission gear set.
9

SECOND
CLUTCH
APPLIED

SECOND
CLUTCH
SPRAG
(547)
OVERRUNNING

INPUT AND
REACTION
CARRIER
(553)
DRIVING

The intermediate clutch, which is located within the overdrive


and intermediate clutch assembly (15), is applied and holds
the intermediate clutch sprag outer race (474).
10 Intermediate Clutch Sprag Overrunning

With the input and reaction carrier (553) locked together


and driving as a unit, the intermediate clutch sprag (473) is
overrunning.
11 Second Clutch Applied

INTERMEDIATE
CLUTCH
APPLIED

The second clutch, which is located within the center support


(518), is applied and holds the second clutch sprag outer
race (545).

INTERMEDIATE
CLUTCH
SPRAG
(473)
OVERRUNNING

12 Second Clutch Sprag Overrunning

REAR
INPUT
SUN
GEAR
DRIVING

70

Intermediate Clutch Applied

Figure 66

REAR
INTERNAL
GEAR
(560)
DRIVEN

With the input and reaction carrier (553) locked together and
driving as a unit, the second clutch sprag (547) is overrunning.

When the throttle is released in Overdrive Range Fourth


Gear, the vehicle is allowed to coast brake. Because none of
the sprag clutches are used in driving the vehicle during
acceleration, there are no elements to overrun to allow the
vehicle to coast freely in fourth gear. Therefore, engine
compression slows the vehicle when the throttle is released.
Refer to Manual Fourth Fourth Gear (page 76A) a for
description of power flow during coast conditions.
As vehicle speed increases, less torque multiplication is required
to operate the engine efficiently. Therefore, it is desirable to
shift to an overdrive gear ratio, or Fifth gear.

70A

OVERDRIVE RANGE FOURTH GEAR

SOLENOID

FORWARD OVER- INTERM. INTER- LOW LOW AND


SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

The 1-2 SS valve is de-energized, blocking feed limit fluid


from entering the 1-2 signal fluid circuit and 1-2 signal fluid
pressure exhausts through the 1-2 SS valve.

AIR
BLEED
(203)

EX

OVERDRIVE
CLUTCH
ACCUMULATOR

AIR
BLEED
(203)

EX

SECOND
CLUTCH
ACCUMULATOR

EX

EX

2a

LINE

LINE
INTERMEDIATE CLUTCH

Direct clutch fluid is routed to the direct clutch piston to


apply the direct clutch plates and obtain Fourth gear.

FEED LIMIT

FEED LIMIT
D432
SECOND CLUTCH

DIRECT CL

2 3-4 SHIFT ACCUMULATION


2a Direct Clutch Accumulator:

1-2 SIGNAL

EX

D432
EX

EX

2345

EX

345
2345

(C)

EX

FEED LIMIT

ON
11

FEED LIMIT

3a

LINE SAFETY MODE


123
123

COAST CLUTCH FEED


45

2345

345

REGULATED APPLY

123
D432

LINE

123

32
45
123

2345

#2
345

45

45

5b

X-4

LINE

LINE

R N D 4 3 2

D432

REV

EX

345
45

MANUAL VALVE

D432

EX

EX

REGULATED APPLY

FEED LIMIT

FDL

FDL

EX

2-3 SIGNAL
EX

EX

DIRECT CLUTCH
COAST CLUTCH

EX

EX

EX

EX

25

4-5 SHIFT
SOLENOID
VALVE
N/C

4-5 SHIFT VLV CNTRL

3b

5a

4-5 SIGNAL

OVERDRIVE CL FD 2
COAST CLUTCH

5c 4-5 Shift Valve:

45 fluid is routed to the 4-5 shift valve (374) where it is


blocked by the valve in preparation for an upshift to fifth gear.

OVERDRIVE CL FD 1

5a

345

FILTER
(308)

OFF

EX
EX
SECOND COAST CLUTCH
2345
2345

28

5b #3 Ball Check Valve:

45 fluid seats the #3 ball check valve and passes through


orifice #27. This orifice helps to control overdrive clutch
apply in fifth gear.

(B)
29

18

REVERSE

TCC SIGNAL

4a

345 fluid is routed through the 3-4 shift valve (345) into the
45 fluid circuit.

X-1

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

EX

EX
EX

2345 OR REVERSE

EX

TCC PWM
SOLENOID
VALVE
N/C

10

FEED LIMIT

2-3 SHIFT VALVE

LINE

TCC REGULATOR VALVE


FORWARD CLUTCH
LINE

5 FLUID PRESSURE DIRECTED IN PREPARATION


FOR A SHIFT TO FIFTH GEAR
5a 3-4 Shift Valve:

2345

345

26

FEED LIMIT VALVE

2-3 SIGNAL

23 REGULATED

EX

FEED LIMIT

4 TORQUE CONVERTER CLUTCH RELEASED


4a TCC PWM Solenoid Valve:

OFF

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH

345
45

123
D432
345
DIRECT CLUTCH

EX

(A)

23 REGULATED

CNTRL 3-4 SHIFT

FEED LIMIT

Filtered 2345 or reverse fluid is still available at the TCC


PWM solenoid valve. However, depending on the shift
pattern, the TCM keeps the pulse width modulated (PWM)
solenoid de-energized blocking filtered 2345 or reverse fluid
from entering the TCC signal fluid circuit, thereby keeping
the torque converter clutch released.

EX

EX

1b

2-3 SIGNAL

FILTER
(312)

FEED LIMIT

2345
24

1-2 SIGNAL

In first through third gears, the coast clutch has been fed by
123 fluid. In fourth gear the 4-5 shift valve (374) is applied
in preparation for a shift to fifth gear. This causes the coast
clutch fluid circuit to be supplied by coast clutch feed fluid,
and 123 fluid to exhaust.

1-2 SHIFT CONTROL VALVE

SAFETY MODE

3b 4-5 Shift Valve:

FEED LIMIT

1-2 SHIFT
SOLENOID
VALVE
N/C

CST CL
123
123
123 BRAKING

PRESSURE
CONTROL
SOLENOID
VALVE

1a

1-2 SHIFT VALVE

45

EX

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

32
32 SAFETY MODE

MEMORY
FEED LIMIT
LINE
LINE SAFETY MODE

FORWARD CLUTCH
LINE
FEED LIMIT

MEMORY PILOT

X-3

SECOND CL
D432

MEMORY

14

EX

1-2 SIGNAL

21

D432
SECOND CL
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REV CL

1-2 SIGNAL

Direct clutch fluid is also sent to the direct clutch accumulator


assembly. Direct clutch fluid, together with accumulator
spring force, moves the direct clutch accumulator piston
against accumulator fluid pressure to cushion the apply of
the direct clutch.

The 4-5 SS valve is energized, allowing feed limit fluid to


enter the 4-5 signal fluid circuit. 4-5 signal fluid overcomes
4-5 shift valve spring (373) force and moves the 4-5 shift
control valve (375) and the 4-5 shift valve (374) to the
applied position.

LINE

1c Direct Clutch:

3 COAST CLUTCH FEED


3a 4-5 Shift Solenoid (SS) Valve:

SECOND COAST CL
LOW AND REV CL OR RLO

INTERMEDIATE
CLUTCH
ACCUMULATOR

ACCUM

DIRECT CLUTCH

When 1-2 signal fluid pressure exhausts from the 3-4 shift
valve (345), the 3-4 shift valve spring (344) moves the
valve to the released position. 345 fluid from the 2-3 shift
valve flows through the 3-4 shift valve and enters the direct
clutch circuit.

OVERDRIVE CLUTCH

DIRECT
CLUTCH
ACCUMULATOR

AIR
BLEED
(203)

REVERSE LOCKOUT
SECOND CLUTCH

REVERSE CLUTCH
DIRECT CLUTCH

1 DIRECT CLUTCH APPLIED


1a 1-2 Shift Solenoid (SS) Valve:

1b 3-4 Shift Valve:

FORWARD CLUTCH
COAST CL
LUBE

1c

CENTER
SUPPORT
ASSEMBLY
(510535)

SECOND CL

As vehicle speed increases, the TCM receives input signals


from both speed sensors, the To sensor and other vehicle sensors
to determine the precise moment to de-energize or turn OFF
the 1-2 shift solenoid (SS) valve, and to energize or turn ON
the 4-5 SS valve.

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

INTERMEDIATE CLUTCH

APPLIED

ACCUMULATOR

APPLIED

INTERMED CL

LD

ACCUMULATOR
OVERDR CL FD 2

APPLIED APPLIED

FORWARD CLUTCH
COAST CLUTCH

OFF OFF ON APPLIED


LD = LOCKED IN DRIVE

ACCUMULATOR
DIRECT CL

WWW.ALL-TRANS.BY

OVERDRIVE RANGE FOURTH GEAR

#3

2345 OR REVERSE
45
LINE
D432

27

X-5

#4

16

#7

17

#5

15

#6

123
D432

2345 OR REVERSE

COMPLETE HYDRAULIC CIRCUIT


Page 98

70B

123

LINE (from Pump)


FORWARD CLUTCH

FORWARD CLUTCH

Figure 67

71

OVERDRIVE RANGE FIFTH GEAR


(Torque Converter Clutch Released)

(Torque Converter Clutch Released)


12
3
9
11
13
8
4
1
2
10
7
POWER FROM DIRECT DIRECT CLUTCH FORWARD OVERDRIVE FORWARD INTERMEDIATE INTERMEDIATE SECOND
SECOND
REAR
TORQUE
CLUTCH INPUT AND HUB CLUTCH
CLUTCH
CLUTCH
CLUTCH
CLUTCH
CLUTCH
CLUTCH
INTERNAL
CONVERTER APPLIED ASSEMBLY (466) APPLIED
SPRAG (473) APPLIED SPRAG (547)
GEAR
APPLIED SPRAG (461)
APPLIED
(1)
(560)
DRIVING
OVERRUNNING
INEFFECTIVE
OVERRUNNING
DRIVEN

POWER TO
DIFFERENTIAL
ASSEMBLY

5
FRONT
INPUT
SUN GEAR
HELD

WWW.ALL-TRANS.BY

OVERDRIVE RANGE FIFTH GEAR

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF OFF OFF APPLIED

APPLIED

APPLIED

APPLIED

To maximize engine performance and fuel economy, a Fifth


gear (Overdrive) is used to achieve an approximate ratio of
0.75:1 through the transmission gear set to the vehicle drive
shaft. This allows the vehicle to maintain a given road speed
with less engine output speed.
1

Power from Torque Converter

The input shaft forward and coast clutch housing assembly


(433) is splined to and driven by the converter turbine.
2

Direct Clutch Applied

The direct clutch, which is located within the reverse clutch


housing assembly (401), is applied and engine torque is
transferred to the direct clutch input and hub assembly (466).
3

6
INPUT AND
REACTION
CARRIER
(553)
DRIVING

APPLIED

LD = LOCKED IN DRIVE

Direct Clutch Input and Hub Assembly Driving

The direct clutch input and hub assembly (466) is splined to


and drives the input and reaction carrier (553).
4

Overdrive Clutch Applied

The overdrive clutch, which is located within the overdrive


clutch housing (493), is applied and holds the overdrive and
reverse clutch hub assembly (470) stationary.
5

Front Input Sun Gear Held

The overdrive and reverse clutch hub assembly (470) is


splined to the front input sun gear and holds it stationary.
6

FORWARD
CLUTCH SPRAG
ASSEMBLY
(461)
OVERRUNNING

FORWARD
CLUTCH
APPLIED

Input and Reaction Carrier Driving

With the front input sun gear held, and the input and reaction
carrier being driven by the direct clutch input and hub
assembly (466), the long planetary pinion gears are forced to
walk in the direction of engine rotation around the stationary
front input sun gear and drive the rear internal gear (560).

DIRECT CLUTCH
INPUT AND HUB
ASSEMBLY
(466)
DRIVING

Rear Internal Gear Driven

The input and reaction carrier long pinion gears drive the
rear internal gear (560) faster than converter turbine speed
to obtain a 0.75:1 overdrive drive gear ratio through the
transmission gear set.

DIRECT
CLUTCH
APPLIED

Forward Clutch Applied

The forward clutch is applied and holds the forward clutch


sprag outer race (459).
9

Forward Clutch Sprag Overrunning

The input sun gear shaft assembly is splined to and driven


by the rear input sun gear, causing the forward clutch sprag
(461) to overrun.

OVERDRIVE
CLUTCH
APPLIED

INTERMEDIATE
CLUTCH
APPLIED

SECOND
CLUTCH
APPLIED

SECOND
CLUTCH
SPRAG
(547)
OVERRUNNING

INPUT AND
REACTION
CARRIER
(553)
DRIVING

10 Intermediate Clutch Applied

The intermediate clutch is applied and holds the intermediate


clutch sprag outer race (474) stationary.
11 Intermediate Clutch Sprag Ineffective

With the intermediate clutch sprag outer race (474) and the
overdrive and reverse clutch hub assembly (470) both held,
the intermediate clutch sprag (473) has no effect in fifth gear.
12 Second Clutch Applied

The second clutch is applied and holds the second clutch


sprag outer race (545) stationary.

INTERMEDIATE
CLUTCH
SPRAG
(473)
INEFFECTIVE

13 Second Clutch Sprag Overrunning

FRONT INPUT
SUN GEAR
HELD

OVERDRIVE AND
REVERSE CLUTCH
HUB ASSEMBLY
(470)
HELD

72

Figure 68

REAR
INTERNAL
GEAR
(560)
DRIVEN

The power transferred to the front short pinions by the long


planetary pinions drives the reaction internal gear (550)
causing the second clutch sprag (547) to overrun.

When the throttle is released in Overdrive Range Fifth Gear,


the vehicle is allowed to coast brake. Because none of the sprag
clutches are used in driving the vehicle during acceleration,
there are no elements to overrun to allow the vehicle to coast
freely in Fifth gear. Therefore, engine compression slows the
vehicle when the throttle is released until the transmission
downshifts into Overdrive Range Fourth Gear.
However, due to the gear ratio in Overdrive, engine compression
braking is not as noticeable by the driver as it is in the Manual
gear ranges.

72A

OVERDRIVE RANGE FIFTH GEAR

(Torque Converter Clutch Released)

AIR
BLEED
(203)

EX

AIR
BLEED
(203)

#12

DIRECT CLUTCH

1c

1b 4-5 Shift Valve:

45 fluid is routed through the 4-5 shift valve and enters the
overdrive clutch feed 2 fluid circuit through orifice #28.

OVERDRIVE
CLUTCH
ACCUMULATOR

3a

EX

SECOND COAST CL
LOW AND REV CL OR RLO

EX
ACCUM

2a

LINE

FEED LIMIT

FEED LIMIT

D432
2345
(B)

REGULATED APPLY

EX
EX
SECOND COAST CLUTCH
OVERDRIVE CLUTCH FEED 1
2345
2345
23 REGULATED

(C)

EX

EX

45

COAST CL
123
123

1a

4-5 SHIFT
SOLENOID
VALVE
N/C

4-5 SHIFT VLV CNTRL


EX

OFF

EX

29

4-5 SIGNAL

OFF
11

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
123
123
COAST CLUTCH FEED
45

28

OVERDRIVE CL FD 2

123
D432

LINE

R N D 4 3 2

123

45

45

32

D432

LINE

EX

345
45

MANUAL VALVE

D432

2345

345

REVERSE

REV

REGULATED APPLY

FEED LIMIT

EX

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

EX

EX

X-1

2345

EX

345
2345

2-3 SHIFT VALVE

1b

FILTER
(308)

45
123

2345

345
25

FDL

10

FEED LIMIT

3b

EX

TCC SIGNAL

2345 OR REVERSE

4a

2-3 SIGNAL

26

EX

EX

EX
EX

LINE

FORWARD CLUTCH

TCC PWM
SOLENOID
VALVE
N/C

24

18

LINE

TCC REGULATOR VALVE

OFF

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH
23 REGULATED

345

FEED LIMIT VALVE

4 TORQUE CONVERTER CLUTCH RELEASED


4a TCC PWM Solenoid Valve:

(A)

FEED LIMIT

EX

Coast clutch fluid passes through the 4-5 shift valve and into
the 123 circuit and on to the 3-4 shift valve where it exhausts.

EX

123
D432
345
DIRECT CLUTCH

FEED LIMIT
FEED LIMIT

1-2 SHIFT CONTROL VALVE

345
45

EX

CNTRL 3-4 SHIFT

3b 4-5 Shift Valve:

1-2 SHIFT
SOLENOID
VALVE
N/C

EX

EX

1-2 SIGNAL

DIRECT CLUTCH
COAST CLUTCH

EX

EX

SAFETY MODE

FEED LIMIT

2345

2-3 SIGNAL

When the 4-5 shift valve is shifted to the released position,


coast clutch feed fluid is blocked and coast clutch fluid
exhausts through the valve allowing the coast clutch to release.

FEED LIMIT
1-2 SIGNAL

1-2 SHIFT VALVE

OVERDRIVE CLUTCH FEED 2

PRESSURE
CONTROL
SOLENOID
VALVE

32
32 SAFETY MODE

MEMORY
FEED LIMIT
LINE
LINE SAFETY MODE

MEMORY

EX

FORWARD CLUTCH

THROTTLE SIGNAL
FILTERED FEED LIMIT

LINE
FEED LIMIT

3 COAST CLUTCH RELEASES


3a Coast Clutch:

MEMORY PILOT

FILTER
(312)

X-3

FDL

SECOND CLUTCH
D432

MEMORY

14

2-3 SIGNAL

21

Overdrive clutch fluid is then directed to the overdrive


clutch piston to apply the overdrive clutch plates and achieve
Fifth gear.

EX

LINE

D432
SECOND CLUTCH

DIRECT CLUTCH

1d Overdrive Clutch:

Filtered 2345 or reverse fluid is still available at the TCC


PWM solenoid valve. However, depending on the shift
pattern, the TCM keeps the pulse width modulated (PWM)
solenoid de-energized blocking filtered 2345 or reverse fluid
from entering the TCC signal fluid circuit, thereby keeping
the torque converter clutch released.

EX

INTERMEDIATE CLUTCH

Overdrive clutch feed 2 fluid seats the #12 ball check valve
against the overdrive clutch feed 1 passage and enters the
overdrive clutch fluid circuit.

Overdrive clutch fluid is also sent to the overdrive clutch


accumulator assembly. Overdrive clutch fluid, together with
accumulator spring force, moves the overdrive clutch
accumulator piston against accumulator fluid pressure to
cushion the apply of the overdrive clutch.

SECOND
CLUTCH
ACCUMULATOR

LINE

1c #12 Ball Check Valve:

2 4-5 SHIFT ACCUMULATION


2a Overdrive Clutch Accumulator:

INTERMEDIATE
CLUTCH
ACCUMULATOR

LINE

DIRECT
CLUTCH
ACCUMULATOR

SECOND CL

The 4-5 SS valve is de-energized, blocking feed limit fluid


from entering the 4-5 signal fluid circuit. 4-5 signal fluid
pressure exhausts through the 4-5 SS valve and 4-5 shift
valve spring (373) force moves the 4-5 shift valve (374) and
the 4-5 shift control valve (375) to the released position.

OVERDRIVE CLUTCH

ACCUMULATOR

1 OVERDRIVE CLUTCH APPLIED


1a 4-5 Shift Solenoid (SS) Valve:

CENTER
SUPPORT
ASSEMBLY
(510535)

REVERSE LOCKOUT
SECOND CLUTCH

1d

REVERSE CLUTCH
DIRECT CLUTCH

AIR
BLEED
(203)

INTERMEDIATE CLUTCH

FORWARD CLUTCH
COAST CL
LUBE

INTERMEDIATE CL

Overdrive Range Fifth Gear is used to maximize engine


efficiency and fuel economy under most normal driving
conditions. In order to shift the transmission into Fifth gear, the
TCM receives input signals from both speed sensors, the To
sensor and other vehicle sensors to determine the precise moment
to de-energize or turn OFF the 4-5 shift solenoid (SS) valve.

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REVERSE CL

APPLIED

EX

APPLIED

EX

APPLIED

ACCUMULATOR
OVERDRIVE CL FD 2

APPLIED

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

OVERDRIVE CLUTCH FEED 1

OFF OFF OFF APPLIED


LD = LOCKED IN DRIVE

(Torque Converter Clutch Released)

OVERDRIVE CLUTCH FEED 2

FORWARD OVER- INTERM. INTER- LOW LOW AND


SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

FORWARD CLUTCH
COAST CLUTCH

SOLENOID

ACCUMULATOR
DIRECT CL

WWW.ALL-TRANS.BY

OVERDRIVE RANGE FIFTH GEAR

#2

X-4

#3

27

X-5

#4

16

#7

17

#5

15

#6

345
LINE
2345 OR REVERSE

COMPLETE HYDRAULIC CIRCUIT


Page 100

72B

45
LINE
D432
2345 OR REVERSE

123
D432
123

LINE (from Pump)


FORWARD CLUTCH

FORWARD CLUTCH

Figure 69

73

OVERDRIVE RANGE FIFTH GEAR


(Torque Converter Clutch from Released to Applied)

(Torque Converter Clutch from Released to Applied)

A
S

TIME

TCC
CONTROL
VALVE

TCC APPLY AND RELEASE


APPLY

RELEASE
CONVERTER FEED

REGULATED APPLY

25

TO COOLER

TCC
APPLY
FLUID
PRESSURE

50

2345 OR REVERSE

EX

STAGE
1

75

TCC SIGNAL

TCC PWM
SOLENOID
VALVE
N/C

100%

REGULATED APPLY

PERCENT DUTY CYCLE

TORQUE
CONVERTER
ASSEMBLY
(1)

LINE

EX

TCC REGULATOR VALVE

WWW.ALL-TRANS.BY

OVERDRIVE RANGE FIFTH GEAR

When the Transmission Control Module (TCM) determines that


the engine and transmission are operating properly to engage
the Torque Converter Clutch (TCC), the TCM energizes the
TCC PWM solenoid valve. The following events occur in order
to apply the torque converter clutch:
OFF
At this time the Torque Converter Clutch is
considered to be disengaged (OFF).
TCM decision to apply TCC (see page 50, in the Electrical
Components section, for more information).

APPLY

TCC
ENABLE
VALVE

EX

REG APPLY
EX

25

A
S

EX

50

TCC
APPLY
FLUID
PRESSURE
TIME

TCC
CONTROL
VALVE

TCC APPLY AND RELEASE


APPLY

RELEASE
CONVERTER FEED

TCC SIGNAL

STAGE
2

75

2345 OR REVERSE

100%

TCC PWM
SOLENOID
VALVE
N/C

TO COOLER

PERCENT DUTY CYCLE

TORQUE
CONVERTER
ASSEMBLY
(1)

LINE

EX

TCC REGULATOR VALVE

REGULATED APPLY

RELEASE

REGULATED APPLY

STAGE 1
(S - A)

REGULATED APPLY

TCC SIGNAL

RELEASE

CONVERTER FDL
CONV FD

APPLY

APPLY

TCC
ENABLE
VALVE

EX

75

25
0

A
S

TCC
APPLY
FLUID
PRESSURE
TIME

TCC
CONTROL
VALVE

APPLY

TCC APPLY AND RELEASE


RELEASE
CONVERTER FEED

2345 OR REVERSE

50

LINE

EX

TCC SIGNAL

100%

EX

TORQUE
CONVERTER
ASSEMBLY
(1)

TCC PWM
SOLENOID
VALVE
N/C

C
B

TO COOLER

PERCENT DUTY CYCLE

TCC REGULATOR VALVE


STAGE
3

Stage 3 Now the Regulated Apply pressure is increased.


This is caused by the TCC PWM solenoid valve duty cycle
being increased from point B to point C, to maximum duty
cycle. This extra pressure ensures that the apply force on the
TCC pressure plate is not at the slip threshold, but in the
condition of full lock up.

REGULATED APPLY

RELEASE

Stage 2 The TCC PWM solenoid valve duty cycle is ramped


up from point A to point B. TCC Signal fluid pressure is
now strong enough to move the TCC Regulator valve against
spring force. Line pressure from the pump enters the
Regulated Apply circuit at the TCC Regulator valve.
Regulated Apply fluid is routed through the TCC Enable
valve and through the TCC Control valve into the Apply
circuit. The pressure value in the Regulated Apply circuit is
precisely controlled to maintain a small amount of slippage
(20 to 80 RPM) between the engine and the turbine, reducing
driveline torsional disturbances.

REG APPLY
EX

REGULATED APPLY

STAGE 2
(A - B)

REGULATED APPLY

TCC SIGNAL

RELEASE

CONVERTER FDL
CONV FD

APPLY

Stage 1 The TCM pulses the TCC PWM solenoid valve to


approximately 15% duty cycle from point S to point A. 2345
or Reverse fluid at the TCC PWM solenoid valve is pulsed
into the TCC Signal fluid circuit. The TCC Signal fluid
pressure at point A is strong enough to move the TCC Control,
and TCC Enable valves against spring force. The TCC
Control valve moves and allows Release fluid to begin to
exhaust from the torque converter and enter the Converter
FDL fluid circuit. The TCC Enable valve moves and allows
Release/Converter FDL fluid to exhaust into the sump. This
stage is designed to move the TCC Control and TCC Enable
valves from the released position toward the applied position;
there is not enough pressure to apply the TCC.

TCC
ENABLE
VALVE

STAGE 3
(B - C)

74

RELEASE

Figure 70

EX

REGULATED APPLY

APPLY

TCC SIGNAL

RELEASE

CONVERTER FDL
CONV FD

APPLY

REG APPLY
EX

COMPLETE HYDRAULIC CIRCUIT


Page 102

74A

OVERDRIVE RANGE FIFTH GEAR

(Torque Converter Clutch from Applied to Released)

TIME

APPLY

RELEASE

TCM decision to release TCC (see page 50, in the Electrical


Components section, for more information).

CONVERTER FEED

APPLY

TCC
ENABLE
VALVE

EX

REG APPLY
EX

A
S

F
TIME

TCC
CONTROL
VALVE

TO COOLER

25

TCC
APPLY
FLUID
PRESSURE

EX

STAGE
5

E
50

TCC APPLY AND RELEASE


APPLY

RELEASE
CONVERTER FEED

TCC SIGNAL

75

2345 OR REVERSE

100%

TCC PWM
SOLENOID
VALVE
N/C

LINE

EX

PERCENT DUTY CYCLE

TORQUE
CONVERTER
ASSEMBLY
(1)

C
B

REGULATED APPLY

RELEASE

REGULATED APPLY

STAGE 4
(D - E)

REGULATED APPLY

TCC SIGNAL

RELEASE

CONVERTER FDL
CONV FD

APPLY

TCC REGULATOR VALVE

Stage 5 The TCC PWM solenoid valve duty cycle is ramped


down from point E to point F through this stage. This action
allows the Regulated Apply pressure to start at the slip
threshold, and decrease to near 0 pressure over a very short
time to point F. The Regulated Apply pressure value from
the TCC Regulator valve at this duty cycle (point F) should
fully release the TCC pressure plate. Slip speed should be at
the maximum value.

REGULATED APPLY

TCC
CONTROL
VALVE

REGULATED APPLY

A
S

TCC
APPLY
FLUID
PRESSURE

2345 OR REVERSE

25

EX

E
50

TCC SIGNAL

75

TCC APPLY AND RELEASE

ON
At this time the Torque Converter Clutch is
considered to be engaged (ON).

Stage 4 During this stage, the apply pressure from the TCC
Regulator valve is decreased by the TCC PWM solenoid
valve duty cycle dropping from point D to point E. Spring
force pushes the valve back and reduces the Regulated Apply
pressure. This reduces the apply force on the TCC pressure
plate to the slip threshold. This gets the TCC pressure plate
ready for a smooth release.

TCC PWM
SOLENOID
VALVE
N/C

STAGE
4

TO COOLER

TORQUE
CONVERTER
ASSEMBLY
(1)

C
B

100%

LINE

EX

TCC REGULATOR VALVE

When the TCC pressure plate is applied, it is held against the


torque converter cover. Since it is splined to the converter
turbine hub, it provides a mechanical coupling (direct drive) of
the engine to the transmission gear sets. This mechanical
coupling eliminates the small amount of slippage that occurs in
the fluid coupling of a torque converter, resulting in a more
efficient transfer of engine torque through the transmission and
to the drive wheels.

PERCENT DUTY CYCLE

WWW.ALL-TRANS.BY

OVERDRIVE RANGE FIFTH GEAR

(Torque Converter Clutch from Applied to Released)

TCC
ENABLE
VALVE

75

25
0

A
S

EX

E
50

STAGE
6

TCC
APPLY
FLUID
PRESSURE

TIME

TCC
CONTROL
VALVE

APPLY

TCC APPLY AND RELEASE


RELEASE
CONVERTER FEED

TCC SIGNAL

2345 OR REVERSE

100%

TCC PWM
SOLENOID
VALVE
N/C

REGULATED APPLY

TORQUE
CONVERTER
ASSEMBLY
(1)

C
B

LINE

EX

TCC REGULATOR VALVE


PERCENT DUTY CYCLE

(Some TCM calibrations may allow stages 4 - 6 to happen very


rapidly in almost a straight line down from point D to point G.)

REG APPLY
EX

RELEASE

OFF
At this time the Torque Converter Clutch is
considered to be disengaged (OFF).

EX

REGULATED APPLY

STAGE 5
(E - F)

REGULATED APPLY

APPLY

TO COOLER

Stage 6 The TCM pulses the TCC PWM solenoid valve to


a value of 0. Now the TCC Control and TCC Enable
valves return to their released positions (away from the spring).
Release fluid is now directed back to the torque converter.
This stage is designed to move the TCC Control and TCC
Enable valves to the released position.

TCC SIGNAL

RELEASE

CONVERTER FDL
CONV FD

APPLY

COMPLETE HYDRAULIC CIRCUIT


Page 102

74B

TCC
ENABLE
VALVE

STAGE 6
(F - G)

RELEASE

Figure 71

EX

REGULATED APPLY

APPLY

TCC SIGNAL

RELEASE

CONVERTER FDL
CONV FD

APPLY

REG APPLY
EX

75

MANUAL FOURTH FOURTH GEAR


(from Overdrive Range Fifth Gear)

(from Overdrive Range Fifth Gear)

REAR
INTERNAL
GEAR
(560)
DRIVEN
INPUT AND
REACTION
CARRIER
(553)
DRIVING

3
FORWARD INTERMEDIATE INTERMEDIATE DIRECT CLUTCH SECOND SECOND
CLUTCH
INPUT AND HUB CLUTCH CLUTCH
CLUTCH
CLUTCH
SPRAG (461)
ASSEMBLY
SPRAG
APPLIED
APPLIED
SPRAG
INEFFECTIVE
(466)
(473)
(547)
DRIVING
OVERRUNNING
OVERRUNNING

2
FORWARD
CLUTCH
APPLIED

1
POWER FROM
DIFFERENTIAL
ASSEMBLY

2a
5
4
POWER TO
DIRECT COAST
TORQUE
CLUTCH CLUTCH
CONVERTER APPLIED APPLIED
(1)
FOR ENGINE
BRAKING

WWW.ALL-TRANS.BY

MANUAL FOURTH FOURTH GEAR

REAR
INPUT
SUN
GEAR
DRIVING

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF OFF ON APPLIED

APPLIED APPLIED

LD

APPLIED

APPLIED

LD = LOCKED IN DRIVE

Manual Fourth Fourth Gear (4) is available to the driver when


vehicle operating conditions make it desirable to use only four
gear ratios. These conditions include city driving [where speeds
are generally below 72 km/h (45 mph)], towing a trailer, or
driving in hilly terrain. Manual Fourth also provides for engine
compression braking when descending slight grades and can be
used to retain Fourth gear when ascending slight grades for
additional engine performance. Manual Fourth is also referred
to as Drive Range because it has a 1:1 direct drive gear ratio
available through the transmission gear set.
In Manual Fourth, the transmission can upshift and downshift
between First, Second, Third and Fourth gears in the same
manner as Overdrive Range. However, the transmission is
prevented from shifting into Fifth gear while operating in this
gear selector position. If the transmission is in Overdrive Range
Fifth Gear when Manual Fourth is selected, the transmission
will not shift into Fourth gear until vehicle speed is low enough
not to overrev the engine (calibratable in the TCM).
Note: Transfer of engine torque during acceleration is identical
to Overdrive Range Fourth Gear (refer to page 70A). The
power flow in Figure 72 and the following text describes
conditions during deceleration (zero or minimum throttle
conditions) and how engine compression braking is achieved.

COAST
CLUTCH
APPLIED

FORWARD
CLUTCH
APPLIED

DIRECT CLUTCH
INPUT AND HUB
ASSEMBLY
(466)
DRIVING

FORWARD
CLUTCH
SPRAG
(461)
INEFFECTIVE

Vehicle speed provides the torque input to the transmission


through the drive shaft and transmission output shaft assembly
(562). This is shown by the direction of the power flow arrows
in the drawing at the top of Figure 72. Notice that this flow is
identical to Overdrive Range Fourth Gear except that the
arrows are in the opposite direction.
1

Power From the Differential Assembly

Power flow is transferred back through the transmission


from the output shaft to the input shaft forward and coast
clutch housing assembly (433). Each of the components
function and rotation direction is the same as during
acceleration (compare Figures 66 and 72).

DIRECT
CLUTCH
APPLIED

SECOND
CLUTCH
APPLIED

SECOND
CLUTCH
SPRAG
(547)
OVERRUNNING

Forward and Coast Clutches Applied

The forward clutch, which is located within the input shaft


forward and coast clutch housing assembly (433), is applied
and holds the forward clutch sprag outer race (459). The
coast clutch is also located in the input shaft forward and
coast clutch housing assembly (433) and is also applied.

INPUT AND
REACTION
CARRIER
(553)
DRIVING

Forward Clutch Sprag Ineffective

With the forward and coast clutches both applied, the forward
clutch sprag (461) has no effect in Manual Fourth.

INTERMEDIATE
CLUTCH
APPLIED

Direct Clutch Applied

The direct clutch is applied and input torque from the input
and reaction carrier (553) is transferred through the direct
clutch input and hub assembly (466) to the reverse clutch
housing assembly (401).

INTERMEDIATE
CLUTCH
SPRAG
(473)
OVERRUNNING

REAR
INPUT
SUN
GEAR
DRIVING

REAR
INTERNAL
GEAR
(560)
DRIVEN

Engine Compression Braking

The reverse clutch housing assembly (401) is splined to the


input shaft forward and coast clutch housing assembly (433),
creating a mechanical link between the output shaft and
torque converter turbine. This creates a 1:1 direct drive gear
ratio and allows engine compression to slow the vehicle
when the throttle is released.

In Manual Fourth range, First, Second and Third gears operate


the same as in Overdrive Range.

76

Figure 72

76A

MANUAL FOURTH FOURTH GEAR

(from Overdrive Range Fifth Gear)

AIR
BLEED
(203)

AIR
BLEED
(203)

EX

AIR
BLEED
(203)

3b
#12

FORWARD CLUTCH
COAST CLUTCH

ACCUMULATOR
DIRECT CL

DIRECT CLUTCH

1e

4-5 Shift Solenoid (SS) Valve:

OVERDRIVE
CLUTCH
ACCUMULATOR
EX

INTERMEDIATE
CLUTCH
ACCUMULATOR

SECOND
CLUTCH
ACCUMULATOR

EX

EX
ACCUM

2a

LINE

LINE
INTERMEDIATE CLUTCH

FEED LIMIT

FEED LIMIT
D432
SECOND CLUTCH

DIRECT CL

2-3 SIGNAL

D432
2345
10

FEED LIMIT

23 REGULATED

X-1

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

(B)

EX

2345

EX

EX

EX

345
2345

2-3 SHIFT VALVE

29

18

3a

OVERDRIVE CL FD 1

4-5 SIGNAL

4-5 SHIFT
SOLENOID
VALVE
N/C

EX

11

FEED LIMIT

1b

LINE SAFETY MODE

D432

LINE

1a

R N D 4 3 2

45

2345
45
32

LINE

REV

EX

345
45

MANUAL VALVE

D432

COAST CLUTCH FEED


45

345

REGULATED APPLY

REGULATED APPLY

TCC SIGNAL

ON

OVERDRIVE CL FD 2
COAST CLUTCH

45

2345

345
25

(C)

EX

CST CL
123
123
123 BRAKING

EX

45

EX

1c

28

REVERSE

FILTER
(308)

OFF

EX
EX
SECOND COAST CLUTCH
2345
2345

345

EX

EX

EX
TCC PWM
SOLENOID
VALVE
N/C

FEED LIMIT

FDL

EX

EX

EX

EX

2-3 SIGNAL

23 REGULATED

LINE

TCC REGULATOR VALVE

OFF

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH

24

26

FEED LIMIT VALVE

2345 OR REVERSE

In Manual Fourth Fourth Gear, the TCC will not release if


Manual Fourth was selected while the vehicle was operating in
Overdrive Range Fifth Gear with the TCC applied. Under
normal operating conditions, the converter clutch operates the
same way in Manual Fourth Fourth Gear as in Overdrive
Range Fourth Gear. Refer to pages 74A and 74B for
descriptions of TCC release and apply.

(A)

4-5 SHIFT VLV CNTRL

EX

Coast clutch fluid is routed to the coast clutch piston to


apply the coast clutch plates.

1-2 SHIFT CONTROL VALVE

FEED LIMIT

EX

FEED LIMIT

1-2 SHIFT
SOLENOID
VALVE
N/C

345
45

123
D432
345
DIRECT CLUTCH

FEED LIMIT

FORWARD CLUTCH
LINE
REGULATED APPLY (from TCC Enable Valve

3b Coast Clutch:

EX

CNTRL 3-4 SHIFT

3 COAST CLUTCH APPLIES


3a 4-5 Shift Valve:

Coast clutch feed fluid passes through the 4-5 shift valve
(374) and into the coast clutch circuit.

EX

EX

1-2 SIGNAL

FILTER
(312)

FEED LIMIT

2345

2-3 SIGNAL

Overdrive clutch fluid also exhausts from the overdrive clutch


accumulator assembly. Accumulator fluid moves the
overdrive clutch accumulator piston against accumulator
spring force in preparation for another application of the
overdrive clutch.

FEED LIMIT

1-2 SHIFT VALVE

SAFETY MODE

2 SHIFT ACCUMULATION
2a Overdrive Clutch Accumulator:

X-3

DIRECT CLUTCH
COAST CLUTCH
OVERDRIVE CLUTCH FEED 2

PRESSURE
CONTROL
SOLENOID
VALVE

32
32 SAFETY MODE

MEMORY
FEED LIMIT
LINE
LINE SAFETY MODE

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

EX

Overdrive clutch fluid seats the #12 ball check valve


against the overdrive clutch feed 1 passage and enters the
overdrive clutch feed 2 fluid circuit where it exhausts at
the 4-5 shift valve.

MEMORY PILOT

EX

1e #12 Ball Check Valve:

MEMORY

FORWARD CLUTCH
LINE
FEED LIMIT

Overdrive clutch fluid exhausts from the overdrive clutch


piston, allowing the overdrive clutch plates to disengage.

SECOND CL
D432

1d Overdrive Clutch Assembly:

14

FDL

21

EX

4-5 fluid is blocked at the 4-5 shift valve (374) allowing


overdrive clutch feed 2 fluid to exhaust.

D432
SECOND CL
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REV CL

1c 4-5 Shift Valve:

EX

The 4-5 SS valve is energized, allowing feed limit fluid to


enter the 4-5 signal fluid circuit. 4-5 signal fluid overcomes
4-5 shift valve spring (373) force and moves the 4-5 shift
control valve (375) and the 4-5 shift valve (374) to the
applied position.

1-2 SIGNAL

1b

SECOND COAST CL
LOW AND REV CL OR RLO

OVERDRIVE CLUTCH

DIRECT
CLUTCH
ACCUMULATOR

1 OVERDRIVE CLUTCH RELEASES


1a Manual Valve:

The manual valve moves only to activate the transmission


manual shift shaft switch assembly. The transmission manual
shift shaft switch assembly signals the TCM that the
transmission is in Manual Fourth Range. There is no
hydraulic difference between Overdrive Range and Manual
Fourth Range at the manual valve.

1d

REVERSE CLUTCH
DIRECT CLUTCH

REVERSE LOCKOUT
SECOND CLUTCH

FORWARD CLUTCH
COAST CL
LUBE

LINE

Manual Fourth Fourth Gear (Drive Range) may be selected at


any time while the vehicle is being operated in a forward gear
range. However, TCM control prevents the transmission from
shifting into Fifth gear. When the gear selector lever is moved
to Drive Range (4) from Overdrive Range D , the manual valve
also moves. Changes to the hydraulic and electrical systems are
as follows:

D432

APPLIED

SECOND CL

APPLIED

INTERMEDIATE CLUTCH

LD

CENTER
SUPPORT
ASSEMBLY
(510535)

ACCUMULATOR

APPLIED APPLIED

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

INTERMED CL

OFF OFF ON APPLIED


LD = LOCKED IN DRIVE

(from Overdrive Range Fifth Gear)

ACCUMULATOR
OVERDR CL FD 2

FORWARD OVER- INTERM. INTER- LOW LOW AND


SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

OVERDRIVE CLUTCH FEED 1

SOLENOID

OVERDRIVE CLUTCH FEED 2

WWW.ALL-TRANS.BY

MANUAL FOURTH FOURTH GEAR

#2

X-4
345

LINE

2345 OR REVERSE
45
LINE
D432

#3

27

X-5

#7

17

#5

15

#6

D432

2345 OR REVERSE

COMPLETE HYDRAULIC CIRCUIT


Page 104

76B

LINE (from Pump)


FORWARD CLUTCH

FORWARD CLUTCH

Figure 73

77

MANUAL THIRD THIRD GEAR


(from Manual Fourth Fourth Gear)

(from Manual Fourth Fourth Gear)


2
3
4
5
4a
REAR
INPUT AND
FRONT
FORWARD OVERDRIVE INTERMEDIATE INTERMEDIATE SECOND SECOND
POWER TO COAST FORWARD
INPUT INTERNAL REACTION
CLUTCH
CLUTCH CLUTCH
TORQUE
CLUTCH CLUTCH CLUTCH SPRAG CLUTCH
CLUTCH
GEAR
CARRIER
APPLIED
SUN
(461)
SPRAG
APPLIED SPRAG
CONVERTER APPLIED APPLIED
APPLIED
(560)
(553)
GEAR
INEFFECTIVE
(473)
(1)
(547)
DRIVEN
DRIVEN
INEFFECTIVE
FOR ENGINE
OVERRUNNING HELD
BRAKING

1
POWER FROM
DIFFERENTIAL
ASSEMBLY

LONG
PINION
GEAR
DRIVING

WWW.ALL-TRANS.BY

MANUAL THIRD THIRD GEAR

REAR
INPUT
SUN GEAR
DRIVING
REAR SHORT
PINION
GEAR
DRIVING
INTERMEDIATE
CLUTCH SPRAG
(473)
INEFFECTIVE

REVERSE
CLUTCH
HOUSING
ASSEMBLY
(401)

COAST
CLUTCH
APPLIED

FORWARD
CLUTCH
APPLIED

FORWARD
CLUTCH
SPRAG
(461)
INEFFECTIVE

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
ON OFF ON

APPLIED APPLIED

LD

APPLIED

LD

APPLIED

APPLIED

LD = LOCKED IN DRIVE

Manual Third Third Gear (3) is available to the driver when


vehicle operating conditions make it desirable to use only three
gear ratios. These conditions include descending a steep grade
when engine compression braking is needed, or to retain third gear
when ascending a steep grade for additional engine performance.
In Manual Third, the transmission can upshift and downshift
between First, Second and Third gears in the same manner as
Overdrive Range but is prevented from shifting into Fourth or
Fifth gear while operating in this gear selector position. If the
transmission is in Fourth or Fifth Gear when Manual Third is
selected, the transmission will not shift into Third gear until
vehicle speed is low enough not to overrev the engine
(calibratable in the TCM).
Note: Transfer of engine torque during acceleration is identical
to Overdrive Range Third Gear (refer to page 68A) to obtain
an approximate gear ratio reduction of 1.60:1 through the
transmission gear set. The power flow in Figure 74 and the
following text describes conditions during deceleration (zero or
minimum throttle conditions) and how engine compression
braking is achieved.
Vehicle speed provides the torque input to the transmission
through the drive shaft and transmission output shaft assembly
(562). This is shown by the direction of the power flow arrows
in the drawing at the top of Figure 74. Notice that this flow is
identical to Overdrive Range Third Gear except that the arrows
are in the opposite direction.
1

Power From the Differential Assembly

Power flow is transferred back through the transmission


from the output shaft to the input shaft forward and coast
clutch housing assembly (433). Each of the components
function and rotation direction is the same as during
acceleration (compare Figures 64 and 74).
2

Overdrive Clutch Applied

The overdrive clutch, which is located within the overdrive


clutch housing (493), is applied and holds the overdrive and
reverse clutch hub assembly (470) stationary.
3

Front Input Sun Gear Held

The overdrive and reverse clutch hub assembly (470) is


splined to the front input sun gear and holds it stationary.
4

OVERDRIVE
CLUTCH
APPLIED

SECOND
CLUTCH
APPLIED

SECOND
CLUTCH
SPRAG
(547)
OVERRUNNING

REAR
SHORT
PINION
GEAR
DRIVING

INTERMEDIATE
CLUTCH
APPLIED

INPUT AND
REACTION
CARRIER
(553)
DRIVEN

78

Figure 74

REAR INPUT
SUN GEAR
DRIVING

LONG
PINION
GEAR
DRIVING

Forward and Coast Clutches Applied

The forward clutch, which is located within the input shaft


forward and coast clutch housing assembly (433), is applied
and holds the forward clutch sprag outer race (459). The
coast clutch is also located in the input shaft forward and
coast clutch housing assembly (433) and is also applied. Input
torque from the rear input sun gear of the input and reaction
carrier (553) is transferred through the coast clutch to the
input shaft forward and coast clutch housing assembly (433).

FRONT INPUT
SUN GEAR
HELD

REAR
INTERNAL
GEAR
(560)
DRIVEN

Engine Compression Braking

With the overdrive clutch applied, power flow is


mechanically connected between the output shaft and torque
converter turbine. This allows engine compression to slow
the vehicle when the throttle is released.

In Manual Third range, First and Second gears operate the same
as in Overdrive Range.

78A

MANUAL THIRD THIRD GEAR

(from Manual Fourth Fourth Gear)

#12

ACCUMULATOR
DIRECT CL

DIRECT CLUTCH

The 1-2 SS valve is energized, allowing feed limit fluid to


enter the 1-2 signal fluid circuit. 1-2 signal fluid is routed to
the safety mode valve and to the 3-4 shift valve.
1c 3-4 Shift Valve:

1-2 signal fluid overcomes 3-4 shift valve spring force and
moves the 3-4 shift valve to the applied position. This
allows D432 fluid to enter the 123 fluid circuit, and allows
direct clutch and 45 fluids to exhaust.

FORWARD CLUTCH
COAST CLUTCH

1j

3a

EX

LINE
INTERMEDIATE CLUTCH
FEED LIMIT
D432
SECOND CLUTCH

DIRECT CL
1-2 SIGNAL

COMPLETE HYDRAULIC CIRCUIT


Page 106

2-3 SIGNAL

FEED LIMIT
1-2 SHIFT
SOLENOID
VALVE
N/C

(A)

D432

1h

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH

24

#11

2345

2-3 SIGNAL

1i

23 REGULATED

10

FEED LIMIT

23 REGULATED

X-1

(B)
29

EX
EX
SECOND COAST CLUTCH
2345
2345

18

OVERDRIVE CL FD 1

4-5 SIGNAL

4-5 SHIFT
SOLENOID
VALVE
N/C

19

123
123

2345

COAST CLUTCH FEED


45

45

123

45

1d

R N D 4 3 2

32

EX

32

345
45
123
D432

EX

LINE SAFETY MODE

D432

345

REGULATED APPLY
LINE

11

MANUAL VALVE

45
123

2345

345
25

ON

FEED LIMIT

1e

123 BRAKING
OVERDRIVE CL FD 2
COAST CLUTCH

1a

(C)

LINE

EX

REGULATED APPLY

FILTER
(308)

1f

28

REVERSE
TCC SIGNAL

2345 OR REVERSE

EX

LINE

FORWARD CLUTCH

TCC PWM
SOLENOID
VALVE
N/C

EX

EX

EX

EX

EX

LOW PRESSURE

EX

26

OFF

EX

#9

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

EX

22

EX

2-3 SHIFT VALVE

D432

23

345

LINE

TCC REGULATOR VALVE

ON

EX

EX

1-2 SHIFT CONTROL VALVE

4-5 SHIFT VLV CNTRL


FEED LIMIT VALVE

FEED LIMIT

FDL

FDL

EX

SECOND CL
D432

EX

EX
EX

EX

345
45

FEED LIMIT

FEED LIMIT

EX

1b

1-2 SHIFT VALVE

32
OVERDRIVE CLUTCH FEED 1
DIRECT CLUTCH
COAST CLUTCH
OVERDRIVE CLUTCH FEED 2
123 REGULATED

EX

EX

1c

FEED LIMIT

123
D432
345
DIRECT CLUTCH

EX

FEED LIMIT

2 DIRECT CLUTCH RELEASES


2a Direct Clutch:

In Manual Third Third Gear, the TCC will not release if Manual
Third was selected while the vehicle was operating in Overdrive
Range Fifth Gear with the TCC applied. Under normal operating
conditions, the converter clutch operates the same way in Manual
Third Third Gear as in Overdrive Range Third Gear. Refer to
pages 74A and 74B for descriptions of TCC release and apply.

3-4 SHIFT

Overdrive clutch fluid is then directed to the overdrive clutch


piston to apply the overdrive clutch plates.

Direct clutch fluid also exhausts from the direct clutch


accumulator assembly. Accumulator fluid moves the direct
clutch accumulator piston against accumulator spring force
in preparation for another application of the direct clutch.

2b

CNTRL

FILTER
(312)

1k Overdrive Clutch:

78B

SAFETY MODE

1-2 SIGNAL

X-3

1g

2345

2-3 SIGNAL

Overdrive clutch feed 1 fluid seats the #12 ball check valve
against the overdrive clutch feed 2 passage and enters the
overdrive clutch fluid circuit.

3 SHIFT ACCUMULATION
3a Direct Clutch Accumulator:

32
32 SAFETY MODE

EX

PRESSURE
CONTROL
SOLENOID
VALVE

#12 Ball Check Valve:

Direct clutch fluid flows through orifice #26 to the 3-4 shift
valve where it exhausts.

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

23 regulated fluid passes through the 2-3 shift valve into the
overdrive clutch feed 1 fluid circuit.

2b 3-4 Shift Valve:

MEMORY
FEED LIMIT
LINE
LINE SAFETY MODE

MEMORY PILOT

2-3 Shift Valve:

Direct clutch fluid is exhausts from the direct clutch piston


to release the direct clutch plates.

23 REGULATED

1-2 SIGNAL
FORWARD CLUTCH

23 regulated fluid seats the #9 and the #11 ball check valves
and is forced through orifices #22 and #23.

MEMORY

LINE
FEED LIMIT

1h #9 and #11 Ball Check Valves:

14

1-2 SIGNAL

20
21

1f Low Pressure Control Valve:

1j

FEED LIMIT

123 fluid passes through the 4-5 shift valve (333) into the
123 braking fluid circuit.

1i

EX

1e 4-5 Shift Valve:

123 regulated fluid passes through the 1-2 shift valve into
the 23 regulated fluid circuit.

EX

LINE

123 fluid seats the #4 ball check valve and passes through
orifice #16 on the way to the 4-5 shift valve.

1g 1-2 shift Valve:

SECOND
CLUTCH
ACCUMULATOR

ACCUM

1d #4 Ball Check Valve:

123 braking fluid is regulated into the 123 regulated fluid


circuit through the low pressure control valve (383).

INTERMEDIATE
CLUTCH
ACCUMULATOR

LINE

EX

AIR
BLEED
(203)

OVERDRIVE
CLUTCH
ACCUMULATOR

SECOND CLUTCH

AIR
BLEED
(203)

Line pressure enters the 32 fluid circuit at the manual valve.


32 fluid is routed to the safety mode valve.
1b 1-2 Shift Solenoid (SS) Valve:

SECOND COAST CL
LOW AND REV CL OR RLO

OVERDRIVE CLUTCH

DIRECT
CLUTCH
ACCUMULATOR

ACCUMULATOR

1 OVERDRIVE CLUTCH APPLIES


1a Manual Valve:

REVERSE LOCKOUT
SECOND CLUTCH

1k

REVERSE CLUTCH
DIRECT CLUTCH

AIR
BLEED
(203)

INTERMEDIATE CLUTCH

FORWARD CLUTCH
COAST CL
LUBE

2a

2345

Manual Third Third Gear may be selected at any time while the
vehicle is being operated in a forward gear range. However, TCM
control prevents the transmission from shifting above Third gear.
When the gear selector lever is moved to Manual Third range (3)
from Manual Fourth Fourth Gear, the manual valve also moves.
Changes to the hydraulic and electrical systems are as follows:

CENTER
SUPPORT
ASSEMBLY
(510535)

CST CL
123
123
123 BRK

APPLIED

EX

APPLIED

45

LD

INTERMEDIATE CL

APPLIED

REV

LD

D432
SECOND CL
23 REG
123 REG
123 REGULATED
LOW AND REV CL

APPLIED APPLIED

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

345
2345

ON OFF ON
LD = LOCKED IN DRIVE

(from Manual Fourth Fourth Gear)

ACCUMULATOR
OVERDRIVE CL FD 2

FORWARD OVER- INTERM. INTER- LOW LOW AND


SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

OVERDRIVE CLUTCH FEED 1

SOLENOID

OVERDRIVE CLUTCH FEED 2

WWW.ALL-TRANS.BY

MANUAL THIRD THIRD GEAR

#2

X-4
345

LINE

#3

27

2345 OR REVERSE
45
LINE
D432

X-5

#4

16

#7

17

#5

15

#6

123
D432

2345 OR REVERSE

32
123

LINE (from Pump)


FORWARD CLUTCH

FORWARD CLUTCH

Figure 75

79

MANUAL SECOND SECOND GEAR

(from Manual Third Third Gear)

(from Manual Third Third Gear)

4a
COAST
CLUTCH
APPLIED

5
POWER TO
TORQUE
CONVERTER
(1)
FOR ENGINE
BRAKING

4
FORWARD
CLUTCH
APPLIED

FORWARD
SECOND SECOND
CLUTCH
CLUTCH CLUTCH
APPLIED
SPRAG
SPRAG
(461)
(547)
INEFFECTIVE INEFFECTIVE

2
SECOND
COAST
CLUTCH
APPLIED

3
REACTION
INTERNAL
GEAR
(550)
HELD

INPUT AND
REAR
REACTION INTERNAL
CARRIER
GEAR
(553)
(560)
DRIVEN
DRIVEN

LONG
PINION GEAR
DRIVING

1
POWER FROM
DIFFERENTIAL
ASSEMBLY

REAR SHORT
PINION
GEAR
DRIVING
FRONT SHORT
PINION
GEAR
DRIVING

COAST
CLUTCH
APPLIED

REVERSE
CLUTCH
HOUSING
ASSEMBLY
(401)

FORWARD
CLUTCH
SPRAG
(461)
INEFFECTIVE

FORWARD
CLUTCH
APPLIED

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
ON ON ON

APPLIED APPLIED

LD

APPLIED

LD

APPLIED

LD = LOCKED IN DRIVE

REAR INPUT
SUN GEAR
DRIVING

WWW.ALL-TRANS.BY

MANUAL SECOND SECOND GEAR

Manual Second (2) gear range is available to the driver when


vehicle operating conditions require maximum engine
compression braking for slowing the vehicle, or maximum engine
torque transfer to the wheels. These conditions include
descending a steep grade when maximum engine compression
braking is needed, to retain second gear when ascending a steep
grade, or pulling a heavy load for maximum engine power.
In Manual Second, the transmission can upshift and downshift
between First and Second gear in the same manner as Overdrive
Range but is prevented from shifting into Third, Fourth or Fifth
gear while operating in this gear selector position. If the
transmission is in any other forward gear range when Manual
Second is selected, the transmission will not shift into Second
gear until vehicle speed is low enough not to overrev the engine
(calibratable in the TCM). Above this speed, the transmission
will first shift into Third gear until vehicle speed slows sufficiently.
Note: Transfer of engine torque during acceleration is identical to
Overdrive Range Second Gear (refer to page 66A) to obtain an
approximate gear ratio reduction of 2.21:1 through the transmission
gear set. The power flow in Figure 76 and the following text
describes conditions during deceleration (zero or minimum throttle)
and how engine compression braking is achieved.
Vehicle speed provides the torque input to the transmission
through the drive shaft and transmission output shaft assembly
(562). This is shown by the direction of the power flow arrows
in the drawing at the top of Figure 76. Notice that this flow is
identical to Overdrive Range Second Gear except that the
arrows are in the opposite direction.
1

Power From the Differential Assembly

Power flow is transferred back through the transmission


from the output shaft to the input shaft forward and coast
clutch housing assembly (433). Each of the components
function and rotation direction is the same as during
acceleration (compare Figures 62 and 76).
2

Second Coast Clutch Applied

The second coast clutch, which is located within the center


support (518), is applied and holds the second clutch sprag
inner race (549) stationary.
3

SECOND
COAST
CLUTCH
APPLIED
SECOND
CLUTCH
APPLIED

SECOND
CLUTCH
SPRAG
(547)
INEFFECTIVE

The second clutch sprag inner race (549) is splined to the


reaction internal gear (550) and holds it stationary.

REACTION
INTERNAL
GEAR
(550)
HELD

REAR
INPUT
SUN GEAR
DRIVING

80

Figure 76

LONG
PINION
GEAR
DRIVING

Forward and Coast Clutches Applied

The forward clutch, which is located within the input shaft


forward and coast clutch housing assembly (433), is applied
and holds the forward clutch sprag outer race (459). The
coast clutch is also located in the input shaft forward and
coast clutch housing assembly (433) and is also applied. Input
torque from the rear input sun gear of the input and reaction
carrier (553) is transferred through the coast clutch to the
input shaft forward and coast clutch housing assembly (433).

REAR SHORT
PINION GEAR
DRIVING

INPUT AND
REACTION
CARRIER
(553)
DRIVEN

Reaction Internal Gear Held

REAR
INTERNAL
GEAR
(560)
DRIVEN

Engine Compression Braking

With the second coast clutch applied, power flow is


mechanically connected between the output shaft and torque
converter turbine. This allows engine compression to slow
the vehicle when the throttle is released.

In Manual Second range, First gear operates the same as in


Overdrive Range.

80A

MANUAL SECOND SECOND GEAR

(from Manual Third Third Gear)

(from Manual Third Third Gear)

FORWARD CLUTCH
COAST CLUTCH

D432
SECOND CLUTCH

COMPLETE HYDRAULIC CIRCUIT


Page 108

80B

EX

FEED LIMIT

EX

D432
2-3 SIGNAL

#11

2345

1b

23 REGULATED

10

FEED LIMIT

23 REGULATED

X-1

(B)
29

EX
EX
SECOND COAST CLUTCH

2c

2345
2345

345

18

OVERDRIVE CL FD 1

4-5 SIGNAL

4-5 SHIFT
SOLENOID
VALVE
N/C

19

28

EX

EX

123
123
COAST CLUTCH FEED
45

2345

345

REGULATED APPLY

123
D432

45

32

123

45

LINE

1a

R N D 4 3 2

D432

REV

EX

345
45

MANUAL VALVE

45
123

2345

345
25

11

LINE SAFETY MODE

REVERSE

LINE

FILTER
(308)

ON

FEED LIMIT

123 BRAKING
OVERDRIVE CL FD 2
COAST CLUTCH

REGULATED APPLY

2345 OR REVERSE

EX

FORWARD CLUTCH
LINE

TCC PWM
SOLENOID
VALVE
N/C

(C)

EX

CST CL
123
123
123 BRK

EX

EX

EX

EX

EX

LOW PRESSURE

45

26

ON

EX

#9

2345

22

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

EX

2-3 SHIFT VALVE

LINE

TCC REGULATOR VALVE

FEED LIMIT

FDL
EX

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH

24

SECOND COAST CLUTCH

1-2 SIGNAL

2-3 SIGNAL

FDL

EX

SECOND CL
D432

EX

3b

4-5 SHIFT VLV CNTRL


FEED LIMIT VALVE

ON

FEED LIMIT

FEED LIMIT

(A)

D432

123
D432
345
DIRECT CLUTCH

1c

EX

EX

CNTRL 3-4 SHIFT

23

EX

1-2 SIGNAL

FEED LIMIT
1-2 SHIFT
SOLENOID
VALVE
N/C

1-2 SHIFT CONTROL VALVE

EX

EX

SAFETY MODE

FILTER
(312)

FEED LIMIT

1-2 SHIFT VALVE

345
2345

EX
PRESSURE
CONTROL
SOLENOID
VALVE

X-3

2345

2-3 SIGNAL

3 INTERMEDIATE CLUTCH RELEASES


3a Intermediate Clutch Assembly:

If the converter clutch was applied when Manual Second was


selected it will release during downshifting. Under normal operating
conditions the converter clutch will not re-apply in Second gear.

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

EX

MEMORY PILOT

Exhausting overdrive clutch feed 2 fluid is routed through


the 2-3 shift valve into the intermediate clutch fluid circuit.

Intermediate clutch fluid also exhausts from the intermediate


clutch accumulator assembly. Accumulator fluid moves the
intermediate clutch accumulator piston against accumulator
spring force in preparation for another application of the
intermediate clutch.

MEMORY
FEED LIMIT
LINE
LINE SAFETY MODE

MEMORY

2c 2-3 Shift Valve:

4 SHIFT ACCUMULATION
4a Intermediate Clutch Accumulator:

23 REGULATED

14

D432
SECOND CL
23 REG
123 REG
123 REGULATED
LOW AND REV CL

20
21

2-3 SIGNAL

2-3 SIGNAL
1-2 SIGNAL

Overdrive clutch fluid seats the #12 ball check valve


against the overdrive clutch feed 2 passage and enters the
overdrive clutch feed 1 fluid circuit.

Intermediate clutch fluid is routed through orifice #24 to the


2-3 shift valve where it exhausts.

SECOND COAST CL
LOW AND REV CL OR RLO

FEED LIMIT
DIRECT CL

2b #12 Ball Check Valve:

3b 2-3 Shift Valve:

INTERMEDIATE CLUTCH

Overdrive clutch fluid exhausts from the overdrive clutch


piston, allowing the overdrive clutch plates to disengage.

Intermediate clutch fluid exhausts from the intermediate clutch


piston, allowing the intermediate clutch plates to disengage.

4a
LINE

TCC SIGNAL

2 OVERDRIVE CLUTCH RELEASES


2a Overdrive Clutch Assembly:

1d

FEED LIMIT

FORWARD CLUTCH
LINE
FEED LIMIT
2-3 SIGNAL
1-2 SIGNAL

Note: Figure 77 is shown in Second gear with the 2-3 SS valve


energized. However, if vehicle operating conditions are such
that the TCM signals a Third, Fourth or Fifth gear state, the 2-3
solenoid will be de-energized. Thus a downshift will not occur
until the vehicle speed is low enough not to overrev the engine
(calibratable in the TCM).

EX

LINE

2-3 signal fluid is also routed to the 3-4 shift control valve
(346) and moves the valve against 1-2 signal fluid pressure
to keep the 3-4 shift valve (345) in the applied position.
Second coast clutch fluid is directed to the second coast
clutch piston to apply the second coast clutch plates.

EX

ACCUM

1c 3-4 Shift Control Valve:

1d Second Coast Clutch:

EX

SECOND
CLUTCH
ACCUMULATOR

LINE

2b
ACCUMULATOR
DIRECT CL

The 2-3 SS valve is energized, allowing feed limit fluid to


enter the 2-3 signal fluid circuit. 2-3 signal fluid overcomes
2-3 shift valve spring (372) force and moves the 2-3 shift
valve (371) to the applied position. This allows 23 regulated
fluid to enter the second coast clutch fluid circuit and also
opens the overdrive clutch feed 1, intermediate clutch and
345 fluid circuits to exhaust.

REVERSE LOCKOUT
SECOND CLUTCH

#12

INTERMEDIATE
CLUTCH
ACCUMULATOR

SECOND CL

AIR
BLEED
(203)

OVERDRIVE
CLUTCH
ACCUMULATOR

INTERMED CL

AIR
BLEED
(203)

EX

DIRECT CLUTCH

1b 2-3 Shift Solenoid (SS) Valve:

3a

OVERDRIVE CLUTCH

DIRECT
CLUTCH
ACCUMULATOR

1 SECOND COAST CLUTCH APPLIED


1a Manual Valve:

The volume of line pressure entering the 32 fluid circuit at the


manual valve is increased to accommodate the added torque
requirements for engine braking or increased engine load.

2a

REVERSE CLUTCH
DIRECT CLUTCH

AIR
BLEED
(203)

INTERMEDIATE CLUTCH

FORWARD CLUTCH
COAST CL
LUBE

CENTER
SUPPORT
ASSEMBLY
(510535)

ACCUMULATOR

Manual Second Second Gear may be selected at any time


while the vehicle is being operated in a forward gear range.
However, TCM control prevents the transmission from upshifting
above Second gear. When the gear selector lever is moved to
Manual Second (2) from Manual Third Third Gear, the manual
valve also moves. Changes to the hydraulic and electrical systems
are as follows:

ACCUMULATOR
OVERDR CL FD 2

APPLIED

32
OVERDRIVE CLUTCH FEED 1
DIRECT CLUTCH
COAST CLUTCH
OVERDRIVE CLUTCH FEED 2
123 REGULATED

LD

32

APPLIED

OVERDRIVE CLUTCH FEED 1

LD

OVERDRIVE CLUTCH FEED 2

APPLIED APPLIED

EX

ON ON ON
LD = LOCKED IN DRIVE

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

EX

FORWARD OVER- INTERM. INTER- LOW LOW AND


SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH

32
32 SAFETY MODE

SOLENOID

345
45

WWW.ALL-TRANS.BY

MANUAL SECOND SECOND GEAR

#2

X-4
345

LINE

#3

27

2345 OR REVERSE
45
LINE
D432

X-5

#4

16

#7

17

#5

15

#6

123
D432

2345 OR REVERSE

32
123

LINE (from Pump)


FORWARD CLUTCH

FORWARD CLUTCH

Figure 77

81

MANUAL SECOND FIRST GEAR


(from Manual Second Second Gear)

(from Manual Second Second Gear)


5
POWER TO
TORQUE
CONVERTER
(1)
FOR ENGINE
BRAKING

4a
COAST
CLUTCH
APPLIED

4
FORWARD
CLUTCH
APPLIED

FORWARD
LOW
CLUTCH
CLUTCH
SPRAG
SPRAG
(461)
(503)
INEFFECTIVE INEFFECTIVE

2
LOW AND
REVERSE
CLUTCH
APPLIED

3
INPUT AND
REACTION
CARRIER
(553)
HELD

LONG
PLANETARY
PINION
GEAR
DRIVING

REAR
INTERNAL
GEAR
(560)
DRIVEN

REAR
INPUT SUN
GEAR
DRIVING

1
POWER FROM
DIFFERENTIAL
ASSEMBLY

WWW.ALL-TRANS.BY

MANUAL SECOND FIRST GEAR

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF ON ON

FORWARD
CLUTCH
APPLIED

COAST
CLUTCH
APPLIED

REVERSE
CLUTCH
HOUSING
ASSEMBLY
(401)

LD

LD

APPLIED

Manual Second First Gear is commanded by the TCM when


vehicle speed is low enough not to overrev the engine
(calibratable in the TCM). Manual Second First Gear is
commanded in order to achieve maximum engine compression
braking for slowing the vehicle.
Note: Transfer of engine torque during acceleration is identical to
Overdrive Range First Gear (refer to page 64A) to obtain an
approximate gear ratio reduction of 3.42:1 through the transmission
gear set. The power flow in Figure 78 and the following text
describes conditions during deceleration (zero or minimum throttle)
and how engine compression braking is achieved.
Vehicle speed provides the torque input to the transmission
through the drive shaft and transmission output shaft assembly
(562). This is shown by the direction of the power flow arrows
in the drawing at the top of Figure 78. Notice that this flow is
identical to Overdrive Range First Gear except that the arrows
are in the opposite direction.

REAR SHORT
PINION GEAR
DRIVING

FORWARD
CLUTCH
SPRAG
(461)
INEFFECTIVE

APPLIED APPLIED

LD = LOCKED IN DRIVE

Power From the Differential Assembly

Power flow is transferred back through the transmission


from the output shaft to the input shaft forward and coast
clutch housing assembly (433). Each of the components
function and rotation direction is the same as during
acceleration (compare Figures 60 and 78).
2

Low and Reverse Clutch Applied

The low and reverse clutch, which is located within the


center support (518), is applied and holds the low clutch
sprag inner race (505) stationary.
3

Input and Reaction Carrier Held

The low clutch sprag inner race (505) is splined to the input
and reaction carrier (553) and holds it stationary.
4

Forward and Coast Clutches Applied

The forward clutch, which is located within the input shaft


forward and coast clutch housing assembly (433), is applied
and holds the forward clutch sprag outer race (459). The
coast clutch is also located in the input shaft forward and
coast clutch housing assembly (433) and is also applied. Input
torque from the rear input sun gear of the input and reaction
carrier (553) is transferred through the coast clutch to the
input shaft forward and coast clutch housing assembly (433).
5

LOW
CLUTCH
SPRAG
(503)
INEFFECTIVE

LOW AND
REVERSE
CLUTCH
APPLIED

INPUT AND
REACTION
CARRIER
(553)
HELD

REAR
INPUT
SUN GEAR
DRIVING

82

Figure 78

With the low and reverse clutch applied, power flow is


mechanically connected between the output shaft and torque
converter turbine. This allows engine compression to slow
the vehicle when the throttle is released.

LONG
PLANETARY
PINION
GEAR
DRIVING

REAR SHORT
PINION GEAR
DRIVING

Engine Compression Braking

REAR
INTERNAL
GEAR
(560)
DRIVEN

82A

(from Manual Second Second Gear)

(from Manual Second Second Gear)

FORWARD OVER- INTERM. INTER- LOW LOW AND


SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF ON ON

APPLIED APPLIED

LD

LD

CENTER
SUPPORT
ASSEMBLY
(510535)

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

APPLIED

LD = LOCKED IN DRIVE

Manual Second First Gear is commanded by the TCM, when


vehicle speed is low enough not to overrev the engine (calibratable
in the TCM), in order to achieve maximum engine braking.
Changes to the hydraulic and electrical systems are as follows:

2e

FORWARD CLUTCH
COAST CL
LUBE

DIRECT
CLUTCH
ACCUMULATOR

1 MANUAL VALVE

Manual Second First Gear is commanded by the TCM


only, there is no movement of the manual valve.

AIR
BLEED
(203)

EX

SECOND COAST CL
LOW AND REV CL OR RLO

SOLENOID

OVERDRIVE
CLUTCH
ACCUMULATOR

AIR
BLEED
(203)

EX

INTERMEDIATE
CLUTCH
ACCUMULATOR

SECOND
CLUTCH
ACCUMULATOR

EX

EX

REVERSE LOCKOUT
SECOND CLUTCH

WWW.ALL-TRANS.BY

MANUAL SECOND FIRST GEAR

MANUAL SECOND FIRST GEAR

3a

3b

ACCUM

2 LOW AND REVERSE CLUTCH APPLIED


2a 1-2 Shift Solenoid (SS) Valve:

#8

LINE

D432
EX

EX

FEED LIMIT

4-5 SIGNAL

4-5 SHIFT
SOLENOID
VALVE
N/C

EX

ON
11

FEED LIMIT
LINE SAFETY MODE

EX

123 BRAKING
OVERDRIVE CL FD 2
COAST CLUTCH

123
123

2345

COAST CLUTCH FEED


45

REVERSE

(C)

EX

45

CST CL
123
123
123 BRK

4-5 SHIFT VLV CNTRL

123
D432

R N D 4 3 2

123

45

45

32

D432

LINE

REV

EX

32

45

MANUAL VALVE

SECOND COAST CLUTCH

FEED LIMIT

FDL

EX

EX

EX

29

EX

LOW PRESSURE

LINE

2-3 SIGNAL

1-2 SIGNAL

2-3 SIGNAL

LOW AND REV CL


FDL

SECOND CL
D432

EX

SECOND COAST CLUTCH


OVERDRIVE CL FD 1
2345
2345

18

EX

28

REGULATED APPLY

ON

D432

FDL

#10

19

REGULATED APPLY

(B)

EX

EX

EX

2345

123 REGULATED

X-1

32 SM

EX

TCC SIGNAL

2345 OR REVERSE

EX

FORWARD CLUTCH
LINE

TCC PWM
SOLENOID
VALVE
N/C

FILTER
(308)

#9

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

32 SM/FDL

LINE

TCC REGULATOR VALVE

10

FEED LIMIT

2-3 SHIFT VALVE

EX

EX

EX

FEED LIMIT VALVE

Second coast clutch fluid is routed through the 2-3 shift


valve to the 1-2 shift valve where it enters the second clutch
fluid circuit. Second clutch fluid is routed through orifice
#21 to the 1-2 shift valve where it exhausts.

2-3 SIGNAL
2345

EX

3c 1-2 Shift Valve:

OFF

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH

24

3c

#11

22

EX

EX

EX

FEED LIMIT

(A)

23 REGULATED

DIRECT CLUTCH

FEED LIMIT

26

FEED LIMIT

23 REGULATED

345
45

123
D432
345

Second coast clutch fluid exhausts from the second coast


clutch piston, allowing the second coast clutch plates to
disengage.

23

CNTRL 3-4 SHIFT

FEED LIMIT

1-2 SHIFT
SOLENOID
VALVE
N/C

1-2 SHIFT CONTROL VALVE

345
2345

1-2 SIGNAL
2-3 SIGNAL

FILTER
(312)

2a

2b

1-2 SHIFT VALVE


EX

EX

EX

SAFETY MODE

3b Second Coast Clutch Assembly:

Second clutch fluid also exhausts from the second clutch


accumulator assembly. Accumulator fluid moves the second
clutch accumulator piston against accumulator spring force
in preparation for another application of the second clutch.

FDL

PRESSURE
CONTROL
SOLENOID
VALVE

2c

X-3

2345

32
COAST CLUTCH

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

32
32 SAFETY MODE

MEMORY
FEED LIMIT
LINE
LINE SAFETY MODE

MEMORY PILOT

Second clutch fluid exhausts from the second clutch piston,


allowing the second clutch plates to disengage.

4 SHIFT ACCUMULATION
4a Second Clutch Accumulator:

23 REGULATED

MEMORY

14

D432
SECOND CL
23 REG
123 REG
123 REGULATED

20
21

EX

3 SECOND CLUTCH AND


SECOND COAST CLUTCH RELEASE
3a Second Clutch Assembly:

FDL

EX

Low and reverse clutch or reverse lockout fluid pressure


enters the outer area of the low and reverse clutch piston
and moves the piston against spring force to apply the low
and reverse clutch plates.

ACCUMULATOR

D432
SECOND CLUTCH

FORWARD CLUTCH
LINE
FEED LIMIT
2-3 SIGNAL
1-2 SIGNAL

2e Low and Reverse Clutch:

2d

2-3 SIGNAL
1-2 SIGNAL

FDL fluid is routed to the 1-2 shift valve (387) and moves
the valve against 1-2 shift valve spring (388) force to the
applied position. This allows 123 regulated fluid to enter
the low and reverse clutch fluid circuit.
Low and reverse clutch fluid seats the #8 ball check valve
against the reverse lockout fluid passage and enters the low
and reverse clutch or reverse lockout fluid passage.

4a

LINE
FEED LIMIT

2c 1-2 Shift Valve:

2d #8 Ball Check Valve:

REVERSE LOCKOUT

LINE
FEED LIMIT

LOW AND REVERSE CL

SECOND CL

With 1-2 signal fluid exhausted, 2-3 signal fluid is able to


move the 1-2 shift control valve (366) against 1-2 shift
control valve spring (367) force to the applied position.
This allows feed limit fluid to enter the FDL fluid circuit.

INTERMED CL

2b 1-2 Shift Control Valve:

FORWARD CLUTCH
COAST CLUTCH

ACCUMULATOR
DIRECT CL

The 1-2 SS valve is de-energized, blocking feed limit fluid


from entering the 1-2 signal fluid circuit and 1-2 signal fluid
pressure exhausts through the 1-2 SS valve.

ACCUMULATOR
OVERDR CL FD 2

45
123

2345

#2

#3

2345 OR REVERSE
45
LINE
D432

LINE

82B

X-5

#4

16

#7

17

#5

15

#6

123
D432

2345 OR REVERSE

COMPLETE HYDRAULIC CIRCUIT


Page 110

27

32
123

LINE (from Pump)


FORWARD CLUTCH

FORWARD CLUTCH

Figure 79

83

WWW.ALL-TRANS.BY

OPERATING CONDITIONS
RANGE REFERENCE CHART
1-2 SHIFT 2-3 SHIFT 4-5 SHIFT
ENGINE
GEAR
RATIO SOLENOID SOLENOID SOLENOID
BRAKING
VALVE
VALVE
VALVE

RANGE

1
2
3
4
5
6
7
8
9
10
11
12
13
TCC
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT COAST REVERSE FORWARD
SECOND
SOLENOID
CLUTCH DRIVE CLUTCH MEDIATE CLUTCH REVERSE
CLUTCH COAST
CLUTCH CLUTCH CLUTCH CLUTCH
CLUTCH
VALVE
SPRAG CLUTCH SPRAG CLUTCH SPRAG CLUTCH
SPRAG CLUTCH

*NO

3.42

OFF

ON

OFF

OFF

APPLIED

APPLIED

LD

LD

YES

3.42

OFF

ON

ON

OFF

APPLIED

APPLIED

LD

LD

*NO

2.21

ON

ON

OFF

ON/OFF @

APPLIED

APPLIED

LD

APPLIED

LD

YES

2.21

ON

ON

ON

ON/OFF @

APPLIED

APPLIED

LD

APPLIED

LD

*NO

1.60

ON

OFF

OFF

ON/OFF @

APPLIED

APPLIED

LD

YES

1.60

ON

OFF

ON

ON/OFF @

APPLIED

APPLIED

LD

YES

1.00

OFF

OFF

ON

ON/OFF @ APPLIED APPLIED

APPLIED

LD

YES

0.75

OFF

OFF

OFF

ON/OFF @ APPLIED

APPLIED

NEUTRAL

@
ON/OFF

@
ON/OFF

@
ON/OFF

REVERSE

YES

3.03

@
ON/OFF

@
ON/OFF

@
ON/OFF

OFF

@
ON/OFF

@
ON/OFF

@
ON/OFF

ON

@
ON/OFF

@
ON/OFF

@
ON/OFF

APPLIED

APPLIED

D432

REVERSE
LOCK OUT
PARK

LD = LOCKED IN DRIVE
ON = SOLENOID ENERGIZED
OFF = SOLENOID DE-ENERGIZED

APPLIED

APPLIED

LD

APPLIED

APPLIED

LD

APPLIED

APPLIED

APPLIED

APPLIED

APPLIED

APPLIED

APPLIED

APPLIED

@ THE SOLENOID'S STATE FOLLOWS A SHIFT PATTERN WHICH DEPENDS UPON VEHICLE
SPEED AND THROTTLE POSITION. IT DOES NOT DEPEND UPON THE SELECTED GEAR.
ENGINE BRAKING IS ELECTRONICALLY CONTROLLED BY THE TCM, AND IS AVAILABLE AS
CALIBRATED FOR EACH MODEL AND APPLICATION.
REVERSE LOCK OUT IS A CONDITION THAT OCCURS WHEN TCC APPLY IS COMMANDED BY
THE TCM. TCC SIGNAL FLUID FROM THE TCC PWM SOLENOID VALVE APPLIES THE REVERSE
LOCKOUT VALVE TO PREVENT REVERSE CLUTCH OR LOW AND REVERSE CLUTCH APPLY
EVEN IF THE MANUAL VALVE IS IN REVERSE POSITION.

NOTE: DESCRIPTIONS ABOVE EXPLAIN COMPONENT FUNCTION DURING ACCELERATION.

EXPECTED OPERATING CONDITION IF COMPONENT IN COLUMN NUMBER IS INOPERATIVE:


COLUMN #

84

CONDITION

NO 4TH OR FIFTH GEARS.

NO ENGINE BRAKING IN OVERDRIVE RANGE FIRST, SECOND, THIRD AND FOURTH GEARS;
OR IN MANUAL FOURTH, MANUAL THIRD AND MANUAL SECOND RANGES.

NO REVERSE.

NO FORWARD.

NO FORWARD.

NO FIFTH GEAR OR,


NO ENGINE BRAKING IN THIRD GEAR ALL FORWARD RANGES.

NO THIRD GEAR.

NO THIRD, FOURTH, OR FIFTH GEARS.

NO FIRST GEAR.

10

NO REVERSE, NO ENGINE BRAKING IN MANUAL FIRST.

11

NO SECOND, THIRD, FOURTH, OR FIFTH GEARS.

12

NO SECOND GEAR.

13

NO ENGINE BRAKING IN SECOND GEAR ALL FORWARD RANGES.

Figure 80

The hydraulic circuitry of the Hydra-matic


4/5L40-E transmission is better understood when
fluid flow can be related to the specific
components in which the fluid travels. In the
Power Flow section, a simplified hydraulic
schematic was given to show what hydraulically
occurs in a specific gear range. The purpose was
to isolate the hydraulics used in each gear range
in order to provide the user with a basic
understanding of the hydraulic system.
In contrast, this section shows a complete
hydraulic schematic with fluid passages active in
the appropriate component for each gear range.
This is accomplished using two opposing foldout
pages that are separated by a half page of
supporting information.
The left side foldout contains the complete color
coded hydraulic circuit used in that gear range
along with the relative location of valves, ball
check valves and orifices within specific
components. A broken line is also used to separate

PASSAGE
PASSAGE
PASSAGE
PASSAGE
PASSAGE
PASSAGE
PASSAGE
PASSAGE

A
B
C
D
E
F
G
H

components such as the pump, control valve


bodies, channel plates and case to assist the user
when following the hydraulic circuits as they
pass between them. The half page of information
facing this foldout lists possible conditions and
component diagnostic tips. Always refer to the
appropriate vehicle platform service manual when
diagnosing specific concerns.
The right side foldout shows a two-dimensional
line drawing of the fluid passages within each
component. The active fluid passages for each
gear range are appropriately colored to correspond
with the hydraulic schematic used for that range.
The half page of information facing this foldout
identifies the various fluid circuits with numbers
that correspond to the circuit numbers used on
the foldout page.
For a more complete understanding of the
different hydraulic systems used in a specific gear
range, refer to the Hydraulic Control Components
section and/or Power Flow section.

IS LOCATED IN THE FLUID PUMP BODY (LIGHT GREY AREA)


IS LOCATED IN THE FRONT CONTROL VALVE BODY (LIGHT BLUE AREA)
IS LOCATED IN THE REAR CONTROL VALVE BODY (LIGHT GREEN AREA)
IS LOCATED ON THE SPACER PLATE (DASHED LINE)
IS LOCATED IN THE BOTTOM CHANNEL PLATE (LIGHT RED AREA)
IS LOCATED IN THE TOP CHANNEL PLATE (LIGHT PURPLE AREA)
IS LOCATED IN THE ACCUMULATOR HOUSING (LIGHT YELLOW AREA)
IS LOCATED IN THE CASE (WHITE AREA)

FLUID FLOW SCHEMATIC


(FOLDOUT)
A

FLUID FLOW THROUGH


COMPONENTS (FOLDOUT)

RK g)
PA nnin
Ru

e
gin
(En

32 SAFETY MODE
D432
32
2-3 SIGNAL
REVERSE LOCKOUT
COAST CLUTCH

52

34

30

48

19
48

48

52

28
48

48
48

18
10

21

20
52

2
48

48

TOP CHANNEL PLATE (301)


(Bottom Channel Plate Side)

19

27

48

48

48

43

#10
10

Figure 83

48
10

17

21b/31
21a

#9

#8

BOTTOM CHANNEL PLATE (304)


(Control Valve Body Side)

35b
39a
33e
33c

23

13b 33d
19c/21
15e 33b
19d/21

22

15

15f/18
19b/21 19a 10i
42a

11

17c/18
2f

48

52

40
52
54

48

48

28a

25
26
25

35d
22

14

19

24

38
52

31

30d
28b 52

52

2e

44a 2
34a
27a 44b 10f
44d
43c/45 9
44c 10g

32

38

2m/54g

48

SPACER PLATE (307)


(Bottom Channel Plate Side)

20

35
22
35
39

52

21

15

19
2

10
48

44

34
33
17

35
52

52

52

30
28

33
13

22
30
33
54
25
25
17
30
44

26

42

22

36

20

52

35
19

52

40
2d/54e
25d
25e
17a 3
30c

44e

44f/45
10h

48
30

19

15
14

52

54f

18

17b
48a
29 48b

43b
10

48

52
30b

22a

20

35a
22e

20b
26a
16

39

38
48

52

42
43

21c/31 27
20c
2h 20d

#7
(Spring)

52

47
10
2

FRONT CONTROL VALVE BODY (311)


(Bottom Channel Plate Side)

40d

19f

30a
33a

22b
22d 22c

22f
24

54

47

36

54d
2c/54c

14

35c
19e

28

38c

37

28

46
13

37
40

25

15a

24c
36a

25c
40a
32a

FRONT

48
10 42

13

28

45

34
27

43
28

19

18

30

52

BOTTOM CHANNEL PLATE (304)


(Top Channel Plate Side)

22g/23
38b

#6

10

TOP CHANNEL PLATE (301)


(Case Side)

38d
38e

21

15

21

19h

14a/23 26b

#5
17

48

19g
19i
25b
19

25a

#4

19

52

34

44
18

48
10
42

28

15

13
21

48
48

10

21
48

X-5

38

20

35
52

44
2

20
19

36
36

52

18

15

#3
38

52 26 32
33

28

#11

22

32

23

22
22
17

35

38

52

36

22 19
25

19
2

40
25

35

30
13
42 52

47a
27c/46
10e

8
19j
2b
13a
37a
40c/41
39c/41
36e
42b 52
43a
39b

40b

FRONT

12

52

39

30

X-1

19
15

38
20 21

15

52 43

52
12
48

27
52

52

32
22

27

11
10

10
23

37c

54b

26

25

38a

FRONT

48

19

34
10

36c

48
37

20a
36f

23a

15

35

#2

52

30

52

23b

FILTER
(308)

23
38

36d 36b

19

REVERSE LOCKOUT
COAST CLUTCH

D432

123 REGULATED
123 BRAKING

1-2 SIGNAL

13

52

28

52

24

27b

19

43

48

48

11b
10c
12a
4
52
28c
48
47b 2a/54a

10d

X-3

41

15b
11a/10b

37b
10a

2g

7b

X-4

36
48

48

7a
6

24

13

24b

41

43
2

10
42

48

16a
23c

24a
48

13
36

48
37d
48

52

40

FILTER
(312)

15c/16
7

48

23

FRONT

FRONT

FRONT

21

19

48
41

35

FRONT

23 REGULATED

INTERMEDIATE CL

LINE

2-3 SIGNAL
D432
FEED LIMIT

1-2 SIGNAL

42
27

20

2
41

19

52

Figure 82

42

48
43

15
48

24
7

24

36
37
15

36

52

48
16

15d/16

48
2
10

20
19

13
#12

48

48
37

37

27
27

47

28

23
48

11

48

48

12
48

2
27

48

COMP

(36) ONENTS
TRA
(40) NSMIS ( )
(203 TRANSMIS SION FLU
(213) CHECK VA SION FLU ID LEV
EL
(214) TRANSMISLVE RET ID PRE HOLE PLU
AIN SS
(230) BRASS OR SION FLU ER AN URE TES G
D
(232) TRANSMIS IFICE IN ID PUMP BALL AS T PLUG
SER
(233) ORIFICE SION VEN T SCREEN SEMBLY
SLE
ASSEM
(306) ORIFICE EVE T ASSEM
BLY
CONT CUP PLU
BLY
RO
(#1 L G
(308) , 2, 3, VALVE BO
4,
(312) TCC PWM 5, 6, 7, 8, DY BALL
PRESS SOLEN 9, 10, CHECK
11,
FIL URE CO OID VA 12 VALVE
86 TER ASSEMNTROL SOLVE FILTER
BLY LENOID ASSEM
B
VALVE BLY
FEED LIMIT

OVERDRIVE CL FD 2
OVERDRIVE CL FD 1
RLO

32
FEED LIMIT

TOP CHANNEL PLATE (301)


CASE (24)

FORWARD CLUTCH

48
2

24
48

1-2 SIGNAL
123

REVERSE LOCKOUT
D432

41

48

48
16
48

10

12
28

48
16
37

48
36

(36)

CASE (24)
(Top Channel Plate Side)

ARE USED FOR


23

16

15

48

20

13

2-3 SIGNAL

D432

LINE SAFETY MODE

31

21

21

20b

19

19d

21c

19c

20d

31

19b

21a

42a

19a

20c

22f

LINE SAFETY MODE

15

123 REGULATED
23 REGULATED

32 SM/FDL
2345
LOW AND REVERSE CL

EX

2345
2345
2345
32 SM
123
123
2345

45

#8

#6

LINE

2-3 SIGNAL

32

35 15

123

REVERSE LOCKOUT
COAST CLUTCH

48

37

48
21
27

10

52

52

EXHAUST FLUID NOT SHOWN

48

10

21

21b

2f

2h

38

38d

15

48

16

28
48

18

22e

#5

48

48

12

15f
15e

17

32

21

52

PASSAGES MARKED WITH


THE 5L40-E ONLY

X-2
48

48
48

17b

32 SM

32

D432

LINE

EX

REV
38e

38c

38b

22g

14a

#7

32 SAFETY MODE

32

2-3 SIGNAL

LINE

X-1

48

24

52
52

INDICATES BOLT HOLES

DUAL PURPOSE PASSAGES HAVE


CHANNEL PLATE SIDE NUMBERS LISTED FIRST

48

24

17c

43b

16

32

21

52

48
16
37

LOW AND REV CL OR RLO

13
22c

22

1-2 SIGNAL
123

12

COAST CLUTCH
FORWARD CLUTCH

LOW AND REV CL OR RLO


REVERSE LOCKOUT
SECOND COAST CLUTCH

FDL

EX
EX

EX

10i

18

2345

#4

LINE

32
2-3 SIGNAL

EX
EX
EX

11
13b

45
123

X-5

32
12 (203)

52
1

16

48

EX
EX

22b
39a

28

2
16

(203)

15

18

NON FUNCTIONAL HOLES HAVE BEEN


REMOVED FROM COMPONENT DRAWINGS
TO SIMPLIFY TRACING FLUID FLOW.

52

21

(203)

52

FLUID PUMP COVER (202)


(Case Side)

32

22

#9

43

26a

123 REGULATED
LINE
123 BRAKING
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2
45
OVERDRIVE CLUTCH FEED 1

52

48

33c

2345

52

34

30

52

#1

12

33b

OFF

CASE (24)
(Fluid Pump Cover Side)

NOTE:

24

TORQUE CONVERTER HOUSING (227)


(Fluid Pump Cover Side)

32a

27

30b
35c

30c

30a

54g

2d
2e

FDL
EX
EX

45

COAST CLUTCH
123
123

REVERSE

EX

35

48

32

48b

52

21

(40)

32
9
37 16 21

52

12
21

FRONT

INTERMEDIATE CLUTCH

2m

54e

2-3 SIGNAL

SECOND CLUTCH
D432

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED

FDL
2345

EX

345
2345
EX

EX

123 REGULATED
123 BRAKING
345

123 REGULATED

(C)

23

19i

19g

26b

36a

25a

25b

24c

13a

38a

37b

15a

36b

37a

36c

36d

EX

EX

TCC SIGNAL
DIRECT CLUTCH
345
45
LINE SAFETY MODE

REVERSE LOCKOUT
TCC SIGNAL
123 REGULATED
123 BRAKING
123 REGULATED
345

345
LINE

123
D432
19j

7a

36f

24b

36e

7b

23a
23b

29

4-5 SHIFT
SOLENOID
VALVE
N/C

CNTRL

GASKET (303)

FEED LIMIT
32 SAFETY MODE

52

34a

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
123
123

45

#3

16

48a

EX

COAST CLUTCH FEED


OVERDRIVE CLUTCH FEED 2
45

LINE

1-2 SIGNAL

FORWARD CLUTCH
COAST CLUTCH

EX

EX
EX

EX

EX

EX

345
45

EX

45

#2

52

37

22e

R N D 4 3 2

SPACER PLATE (307)


GASKET (305)
BOTTOM CHANNEL PLATE (304)

D432

48

8
52

(203)

45

48

40a

REAR CONTROL VALVE BODY (310)


GASKET (309)
19

345

48

37

45

#10

MANUAL VALVE

26

10h

44f
43c

OFF

2345

TCC SIGNAL

LINE

EX

32
32 SAFETY MODE

DIRECT CLUTCH

MEMORY
FEED LIMIT
LINE

EX

MEMORY

EX

EX

123
D432
345
DIRECT CLUTCH

EX

EX

EX
EX

TCC SIGNAL

2345 OR REVERSE

REGULATED APPLY

REGULATED APPLY

2345 OR REVERSE

REVERSE LOCKOUT

REVERSE LOCKOUT
LINE

OVERDRIVE CLUTCH FEED 1


OVERDRIVE CLUTCH FEED 2
345

REVERSE CLUTCH

23c

2345 OR REVERSE

32 SAFETY MODE

REGULATED APPLY

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

X-4

OVERDRIVE CLUTCH FEED 1

FLUID
PAN
(62)

345

345
25

20a

OVERDRIVE CL FD 1
OVERDRIVE CL FD 2
345

FEED LIMIT
LINE

345
32
1-2 SIGNAL

FEED LIMIT
2-3 SIGNAL

REVERSE CLUTCH

RELEASE
TO COOLER

THROTTLE SIGNAL

CONVERTER FDL
CONVERTER FEED

TCC SIGNAL
REGULATED APPLY

LINE

SUCTION
2
21

345

SUCTION

TCC SIGNAL

FILTER
(308)

REVERSE LOCKOUT
LINE
REGULATED APPLY
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2

THROTTLE SIGNAL

30d

ACCUM
OVERDRIVE CL FD 2 40d

37c

DIRECT CL

54f

54d

54b

OVERDRIVE CLUTCH

35d

APPLY
RELEASE
REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH
LUBE
APPLY

32
1-2 SIGNAL
32 SAFETY MODE

LINE

DIRECT CLUTCH

DIRECT CLUTCH

CASE (24)

COAST CLUTCH

DECREASE

CONVERTER FEED
DECREASE

FORWARD CLUTCH

LINE

COAST CLUTCH

PRESS REG VALVE


BOOST VALVE

REVERSE CLUTCH

15

345

REVERSE CLUTCH

FLUID FILTER
ASSEMBLY
(59)

16a

4-5 SHIFT VLV

37

32

10

(B)

30

COAST CLUTCH

FORWARD CLUTCH

PRESSURES
INTAKE & DECREASE (SUCTION)
CONVERTER & LUBE
MAINLINE
REGULATED LINE
SOLENOID SIGNAL
ACCUMULATOR
FEED LIMIT
THROTTLE SIGNAL

X-2

TCC PWM
SOLENOID
VALVE
N/C

52

28a

FDL 44 45
FDL 44c

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

EX
SECOND COAST CLUTCH
OVERDRIVE CLUTCH FEED 1
2345
2345
23 REGULATED
4-5 SIGNAL

LOW PRESSURE

LINE

TCC REGULATOR VALVE

(213)
1

52

LINE

(214)

16

24a

1
FLUID
PUMP
COVER
(202)

16

FLUID PUMP COVER (202)


(Torque Converter Housing Side)

12

22a

2-3 SIGNAL
FEED LIMIT

REV

52

12

16
2/21

(214) 21

16

THROTTLE SIGNAL

13

EX

FLUID PUMP
SCREEN
ASSEMBLY
(213)

LINE

FEED LIMIT VALVE

23
15b
15c

#11

2345
INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH
23 REGULATED

RLO

REVERSE
LOCKOUT
VALVE

32
48

16

24

TCC
ENABLE
VALVE
CONVERTER
HOUSING
(224)

FEED LIMIT
FEED LIMIT

10c
10

15d

2345
TCC SIGNAL

2-3 SHIFT VALVE

10a

#1

33d

LINE SAFETY MODE

CNTRL 3-4 SHIFT

23
33e

OFF

12

50

48

48

APPLY

EX

(A)

35a

4
6

24
4
53
48
7
7

TCC
CONTROL
VALVE

10g

24
35b

52

41

SAFETY MODE

1-2 SIGNAL

FD LIMIT
1-2 SHIFT
SOLENOID
VALVE
N/C

1-2 SHIFT CONTROL VALVE

44b

1-2 SHIFT VALVE

2-3 SIGNAL

28c

44a
10f
27a

16

PRESSURE
CONTROL
SOLENOID
VALVE

10b

27b

10d

44d
28b

FDL

FILTER
(312)

11a

LINE
CONVERTER FEED

25d

17a
44e

2-3 SIGNAL
FDL

52

24

37

PRESSURE
RELIEF
BALL
VALVE

DIRECT CLUTCH

20
25c
25e

FDL

52

(233)
37

THROTTLE SIGNAL
FILTERED FEED LIMIT

11b

D432

19e

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED

FEED LIMIT
1-2 SIGNAL

52
48

48

SECOND CLUTCH

24
52

52

52

8
7

EX

47b
12a

37

21

24
4
53
48
7

48

52

2
4

53

D432

19f

32

52
24

52
48

14
33a

16

2
12

12

51
48

50
19h

D432

FEED LIMIT
MEMORY
MEMORY PILOT
MEMORY PILOT

30

46

X-3
D432

LOW AND REVERSE CLUTCH


32

LINE

46

16

19

ACCUM
SECOND CLUTCH

32 SAFETY MODE

36

32 5
21 9

51

ACCUMULATOR
INTERMEDIATE CLUTCH

DIRECT CLUTCH

27c

LINE
SECOND CLUTCH
21

52

52

8
6

48

AIR
BLEED
(233)

53
5

AIR
BLEED
(203)

(232)
52

3
48

OVERDRIVE CLUTCH FEED 1


OVERDRIVE CLUTCH FEED 2

2b

47a

INTERMEDIATE CLUTCH

ACCUM

39c

43a
42b

10e

AIR
BLEED
(203)

EX

SECOND
CLUTCH
ACCUMULATOR

31

OVERDRIVE CLUTCH FEED 2

40c

40b

INTERMEDIATE
CLUTCH
ACCUMULATOR

31

AIR
BLEED
(203)

86

ACCUMULATOR

39b

37d

32

EX

54c

41

COAST CLUTCH
DIRECT CLUTCH

AIR
BLEED
(233)

ACCUMULATOR

54a

5
2c

TO COOLER

FLUID
PRESSURE
TEST PLUG
(40)

GASKET (309)
FRONT CONTROL VALVE BODY (311)

4
2a

#12

REVERSE CLUTCH
FORWARD CLUTCH

AIR
BLEED
(203)

OVERDRIVE
CLUTCH
ACCUMULATOR

(231)
48

SPACER PLATE (307)

LUBE

LINE

EX

DIRECT
CLUTCH
ACCUMULATOR

48
4
48

COOLER

ER
COOL

BOTTOM CHANNEL PLATE (304)


GASKET (305)

EX

EX

ACCUMULATOR HOUSING (333)

52

GASKET (303)

ACCUMULATOR HOUSING (328)

51

51

TRANSMISSION
VENT
ASSEMBLY

CASE (24)
TOP CHANNEL PLATE (301)

ACCUMULATOR HOUSING (323)

(229)
(233)

p
sure mp ou transpum
Preses pu to the hen mand
ulat rdingents. Wthe defrom
accoirem ceeds, fluidr
requut ex sure lato
outp e presre regu
of linpressu
the

SECOND CLUTCH
REVERSE LOCKOUT

OVERDRIVE CLUTCH

ACCUMULATOR HOUSING (317)

(Engine Running)

OVERDRIVE CLUTCH

LOW AND REV CL OR RLO


SECOND COAST CLUTCH

CENTER
SUPPORT
ASSEMBLY
(510535)

FORWARD CLUTCH
COAST CLUTCH
LUBE

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH
LUBE

TO

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

LUBE

(P)
Park l
the e oi
r in th
leve fromwing:
ctor sure follo
sele pres the Regthe line to
8): )
Withsition, rected Valve(21essure
po p is di lator (line prion
pum Regu tput miss

PARK

TORQUE
CONVERTER
ASSEMBLY
(1)

NOTE:
PASSAGES AND
COMPONENTS
MARKED WITH
ARE USED FOR
THE 5L40-E ONLY

PARK

(Engine Running)

WWW.ALL-TRANS.BY

COMPLETE HYDRAULIC CIRCUITS

52
2

10
48

48

27

43

44
10

28
48
10

44

48

48

REAR CONTROL VALVE BODY (310)


(Bottom Channel Plate Side)

FOLDOUT 87

HALF PAGE TEXT AND LEGEND

COMPLETE ILLUSTRATED
PARTS LIST

Figure 81

FOLDOUT 85

PARK

(Engine Running)

FORWARD CLUTCH
COAST CLUTCH
LUBE

30a

30b
35c

30c

2e

54e

29

EX

2345
2345
2345
32 SM

22
33c

EX
EX

33b

#9

EX
EX
EX

22b

OFF

11
10i

43

LINE

13b
13

18

2345

LOW AND REV CL OR RLO

2-3 SIGNAL

EX

39a

22c

22

X-1

28

32 SM

LINE

123 BRAKING
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2
45
OVERDRIVE CLUTCH FEED 1

123
D432

32

1-2 SIGNAL
123
FEED LIMIT

32 SAFETY MODE

32 SAFETY MODE
REVERSE LOCKOUT
D432

32

D432
32

2-3 SIGNAL

2-3 SIGNAL

TOP CHANNEL PLATE (301)


CASE (24)

REVERSE LOCKOUT
COAST CLUTCH

REVERSE LOCKOUT
COAST CLUTCH
FORWARD CLUTCH

REVERSE LOCKOUT
COAST CLUTCH

D432
1-2 SIGNAL

21

123 REGULATED

LINE

FEED LIMIT

19

#6

19c

21

15
19d

20b

31

#5

21c

31

17
21b

21a

#7

42a

16

19b

20d

20c

#4

22f

123 REGULATED
123 BRAKING

123
123
2345

15e
22d
43b

19a

2f

2h

X-5

38d

27

18
15f

#8

2345
38

38c

#3

38b

22g

14a

#2

17c

45
123

23

19i

19g

26b

SPACER PLATE (307)

17b

45

45

32

D432

LINE

EX

REV

32a

LINE

15

LOW AND REV CL OR RLO


REVERSE LOCKOUT
SECOND COAST CLUTCH

48b

LINE SAFETY MODE

COAST CLUTCH
FORWARD CLUTCH

2-3 SIGNAL

34a

EX

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
123
123

1-2 SIGNAL

32
2-3 SIGNAL

1-2 SIGNAL

45

48
48a

D432
FEED LIMIT

#10

123 REGULATED
23 REGULATED

45
43c

EX
(C)

44c

44f

OFF

4-5 SHIFT
SOLENOID
VALVE
N/C

CNTRL

45

32 SM/FDL
2345
LOW AND REVERSE CL

(B)

EX

45

EX

FDL

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

EX

EX

2345

345
2345

EX

REVERSE

23 REGULATED

10h

FDL 44

26a

123
FEED LIMIT
32 SAFETY MODE

INTERMEDIATE CL

10
28a

22e

LINE
1-2 SIGNAL

FDL

22a

2-3 SIGNAL

D432

LINE

FDL
EX

EX

#11

COAST CLUTCH FEED


OVERDRIVE CLUTCH FEED 2
45

R N D 4 3 2

GASKET (305)
BOTTOM CHANNEL PLATE (304)

TCC SIGNAL

LINE

2d

54g
2m
30d

FDL

EX

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED
EX

123 REGULATED
123 BRAKING
345

4-5 SHIFT VLV

GASKET (303)

FORWARD CLUTCH
COAST CLUTCH

SUCTION

36a

25a

19

345

12

Figure 82

EX

EX

TCC SIGNAL
REVERSE LOCKOUT
TCC SIGNAL
123 REGULATED
123 BRAKING
123 REGULATED
345
25b

24c

15a

13a

38a

36b

37b

26
37a

OVERDRIVE CLUTCH FEED 1

FLUID
PAN
(62)

33d

EX
SECOND COAST CLUTCH
OVERDRIVE CLUTCH FEED 1
2345
2345
23 REGULATED
4-5 SIGNAL

LOW PRESSURE

REAR CONTROL VALVE BODY (310)


GASKET (309)

45

FLUID FILTER
ASSEMBLY
(59)

33e

OFF

LINE SAFETY MODE

THROTTLE SIGNAL

23

MANUAL VALVE

REVERSE LOCKOUT
LINE
REGULATED APPLY
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2

REVERSE CLUTCH

(A)

35a
35b

OVERDRIVE CL FD 2
OVERDRIVE CL FD 1
RLO

345

10g

2345
19j

24b

36f

36d

36e

23a
23b

X-4

40a

345
25

44b

24

2345

REV

345

123
D432

LINE

345

44a
10f
27a

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH
23 REGULATED

EX
EX

DIRECT CLUTCH
345
45
LINE SAFETY MODE

REGULATED APPLY

345

FILTER
(308)

44e
44d
28b

2-3 SIGNAL
FEED LIMIT

REVERSE
LOCKOUT
VALVE

EX

REGULATED APPLY

TCC SIGNAL

TCC SIGNAL

17a

FDL

345
45

123
D432
345
DIRECT CLUTCH

EX

EX

EX

EX

EX

EX

2345 OR REVERSE

EX

15

2345 OR REVERSE

REVERSE CLUTCH

2345 OR REVERSE

REVERSE LOCKOUT

REVERSE CLUTCH

REVERSE LOCKOUT
LINE

16a

25c
25e

21

COAST CLUTCH

FORWARD CLUTCH

PRESSURES
INTAKE & DECREASE (SUCTION)
CONVERTER & LUBE
MAINLINE
REGULATED LINE
SOLENOID SIGNAL
ACCUMULATOR
FEED LIMIT
THROTTLE SIGNAL

X-2

TCC PWM
SOLENOID
VALVE
N/C

23c

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

LINE

(214)

16

#1

32 SAFETY MODE

21

1
FLUID
PUMP
COVER
(202)

16

25d

FD LIMIT

RLO

LINE

TCC REGULATOR VALVE

36c

345

15c

24a

REGULATED APPLY

SUCTION
2

LINE

15b

15d

EX

FLUID PUMP
SCREEN
ASSEMBLY
(213)

FEED LIMIT VALVE

23

13

OVERDRIVE CLUTCH FEED 1


OVERDRIVE CLUTCH FEED 2

CONVERTER
HOUSING
(224)

10c

345

TCC
ENABLE
VALVE

FEED LIMIT
FEED LIMIT

20

1-2 SHIFT
SOLENOID
VALVE
N/C

TCC SIGNAL

CNTRL 3-4 SHIFT

10

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

TCC SIGNAL
REGULATED APPLY

LINE

APPLY

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REVERSE CLUTCH
FDL
2-3 SIGNAL
FDL
FEED LIMIT
1-2 SIGNAL

1-2 SHIFT CONTROL VALVE

D432

19e

2-3 SHIFT VALVE

10a

D432

19f
33a

2345

2-3 SIGNAL

10d

THROTTLE SIGNAL

RELEASE
TO COOLER

TCC
CONTROL
VALVE

19h

14

LINE SAFETY MODE

1-2 SIGNAL

CONVERTER FEED

MEMORY
FEED LIMIT
LINE

SAFETY MODE

28c

CONVERTER FDL
CONVERTER FEED

FORWARD CLUTCH

DECREASE

LINE

D432

SECOND CLUTCH

1-2 SHIFT VALVE

123 REGULATED

10b

DIRECT CLUTCH

COAST CLUTCH

LINE

SECOND CLUTCH
D432

PRESSURE
CONTROL
SOLENOID
VALVE

EX

11a

EX

FILTER
(312)

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

11b

7a

PRESSURE
RELIEF
BALL
VALVE

EX

REVERSE CLUTCH

54f

54d

54b

MEMORY PILOT

DIRECT CLUTCH

46

20a

APPLY

36

12a

OVERDRIVE CL FD 1
OVERDRIVE CL FD 2
345
FEED LIMIT
LINE

EX

46

47b

32
1-2 SIGNAL
32 SAFETY MODE

DIRECT CLUTCH

DIRECT CLUTCH

30

27c

FEED LIMIT
MEMORY
MEMORY PILOT

EX

47a

AIR
BLEED
(233)

X-3

ACCUM

D432

32
32 SAFETY MODE

10e

AIR
BLEED
(203)

AIR
BLEED
(203)

21

SECOND CLUTCH

LINE

2b

ACCUMULATOR
INTERMEDIATE CLUTCH

32

42b

LINE
SECOND CLUTCH

19

32 SAFETY MODE

43a

INTERMEDIATE CLUTCH

ACCUM

DIRECT CLUTCH

37d

LINE

COAST CLUTCH

CASE (24)

CONVERTER FEED
DECREASE
PRESS REG VALVE

SECOND
CLUTCH
ACCUMULATOR

OVERDRIVE CLUTCH FEED 2

40b

27b

AIR
BLEED
(203)

INTERMEDIATE
CLUTCH
ACCUMULATOR

31

BOOST VALVE

OVERDRIVE CLUTCH FEED 1

EX

COAST CLUTCH
123
123

39c
39b

LUBE

THROTTLE SIGNAL

OVERDRIVE CLUTCH FEED 2

41

32

EX

ACCUMULATOR

40c

DIRECT CLUTCH

FLUID
PRESSURE
TEST PLUG
(40)

54c

#12

COAST CLUTCH

AIR
BLEED
(233)

ACCUMULATOR

54a

5
2c

SECOND CLUTCH
REVERSE LOCKOUT

ACCUMULATOR HOUSING (333)

EX

ACCUM
OVERDRIVE CL FD 2 40d

2a

TO COOLER

LINE

OVERDRIVE
CLUTCH
ACCUMULATOR

GASKET (309)
FRONT CONTROL VALVE BODY (311)

REVERSE CLUTCH
FORWARD CLUTCH

AIR
BLEED
(203)

DIRECT
CLUTCH
ACCUMULATOR

37c

COOLER

SPACER PLATE (307)

ACCUMULATOR HOUSING (328)

EX

DIRECT CL

OVERDRIVE CLUTCH

CO

R
OLE

BOTTOM CHANNEL PLATE (304)


GASKET (305)

LOW AND REV CL OR RLO


SECOND COAST CLUTCH

CENTER
SUPPORT
ASSEMBLY
(510535)

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (323)

EX

35d

APPLY

GASKET (303)

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH
LUBE

TO

86

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (317)
CASE (24)
TOP CHANNEL PLATE (301)

38e

LUBE

2-3 SIGNAL

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH

E
LUB

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

INTERMEDIATE CLUTCH

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

7b

NOTE:
PASSAGES AND
COMPONENTS
MARKED WITH
ARE USED FOR
THE 5L40-E ONLY

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

RELEASE

WWW.ALL-TRANS.BY

TORQUE
CONVERTER
ASSEMBLY
(1)

PARK
(Engine Running)

WWW.ALL-TRANS.BY

The following conditions and component problems could happen


in any gear range, and are only some of the possibilities
recommended to diagnose hydraulic problems. Always refer to
the appropriate vehicle platform service manual when diagnosing
specific concerns.

HIGH LINE PRESSURE

Pressure Regulator Valve (210), or


Line Boost Valve (207)
Stuck, damaged

Pump Slide (216)


Stuck

Pressure Control Solenoid Valve (357)


Loose connector
Valve has failed Off
LOW LINE PRESSURE

Pressure Regulator Valve (210), Line Boost Valve (207),


or Pressure Regulator Valve Spring (209)
Stuck, damaged, broken

Fluid Pump Cover (202)


Cross channel leak, converter housing to cover or cover to
case

Fluid Pump Cover Gasket (46)


Damaged

Pump Valve Bores


Excessive valve clearance due to wear

Front Control Valve Body (340)


Cross channel leaks
Cross valve land leaks

Rear Control Valve Body (365)


Cross channel leaks
Cross valve land leaks

Gasket/Spacer Plate
Damaged
Missing

Pressure Control Solenoid Valve (357)


Valve is stuck On
Broken clip causes leakage

Pressure Control Solenoid Valve Filter (312)


Clogged or restricted

Feed Limit Valve (353), Spring (354) or Retainer (343)


Stuck, damaged, broken

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF OFF OFF
LD = LOCKED IN DRIVE

86A

PARK
(Engine Running)

WWW.ALL-TRANS.BY

PASSAGES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54

SUCTION
LINE
DECREASE
CONVERTER FEED
RELEASE
APPLY
REGULATED APPLY
TO COOLER
LUBE
FEED LIMIT
FILTERED FEED LIMIT
THROTTLE SIGNAL
LINE SAFETY MODE
REVERSE
REVERSE LOCK OUT (RLO)
REVERSE CLUTCH
LOW AND REVERSE CLUTCH
LOW AND REVERSE CLUTCH OR RLO
D432
123
FORWARD CLUTCH
2345
2345 OR REVERSE
TCC SIGNAL
123 REGULATED
123 BRAKING
1-2 SIGNAL
2-3 SIGNAL
4-5 SIGNAL
SECOND CLUTCH
COAST CLUTCH FEED
COAST CLUTCH
23 REGULATED
SECOND COAST CLUTCH
INTERMEDIATE CLUTCH
345
DIRECT CLUTCH
45
OVERDRIVE CLUTCH FEED 1
OVERDRIVE CLUTCH FEED 2
OVERDRIVE CLUTCH
32
32 SAFETY MODE
FDL
32 SAFETY MODE/FDL
MEMORY PILOT
MEMORY
EXHAUST
OIL RESERVOIR
TORQUE CONVERTER SEAL DRAINBACK
VENT
VOID
CONVERTER FDL
ACCUMULATOR

COMPONENTS ( )
(36)
(40)
(203)
(213)
(214)
(232)
(233)
(306)
(308)
(312)

86B

TRANSMISSION FLUID LEVEL HOLE PLUG


TRANSMISSION FLUID PRESSURE TEST PLUG
CHECK VALVE RETAINER AND BALL ASSEMBLY
TRANSMISSION FLUID PUMP SCREEN ASSEMBLY
BRASS ORIFICE INSERT
ORIFICE SLEEVE
ORIFICE CUP PLUG
CONTROL VALVE BODY BALL CHECK VALVE
(#1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
TCC PWM SOLENOID VALVE FILTER ASSEMBLY
PRESSURE CONTROL SOLENOID VALVE
FILTER ASSEMBLY

PARK

(Engine Running)

WWW.ALL-TRANS.BY

(229)

51

51
48
4

4
53
48
7

50

48

52

(213)

52

30

52

52

48

NOTE:

21

(203)

52

FLUID PUMP COVER (202)


(Case Side)
#1
48

27
32

10

48
48

FRONT

41

42

24
48

28

21

41

43

42

19

43

32

15

22
52

35

15

34

52

34

30

48

48

48

48

48

18
10

21

48

20
52

2
48

48
21

TOP CHANNEL PLATE (301)


(Bottom Channel Plate Side)

18
48
10

42

17

48

48

34
27

43
28

#10
10

BOTTOM CHANNEL PLATE (304)


(Top Channel Plate Side)

Figure 83

FOLDOUT 87

22g/23
38b

19

18

48
10 42

13

28
2

48
10

#9

#8

BOTTOM CHANNEL PLATE (304)


(Control Valve Body Side)

10

TOP CHANNEL PLATE (301)


(Case Side)

48

45

54b

20
19

36

54

47
52

47
10
2

46
13

52

37

36
40

36

52

52
54

48

48

52

40

42
43

39

38

FRONT CONTROL VALVE BODY (311)


(Bottom Channel Plate Side)

40d
54d
2c/54c

19h
15a

48
30b

40a

22b
22d 22c

28

32a

22f
24

20

35a
22e

18

22

14

54f
30a
33a

25
26
25

35d

22a

24c
36a

48
30

19

15

19
14

52

19f

19e

38c

21c/31 27
20c
17
2h 20d

14

35c

25c

48

52
25

21

25b
19

38e

21

15

#6
43

44

38d

52

30

37c

47a

19i

14a/23 26b

#5

52

13
19

28

15

#4

34

27

23

11b
10c

27c/46
10e

8
19j
2b
36c 25
13a
23a
37a
40c/41
40b
39c/41
36e
42b 52
36d 36b
43a
39b
38a
48 5
19g

25a

19

52

44
2
10

21

48
48

22

32

19

28

48

35

38

52

15
52

28

#11

38

20

35

X-5

24

2d/54e
25d
25e
17a 3
30c

19

52

38
52

31

30d

20b
26a

2m/54g

SPACER PLATE (307)


(Bottom Channel Plate Side)

32

38

52

15

19
2

10
48

52

44

34

52
2

10
48

48

27

43

44
10

28
48
10

52

30

33
17

52

30
33
54
25
25
17
30

28

33
13

35

22

44

26

21

42

35
22
35
39

20
20

22

36

52

35

40

35b
44e
28b 52
39a
#7
16
(Spring)
23 33e
52
2e
13b 33d
33c

21b/31
19c/21
44a 2
15e 33b 22
17b
19d/21
34a
15
21a
48a
27a 44b 10f
15f/18
17c/18
29 48b
44d
19b/21 19a 10i
43b
2f

43c/45
9
28a
11
42a
44c 10g
10
48
44f/45

48
10h

52

18

19

42 52

52 43

38
52 26 32

33

17

13

30

#3

22
22

30

10
12

25

20 21

23

36

22 19

52

52

40
25

35

38

27
52

#2

19

37

28

27
52

20a

52

48

10

36f 26

52

23b

FILTER
(308)

38

39

30

X-1

27b

10

48

12a
4
52
28c
48
47b 2a/54a

10d

15

35

48

19

28

19

2g

7b

X-3

41

13

24

7a
6

23

48

36

37b
10a

24a
48

X-4

36

19

52

40

10

35 15

41

15

36

10
48

36
37

27
13

FRONT

19

19

24b

52

15b
48 11a/10b

23c

48
23

13

37d

37
2

16a

48

24

48

FRONT

2
41

13
#12

48

11
12

48

20

42

20

43

27

47

12

27

48

48

10

27

24
7

36

48

48

48

20

13
48

16

37

48
48

48

24

21

48

48

16

48

28

48
48

48

12

48

24

48

37

FILTER
(312)

15c/16

37
7

32

21

48
15d/16

48

24

12
28

15

48
37

23
48

11

52

48
16

FRONT

2
10

48

48

37

48

16

15

FRONT

48

16

48

48

48

ARE USED FOR


23

FRONT

32

48

12

PASSAGES MARKED WITH


THE 5L40-E ONLY

X-2

48
16

(36)

CASE (24)
(Top Channel Plate Side)

EXHAUST FLUID NOT SHOWN

FRONT

52

52

DUAL PURPOSE PASSAGES HAVE


CHANNEL PLATE SIDE NUMBERS LISTED FIRST

32

21

12 (203)

52

TORQUE CONVERTER HOUSING (227)


(Fluid Pump Cover Side)

16

(203)

32

52

16

37

(203)

INDICATES BOLT HOLES

NON FUNCTIONAL HOLES HAVE BEEN


REMOVED FROM COMPONENT DRAWINGS
TO SIMPLIFY TRACING FLUID FLOW.

52

37

52
52

24

16

52

32

15

18

CASE (24)
(Fluid Pump Cover Side)
52

12
21

32
9
37 16 21

34

30

52

52

48

37

52

52

48

52

16

(40)

24

35

12

48

48

41
52

21

FLUID PUMP COVER (202)


(Torque Converter Housing Side)

16

32

2/21

16

12

37
16

(214) 21
24
4
53
48
7

24

32

52

2
12

52

(233)
37

48

52

7
48

48

2
4

5
8

52

24

52

52

52

52

48
53

21

52

48

50

37

24

24

12

51

32

52

51

16

2
12

48

32 5
21 9

16

52

48

FRONT

53
5

31

52

52

52

TRANSMISSION
VENT
ASSEMBLY

48

(232)

(231)
48

(233)

44

48

48

REAR CONTROL VALVE BODY (310)


(Bottom Channel Plate Side)

REVERSE

FORWARD CLUTCH
COAST CLUTCH
LUBE

30a

30b
35c

30c

2e

2d

54g

54e

2m

29

EX

2345
2345
2345
32 SM

22
33c

EX
EX

33b

#9

EX
EX
EX

22b

OFF

11
10i

43

LINE

13b
13

18

2345

LOW AND REV CL OR RLO

2-3 SIGNAL

EX

39a

22c

22

X-1

28
26a

32 SM

LINE

123 BRAKING
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2
45
OVERDRIVE CLUTCH FEED 1

123
D432

32

1-2 SIGNAL
123
FEED LIMIT

32 SAFETY MODE

32 SAFETY MODE
REVERSE LOCKOUT
D432

32

D432
32

2-3 SIGNAL

2-3 SIGNAL

TOP CHANNEL PLATE (301)


CASE (24)

REVERSE LOCKOUT
COAST CLUTCH

REVERSE LOCKOUT
COAST CLUTCH
FORWARD CLUTCH

REVERSE LOCKOUT
COAST CLUTCH

D432
1-2 SIGNAL

21

123 REGULATED

LINE

FEED LIMIT

19

#6

19c

21

15
19d

20b

31

#5

21c

31

17
21b

21a

#7

42a

16

19b

20d

20c

#4

22f

123 REGULATED
123 BRAKING

123
123
2345

15e
22d
43b

19a

2f

2h

X-5

38d

27

18
15f

#8

2345
38

38c

#3

38b

22g

14a

#2

17c

45
123

23

19i

19g

26b

SPACER PLATE (307)

17b

45

45

32

D432

LINE

EX

REV

32a

LINE

15

2-3 SIGNAL

48b

LINE SAFETY MODE

COAST CLUTCH
FORWARD CLUTCH

1-2 SIGNAL

34a

EX

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
123
123

1-2 SIGNAL

32
2-3 SIGNAL

LOW AND REV CL OR RLO


REVERSE LOCKOUT
SECOND COAST CLUTCH

23 REGULATED

45

48
48a

D432
FEED LIMIT

#10

123 REGULATED
23 REGULATED

45
43c

EX
(C)

44c

44f

OFF

4-5 SHIFT
SOLENOID
VALVE
N/C

EX

45

EX

REVERSE

(B)

EX

EX

2345

345
2345

EX
EX

123 REGULATED
123 BRAKING
345

FDL

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

45

22e

123
FEED LIMIT
32 SAFETY MODE

INTERMEDIATE CL

10h

FDL 44

COAST CLUTCH FEED


OVERDRIVE CLUTCH FEED 2
45

LINE
1-2 SIGNAL

LINE

10
28a

2-3 SIGNAL

D432

FDL

22a

32 SM/FDL
2345
LOW AND REVERSE CL

30d

FDL

EX

FDL
EX

EX

EX

#11

OVERDRIVE CL FD 2
OVERDRIVE CL FD 1
RLO

TCC SIGNAL

LINE

33d

CNTRL

GASKET (303)

FORWARD CLUTCH
COAST CLUTCH

SUCTION

4-5 SHIFT VLV

R N D 4 3 2

GASKET (305)
BOTTOM CHANNEL PLATE (304)

345

12

Figure 84

36a

19

25a

25b

24c

15a

13a

38a

36b

37b

26
37a

45

FLUID FILTER
ASSEMBLY
(59)

33e

OFF

EX
SECOND COAST CLUTCH
OVERDRIVE CLUTCH FEED 1
2345
2345
23 REGULATED
4-5 SIGNAL

LOW PRESSURE

REAR CONTROL VALVE BODY (310)


GASKET (309)

OVERDRIVE CLUTCH FEED 1

FLUID
PAN
(62)

23

LINE SAFETY MODE

THROTTLE SIGNAL

(A)

35a
35b

MANUAL VALVE

REVERSE LOCKOUT
LINE
REGULATED APPLY
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2

REVERSE CLUTCH

10g

2345
19j

24b

36f

36d

36e

23b

345

40a

345

X-4

44b

24

2345

REV

345

123
D432

LINE

345

25

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED

SECOND CLUTCH
D432
EX

TCC SIGNAL
REVERSE LOCKOUT
TCC SIGNAL
123 REGULATED
123 BRAKING
123 REGULATED
345

DIRECT CLUTCH
345
45
LINE SAFETY MODE

REGULATED APPLY

345

FILTER
(308)

44a
10f
27a

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH
23 REGULATED

EX
EX

EX

REGULATED APPLY

TCC SIGNAL

TCC SIGNAL

44e
44d
28b

FDL

345
45

123
D432
345
DIRECT CLUTCH

EX

EX

EX

EX

EX

EX

2345 OR REVERSE

EX

15

23a

REVERSE CLUTCH

2345 OR REVERSE

REVERSE LOCKOUT

REVERSE CLUTCH

REVERSE LOCKOUT
LINE

16a

17a

21

COAST CLUTCH

FORWARD CLUTCH

PRESSURES
INTAKE & DECREASE (SUCTION)
CONVERTER & LUBE
MAINLINE
REGULATED LINE
SOLENOID SIGNAL
ACCUMULATOR
FEED LIMIT
THROTTLE SIGNAL

X-2

TCC PWM
SOLENOID
VALVE
N/C

23c

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

LINE

(214)

16

#1

32 SAFETY MODE

21

1
FLUID
PUMP
COVER
(202)

16

25c
25e

2-3 SIGNAL
FEED LIMIT

REVERSE
LOCKOUT
VALVE

LINE

TCC REGULATOR VALVE

36c

345

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

15c

24a

REGULATED APPLY

SUCTION
2

LINE

15b

15d

EX

FLUID PUMP
SCREEN
ASSEMBLY
(213)

FEED LIMIT VALVE

23

13

OVERDRIVE CLUTCH FEED 1


OVERDRIVE CLUTCH FEED 2

CONVERTER
HOUSING
(224)

FEED LIMIT
FEED LIMIT

25d

1-2 SHIFT
SOLENOID
VALVE
N/C

1-2 SHIFT CONTROL VALVE

D432

20

FD LIMIT

2-3 SHIFT VALVE

10c
10

345

TCC
ENABLE
VALVE

THROTTLE SIGNAL

RELEASE
TO COOLER
APPLY

TCC SIGNAL
REGULATED APPLY

LINE

CONVERTER FDL
CONVERTER FEED

TCC
CONTROL
VALVE

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REVERSE CLUTCH
FDL
2-3 SIGNAL
FDL
FEED LIMIT
1-2 SIGNAL

LINE SAFETY MODE

10a

D432

19e

RLO

CNTRL 3-4 SHIFT

10d

2345 OR REVERSE

DECREASE

FORWARD CLUTCH

CONVERTER FEED

14
19f

TCC SIGNAL

2-3 SIGNAL

28c

DIRECT CLUTCH

COAST CLUTCH

LINE

LINE

MEMORY
FEED LIMIT
LINE

SAFETY MODE

1-2 SIGNAL

19h

33a

2345

123 REGULATED

10b

D432

SECOND CLUTCH

1-2 SHIFT VALVE


DIRECT CLUTCH

PRESSURE
CONTROL
SOLENOID
VALVE

EX

11a

EX

FILTER
(312)

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

11b

7a

PRESSURE
RELIEF
BALL
VALVE

EX

REVERSE CLUTCH

54f

54d

54b

MEMORY PILOT

EX

46

20a

APPLY

36

12a

OVERDRIVE CL FD 1
OVERDRIVE CL FD 2
345
FEED LIMIT
LINE

EX

46

47b

32
1-2 SIGNAL
32 SAFETY MODE

DIRECT CLUTCH

DIRECT CLUTCH

30

27c

FEED LIMIT
MEMORY
MEMORY PILOT

32
32 SAFETY MODE

47a

AIR
BLEED
(233)

LINE

COAST CLUTCH

CASE (24)

CONVERTER FEED
DECREASE
PRESS REG VALVE

10e

AIR
BLEED
(203)

AIR
BLEED
(203)

X-3

ACCUM

D432

LINE

2b

21

SECOND CLUTCH

32

42b

ACCUMULATOR
INTERMEDIATE CLUTCH

32 SAFETY MODE

43a

LINE
SECOND CLUTCH

19

DIRECT CLUTCH

37d

INTERMEDIATE CLUTCH

ACCUM

OVERDRIVE CLUTCH FEED 2

40b

27b

AIR
BLEED
(203)

EX

SECOND
CLUTCH
ACCUMULATOR

31

BOOST VALVE

OVERDRIVE CLUTCH FEED 1

EX

COAST CLUTCH
123
123

39c
39b

LUBE

THROTTLE SIGNAL

OVERDRIVE CLUTCH FEED 2

41

32

EX

ACCUMULATOR

40c

DIRECT CLUTCH

FLUID
PRESSURE
TEST PLUG
(40)

54c

#12

COAST CLUTCH

AIR
BLEED
(233)

ACCUMULATOR

54a

5
2c

SECOND CLUTCH
REVERSE LOCKOUT

ACCUMULATOR HOUSING (333)

INTERMEDIATE
CLUTCH
ACCUMULATOR

ACCUM
OVERDRIVE CL FD 2 40d

2a

TO COOLER

LINE

OVERDRIVE
CLUTCH
ACCUMULATOR

GASKET (309)
FRONT CONTROL VALVE BODY (311)

REVERSE CLUTCH
FORWARD CLUTCH

AIR
BLEED
(203)

EX

DIRECT
CLUTCH
ACCUMULATOR

37c

COOLER

SPACER PLATE (307)

ACCUMULATOR HOUSING (328)

EX

DIRECT CL

OVERDRIVE CLUTCH

CO

R
OLE

BOTTOM CHANNEL PLATE (304)


GASKET (305)

LOW AND REV CL OR RLO


SECOND COAST CLUTCH

CENTER
SUPPORT
ASSEMBLY
(510535)

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (323)

35d

APPLY

GASKET (303)

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH
LUBE

TO

88

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (317)
CASE (24)
TOP CHANNEL PLATE (301)

38e

LUBE

2-3 SIGNAL

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH

E
LUB

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

INTERMEDIATE CLUTCH

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

7b

NOTE:
PASSAGES AND
COMPONENTS
MARKED WITH
ARE USED FOR
THE 5L40-E ONLY

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

RELEASE

WWW.ALL-TRANS.BY

TORQUE
CONVERTER
ASSEMBLY
(1)

REVERSE
WWW.ALL-TRANS.BY

NO REVERSE OR SLIPS IN REVERSE

Center Support (518)


Broken
Leaking at case

Fluid Passage Sleeve (38)


Leaking

Low and Reverse Clutch Piston (517)


Leaking
Jammed or cracked

Reverse Lockout Valve


Stuck

#2 Ball Check Valve


Stuck
Missing

#8 Ball Check Valve


Stuck
Missing

Reverse Clutch Piston (404)


Leaking
Jammed or cracked

Reverse Clutch Housing Ball Check Valve (403)


Leaking

Reverse Clutch Housing Seal Ring (200)


Leaking

TCC PWM Solenoid Valve (352)


Stuck On

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF OFF OFF

APPLIED

APPLIED

LD = LOCKED IN DRIVE

88A

REVERSE
WWW.ALL-TRANS.BY

PASSAGES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54

SUCTION
LINE
DECREASE
CONVERTER FEED
RELEASE
APPLY
REGULATED APPLY
TO COOLER
LUBE
FEED LIMIT
FILTERED FEED LIMIT
THROTTLE SIGNAL
LINE SAFETY MODE
REVERSE
REVERSE LOCK OUT (RLO)
REVERSE CLUTCH
LOW AND REVERSE CLUTCH
LOW AND REVERSE CLUTCH OR RLO
D432
123
FORWARD CLUTCH
2345
2345 OR REVERSE
TCC SIGNAL
123 REGULATED
123 BRAKING
1-2 SIGNAL
2-3 SIGNAL
4-5 SIGNAL
SECOND CLUTCH
COAST CLUTCH FEED
COAST CLUTCH
23 REGULATED
SECOND COAST CLUTCH
INTERMEDIATE CLUTCH
345
DIRECT CLUTCH
45
OVERDRIVE CLUTCH FEED 1
OVERDRIVE CLUTCH FEED 2
OVERDRIVE CLUTCH
32
32 SAFETY MODE
FDL
32 SAFETY MODE/FDL
MEMORY PILOT
MEMORY
EXHAUST
OIL RESERVOIR
TORQUE CONVERTER SEAL DRAINBACK
VENT
VOID
CONVERTER FDL
ACCUMULATOR

COMPONENTS ( )
(36)
(40)
(203)
(213)
(214)
(232)
(233)
(306)
(308)
(312)

88B

TRANSMISSION FLUID LEVEL HOLE PLUG


TRANSMISSION FLUID PRESSURE TEST PLUG
CHECK VALVE RETAINER AND BALL ASSEMBLY
TRANSMISSION FLUID PUMP SCREEN ASSEMBLY
BRASS ORIFICE INSERT
ORIFICE SLEEVE
ORIFICE CUP PLUG
CONTROL VALVE BODY BALL CHECK VALVE
(#1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
TCC PWM SOLENOID VALVE FILTER ASSEMBLY
PRESSURE CONTROL SOLENOID VALVE
FILTER ASSEMBLY

REVERSE
WWW.ALL-TRANS.BY

(229)

51

4
53
48
7

12

NOTE:

21

(203)

52

FLUID PUMP COVER (202)


(Case Side)

48

48

FRONT

41

48

42

48

28

21

41

43

42

19

43
13
52

32

52

35

34

52

34

30

48

48

48
28

48

48
48

18
10

21

48

20
52

2
48

48
21

TOP CHANNEL PLATE (301)


(Bottom Channel Plate Side)

18
48
10

42

17

48

48

34
27

43
28

#10
10

BOTTOM CHANNEL PLATE (304)


(Top Channel Plate Side)

Figure 85

19

18

48
10 42

13

28
2

FOLDOUT 89

54b

20
19

36

37
54

47
52

47
10
2

46
13

52

37

36
40

36

52

52
54

48

48

52

40

42
43

39

38

FRONT CONTROL VALVE BODY (311)


(Bottom Channel Plate Side)

40d
54d
2c/54c

19h
15a

22g/23

48
10

#9

#8

48
30b

40a

22b
22d 22c

28

32a

22f
24

20

35a
22e

18

22

14

54f
30a
33a

25
26
25

35d

22a

24c
36a

48
30

19

15

19
14

52

19f

19e

38c

21c/31 27
20c
17
2h 20d

14

35c

25c

48

52
25

21

25b
19

38b

BOTTOM CHANNEL PLATE (304)


(Control Valve Body Side)

10

TOP CHANNEL PLATE (301)


(Case Side)

48

45

37c

47a

19i

38e

21

15

#6
43

44

38d

52

30

23

11b
10c

27c/46
10e

8
19j
2b
36c 25
13a
23a
37a
40c/41
40b
39c/41
36e
42b 52
36d 36b
43a
39b
38a
48 5
19g

14a/23 26b

#5

52

13
19

28

15

#4

34

27

27
52

20a

52
28

48

10

36f 26

25a

19

52

44
2
10

21

48
48

22

32

19

15
52

35

38

28

#11

38

20

35

X-5

24

19

52

38
52

31

30d

20b
26a

2m/54g

SPACER PLATE (307)


(Bottom Channel Plate Side)

32

38

52

15

19
2

10
48

52

44

34

52
2

10
48

48

27

43

44
10

28
48
10

52

30

33
17

52

30
33
54
25
25
17
30

28

33
13

35

22

44

26

21

42

35
22
35
39

20
20

22

36

52

35

40
2d/54e
25d
25e
17a 3
30c

35b
44e
28b 52
39a
#7
16
(Spring)
23 33e
52
2e
13b 33d
33c

21b/31
19c/21
44a 2
15e 33b 22
17b
19d/21
34a
15
21a
48a
27a 44b 10f
15f/18
17c/18
29 48b
44d
19b/21 19a 10i
43b
2f

43c/45
9
28a
11
42a
44c 10g
10
48
44f/45

48
10h

52

18

2
52

10
12

19

38
52 26 32

33

17

13
42 52

52 43

#3

22
22

30

30

52

52

25

20 21

15

23

36

22 19

52
27

23b

40
25

27b

10

48

12a
4
52
28c
48
47b 2a/54a

10d

FILTER
(308)

23

#2

35

38

7b

38

39

30

X-1

19
15

22

15

35

2g

28

19

48

19

24

7a

X-3

41

37b
10a

24a
48

X-4

36

19

52

40

10

35 15

41

15

36

10
48

36
37

48

36

24b

52

15b
48 11a/10b

23c

48
23

13

37d

37
2

16a

48

24

48

19

19

#12

27
13

FRONT

2
41

13

48

11
12

48
43

20

42

20

FRONT

24
2

27

47

12

27

48

10

27

48

24
7

36

13

24

48

48

48

20

37

FILTER
(312)

15c/16

32

10

16

37

48
48

48

48
48

27

48

21

48

48

16

48

28

48
15d/16

48

48

12

48

24

48

15

37
7

32

21

48

11

52

48
16

48
37

23

FRONT

24

12
28

16

15

2
10

48

FRONT

48

37

ARE USED FOR


23

48

48
2

48

FRONT

48

16

48

16

PASSAGES MARKED WITH


THE 5L40-E ONLY

X-2

48
2

CASE (24)
(Top Channel Plate Side)

EXHAUST FLUID NOT SHOWN


#1

16

(36)

DUAL PURPOSE PASSAGES HAVE


CHANNEL PLATE SIDE NUMBERS LISTED FIRST

52

52

FRONT

32

21

12 (203)

TORQUE CONVERTER HOUSING (227)


(Fluid Pump Cover Side)

16

(203)

32

52

16

52

37

(203)

48

INDICATES BOLT HOLES

52

NON FUNCTIONAL HOLES HAVE BEEN


REMOVED FROM COMPONENT DRAWINGS
TO SIMPLIFY TRACING FLUID FLOW.

52

37

32

52

24

12

52
52

32

15

18

CASE (24)
(Fluid Pump Cover Side)

52

52
21

52

37

48

34

30

52

48

52

48

32
9
37 16 21

16

24

48

52

52

12

48

(40)

35

FLUID PUMP COVER (202)


(Torque Converter Housing Side)

16

52

21

30

52

52

32

48

(213)
1

41

16

12

37

50

2/21

52

24

32

24
4
53
48
7

(233)

16

(214) 21

2
12

52

37

52

48

2
4

5
8

52

52

52

52

7
48
24

21

48

52

48
53

50

52

48

37

24

24

12

51

32

52

51

16

2
12

48

32 5
21 9

16

52

48

FRONT

53
5

31

52

52

52

TRANSMISSION
VENT
ASSEMBLY

48

(232)

48

48
4

(231)

51

(233)

44

48

48

REAR CONTROL VALVE BODY (310)


(Bottom Channel Plate Side)

NEUTRAL

(Engine Running)

FORWARD CLUTCH
COAST CLUTCH
LUBE

30a

30b
35c

30c

2e

2d

54g

54e

2m

29

EX

2345
2345
2345
32 SM

22
33c

EX
EX

33b

#9

EX
EX
EX

22b

OFF

11
10i

43

LINE

13b
13

18

2345

LOW AND REV CL OR RLO

2-3 SIGNAL

EX

39a

22c

22

X-1

28
26a

32 SM

LINE

123 BRAKING
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2
45
OVERDRIVE CLUTCH FEED 1

123
D432

32

1-2 SIGNAL
123
FEED LIMIT

32 SAFETY MODE

32 SAFETY MODE
REVERSE LOCKOUT
D432

32

D432
32

2-3 SIGNAL

2-3 SIGNAL

TOP CHANNEL PLATE (301)


CASE (24)

REVERSE LOCKOUT
COAST CLUTCH

REVERSE LOCKOUT
COAST CLUTCH
FORWARD CLUTCH

REVERSE LOCKOUT
COAST CLUTCH

D432
1-2 SIGNAL

21

123 REGULATED

LINE

FEED LIMIT

19

#6

19c

21

15
19d

20b

31

#5

21c

31

17
21b

21a

#7

42a

16

19b

20d

20c

#4

22f

123 REGULATED
123 BRAKING

123
123
2345

15e
22d
43b

19a

2f

2h

X-5

38d

27

18
15f

#8

2345
38

38c

#3

38b

22g

14a

#2

17c

45
123

23

19i

19g

26b

SPACER PLATE (307)

17b

45

45

32

D432

LINE

EX

REV

32a

LINE

15

2-3 SIGNAL

48b

LINE SAFETY MODE

COAST CLUTCH
FORWARD CLUTCH

1-2 SIGNAL

34a

EX

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
123
123

1-2 SIGNAL

32
2-3 SIGNAL

LOW AND REV CL OR RLO


REVERSE LOCKOUT
SECOND COAST CLUTCH

23 REGULATED

45

48
48a

D432
FEED LIMIT

#10

123 REGULATED
23 REGULATED

45
43c

EX
(C)

44c

44f

OFF

4-5 SHIFT
SOLENOID
VALVE
N/C

EX

45

EX

REVERSE

(B)

EX

EX

2345

345
2345

EX
EX

123 REGULATED
123 BRAKING
345

FDL

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

45

22e

123
FEED LIMIT
32 SAFETY MODE

INTERMEDIATE CL

10h

FDL 44

COAST CLUTCH FEED


OVERDRIVE CLUTCH FEED 2
45

LINE
1-2 SIGNAL

LINE

10
28a

2-3 SIGNAL

D432

FDL

22a

32 SM/FDL
2345
LOW AND REVERSE CL

30d

FDL

EX

FDL
EX

EX

EX

#11

OVERDRIVE CL FD 2
OVERDRIVE CL FD 1
RLO

TCC SIGNAL

LINE

33d

CNTRL

GASKET (303)

FORWARD CLUTCH
COAST CLUTCH

SUCTION

4-5 SHIFT VLV

R N D 4 3 2

GASKET (305)
BOTTOM CHANNEL PLATE (304)

345

12

Figure 86

36a

19

25a

25b

24c

15a

13a

38a

36b

37b

26
37a

45

FLUID FILTER
ASSEMBLY
(59)

33e

OFF

EX
SECOND COAST CLUTCH
OVERDRIVE CLUTCH FEED 1
2345
2345
23 REGULATED
4-5 SIGNAL

LOW PRESSURE

REAR CONTROL VALVE BODY (310)


GASKET (309)

OVERDRIVE CLUTCH FEED 1

FLUID
PAN
(62)

23

LINE SAFETY MODE

THROTTLE SIGNAL

(A)

35a
35b

MANUAL VALVE

REVERSE LOCKOUT
LINE
REGULATED APPLY
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2

REVERSE CLUTCH

10g

2345
19j

24b

36f

36d

36e

23b

345

40a

345

X-4

44b

24

2345

REV

345

123
D432

LINE

345

25

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED

SECOND CLUTCH
D432
EX

TCC SIGNAL
REVERSE LOCKOUT
TCC SIGNAL
123 REGULATED
123 BRAKING
123 REGULATED
345

DIRECT CLUTCH
345
45
LINE SAFETY MODE

REGULATED APPLY

345

FILTER
(308)

44a
10f
27a

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH
23 REGULATED

EX
EX

EX

REGULATED APPLY

TCC SIGNAL

TCC SIGNAL

44e
44d
28b

FDL

345
45

123
D432
345
DIRECT CLUTCH

EX

EX

EX

EX

EX

EX

2345 OR REVERSE

EX

15

23a

REVERSE CLUTCH

2345 OR REVERSE

REVERSE LOCKOUT

REVERSE CLUTCH

REVERSE LOCKOUT
LINE

16a

17a

21

COAST CLUTCH

FORWARD CLUTCH

PRESSURES
INTAKE & DECREASE (SUCTION)
CONVERTER & LUBE
MAINLINE
REGULATED LINE
SOLENOID SIGNAL
ACCUMULATOR
FEED LIMIT
THROTTLE SIGNAL

X-2

TCC PWM
SOLENOID
VALVE
N/C

23c

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

LINE

(214)

16

#1

32 SAFETY MODE

21

1
FLUID
PUMP
COVER
(202)

16

25c
25e

2-3 SIGNAL
FEED LIMIT

REVERSE
LOCKOUT
VALVE

LINE

TCC REGULATOR VALVE

36c

345

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

15c

24a

REGULATED APPLY

SUCTION
2

LINE

15b

15d

EX

FLUID PUMP
SCREEN
ASSEMBLY
(213)

FEED LIMIT VALVE

23

13

OVERDRIVE CLUTCH FEED 1


OVERDRIVE CLUTCH FEED 2

CONVERTER
HOUSING
(224)

FEED LIMIT
FEED LIMIT

25d

1-2 SHIFT
SOLENOID
VALVE
N/C

1-2 SHIFT CONTROL VALVE

D432

20

FD LIMIT

2-3 SHIFT VALVE

10c
10

345

TCC
ENABLE
VALVE

THROTTLE SIGNAL

RELEASE
TO COOLER
APPLY

TCC SIGNAL
REGULATED APPLY

LINE

CONVERTER FDL
CONVERTER FEED

TCC
CONTROL
VALVE

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REVERSE CLUTCH
FDL
2-3 SIGNAL
FDL
FEED LIMIT
1-2 SIGNAL

LINE SAFETY MODE

10a

D432

19e

RLO

CNTRL 3-4 SHIFT

10d

2345 OR REVERSE

DECREASE

FORWARD CLUTCH

CONVERTER FEED

14
19f

TCC SIGNAL

2-3 SIGNAL

28c

DIRECT CLUTCH

COAST CLUTCH

LINE

LINE

MEMORY
FEED LIMIT
LINE

SAFETY MODE

1-2 SIGNAL

19h

33a

2345

123 REGULATED

10b

D432

SECOND CLUTCH

1-2 SHIFT VALVE


DIRECT CLUTCH

PRESSURE
CONTROL
SOLENOID
VALVE

EX

11a

EX

FILTER
(312)

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

11b

7a

PRESSURE
RELIEF
BALL
VALVE

EX

REVERSE CLUTCH

54f

54d

54b

MEMORY PILOT

EX

46

20a

APPLY

36

12a

OVERDRIVE CL FD 1
OVERDRIVE CL FD 2
345
FEED LIMIT
LINE

EX

46

47b

32
1-2 SIGNAL
32 SAFETY MODE

DIRECT CLUTCH

DIRECT CLUTCH

30

27c

FEED LIMIT
MEMORY
MEMORY PILOT

32
32 SAFETY MODE

47a

AIR
BLEED
(233)

LINE

COAST CLUTCH

CASE (24)

CONVERTER FEED
DECREASE
PRESS REG VALVE

10e

AIR
BLEED
(203)

AIR
BLEED
(203)

X-3

ACCUM

D432

LINE

2b

21

SECOND CLUTCH

32

42b

ACCUMULATOR
INTERMEDIATE CLUTCH

32 SAFETY MODE

43a

LINE
SECOND CLUTCH

19

DIRECT CLUTCH

37d

INTERMEDIATE CLUTCH

ACCUM

OVERDRIVE CLUTCH FEED 2

40b

27b

AIR
BLEED
(203)

EX

SECOND
CLUTCH
ACCUMULATOR

31

BOOST VALVE

OVERDRIVE CLUTCH FEED 1

EX

COAST CLUTCH
123
123

39c
39b

LUBE

THROTTLE SIGNAL

OVERDRIVE CLUTCH FEED 2

41

32

EX

ACCUMULATOR

40c

DIRECT CLUTCH

FLUID
PRESSURE
TEST PLUG
(40)

54c

#12

COAST CLUTCH

AIR
BLEED
(233)

ACCUMULATOR

54a

5
2c

SECOND CLUTCH
REVERSE LOCKOUT

ACCUMULATOR HOUSING (333)

INTERMEDIATE
CLUTCH
ACCUMULATOR

ACCUM
OVERDRIVE CL FD 2 40d

2a

TO COOLER

LINE

OVERDRIVE
CLUTCH
ACCUMULATOR

GASKET (309)
FRONT CONTROL VALVE BODY (311)

REVERSE CLUTCH
FORWARD CLUTCH

AIR
BLEED
(203)

EX

DIRECT
CLUTCH
ACCUMULATOR

37c

COOLER

SPACER PLATE (307)

ACCUMULATOR HOUSING (328)

EX

DIRECT CL

OVERDRIVE CLUTCH

CO

R
OLE

BOTTOM CHANNEL PLATE (304)


GASKET (305)

LOW AND REV CL OR RLO


SECOND COAST CLUTCH

CENTER
SUPPORT
ASSEMBLY
(510535)

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (323)

35d

APPLY

GASKET (303)

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH
LUBE

TO

90

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (317)
CASE (24)
TOP CHANNEL PLATE (301)

38e

LUBE

2-3 SIGNAL

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH

E
LUB

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

INTERMEDIATE CLUTCH

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

7b

NOTE:
PASSAGES AND
COMPONENTS
MARKED WITH
ARE USED FOR
THE 5L40-E ONLY

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

RELEASE

WWW.ALL-TRANS.BY

TORQUE
CONVERTER
ASSEMBLY
(1)

NEUTRAL
(Engine Running)

WWW.ALL-TRANS.BY

FORWARD MOTION IN NEUTRAL

Manual Valve (377)


Mis-positioned

Forward Clutch Piston (436)


Jammed

Coast Clutch Piston (438)


Jammed

Forward Clutch Input Housing (433)


Passage plugged

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF OFF OFF
LD = LOCKED IN DRIVE

90A

NEUTRAL
(Engine Running)

WWW.ALL-TRANS.BY

PASSAGES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54

SUCTION
LINE
DECREASE
CONVERTER FEED
RELEASE
APPLY
REGULATED APPLY
TO COOLER
LUBE
FEED LIMIT
FILTERED FEED LIMIT
THROTTLE SIGNAL
LINE SAFETY MODE
REVERSE
REVERSE LOCK OUT (RLO)
REVERSE CLUTCH
LOW AND REVERSE CLUTCH
LOW AND REVERSE CLUTCH OR RLO
D432
123
FORWARD CLUTCH
2345
2345 OR REVERSE
TCC SIGNAL
123 REGULATED
123 BRAKING
1-2 SIGNAL
2-3 SIGNAL
4-5 SIGNAL
SECOND CLUTCH
COAST CLUTCH FEED
COAST CLUTCH
23 REGULATED
SECOND COAST CLUTCH
INTERMEDIATE CLUTCH
345
DIRECT CLUTCH
45
OVERDRIVE CLUTCH FEED 1
OVERDRIVE CLUTCH FEED 2
OVERDRIVE CLUTCH
32
32 SAFETY MODE
FDL
32 SAFETY MODE/FDL
MEMORY PILOT
MEMORY
EXHAUST
OIL RESERVOIR
TORQUE CONVERTER SEAL DRAINBACK
VENT
VOID
CONVERTER FDL
ACCUMULATOR

COMPONENTS ( )
(36)
(40)
(203)
(213)
(214)
(232)
(233)
(306)
(308)
(312)

90B

TRANSMISSION FLUID LEVEL HOLE PLUG


TRANSMISSION FLUID PRESSURE TEST PLUG
CHECK VALVE RETAINER AND BALL ASSEMBLY
TRANSMISSION FLUID PUMP SCREEN ASSEMBLY
BRASS ORIFICE INSERT
ORIFICE SLEEVE
ORIFICE CUP PLUG
CONTROL VALVE BODY BALL CHECK VALVE
(#1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
TCC PWM SOLENOID VALVE FILTER ASSEMBLY
PRESSURE CONTROL SOLENOID VALVE
FILTER ASSEMBLY

NEUTRAL

(Engine Running)

WWW.ALL-TRANS.BY

(229)

51

51
48
4

4
53
48
7

48

52

(213)

52

30

52

52

NOTE:

(203)

52

FLUID PUMP COVER (202)


(Case Side)
#1
48

FRONT

41

42

48

28

27

FRONT

19

13

21

41

43

42

19

43

32

15

22
52

35

34

34

30

48

48

48
28

48

48
48

18
10

21

48

20
52

2
48

48
21

TOP CHANNEL PLATE (301)


(Bottom Channel Plate Side)

18
48
10

42

17

48

48

34
27

43
28

#10
10

BOTTOM CHANNEL PLATE (304)


(Top Channel Plate Side)

Figure 87

19

18

48
10 42

13

28
2

FOLDOUT 91

54b

20
19

36

37
54

47
52

47
10
2

46
13

52

37

36
40

36

52

52
54

48

48

52

40

42
43

39

38

FRONT CONTROL VALVE BODY (311)


(Bottom Channel Plate Side)

40d
54d
2c/54c

19h
15a

22g/23

48
10

#9

#8

48
30b

40a

22b
22d 22c

28

32a

22f
24

20

35a
22e

18

22

14

54f
30a
33a

25
26
25

35d

22a

24c
36a

48
30

19

15

19
14

52

19f

19e

38c

21c/31 27
20c
17
2h 20d

14

35c

25c

48

52
25

21

25b
19

38b

BOTTOM CHANNEL PLATE (304)


(Control Valve Body Side)

10

TOP CHANNEL PLATE (301)


(Case Side)

48

45

47a

19i

38e

21

15

#6
43

44

38d

52

30

37c

27c/46
10e

8
19j
2b
36c 25
13a
23a
37a
40c/41
40b
39c/41
36e
42b 52
36d 36b
43a
39b
38a
48 5
19g

14a/23 26b

#5

52

13
19

28

15

#4

34

27

27

23

11b
10c

20a

25a

19

52

44
2
10

21

48
48

22

32

19

15
52

35

38

28

#11

38

20

35

X-5

24

19

52

38
52

31

30d

20b
26a

2m/54g

SPACER PLATE (307)


(Bottom Channel Plate Side)

32

38

52

15

19
2

10
48

52

44

34

52
2

10
48

48

27

43

44
10

28
48
10

52

30

33
17

52

30
33
54
25
25
17
30

28

33
13

35

22

44

26

21

42

35
22
35
39

20
20

22

36

52

35

40
2d/54e
25d
25e
17a 3
30c

35b
44e
28b 52
39a
#7
16
(Spring)
23 33e
52
2e
13b 33d
33c

21b/31
19c/21
44a 2
15e 33b 22
17b
19d/21
34a
15
21a
48a
27a 44b 10f
15f/18
17c/18
29 48b
44d
19b/21 19a 10i
43b
2f

43c/45
9
28a
11
42a
44c 10g
10
48
44f/45

48
10h

52

52

2
52

10
18

19

38
52 26 32

33

17

13
42 52

52 43

#3

22
22

30

30

52

12

25

20 21

23

36

22 19

52
15

40
25

35

38

27
52

#2

19

10

36f 26

52

23b

FILTER
(308)

38

39

30

X-1

27b

52
28

48
52

12a
4
52
28c
48
47b 2a/54a

10d

15

35

48

19

28

19

2g

7b

X-3

41

13

24

7a
6

23

48

36

24a
48

X-4

36

19

52

40

10

35 15

41

15

36

10
48

36
37

37b
10a

10

48

FRONT

2
41

19

24b

52

15b
48 11a/10b

23c

48
23

13

37d

48

13

42

20

43

20

#12

27

48

24
48

27

47

12

16a

48

24

48

37

12

36

13
48

48

11

32

10

48

10

27

48

20

48
48

16

37

48

48

24
7

27

48

48

24

FRONT

21

48

48

16

48

28

48
48

48

12

48

24

48

37

FILTER
(312)

15c/16

37
7

32

21

48
15d/16

48

24

12
28

15

48
37

23
48

11

52

48
16

FRONT

2
10

48

48

37

48

16

15

FRONT

48

16

48

48

48

ARE USED FOR


23

FRONT

32

48

12

PASSAGES MARKED WITH


THE 5L40-E ONLY

X-2

48
16

(36)

CASE (24)
(Top Channel Plate Side)

EXHAUST FLUID NOT SHOWN

52

52

DUAL PURPOSE PASSAGES HAVE


CHANNEL PLATE SIDE NUMBERS LISTED FIRST

32

21

52

12 (203)

TORQUE CONVERTER HOUSING (227)


(Fluid Pump Cover Side)

16

(203)

32

52

INDICATES BOLT HOLES

52

16

52

NON FUNCTIONAL HOLES HAVE BEEN


REMOVED FROM COMPONENT DRAWINGS
TO SIMPLIFY TRACING FLUID FLOW.

52

21

37

(203)

16

52

24
37

15

18

CASE (24)
(Fluid Pump Cover Side)

32

34

30

52

48

52

12
21

32
9
37 16 21

52

48

37

52

52

52

48

(40)

16

24

35

48

52

21

12

48

32

FLUID PUMP COVER (202)


(Torque Converter Housing Side)

16

41

16

12

2/21

37

50

24

16

(214) 21

52

32

24
4
53
48
7

(233)

2
12

52

37

48

52

7
48

48

2
4

5
8

52

24

52

52

52

52

48
53

21

52

48

50

37

24

24

12

51

32

52

51

16

2
12

48

32 5
21 9

16

52

48

FRONT

53
5

31

52

52

52

TRANSMISSION
VENT
ASSEMBLY

48

(232)

48

(231)

(233)

44

48

48

REAR CONTROL VALVE BODY (310)


(Bottom Channel Plate Side)

OVERDRIVE RANGE FIRST GEAR

FORWARD CLUTCH
COAST CLUTCH
LUBE

30a

30b
35c

30c

2e

2d

54g

54e

2m

EX

2345
2345
2345
32 SM

22
33c

EX
EX

33b

#9

EX
EX
EX

22b

OFF

11
10i
13b
43

13

18

2345

LOW AND REV CL OR RLO

2-3 SIGNAL

EX

39a

22c

22

X-1

28
26a

32 SM

LINE

123 BRAKING
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2
45
OVERDRIVE CLUTCH FEED 1

123
D432

32

1-2 SIGNAL
123
FEED LIMIT

32 SAFETY MODE

32 SAFETY MODE
REVERSE LOCKOUT
D432

32

D432
32

2-3 SIGNAL

2-3 SIGNAL

TOP CHANNEL PLATE (301)


CASE (24)

REVERSE LOCKOUT
COAST CLUTCH

REVERSE LOCKOUT
COAST CLUTCH
FORWARD CLUTCH

REVERSE LOCKOUT
COAST CLUTCH

D432
1-2 SIGNAL

21

123 REGULATED

LINE

FEED LIMIT

19

#6

19c

21

15
19d

20b

31

#5

21c

31

17
21b

21a

#7

42a

16

19b

20d

20c

#4

22f

123 REGULATED
123 BRAKING

123
123
2345

15e
22d
43b

19a

2f

2h

X-5

38d

27

18
15f

#8

2345
38

38c

#3

38b

22g

14a

#2

17c

45
123

23

19i

19g

26b

SPACER PLATE (307)

17b

45

45

32

D432

LINE

EX

REV

32a

LINE

15

2-3 SIGNAL

48b

LINE SAFETY MODE

COAST CLUTCH
FORWARD CLUTCH

1-2 SIGNAL

34a

EX

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
123
123

1-2 SIGNAL

32
2-3 SIGNAL

LOW AND REV CL OR RLO


REVERSE LOCKOUT
SECOND COAST CLUTCH

23 REGULATED

29

LINE

(C)

45

48
48a

D432
FEED LIMIT

#10

123 REGULATED
23 REGULATED

45
43c

EX

CNTRL

44c

44f

ON

4-5 SHIFT
SOLENOID
VALVE
N/C

EX

45

EX

REVERSE

(B)

EX

EX

2345

345
2345

EX
EX

123 REGULATED
123 BRAKING
345

FDL

2-3 SHIFT
SOLENOID
VALVE
N/C

45

22e

123
FEED LIMIT
32 SAFETY MODE

INTERMEDIATE CL

10h

FDL 44

COAST CLUTCH FEED


OVERDRIVE CLUTCH FEED 2
45

LINE
1-2 SIGNAL

LINE

10
28a

2-3 SIGNAL

D432

FDL

22a

32 SM/FDL
2345
LOW AND REVERSE CL

30d

FDL

EX

FDL
EX

EX

EX

#11

OVERDRIVE CL FD 2
OVERDRIVE CL FD 1
RLO

TCC SIGNAL

LINE

33d

CNTRL

GASKET (303)

FORWARD CLUTCH
COAST CLUTCH

SUCTION

4-5 SHIFT VLV

R N D 4 3 2

GASKET (305)
BOTTOM CHANNEL PLATE (304)

345

12

Figure 88

36a

19

25a

25b

24c

15a

13a

38a

36b

37b

26
37a

45

FLUID FILTER
ASSEMBLY
(59)

33e

OFF

EX
SECOND COAST CLUTCH
OVERDRIVE CLUTCH FEED 1
2345
2345
23 REGULATED
4-5 SIGNAL

LOW PRESSURE

REAR CONTROL VALVE BODY (310)


GASKET (309)

OVERDRIVE CLUTCH FEED 1

FLUID
PAN
(62)

23

LINE SAFETY MODE

THROTTLE SIGNAL

(A)

35a
35b

MANUAL VALVE

REVERSE LOCKOUT
LINE
REGULATED APPLY
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2

REVERSE CLUTCH

10g

2345
19j

7a

24b

36f

36d

36e

23b

345

40a

345

X-4

44b

24

2345

REV

345

123
D432

LINE

345

25

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED

SECOND CLUTCH
D432
EX

TCC SIGNAL
REVERSE LOCKOUT
TCC SIGNAL
123 REGULATED
123 BRAKING
123 REGULATED
345

DIRECT CLUTCH
345
45
LINE SAFETY MODE

345

FILTER
(308)

44a
10f
27a

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH
23 REGULATED

EX
EX

EX

REGULATED APPLY

TCC SIGNAL

TCC SIGNAL

44e
44d
28b

FDL

345
45

123
D432
345
DIRECT CLUTCH

EX

EX

EX

EX

EX

EX

2345 OR REVERSE

EX

15

23a

REVERSE CLUTCH

2345 OR REVERSE

REVERSE LOCKOUT

REVERSE CLUTCH

REVERSE LOCKOUT
LINE

16a

17a

21

COAST CLUTCH

FORWARD CLUTCH

PRESSURES
INTAKE & DECREASE (SUCTION)
CONVERTER & LUBE
MAINLINE
REGULATED LINE
SOLENOID SIGNAL
ACCUMULATOR
FEED LIMIT
THROTTLE SIGNAL

X-2

TCC PWM
SOLENOID
VALVE
N/C

23c

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

LINE

(214)

16

#1

32 SAFETY MODE

21

1
FLUID
PUMP
COVER
(202)

16

25c
25e

2-3 SIGNAL
FEED LIMIT

REVERSE
LOCKOUT
VALVE

LINE

TCC REGULATOR VALVE

36c

345

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

15c

24a

REGULATED APPLY

SUCTION
2

LINE

15b

15d

EX

FLUID PUMP
SCREEN
ASSEMBLY
(213)

FEED LIMIT VALVE

23

13

OVERDRIVE CLUTCH FEED 1


OVERDRIVE CLUTCH FEED 2

CONVERTER
HOUSING
(224)

FEED LIMIT
FEED LIMIT

25d

1-2 SHIFT
SOLENOID
VALVE
N/C

1-2 SHIFT CONTROL VALVE

D432

20

FD LIMIT

2-3 SHIFT VALVE

10c
10

345

TCC
ENABLE
VALVE

THROTTLE SIGNAL

RELEASE
TO COOLER
APPLY

TCC SIGNAL
REGULATED APPLY

LINE

CONVERTER FDL
CONVERTER FEED

TCC
CONTROL
VALVE

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REVERSE CLUTCH
FDL
2-3 SIGNAL
FDL
FEED LIMIT
1-2 SIGNAL

LINE SAFETY MODE

10a

D432

19e

RLO

CNTRL 3-4 SHIFT

10d

2345 OR REVERSE

DECREASE

FORWARD CLUTCH

CONVERTER FEED

14
19f

TCC SIGNAL

2-3 SIGNAL

28c

DIRECT CLUTCH

COAST CLUTCH

LINE

LINE

MEMORY
FEED LIMIT
LINE

SAFETY MODE

1-2 SIGNAL

19h

33a

2345

123 REGULATED

10b

D432

SECOND CLUTCH

1-2 SHIFT VALVE


DIRECT CLUTCH

PRESSURE
CONTROL
SOLENOID
VALVE

EX

11a

EX

FILTER
(312)

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

11b

REGULATED APPLY

PRESSURE
RELIEF
BALL
VALVE

EX

REVERSE CLUTCH

54f

54d

54b

MEMORY PILOT

EX

46

20a

APPLY

36

12a

OVERDRIVE CL FD 1
OVERDRIVE CL FD 2
345
FEED LIMIT
LINE

EX

46

47b

32
1-2 SIGNAL
32 SAFETY MODE

DIRECT CLUTCH

DIRECT CLUTCH

30

27c

FEED LIMIT
MEMORY
MEMORY PILOT

32
32 SAFETY MODE

47a

AIR
BLEED
(233)

LINE

COAST CLUTCH

CASE (24)

CONVERTER FEED
DECREASE
PRESS REG VALVE

10e

AIR
BLEED
(203)

AIR
BLEED
(203)

X-3

ACCUM

D432

LINE

2b

21

SECOND CLUTCH

32

42b

ACCUMULATOR
INTERMEDIATE CLUTCH

32 SAFETY MODE

43a

LINE
SECOND CLUTCH

19

DIRECT CLUTCH

37d

INTERMEDIATE CLUTCH

ACCUM

OVERDRIVE CLUTCH FEED 2

40b

27b

AIR
BLEED
(203)

EX

SECOND
CLUTCH
ACCUMULATOR

31

BOOST VALVE

OVERDRIVE CLUTCH FEED 1

EX

COAST CLUTCH
123
123

39c
39b

LUBE

THROTTLE SIGNAL

OVERDRIVE CLUTCH FEED 2

41

32

EX

ACCUMULATOR

40c

DIRECT CLUTCH

FLUID
PRESSURE
TEST PLUG
(40)

54c

#12

COAST CLUTCH

AIR
BLEED
(233)

ACCUMULATOR

54a

5
2c

SECOND CLUTCH
REVERSE LOCKOUT

ACCUMULATOR HOUSING (333)

INTERMEDIATE
CLUTCH
ACCUMULATOR

ACCUM
OVERDRIVE CL FD 2 40d

2a

TO COOLER

LINE

OVERDRIVE
CLUTCH
ACCUMULATOR

GASKET (309)
FRONT CONTROL VALVE BODY (311)

REVERSE CLUTCH
FORWARD CLUTCH

AIR
BLEED
(203)

EX

DIRECT
CLUTCH
ACCUMULATOR

37c

COOLER

SPACER PLATE (307)

ACCUMULATOR HOUSING (328)

EX

DIRECT CL

OVERDRIVE CLUTCH

CO

R
OLE

BOTTOM CHANNEL PLATE (304)


GASKET (305)

LOW AND REV CL OR RLO


SECOND COAST CLUTCH

CENTER
SUPPORT
ASSEMBLY
(510535)

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (323)

35d

APPLY

GASKET (303)

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH
LUBE

TO

92

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (317)
CASE (24)
TOP CHANNEL PLATE (301)

38e

LUBE

2-3 SIGNAL

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH

E
LUB

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

INTERMEDIATE CLUTCH

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

7b

NOTE:
PASSAGES AND
COMPONENTS
MARKED WITH
ARE USED FOR
THE 5L40-E ONLY

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

RELEASE

WWW.ALL-TRANS.BY

TORQUE
CONVERTER
ASSEMBLY
(1)

OVERDRIVE RANGE FIRST GEAR


WWW.ALL-TRANS.BY

LOSS OF DRIVE

Fluid Pump (202)


Seized

Forward Clutch Piston (436)


Jammed or cracked
Leaking

Forward Clutch Input Housing (433)


Passage plugged

Forward Clutch Housing Ball Check Valve (434)


Leaking

Forward Clutch Sprag (461)


Not Holding

Input Shaft Fluid Seal (432)


Leaking
FIRST, FOURTH AND FIFTH GEAR ONLY

1-2 Shift Solenoid Valve (368)

Stuck Off
Loose connector
No voltage
Leaking

1-2 Shift Valve (387)


Stuck

1-2 Shift Control Valve (366)


Stuck
THIRD, FOURTH AND FIFTH GEAR ONLY

2-3 Shift Solenoid Valve (369)

Stuck Off
Loose connector
No voltage
Leaking

2-3 Shift Valve (371)


Stuck

2-3 Shift Control Valve (370)


Stuck
FIRST, SECOND, THIRD AND FIFTH GEAR ONLY

4-5 Shift Solenoid Valve (376)

Stuck Off
Loose connector
No voltage
Leaking

4-5 Shift Valve (374)


Stuck

4-5 Shift Control Valve (375)


Stuck
SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF ON OFF
LD = LOCKED IN DRIVE

APPLIED APPLIED

LD

LD

*APPLIED

APPLIED BEFORE THE FIRST 1-2 SHIFT HAS OCCURRED

92A

OVERDRIVE RANGE FIRST GEAR


WWW.ALL-TRANS.BY

PASSAGES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54

SUCTION
LINE
DECREASE
CONVERTER FEED
RELEASE
APPLY
REGULATED APPLY
TO COOLER
LUBE
FEED LIMIT
FILTERED FEED LIMIT
THROTTLE SIGNAL
LINE SAFETY MODE
REVERSE
REVERSE LOCK OUT (RLO)
REVERSE CLUTCH
LOW AND REVERSE CLUTCH
LOW AND REVERSE CLUTCH OR RLO
D432
123
FORWARD CLUTCH
2345
2345 OR REVERSE
TCC SIGNAL
123 REGULATED
123 BRAKING
1-2 SIGNAL
2-3 SIGNAL
4-5 SIGNAL
SECOND CLUTCH
COAST CLUTCH FEED
COAST CLUTCH
23 REGULATED
SECOND COAST CLUTCH
INTERMEDIATE CLUTCH
345
DIRECT CLUTCH
45
OVERDRIVE CLUTCH FEED 1
OVERDRIVE CLUTCH FEED 2
OVERDRIVE CLUTCH
32
32 SAFETY MODE
FDL
32 SAFETY MODE/FDL
MEMORY PILOT
MEMORY
EXHAUST
OIL RESERVOIR
TORQUE CONVERTER SEAL DRAINBACK
VENT
VOID
CONVERTER FDL
ACCUMULATOR

COMPONENTS ( )
(36)
(40)
(203)
(213)
(214)
(232)
(233)
(306)
(308)
(312)

92B

TRANSMISSION FLUID LEVEL HOLE PLUG


TRANSMISSION FLUID PRESSURE TEST PLUG
CHECK VALVE RETAINER AND BALL ASSEMBLY
TRANSMISSION FLUID PUMP SCREEN ASSEMBLY
BRASS ORIFICE INSERT
ORIFICE SLEEVE
ORIFICE CUP PLUG
CONTROL VALVE BODY BALL CHECK VALVE
(#1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
TCC PWM SOLENOID VALVE FILTER ASSEMBLY
PRESSURE CONTROL SOLENOID VALVE
FILTER ASSEMBLY

OVERDRIVE RANGE FIRST GEAR


WWW.ALL-TRANS.BY

(229)

51

48

32 5
21 9

4
53
48
7

NOTE:

(203)

52

32

21

52

48
48
48

37

24
48

12

27

48

24

21

48
32

10

48
48

FRONT

41

42

24
48

28

21

36

42

19
19

43

35 15
13

52

41

28

52

32

52

34

52

34

30

48

48

48
28

48

48
48

18
10

21

48

20
52

2
48

48
21

TOP CHANNEL PLATE (301)


(Bottom Channel Plate Side)

18
48
10

42

17

48

48

34
27

43
28

#10
10

BOTTOM CHANNEL PLATE (304)


(Top Channel Plate Side)

Figure 89

FOLDOUT 93

22g/23
38b

19

18

48
10 42

13

28
2

48
10

#9

#8

BOTTOM CHANNEL PLATE (304)


(Control Valve Body Side)

10

TOP CHANNEL PLATE (301)


(Case Side)

48

45

54b

20
19

36

37
54

47
52

47
10
2

46
13

52

37

36
40

36

52

52
54

48

48

52

40

42
43

39

38

FRONT CONTROL VALVE BODY (311)


(Bottom Channel Plate Side)

40d
54d
2c/54c

19h
15a

48
30b

40a

22b
22d 22c

28

32a

22f
24

20

35a
22e

18

22

14

54f
30a
33a

25
26
25

35d

22a

24c
36a

48
30

19

15

19
14

52

19f

19e

38c

21c/31 27
20c
17
2h 20d

14

35c

25c

48

52
25

21

25b
19

38e

21

15

#6
43

44

38d

52

30

37c

47a

19i

14a/23 26b

#5

52

13
19

28

15

#4

34

27

27

23

11b
10c

27c/46
10e

8
19j
2b
36c 25
13a
23a
37a
40c/41
40b
39c/41
36e
42b 52
36d 36b
43a
39b
38a
48 5
19g

25a

19

52

44
2
10

21

48
48

22

32

19

15
52

35

38

28

#11

38

20

35

X-5

24

19

52

38
52

31

30d

20b
26a

2m/54g

SPACER PLATE (307)


(Bottom Channel Plate Side)

32

38

52

15

19
2

10
48

52

44

34

52
2

10
48

48

27

43

44
10

28
48
10

52

30

33
17

52

30
33
54
25
25
17
30

28

33
13

35

22

44

26

21

42

35
22
35
39

20
20

22

36

52

35

40
2d/54e
25d
25e
17a 3
30c

35b
44e
28b 52
39a
#7
16
(Spring)
23 33e
52
2e
13b 33d
33c

21b/31
19c/21
44a 2
15e 33b 22
17b
19d/21
34a
15
21a
48a
27a 44b 10f
15f/18
17c/18
29 48b
44d
19b/21 19a 10i
43b
2f

43c/45
9
28a
11
42a
44c 10g
10
48
44f/45

48
10h

52

18

2
52

10
12

19

38
52 26 32

33

17

13
42 52

52 43

#3

22
22

30

30

52

23

36

25

20 21

15

40
25

22 19

52
27

52

39

10
52

20a

52
28

48

48

36f 26

38

#2

35

38

23b

15

35

30

X-1

19
15

22
35

19

48

19

24

27b

10
12

12a
4
52
28c
48
47b 2a/54a

10d

X-3

41

2g

7b

FILTER
(308)

23

48

36

7a
6

X-4

36

10
48

40

37b
10a

24a
48

37

2
15b
48 11a/10b

23c
24b

41

43

13

48
52

36

10

48

16a
37d

23

15

48

48

24

37

27
13

FRONT

19

19

11

FRONT

2
41

13
#12

48
48

24

48

10
20

42

20

43

27

47

12

27

48

48

24

FILTER
(312)

15c/16

36

37

27

48
15d/16

48

48

48

48

20

13
48

48

16

37

48
48

48

16

48

28

15

37
7

32

21

48

52

48
16

48
37

23

16

12
28

16
48

11

10

48
23

15

48

ARE USED FOR

48

16

48

48

FRONT

48

PASSAGES MARKED WITH


THE 5L40-E ONLY

X-2

48
32

CASE (24)
(Top Channel Plate Side)

EXHAUST FLUID NOT SHOWN


#1

12

(36)

DUAL PURPOSE PASSAGES HAVE


CHANNEL PLATE SIDE NUMBERS LISTED FIRST

FLUID PUMP COVER (202)


(Case Side)

16

52

12 (203)

FRONT

TORQUE CONVERTER HOUSING (227)


(Fluid Pump Cover Side)

16

(203)

32

52

16

52

FRONT

37

(203)

52

21

INDICATES BOLT HOLES

52

37

52

NON FUNCTIONAL HOLES HAVE BEEN


REMOVED FROM COMPONENT DRAWINGS
TO SIMPLIFY TRACING FLUID FLOW.

24

52
52

21

32

52

12

52

52

15

18

CASE (24)
(Fluid Pump Cover Side)

37

48

34

30

52

48

52

48

32
9

37 16 21

16

24

52

48

52

(40)

12

48

FLUID PUMP COVER (202)


(Torque Converter Housing Side)

16

35

30

52

52

52

21

FRONT

48

(213)
1

50

24
4
53
48
7

32

2/21

41

16

12

32

(214) 21

37
16

37

12

52
52

24

24
48

2
4

52

(233)

52

52
7

48
53

52

52

7
48

48

52

21

50

52

48

12

51

51

37

24

24

16

32

52

16

2
12

52

48

FRONT

53
5

31

52

52

52

TRANSMISSION
VENT
ASSEMBLY

48

(232)

48

48
4

(231)

51

(233)

44

48

48

REAR CONTROL VALVE BODY (310)


(Bottom Channel Plate Side)

OVERDRIVE RANGE SECOND GEAR

FORWARD CLUTCH
COAST CLUTCH
LUBE

30a

30b
35c

30c

2e

2d

54g

54e

2m

29

EX

2345
2345
2345
32 SM

33c

EX
EX

33b

#9

OFF

11
10i

43

LINE

13b
13

18

2345

LOW AND REV CL OR RLO

2-3 SIGNAL

39a

22c

22

X-1

28
26a

32 SM

LINE

123 BRAKING
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2
45
OVERDRIVE CLUTCH FEED 1

123
D432

32

1-2 SIGNAL
123
FEED LIMIT

32 SAFETY MODE

32 SAFETY MODE
REVERSE LOCKOUT
D432

32

D432
32

2-3 SIGNAL

2-3 SIGNAL

TOP CHANNEL PLATE (301)


CASE (24)

REVERSE LOCKOUT
COAST CLUTCH

REVERSE LOCKOUT
COAST CLUTCH
FORWARD CLUTCH

REVERSE LOCKOUT
COAST CLUTCH

1-2 SIGNAL

D432
FEED LIMIT

21

123 REGULATED

LINE

OVERDRIVE CL FD 2
OVERDRIVE CL FD 1
RLO

19

#6

19c

21

15
19d

20b

31

#5

21c

31

17
21b

21a

#7

42a

16

19b

20d

20c

#4

22f

123 REGULATED
123 BRAKING

123
123
2345

15e
22d
43b

19a

2f

2h

X-5

38d

27

18
15f

#8

2345
38

38c

#3

38b

22g

14a

#2

17c

45
123

23

19i

19g

26b

SPACER PLATE (307)

17b

45

45

32

D432

LINE

EX

REV

32a

LINE

15

EX
EX
EX

22b

LINE SAFETY MODE

COAST CLUTCH
FORWARD CLUTCH

LOW AND REV CL OR RLO


REVERSE LOCKOUT
SECOND COAST CLUTCH

48b

22

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
123
123

1-2 SIGNAL

32
2-3 SIGNAL

2-3 SIGNAL

34a

EX

22e

123
FEED LIMIT
32 SAFETY MODE

INTERMEDIATE CL

23 REGULATED

45

48
48a

1-2 SIGNAL

EX

#10

D432
FEED LIMIT

45
43c

EX

EX

45

EX

REVERSE

44c

44f

ON

4-5 SHIFT
SOLENOID
VALVE
N/C

(C)

45

123 REGULATED
23 REGULATED

(B)

EX

EX

2345

345
2345

EX
EX

FDL

2-3 SHIFT
SOLENOID
VALVE
N/C

COAST CLUTCH FEED


OVERDRIVE CLUTCH FEED 2
45

LINE
1-2 SIGNAL

LINE

10h

FDL 44

2-3 SIGNAL

D432

FDL

10
28a

32 SM/FDL
2345
LOW AND REVERSE CL

30d

FDL

EX

FDL
EX

EX

EX

#11
22a

4-5 SHIFT VLV CNTRL

R N D 4 3 2

GASKET (305)
BOTTOM CHANNEL PLATE (304)

TCC SIGNAL

LINE

33d

CNTRL

GASKET (303)

FORWARD CLUTCH
COAST CLUTCH

SUCTION

36a

25a

25b

24c

15a

13a

38a

19

345

12

Figure 90

123 REGULATED
123 BRAKING
345

TCC SIGNAL
REVERSE LOCKOUT
TCC SIGNAL
123 REGULATED
123 BRAKING
123 REGULATED
345

345

DIRECT CLUTCH
345
45
LINE SAFETY MODE
36b

37b

26
37a

45

FLUID FILTER
ASSEMBLY
(59)

33e

ON

EX
SECOND COAST CLUTCH
OVERDRIVE CLUTCH FEED 1
2345
2345
23 REGULATED
4-5 SIGNAL

LOW PRESSURE

REAR CONTROL VALVE BODY (310)


GASKET (309)

OVERDRIVE CLUTCH FEED 1

FLUID
PAN
(62)

23

LINE SAFETY MODE

THROTTLE SIGNAL

(A)

35a
35b

MANUAL VALVE

REVERSE LOCKOUT
LINE
REGULATED APPLY
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2

REVERSE CLUTCH

10g

2345
19j

7a

24b

36f

36d

36e

23b

345

40a

345

X-4

44b

24

2345

REV

345

123
D432

LINE

345

25

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED

SECOND CLUTCH
D432
EX
EX
EX

EX

REGULATED APPLY

TCC SIGNAL

FILTER
(308)

44a
10f
27a

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH
23 REGULATED

345
45

123
D432
345
DIRECT CLUTCH

EX

EX

EX

EX

EX

EX

2345 OR REVERSE

EX

TCC SIGNAL

23c

REVERSE CLUTCH

2345 OR REVERSE

15

23a

16a

REVERSE LOCKOUT

REVERSE CLUTCH

X-2

TCC PWM
SOLENOID
VALVE
N/C

44e
44d
28b

21

COAST CLUTCH

FORWARD CLUTCH

PRESSURES
INTAKE & DECREASE (SUCTION)
CONVERTER & LUBE
MAINLINE
REGULATED LINE
SOLENOID SIGNAL
ACCUMULATOR
FEED LIMIT
THROTTLE SIGNAL

REVERSE LOCKOUT
LINE

OVERDRIVE CLUTCH FEED 1


OVERDRIVE CLUTCH FEED 2

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

LINE

(214)

16

#1

32 SAFETY MODE

21

1
FLUID
PUMP
COVER
(202)

16

17a

2-3 SIGNAL
FEED LIMIT

REVERSE
LOCKOUT
VALVE

LINE

TCC REGULATOR VALVE

36c

345

15c

24a

REGULATED APPLY

SUCTION
2

LINE

15b

15d

EX

FLUID PUMP
SCREEN
ASSEMBLY
(213)

FEED LIMIT VALVE

23

13

345

CONVERTER
HOUSING
(224)

10c
10

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

TCC SIGNAL
REGULATED APPLY

TCC
ENABLE
VALVE

THROTTLE SIGNAL

RELEASE
TO COOLER

CONVERTER FDL
CONVERTER FEED

LINE

APPLY

FEED LIMIT
FEED LIMIT

25c
25e

FDL

2-3 SHIFT VALVE

10a

25d

1-2 SHIFT
SOLENOID
VALVE
N/C

1-2 SHIFT CONTROL VALVE

D432

20

FD LIMIT

RLO

CNTRL 3-4 SHIFT

10d

2345 OR REVERSE

DECREASE

FORWARD CLUTCH

TCC
CONTROL
VALVE

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REVERSE CLUTCH
FDL
2-3 SIGNAL
FDL
FEED LIMIT
1-2 SIGNAL

TCC SIGNAL

2-3 SIGNAL

D432

19f

19e

LINE SAFETY MODE

1-2 SIGNAL

CONVERTER FEED

MEMORY
FEED LIMIT
LINE

SAFETY MODE

28c

DIRECT CLUTCH

COAST CLUTCH

LINE

LINE

14

2345

123 REGULATED

10b

19h

33a

1-2 SHIFT VALVE


DIRECT CLUTCH

PRESSURE
CONTROL
SOLENOID
VALVE

EX

11a

EX

FILTER
(312)

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

11b

REGULATED APPLY

PRESSURE
RELIEF
BALL
VALVE

EX

REVERSE CLUTCH

54f

54d

54b

MEMORY PILOT

EX

46

20a

APPLY

36

12a

OVERDRIVE CL FD 1
OVERDRIVE CL FD 2
345
FEED LIMIT
LINE

EX

46

47b

32
1-2 SIGNAL
32 SAFETY MODE

DIRECT CLUTCH

DIRECT CLUTCH

30

27c

FEED LIMIT
MEMORY
MEMORY PILOT

32
32 SAFETY MODE

47a

AIR
BLEED
(233)

LINE

COAST CLUTCH

CASE (24)

CONVERTER FEED
DECREASE
PRESS REG VALVE

10e

AIR
BLEED
(203)

AIR
BLEED
(203)

D432

SECOND CLUTCH

D432

LINE

2b

X-3

ACCUM

SECOND CLUTCH

32

42b

21

ACCUMULATOR
INTERMEDIATE CLUTCH

32 SAFETY MODE

43a

LINE
SECOND CLUTCH

19

DIRECT CLUTCH

37d

INTERMEDIATE CLUTCH

ACCUM

OVERDRIVE CLUTCH FEED 2

40b

27b

AIR
BLEED
(203)

EX

SECOND
CLUTCH
ACCUMULATOR

31

BOOST VALVE

OVERDRIVE CLUTCH FEED 1

EX

COAST CLUTCH
123
123

39c
39b

LUBE

THROTTLE SIGNAL

OVERDRIVE CLUTCH FEED 2

41

32

EX

ACCUMULATOR

40c

DIRECT CLUTCH

FLUID
PRESSURE
TEST PLUG
(40)

54c

#12

COAST CLUTCH

AIR
BLEED
(233)

ACCUMULATOR

54a

5
2c

SECOND CLUTCH
REVERSE LOCKOUT

ACCUMULATOR HOUSING (333)

INTERMEDIATE
CLUTCH
ACCUMULATOR

ACCUM
OVERDRIVE CL FD 2 40d

2a

TO COOLER

LINE

OVERDRIVE
CLUTCH
ACCUMULATOR

GASKET (309)
FRONT CONTROL VALVE BODY (311)

REVERSE CLUTCH
FORWARD CLUTCH

AIR
BLEED
(203)

EX

DIRECT
CLUTCH
ACCUMULATOR

37c

COOLER

SPACER PLATE (307)

ACCUMULATOR HOUSING (328)

EX

DIRECT CL

OVERDRIVE CLUTCH

CO

R
OLE

BOTTOM CHANNEL PLATE (304)


GASKET (305)

LOW AND REV CL OR RLO


SECOND COAST CLUTCH

CENTER
SUPPORT
ASSEMBLY
(510535)

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (323)

35d

APPLY

GASKET (303)

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH
LUBE

TO

94

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (317)
CASE (24)
TOP CHANNEL PLATE (301)

38e

LUBE

2-3 SIGNAL

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH

E
LUB

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

INTERMEDIATE CLUTCH

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

7b

NOTE:
PASSAGES AND
COMPONENTS
MARKED WITH
ARE USED FOR
THE 5L40-E ONLY

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

RELEASE

WWW.ALL-TRANS.BY

TORQUE
CONVERTER
ASSEMBLY
(1)

OVERDRIVE RANGE SECOND GEAR


WWW.ALL-TRANS.BY

NO SECOND GEAR

Center Support (518)


Cracked
Feed hole blocked

Fluid Passage Sleeve (38)


Leaking

Second Clutch Piston (520)


Cracked or jammed
Leaking seals

Second Clutch Sprag (547)


Not holding

1-2 Shift Solenoid Valve (368)


Stuck Off
Leaking
No voltage supply

1-2 Shift Valve (387)


Stuck

1-2 Shift Control Valve (366)


Stuck

Second Clutch Accumulator


Leaking

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
ON ON OFF

APPLIED APPLIED

LD

APPLIED

LD

LD = LOCKED IN DRIVE

94A

OVERDRIVE RANGE SECOND GEAR


WWW.ALL-TRANS.BY

PASSAGES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54

SUCTION
LINE
DECREASE
CONVERTER FEED
RELEASE
APPLY
REGULATED APPLY
TO COOLER
LUBE
FEED LIMIT
FILTERED FEED LIMIT
THROTTLE SIGNAL
LINE SAFETY MODE
REVERSE
REVERSE LOCK OUT (RLO)
REVERSE CLUTCH
LOW AND REVERSE CLUTCH
LOW AND REVERSE CLUTCH OR RLO
D432
123
FORWARD CLUTCH
2345
2345 OR REVERSE
TCC SIGNAL
123 REGULATED
123 BRAKING
1-2 SIGNAL
2-3 SIGNAL
4-5 SIGNAL
SECOND CLUTCH
COAST CLUTCH FEED
COAST CLUTCH
23 REGULATED
SECOND COAST CLUTCH
INTERMEDIATE CLUTCH
345
DIRECT CLUTCH
45
OVERDRIVE CLUTCH FEED 1
OVERDRIVE CLUTCH FEED 2
OVERDRIVE CLUTCH
32
32 SAFETY MODE
FDL
32 SAFETY MODE/FDL
MEMORY PILOT
MEMORY
EXHAUST
OIL RESERVOIR
TORQUE CONVERTER SEAL DRAINBACK
VENT
VOID
CONVERTER FDL
ACCUMULATOR

COMPONENTS ( )
(36)
(40)
(203)
(213)
(214)
(232)
(233)
(306)
(308)
(312)

94B

TRANSMISSION FLUID LEVEL HOLE PLUG


TRANSMISSION FLUID PRESSURE TEST PLUG
CHECK VALVE RETAINER AND BALL ASSEMBLY
TRANSMISSION FLUID PUMP SCREEN ASSEMBLY
BRASS ORIFICE INSERT
ORIFICE SLEEVE
ORIFICE CUP PLUG
CONTROL VALVE BODY BALL CHECK VALVE
(#1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
TCC PWM SOLENOID VALVE FILTER ASSEMBLY
PRESSURE CONTROL SOLENOID VALVE
FILTER ASSEMBLY

OVERDRIVE RANGE SECOND GEAR


WWW.ALL-TRANS.BY

(229)

51

48

32 5
21 9

4
53
48
7

NOTE:

(203)

52

32

21

52

48
48
48

37

24
48

12

27

48

24

21

48
32

10

48
48

FRONT

41

42

24
48

28

21

36

42

19
19

43

35 15
13

52

41

28

52

32

52

34

52

34

30

48

48

48
28

48

48
48

18
10

21

48

20
52

2
48

48
21

TOP CHANNEL PLATE (301)


(Bottom Channel Plate Side)

18
48
10

42

17

48

48

34
27

43
28

#10
10

BOTTOM CHANNEL PLATE (304)


(Top Channel Plate Side)

Figure 91

FOLDOUT 95

22g/23
38b

19

18

48
10 42

13

28
2

48
10

#9

#8

BOTTOM CHANNEL PLATE (304)


(Control Valve Body Side)

10

TOP CHANNEL PLATE (301)


(Case Side)

48

45

54b

20
19

36

37
54

47
52

47
10
2

46
13

52

37

36
40

36

52

52
54

48

48

52

40

42
43

39

38

FRONT CONTROL VALVE BODY (311)


(Bottom Channel Plate Side)

40d
54d
2c/54c

19h
15a

48
30b

40a

22b
22d 22c

28

32a

22f
24

20

35a
22e

18

22

14

54f
30a
33a

25
26
25

35d

22a

24c
36a

48
30

19

15

19
14

52

19f

19e

38c

21c/31 27
20c
17
2h 20d

14

35c

25c

48

52
25

21

25b
19

38e

21

15

#6
43

44

38d

52

30

37c

47a

19i

14a/23 26b

#5

52

13
19

28

15

#4

34

27

27

23

11b
10c

27c/46
10e

8
19j
2b
36c 25
13a
23a
37a
40c/41
40b
39c/41
36e
42b 52
36d 36b
43a
39b
38a
48 5
19g

25a

19

52

44
2
10

21

48
48

22

32

19

15
52

35

38

28

#11

38

20

35

X-5

24

19

52

38
52

31

30d

20b
26a

2m/54g

SPACER PLATE (307)


(Bottom Channel Plate Side)

32

38

52

15

19
2

10
48

52

44

34

52
2

10
48

48

27

43

44
10

28
48
10

52

30

33
17

52

30
33
54
25
25
17
30

28

33
13

35

22

44

26

21

42

35
22
35
39

20
20

22

36

52

35

40
2d/54e
25d
25e
17a 3
30c

35b
44e
28b 52
39a
#7
16
(Spring)
23 33e
52
2e
13b 33d
33c

21b/31
19c/21
44a 2
15e 33b 22
17b
19d/21
34a
15
21a
48a
27a 44b 10f
15f/18
17c/18
29 48b
44d
19b/21 19a 10i
43b
2f

43c/45
9
28a
11
42a
44c 10g
10
48
44f/45

48
10h

52

18

2
52

10
12

19

38
52 26 32

33

17

13
42 52

52 43

#3

22
22

30

30

52

23

36

25

20 21

15

40
25

22 19

52
27

52

39

10
52

20a

52
28

48

48

36f 26

38

#2

35

38

23b

15

35

30

X-1

19
15

22
35

19

48

19

24

27b

10
12

12a
4
52
28c
48
47b 2a/54a

10d

X-3

41

2g

7b

FILTER
(308)

23

48

36

7a
6

X-4

36

10
48

40

37b
10a

24a
48

37

2
15b
48 11a/10b

23c
24b

41

43

13

48
52

36

10

48

16a
37d

23

15

48

48

24

37

27
13

FRONT

19

19

11

FRONT

2
41

13
#12

48
48

24

48

10
20

42

20

43

27

47

12

27

48

48

24

FILTER
(312)

15c/16

36

37

27

48
15d/16

48

48

48

48

20

13
48

48

16

37

48
48

48

16

48

28

15

37
7

32

21

48

52

48
16

48
37

23

16

12
28

16
48

11

10

48
23

15

48

ARE USED FOR

48

16

48

48

FRONT

48

PASSAGES MARKED WITH


THE 5L40-E ONLY

X-2

48
32

CASE (24)
(Top Channel Plate Side)

EXHAUST FLUID NOT SHOWN


#1

12

(36)

DUAL PURPOSE PASSAGES HAVE


CHANNEL PLATE SIDE NUMBERS LISTED FIRST

FLUID PUMP COVER (202)


(Case Side)

16

52

12 (203)

FRONT

TORQUE CONVERTER HOUSING (227)


(Fluid Pump Cover Side)

16

(203)

32

52

16

52

FRONT

37

(203)

52

21

INDICATES BOLT HOLES

52

37

52

NON FUNCTIONAL HOLES HAVE BEEN


REMOVED FROM COMPONENT DRAWINGS
TO SIMPLIFY TRACING FLUID FLOW.

24

52
52

21

32

52

12

52

52

15

18

CASE (24)
(Fluid Pump Cover Side)

37

48

34

30

52

48

52

48

32
9

37 16 21

16

24

52

48

52

(40)

12

48

FLUID PUMP COVER (202)


(Torque Converter Housing Side)

16

35

30

52

52

52

21

FRONT

48

(213)
1

50

24
4
53
48
7

32

2/21

41

16

12

32

(214) 21

37
16

37

12

52
52

24

24
48

2
4

52

(233)

52

52
7

48
53

52

52

7
48

48

52

21

50

52

48

12

51

51

37

24

24

16

32

52

16

2
12

52

48

FRONT

53
5

31

52

52

52

TRANSMISSION
VENT
ASSEMBLY

48

(232)

48

48
4

(231)

51

(233)

44

48

48

REAR CONTROL VALVE BODY (310)


(Bottom Channel Plate Side)

OVERDRIVE RANGE THIRD GEAR

FORWARD CLUTCH
COAST CLUTCH
LUBE

30a

30b
35c

30c

2e

54e

45
43c

OFF

EX

#10
29

EX

2345
2345
2345
32 SM

33c

EX
EX

33b

#9

OFF

11
10i

43

LINE

13b
13

18

2345

LOW AND REV CL OR RLO

2-3 SIGNAL

EX

39a

22c

22

X-1

28
26a

32 SM

LINE

123 BRAKING
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2
45
OVERDRIVE CLUTCH FEED 1

123
D432

32

1-2 SIGNAL
123
FEED LIMIT

32 SAFETY MODE

32 SAFETY MODE
REVERSE LOCKOUT
D432

32

D432
32

2-3 SIGNAL

2-3 SIGNAL

TOP CHANNEL PLATE (301)


CASE (24)

REVERSE LOCKOUT
COAST CLUTCH

REVERSE LOCKOUT
COAST CLUTCH
FORWARD CLUTCH

REVERSE LOCKOUT
COAST CLUTCH

FEED LIMIT

1-2 SIGNAL

D432
2-3 SIGNAL

123 REGULATED

LINE

OVERDRIVE CL FD 2
OVERDRIVE CL FD 1
RLO

21

#6
19

15

19c

21

20b

31

#5

21c

31

17
21b

21a

#7

42a

16

19b

20d

20c

#4

22f

123 REGULATED
123 BRAKING

123
123
2345

32

15e
22d
43b

19a

2f

2h

X-5

38d

27

18
15f

#8

2345
38

38c

#3

38b

22g

14a

#2

17c

45
123

23

19i

19g

26b

SPACER PLATE (307)

17b

45

45

19d

R N D 4 3 2

D432

LINE

EX

REV

32a

LINE

15

EX
EX
EX

22b

LINE SAFETY MODE

COAST CLUTCH
FORWARD CLUTCH

LOW AND REV CL OR RLO


REVERSE LOCKOUT
SECOND COAST CLUTCH

48b

22

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
123
123

1-2 SIGNAL

32
2-3 SIGNAL

2-3 SIGNAL

34a

EX

4-5 SHIFT
SOLENOID
VALVE
N/C

(C)

45

48
48a

1-2 SIGNAL

(B)

44c

44f

D432
FEED LIMIT

FDL

45

123 REGULATED
23 REGULATED

FDL 44

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

EX

45

EX

REVERSE

23 REGULATED

10h
28a

22e

123
FEED LIMIT
32 SAFETY MODE

INTERMEDIATE CL

10

EX

EX

2345

345
2345

EX
EX

123 REGULATED
123 BRAKING
345

LINE

22a

COAST CLUTCH FEED


OVERDRIVE CLUTCH FEED 2
45

LINE
1-2 SIGNAL

FDL

EX

#11

32 SM/FDL
2345
LOW AND REVERSE CL

30d

FDL

EX

FDL
EX

33d

4-5 SHIFT VLV CNTRL

GASKET (303)

FORWARD CLUTCH
COAST CLUTCH

SUCTION

36a

25a

D432

12

Figure 92

33e

ON

MANUAL VALVE

GASKET (305)
BOTTOM CHANNEL PLATE (304)

TCC SIGNAL

LINE

23

EX
SECOND COAST CLUTCH
OVERDRIVE CLUTCH FEED 1
2345
2345
23 REGULATED
4-5 SIGNAL

LOW PRESSURE

123 REGULATED

TCC SIGNAL
REVERSE LOCKOUT
TCC SIGNAL
123 REGULATED
123 BRAKING
123 REGULATED
345
25b

24c

15a

19

345

45

FLUID FILTER
ASSEMBLY
(59)

(A)

35a
35b

2345

REV

REAR CONTROL VALVE BODY (310)


GASKET (309)

OVERDRIVE CLUTCH FEED 1

FLUID
PAN
(62)

10g

LINE SAFETY MODE

THROTTLE SIGNAL

2d

54g
2m

EX
13a

38a

36b

37b

26

REVERSE LOCKOUT
LINE
REGULATED APPLY
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2

REVERSE CLUTCH

EX

EX
EX

345

9
24

2345

44b

40a

37a

24b

36f

36d

36e

23b

X-4

44a
10f
27a

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH
23 REGULATED

345

345
25

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED

SECOND CLUTCH
D432
32
32 SAFETY MODE

345

DIRECT CLUTCH
345
45
LINE SAFETY MODE

REGULATED APPLY
LINE

345

44e
44d
28b

2-3 SIGNAL
FEED LIMIT

REVERSE
LOCKOUT
VALVE

EX

REGULATED APPLY

TCC SIGNAL

FILTER
(308)

17a

FDL

345
45

123
D432
345
DIRECT CLUTCH

EX

EX

EX

EX

EX

EX

2345 OR REVERSE

EX

TCC SIGNAL

23c

REVERSE CLUTCH

2345 OR REVERSE

15

23a

16a

REVERSE LOCKOUT

REVERSE CLUTCH

X-2

TCC PWM
SOLENOID
VALVE
N/C

25c
25e

21

COAST CLUTCH

FORWARD CLUTCH

PRESSURES
INTAKE & DECREASE (SUCTION)
CONVERTER & LUBE
MAINLINE
REGULATED LINE
SOLENOID SIGNAL
ACCUMULATOR
FEED LIMIT
THROTTLE SIGNAL

REVERSE LOCKOUT
LINE

OVERDRIVE CLUTCH FEED 1


OVERDRIVE CLUTCH FEED 2

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

LINE

(214)

16

#1

32 SAFETY MODE

21

1
FLUID
PUMP
COVER
(202)

16

25d

FD LIMIT

RLO

LINE

TCC REGULATOR VALVE

36c

345

15c

24a

REGULATED APPLY

SUCTION
2

LINE

15b

15d

EX

FLUID PUMP
SCREEN
ASSEMBLY
(213)

FEED LIMIT VALVE

23

13

345

CONVERTER
HOUSING
(224)

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

TCC SIGNAL
REGULATED APPLY

TCC
ENABLE
VALVE

THROTTLE SIGNAL

RELEASE
TO COOLER

CONVERTER FDL
CONVERTER FEED

LINE

APPLY

FEED LIMIT
FEED LIMIT

10c
10

1-2 SHIFT CONTROL VALVE

D432

20

1-2 SHIFT
SOLENOID
VALVE
N/C

TCC SIGNAL

3-4 SHIFT

10a

2345 OR REVERSE

DECREASE

FORWARD CLUTCH

TCC
CONTROL
VALVE

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REVERSE CLUTCH
FDL
2-3 SIGNAL
FDL
FEED LIMIT
1-2 SIGNAL

2-3 SHIFT VALVE

CNTRL

10d

D432

19f

19e

2345

2-3 SIGNAL

CONVERTER FEED

14

LINE SAFETY MODE

1-2 SIGNAL

28c

DIRECT CLUTCH

COAST CLUTCH

LINE

LINE

MEMORY
FEED LIMIT
LINE

SAFETY MODE
EX

10b

19h

33a

1-2 SHIFT VALVE


DIRECT CLUTCH

PRESSURE
CONTROL
SOLENOID
VALVE

EX

11a

EX

FILTER
(312)

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

11b

7a

PRESSURE
RELIEF
BALL
VALVE

EX

REVERSE CLUTCH

54f

54d

54b

MEMORY PILOT

123
D432

46

19j

APPLY

36

12a

OVERDRIVE CL FD 1
OVERDRIVE CL FD 2
345
FEED LIMIT
LINE

EX

46

47b

32
1-2 SIGNAL
32 SAFETY MODE

DIRECT CLUTCH

DIRECT CLUTCH

30

27c

FEED LIMIT
MEMORY
MEMORY PILOT

20a

47a

AIR
BLEED
(233)

LINE

COAST CLUTCH

CASE (24)

CONVERTER FEED
DECREASE
PRESS REG VALVE

10e

AIR
BLEED
(203)

AIR
BLEED
(203)

D432

SECOND CLUTCH

D432

LINE

2b

X-3

ACCUM

SECOND CLUTCH

32

42b

21

ACCUMULATOR
INTERMEDIATE CLUTCH

32 SAFETY MODE

43a

LINE
SECOND CLUTCH

19

DIRECT CLUTCH

37d

INTERMEDIATE CLUTCH

ACCUM

OVERDRIVE CLUTCH FEED 2

40b

27b

AIR
BLEED
(203)

EX

SECOND
CLUTCH
ACCUMULATOR

31

BOOST VALVE

OVERDRIVE CLUTCH FEED 1

EX

COAST CLUTCH
123
123

39c
39b

LUBE

THROTTLE SIGNAL

OVERDRIVE CLUTCH FEED 2

41

32

EX

ACCUMULATOR

40c

DIRECT CLUTCH

FLUID
PRESSURE
TEST PLUG
(40)

54c

#12

COAST CLUTCH

AIR
BLEED
(233)

ACCUMULATOR

54a

5
2c

SECOND CLUTCH
REVERSE LOCKOUT

ACCUMULATOR HOUSING (333)

INTERMEDIATE
CLUTCH
ACCUMULATOR

ACCUM
OVERDRIVE CL FD 2 40d

2a

TO COOLER

LINE

OVERDRIVE
CLUTCH
ACCUMULATOR

GASKET (309)
FRONT CONTROL VALVE BODY (311)

REVERSE CLUTCH
FORWARD CLUTCH

AIR
BLEED
(203)

EX

DIRECT
CLUTCH
ACCUMULATOR

37c

COOLER

SPACER PLATE (307)

ACCUMULATOR HOUSING (328)

EX

DIRECT CL

OVERDRIVE CLUTCH

CO

R
OLE

BOTTOM CHANNEL PLATE (304)


GASKET (305)

LOW AND REV CL OR RLO


SECOND COAST CLUTCH

CENTER
SUPPORT
ASSEMBLY
(510535)

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (323)

35d

APPLY

GASKET (303)

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH
LUBE

TO

96

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (317)
CASE (24)
TOP CHANNEL PLATE (301)

38e

LUBE

2-3 SIGNAL

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH

E
LUB

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

INTERMEDIATE CLUTCH

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

7b

NOTE:
PASSAGES AND
COMPONENTS
MARKED WITH
ARE USED FOR
THE 5L40-E ONLY

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

RELEASE

WWW.ALL-TRANS.BY

TORQUE
CONVERTER
ASSEMBLY
(1)

OVERDRIVE RANGE THIRD GEAR


WWW.ALL-TRANS.BY

NO THIRD GEAR

Overdrive Clutch Housing (493)


Cracked
Feed hole blocked

Fluid Passage Sleeve (39)


Leaking

Intermediate Clutch Piston (495)


Leaking
Cracked or jammed

2-3 Shift Solenoid Valve (369)


Stuck On

2-3 Shift Valve (371)


Stuck

2-3 Shift Control Valve (370)


Stuck

Intermediate Clutch Accumulator


Leaking

Intermediate Clutch Sprag (473)


Not holding

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
ON OFF OFF

APPLIED APPLIED

LD

LD

APPLIED

APPLIED

LD = LOCKED IN DRIVE

96A

OVERDRIVE RANGE THIRD GEAR


WWW.ALL-TRANS.BY

PASSAGES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54

SUCTION
LINE
DECREASE
CONVERTER FEED
RELEASE
APPLY
REGULATED APPLY
TO COOLER
LUBE
FEED LIMIT
FILTERED FEED LIMIT
THROTTLE SIGNAL
LINE SAFETY MODE
REVERSE
REVERSE LOCK OUT (RLO)
REVERSE CLUTCH
LOW AND REVERSE CLUTCH
LOW AND REVERSE CLUTCH OR RLO
D432
123
FORWARD CLUTCH
2345
2345 OR REVERSE
TCC SIGNAL
123 REGULATED
123 BRAKING
1-2 SIGNAL
2-3 SIGNAL
4-5 SIGNAL
SECOND CLUTCH
COAST CLUTCH FEED
COAST CLUTCH
23 REGULATED
SECOND COAST CLUTCH
INTERMEDIATE CLUTCH
345
DIRECT CLUTCH
45
OVERDRIVE CLUTCH FEED 1
OVERDRIVE CLUTCH FEED 2
OVERDRIVE CLUTCH
32
32 SAFETY MODE
FDL
32 SAFETY MODE/FDL
MEMORY PILOT
MEMORY
EXHAUST
OIL RESERVOIR
TORQUE CONVERTER SEAL DRAINBACK
VENT
VOID
CONVERTER FDL
ACCUMULATOR

COMPONENTS ( )
(36)
(40)
(203)
(213)
(214)
(232)
(233)
(306)
(308)
(312)

96B

TRANSMISSION FLUID LEVEL HOLE PLUG


TRANSMISSION FLUID PRESSURE TEST PLUG
CHECK VALVE RETAINER AND BALL ASSEMBLY
TRANSMISSION FLUID PUMP SCREEN ASSEMBLY
BRASS ORIFICE INSERT
ORIFICE SLEEVE
ORIFICE CUP PLUG
CONTROL VALVE BODY BALL CHECK VALVE
(#1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
TCC PWM SOLENOID VALVE FILTER ASSEMBLY
PRESSURE CONTROL SOLENOID VALVE
FILTER ASSEMBLY

OVERDRIVE RANGE THIRD GEAR


WWW.ALL-TRANS.BY

(229)

51

48

32 5
21 9

4
53
48
7

NOTE:

(203)

52

32

21

52

48
48
48

37

24
48

12

27

48

24

21

48
32

10

48
48

FRONT

41

42

24
48

28

21

36

42

19
19

43

35 15
13

52

41

28

52

32

52

34

52

34

30

48

48

48
28

48

48
48

18
10

21

48

20
52

2
48

48
21

TOP CHANNEL PLATE (301)


(Bottom Channel Plate Side)

18
48
10

42

17

48

48

34
27

43
28

#10
10

BOTTOM CHANNEL PLATE (304)


(Top Channel Plate Side)

Figure 93

FOLDOUT 97

22g/23
38b

19

18

48
10 42

13

28
2

48
10

#9

#8

BOTTOM CHANNEL PLATE (304)


(Control Valve Body Side)

10

TOP CHANNEL PLATE (301)


(Case Side)

48

45

54b

20
19

36

37
54

47
52

47
10
2

46
13

52

37

36
40

36

52

52
54

48

48

52

40

42
43

39

38

FRONT CONTROL VALVE BODY (311)


(Bottom Channel Plate Side)

40d
54d
2c/54c

19h
15a

48
30b

40a

22b
22d 22c

28

32a

22f
24

20

35a
22e

18

22

14

54f
30a
33a

25
26
25

35d

22a

24c
36a

48
30

19

15

19
14

52

19f

19e

38c

21c/31 27
20c
17
2h 20d

14

35c

25c

48

52
25

21

25b
19

38e

21

15

#6
43

44

38d

52

30

37c

47a

19i

14a/23 26b

#5

52

13
19

28

15

#4

34

27

27

23

11b
10c

27c/46
10e

8
19j
2b
36c 25
13a
23a
37a
40c/41
40b
39c/41
36e
42b 52
36d 36b
43a
39b
38a
48 5
19g

25a

19

52

44
2
10

21

48
48

22

32

19

15
52

35

38

28

#11

38

20

35

X-5

24

19

52

38
52

31

30d

20b
26a

2m/54g

SPACER PLATE (307)


(Bottom Channel Plate Side)

32

38

52

15

19
2

10
48

52

44

34

52
2

10
48

48

27

43

44
10

28
48
10

52

30

33
17

52

30
33
54
25
25
17
30

28

33
13

35

22

44

26

21

42

35
22
35
39

20
20

22

36

52

35

40
2d/54e
25d
25e
17a 3
30c

35b
44e
28b 52
39a
#7
16
(Spring)
23 33e
52
2e
13b 33d
33c

21b/31
19c/21
44a 2
15e 33b 22
17b
19d/21
34a
15
21a
48a
27a 44b 10f
15f/18
17c/18
29 48b
44d
19b/21 19a 10i
43b
2f

43c/45
9
28a
11
42a
44c 10g
10
48
44f/45

48
10h

52

18

2
52

10
12

19

38
52 26 32

33

17

13
42 52

52 43

#3

22
22

30

30

52

23

36

25

20 21

15

40
25

22 19

52
27

52

39

10
52

20a

52
28

48

48

36f 26

38

#2

35

38

23b

15

35

30

X-1

19
15

22
35

19

48

19

24

27b

10
12

12a
4
52
28c
48
47b 2a/54a

10d

X-3

41

2g

7b

FILTER
(308)

23

48

36

7a
6

X-4

36

10
48

40

37b
10a

24a
48

37

2
15b
48 11a/10b

23c
24b

41

43

13

48
52

36

10

48

16a
37d

23

15

48

48

24

37

27
13

FRONT

19

19

11

FRONT

2
41

13
#12

48
48

24

48

10
20

42

20

43

27

47

12

27

48

48

24

FILTER
(312)

15c/16

36

37

27

48
15d/16

48

48

48

48

20

13
48

48

16

37

48
48

48

16

48

28

15

37
7

32

21

48

52

48
16

48
37

23

16

12
28

16
48

11

10

48
23

15

48

ARE USED FOR

48

16

48

48

FRONT

48

PASSAGES MARKED WITH


THE 5L40-E ONLY

X-2

48
32

CASE (24)
(Top Channel Plate Side)

EXHAUST FLUID NOT SHOWN


#1

12

(36)

DUAL PURPOSE PASSAGES HAVE


CHANNEL PLATE SIDE NUMBERS LISTED FIRST

FLUID PUMP COVER (202)


(Case Side)

16

52

12 (203)

FRONT

TORQUE CONVERTER HOUSING (227)


(Fluid Pump Cover Side)

16

(203)

32

52

16

52

FRONT

37

(203)

52

21

INDICATES BOLT HOLES

52

37

52

NON FUNCTIONAL HOLES HAVE BEEN


REMOVED FROM COMPONENT DRAWINGS
TO SIMPLIFY TRACING FLUID FLOW.

24

52
52

21

32

52

12

52

52

15

18

CASE (24)
(Fluid Pump Cover Side)

37

48

34

30

52

48

52

48

32
9

37 16 21

16

24

52

48

52

(40)

12

48

FLUID PUMP COVER (202)


(Torque Converter Housing Side)

16

35

30

52

52

52

21

FRONT

48

(213)
1

50

24
4
53
48
7

32

2/21

41

16

12

32

(214) 21

37
16

37

12

52
52

24

24
48

2
4

52

(233)

52

52
7

48
53

52

52

7
48

48

52

21

50

52

48

12

51

51

37

24

24

16

32

52

16

2
12

52

48

FRONT

53
5

31

52

52

52

TRANSMISSION
VENT
ASSEMBLY

48

(232)

48

48
4

(231)

51

(233)

44

48

48

REAR CONTROL VALVE BODY (310)


(Bottom Channel Plate Side)

OVERDRIVE RANGE FOURTH GEAR

FORWARD CLUTCH
COAST CLUTCH
LUBE

30a

30b
35c

30c

2e

54e

29

EX

48b

2345
2345
2345
32 SM

22
33c

EX
EX

33b

#9

ON

11
10i

43

LINE

13b
13

18

2345

LOW AND REV CL OR RLO

2-3 SIGNAL

EX

39a

22c

22

X-1

28
26a

32 SM

LINE

123 BRAKING
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2
45
OVERDRIVE CLUTCH FEED 1

123
D432

32

1-2 SIGNAL
123
FEED LIMIT

32 SAFETY MODE

32 SAFETY MODE
REVERSE LOCKOUT
D432

32

D432
32

2-3 SIGNAL

2-3 SIGNAL

TOP CHANNEL PLATE (301)


CASE (24)

REVERSE LOCKOUT
COAST CLUTCH

REVERSE LOCKOUT
COAST CLUTCH
FORWARD CLUTCH

REVERSE LOCKOUT
COAST CLUTCH

1-2 SIGNAL

D432
FEED LIMIT

21

123 REGULATED

LINE

OVERDRIVE CL FD 2
OVERDRIVE CL FD 1
RLO

19

#6

19c

21

15
19d

20b

31

#5

21c

31

17
21b

21a

#7

42a

16

19b

20d

20c

#4

22f

123 REGULATED
123 BRAKING

123
123
2345

15e
22d
43b

19a

2f

2h

X-5

38d

27

18
15f

#8

2345
38

38c

#3

38b

22g

14a

#2

17c

45
123

23

19i

19g

26b

SPACER PLATE (307)

17b

45

45

32

D432

LINE

EX

REV

32a

LINE

15

EX
EX
EX

22b

LINE SAFETY MODE

COAST CLUTCH
FORWARD CLUTCH

2-3 SIGNAL

34a

EX

(C)

1-2 SIGNAL

32
2-3 SIGNAL

LOW AND REV CL OR RLO


REVERSE LOCKOUT
SECOND COAST CLUTCH

23 REGULATED

45

48
48a

1-2 SIGNAL

EX

#10

D432
FEED LIMIT

45
43c

OFF

4-5 SHIFT
SOLENOID
VALVE
N/C

EX

45

EX

REVERSE

44c

44f

123 REGULATED
23 REGULATED

(B)

EX

EX

2345

345
2345

EX
EX

123 REGULATED
123 BRAKING
345

FDL

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

45

22e

123
FEED LIMIT
32 SAFETY MODE

INTERMEDIATE CL

10h

FDL 44

COAST CLUTCH FEED


OVERDRIVE CLUTCH FEED 2
45

LINE
1-2 SIGNAL

LINE

10
28a

2-3 SIGNAL

D432

FDL

22a

32 SM/FDL
2345
LOW AND REVERSE CL

30d

FDL

EX

FDL
EX

EX

EX

#11

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
123
123

GASKET (303)

FORWARD CLUTCH
COAST CLUTCH

SUCTION

2d

54g
2m

TCC SIGNAL

LINE

33d

4-5 SHIFT VLV CNTRL

R N D 4 3 2

GASKET (305)
BOTTOM CHANNEL PLATE (304)

345

12

Figure 94

36a

19

25a

25b

24c

15a

13a

38a

36b

37b

26
37a

45

FLUID FILTER
ASSEMBLY
(59)

33e

OFF

EX
SECOND COAST CLUTCH
OVERDRIVE CLUTCH FEED 1
2345
2345
23 REGULATED
4-5 SIGNAL

LOW PRESSURE

REAR CONTROL VALVE BODY (310)


GASKET (309)

OVERDRIVE CLUTCH FEED 1

FLUID
PAN
(62)

23

LINE SAFETY MODE

THROTTLE SIGNAL

(A)

35a
35b

MANUAL VALVE

REVERSE LOCKOUT
LINE
REGULATED APPLY
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2

REVERSE CLUTCH

10g

2345
19j

24b

36f

36d

36e

23b

345

40a

345

X-4

44b

24

2345

REV

345

123
D432

LINE

345

25

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED

SECOND CLUTCH
D432
EX

TCC SIGNAL
REVERSE LOCKOUT
TCC SIGNAL
123 REGULATED
123 BRAKING
123 REGULATED
345

DIRECT CLUTCH
345
45
LINE SAFETY MODE

REGULATED APPLY

345

FILTER
(308)

44a
10f
27a

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH
23 REGULATED

EX
EX

EX

REGULATED APPLY

TCC SIGNAL

TCC SIGNAL

44e
44d
28b

FDL

345
45

123
D432
345
DIRECT CLUTCH

EX

EX

EX

EX

EX

EX

2345 OR REVERSE

EX

15

23a

REVERSE CLUTCH

2345 OR REVERSE

REVERSE LOCKOUT

REVERSE CLUTCH

REVERSE LOCKOUT
LINE

16a

17a

21

COAST CLUTCH

FORWARD CLUTCH

PRESSURES
INTAKE & DECREASE (SUCTION)
CONVERTER & LUBE
MAINLINE
REGULATED LINE
SOLENOID SIGNAL
ACCUMULATOR
FEED LIMIT
THROTTLE SIGNAL

X-2

TCC PWM
SOLENOID
VALVE
N/C

23c

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

LINE

(214)

16

#1

32 SAFETY MODE

21

1
FLUID
PUMP
COVER
(202)

16

25c
25e

2-3 SIGNAL
FEED LIMIT

REVERSE
LOCKOUT
VALVE

LINE

TCC REGULATOR VALVE

36c

345

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

15c

24a

REGULATED APPLY

SUCTION
2

LINE

15b

15d

EX

FLUID PUMP
SCREEN
ASSEMBLY
(213)

FEED LIMIT VALVE

23

13

OVERDRIVE CLUTCH FEED 1


OVERDRIVE CLUTCH FEED 2

CONVERTER
HOUSING
(224)

FEED LIMIT
FEED LIMIT

25d

1-2 SHIFT
SOLENOID
VALVE
N/C

1-2 SHIFT CONTROL VALVE

D432

20

FD LIMIT

2-3 SHIFT VALVE

10c
10

345

TCC
ENABLE
VALVE

THROTTLE SIGNAL

RELEASE
TO COOLER
APPLY

TCC SIGNAL
REGULATED APPLY

LINE

CONVERTER FDL
CONVERTER FEED

TCC
CONTROL
VALVE

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REVERSE CLUTCH
FDL
2-3 SIGNAL
FDL
FEED LIMIT
1-2 SIGNAL

LINE SAFETY MODE

10a

D432

19e

RLO

CNTRL 3-4 SHIFT

10d

2345 OR REVERSE

DECREASE

FORWARD CLUTCH

CONVERTER FEED

14
19f

TCC SIGNAL

2-3 SIGNAL

28c

DIRECT CLUTCH

COAST CLUTCH

LINE

LINE

MEMORY
FEED LIMIT
LINE

SAFETY MODE

1-2 SIGNAL

19h

33a

2345

123 REGULATED

10b

D432

SECOND CLUTCH

1-2 SHIFT VALVE


DIRECT CLUTCH

PRESSURE
CONTROL
SOLENOID
VALVE

EX

11a

EX

FILTER
(312)

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

11b

7a

PRESSURE
RELIEF
BALL
VALVE

EX

REVERSE CLUTCH

54f

54d

54b

MEMORY PILOT

EX

46

20a

APPLY

36

12a

OVERDRIVE CL FD 1
OVERDRIVE CL FD 2
345
FEED LIMIT
LINE

EX

46

47b

32
1-2 SIGNAL
32 SAFETY MODE

DIRECT CLUTCH

DIRECT CLUTCH

30

27c

FEED LIMIT
MEMORY
MEMORY PILOT

32
32 SAFETY MODE

47a

AIR
BLEED
(233)

LINE

COAST CLUTCH

CASE (24)

CONVERTER FEED
DECREASE
PRESS REG VALVE

10e

AIR
BLEED
(203)

AIR
BLEED
(203)

X-3

ACCUM

D432

LINE

2b

21

SECOND CLUTCH

32

42b

ACCUMULATOR
INTERMEDIATE CLUTCH

32 SAFETY MODE

43a

LINE
SECOND CLUTCH

19

DIRECT CLUTCH

37d

INTERMEDIATE CLUTCH

ACCUM

OVERDRIVE CLUTCH FEED 2

40b

27b

AIR
BLEED
(203)

EX

SECOND
CLUTCH
ACCUMULATOR

31

BOOST VALVE

OVERDRIVE CLUTCH FEED 1

EX

COAST CLUTCH
123
123

39c
39b

LUBE

THROTTLE SIGNAL

OVERDRIVE CLUTCH FEED 2

41

32

EX

ACCUMULATOR

40c

DIRECT CLUTCH

FLUID
PRESSURE
TEST PLUG
(40)

54c

#12

COAST CLUTCH

AIR
BLEED
(233)

ACCUMULATOR

54a

5
2c

SECOND CLUTCH
REVERSE LOCKOUT

ACCUMULATOR HOUSING (333)

INTERMEDIATE
CLUTCH
ACCUMULATOR

ACCUM
OVERDRIVE CL FD 2 40d

2a

TO COOLER

LINE

OVERDRIVE
CLUTCH
ACCUMULATOR

GASKET (309)
FRONT CONTROL VALVE BODY (311)

REVERSE CLUTCH
FORWARD CLUTCH

AIR
BLEED
(203)

EX

DIRECT
CLUTCH
ACCUMULATOR

37c

COOLER

SPACER PLATE (307)

ACCUMULATOR HOUSING (328)

EX

DIRECT CL

OVERDRIVE CLUTCH

CO

R
OLE

BOTTOM CHANNEL PLATE (304)


GASKET (305)

LOW AND REV CL OR RLO


SECOND COAST CLUTCH

CENTER
SUPPORT
ASSEMBLY
(510535)

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (323)

35d

APPLY

GASKET (303)

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH
LUBE

TO

98

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (317)
CASE (24)
TOP CHANNEL PLATE (301)

38e

LUBE

2-3 SIGNAL

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH

E
LUB

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

INTERMEDIATE CLUTCH

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

7b

NOTE:
PASSAGES AND
COMPONENTS
MARKED WITH
ARE USED FOR
THE 5L40-E ONLY

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

RELEASE

WWW.ALL-TRANS.BY

TORQUE
CONVERTER
ASSEMBLY
(1)

OVERDRIVE RANGE FOURTH GEAR


WWW.ALL-TRANS.BY

NO FOURTH GEAR

Direct Clutch Piston (406)


Leaking
Cracked or jammed

Direct Clutch Housing Ball Check Valve (405)


Leaking

Direct Clutch Accumulator


Leaking

1-2 Shift Solenoid Valve (368)


Stuck On

3-4 Shift Valve (345)


Stuck

Reverse Clutch Housing Seal Ring (200)


Leaking

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF OFF ON APPLIED

APPLIED APPLIED

LD

APPLIED

APPLIED

LD = LOCKED IN DRIVE

98A

OVERDRIVE RANGE FOURTH GEAR


WWW.ALL-TRANS.BY

PASSAGES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54

SUCTION
LINE
DECREASE
CONVERTER FEED
RELEASE
APPLY
REGULATED APPLY
TO COOLER
LUBE
FEED LIMIT
FILTERED FEED LIMIT
THROTTLE SIGNAL
LINE SAFETY MODE
REVERSE
REVERSE LOCK OUT (RLO)
REVERSE CLUTCH
LOW AND REVERSE CLUTCH
LOW AND REVERSE CLUTCH OR RLO
D432
123
FORWARD CLUTCH
2345
2345 OR REVERSE
TCC SIGNAL
123 REGULATED
123 BRAKING
1-2 SIGNAL
2-3 SIGNAL
4-5 SIGNAL
SECOND CLUTCH
COAST CLUTCH FEED
COAST CLUTCH
23 REGULATED
SECOND COAST CLUTCH
INTERMEDIATE CLUTCH
345
DIRECT CLUTCH
45
OVERDRIVE CLUTCH FEED 1
OVERDRIVE CLUTCH FEED 2
OVERDRIVE CLUTCH
32
32 SAFETY MODE
FDL
32 SAFETY MODE/FDL
MEMORY PILOT
MEMORY
EXHAUST
OIL RESERVOIR
TORQUE CONVERTER SEAL DRAINBACK
VENT
VOID
CONVERTER FDL
ACCUMULATOR

COMPONENTS ( )
(36)
(40)
(203)
(213)
(214)
(232)
(233)
(306)
(308)
(312)

98B

TRANSMISSION FLUID LEVEL HOLE PLUG


TRANSMISSION FLUID PRESSURE TEST PLUG
CHECK VALVE RETAINER AND BALL ASSEMBLY
TRANSMISSION FLUID PUMP SCREEN ASSEMBLY
BRASS ORIFICE INSERT
ORIFICE SLEEVE
ORIFICE CUP PLUG
CONTROL VALVE BODY BALL CHECK VALVE
(#1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
TCC PWM SOLENOID VALVE FILTER ASSEMBLY
PRESSURE CONTROL SOLENOID VALVE
FILTER ASSEMBLY

OVERDRIVE RANGE FOURTH GEAR


WWW.ALL-TRANS.BY

(229)

51

48

32 5
21 9

4
53
48
7

(203)

52

48

48

12

21

48
27
32

10

48
48

FRONT

41

42

48

28

21

36

42

19
19

43

35 15
13

41

28

52

32

52

30

34

52

34

30

48

48

48
28

48

48
48

18
10

21

48

20
52

2
48

48
21

TOP CHANNEL PLATE (301)


(Bottom Channel Plate Side)

18
48
10

42

17

48

48

34
27

43
28

#10
10

TOP CHANNEL PLATE (301)


(Case Side)

BOTTOM CHANNEL PLATE (304)


(Top Channel Plate Side)

Figure 95

38b

48

19

18

48
10 42

13

28

45
2

48
10

#9

#8

BOTTOM CHANNEL PLATE (304)


(Control Valve Body Side)

10

FOLDOUT 99

22g/23

38e

21

15

#6
43

44

38d

52

30

54b

20
19

36

37
54

47
52

47
10
2

46
13

52

37

36
40

36

52

52
54

48

48

52

40

42
43

39

38

FRONT CONTROL VALVE BODY (311)


(Bottom Channel Plate Side)

40d
54d
2c/54c

19h
15a

48
30b

40a

22b
22d 22c

28

32a

22f
24

20

35a
22e

18

22

14

54f
30a
33a

25
26
25

35d

22a

24c
36a

48
30

19

15

19
14

52

19f

19e

38c

21c/31 27
20c
17
2h 20d

14

35c

25c

48

52
25

21

25b
19

14a/23 26b

#5

52

13
19

28

15

#4

34

27

37c

47a

19i

25a

19

52

44
2
10

21

48
48

22

32

19

15
52

35

38

28

#11

38

20

35

X-5

24

19

52

38
52

31

30d

20b
26a

2m/54g

SPACER PLATE (307)


(Bottom Channel Plate Side)

32

38

52

15

19
2

10
48

52

44

34

52
2

10
48

48

27

43

44
10

28
48
10

52

30

33
17

52

30
33
54
25
25
17
30

28

33
13

35

22

44

26

21

42

35
22
35
39

20
20

22

36

52

35

40
2d/54e
25d
25e
17a 3
30c

35b
44e
28b 52
39a
#7
16
(Spring)
23 33e
52
2e
13b 33d
33c

21b/31
19c/21
44a 2
15e 33b 22
17b
19d/21
34a
15
21a
48a
27a 44b 10f
15f/18
17c/18
29 48b
44d
19b/21 19a 10i
43b
2f

43c/45
9
28a
11
42a
44c 10g
10
48
44f/45

48
10h

52

18

2
52

10
12

19

42 52

52 43

38
52 26 32

33

17

13

30

52

#3

22
22

20 21

23

36

25

52
15

40
25

22 19

35

38

27
52

#2
39

23

11b
10c

27c/46
10e

8
19j
2b
36c 25
13a
23a
37a
40c/41
40b
39c/41
36e
42b 52
36d 36b
43a
39b
38a
48 5
19g

38

27
52

20a

52
28

48

10

36f 26

15

35

30

X-1

19
15

22
35

19

48

19

23b

52

24

27b

10

48

12a
4
52
28c
48
47b 2a/54a

10d

X-3

41

2g

7b

FILTER
(308)

23

48

36

7a
6

X-4

36

10
48

40

37b
10a

24a
48

37
2

2
15b
48 11a/10b

23c
24b

41

43

13

48
52

36

10

48

16a
37d

23

15

48

48

24

37

27

19

19

#12
42

13

FRONT

2
41

13

11
12

48

20

48
48

24
7

FRONT

24

20

43

10

27

47

12

27

48

27

48

24

FILTER
(312)

15c/16

36

37

48

48

48

20

13
48

48

16

37

48
48

48

16

48

28

48

24

48

48
15d/16

48

37
7

32

21

48

11

15

48
37

23

24

12
28

16

15

2
10

52

48
16

48

37

48

48

FRONT

48

ARE USED FOR


23

48

16

48

FRONT

48

16

PASSAGES MARKED WITH


THE 5L40-E ONLY

X-2

48
48

CASE (24)
(Top Channel Plate Side)

EXHAUST FLUID NOT SHOWN


#1

32

(36)

DUAL PURPOSE PASSAGES HAVE


CHANNEL PLATE SIDE NUMBERS LISTED FIRST

FLUID PUMP COVER (202)


(Case Side)

16

52

52

52

FRONT

32

21

12 (203)

TORQUE CONVERTER HOUSING (227)


(Fluid Pump Cover Side)

16

(203)

32

52

16

INDICATES BOLT HOLES

NON FUNCTIONAL HOLES HAVE BEEN


REMOVED FROM COMPONENT DRAWINGS
TO SIMPLIFY TRACING FLUID FLOW.

52

21

52
52

37

(203)

52
52

37

12

NOTE:

24

15

18

CASE (24)
(Fluid Pump Cover Side)

32

34

30

52

48

12
21

52

52

32
9

37 16 21

52

48

37

52

48

16

24

52

48

52

(40)

12

48

35

FLUID PUMP COVER (202)


(Torque Converter Housing Side)

16

52

30

41

21

FRONT

52

52

32

48

(213)
1

50

24
4
53
48
7

16

12

37
16

2/21

24
37

32

52

(233)

12

52

24

(214) 21

52

48

2
4

52

5
8

52

52

52

48

48

52

48
53

52

48

50

21

12

51

51

37

24

24

16

32

52

16

2
12

52

48

FRONT

53
5

31

52

52

52

TRANSMISSION
VENT
ASSEMBLY

48

(232)

48

48
4

(231)

51

(233)

44

48

48

REAR CONTROL VALVE BODY (310)


(Bottom Channel Plate Side)

(Torque Converter Clutch Released)

FORWARD CLUTCH
COAST CLUTCH
LUBE

35c

45

48

29

EX

48a

2345
2345
2345
32 SM

22
33c

EX
EX

33b

#9

EX
EX
EX

22b

OFF

11
10i

43

LINE

13b
13

18

2345

LOW AND REV CL OR RLO

2-3 SIGNAL

EX

39a

22c

22

X-1

28
26a

32 SM

LINE

123 BRAKING
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2
45
OVERDRIVE CLUTCH FEED 1

123
D432

1-2 SIGNAL
123
FEED LIMIT

32 SAFETY MODE

32 SAFETY MODE
REVERSE LOCKOUT
D432

32

D432
32

2-3 SIGNAL

2-3 SIGNAL

TOP CHANNEL PLATE (301)


CASE (24)

REVERSE LOCKOUT
COAST CLUTCH

REVERSE LOCKOUT
COAST CLUTCH
FORWARD CLUTCH

REVERSE LOCKOUT
COAST CLUTCH

FEED LIMIT

1-2 SIGNAL

D432
2-3 SIGNAL

123 REGULATED

LINE

LINE SAFETY MODE

21

#6
19

15

19c

21

20b

31

#5

21c

31

17
21b

21a

#7

42a

16

19b

20d

20c

#4

19a

2f

2h

X-5

22f
43b

OVERDRIVE CL FD 2
OVERDRIVE CL FD 1
RLO

15e
22d

123 REGULATED
123 BRAKING

123
123
2345

32

18
15f

#8

2345
38d

27

17c

45
123
38

#3

38b

22g

14a

#2

38c

SPACER PLATE (307)

17b

45

45

19d

R N D 4 3 2

D432

LINE

EX

REV

32a

LINE

15

LOW AND REV CL OR RLO


REVERSE LOCKOUT
SECOND COAST CLUTCH

48b

LINE SAFETY MODE

COAST CLUTCH
FORWARD CLUTCH

2-3 SIGNAL

34a

EX

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
123
123

1-2 SIGNAL

32
2-3 SIGNAL

1-2 SIGNAL

EX

#10

D432
FEED LIMIT

45
43c

123 REGULATED
23 REGULATED

44c

44f

OFF

4-5 SHIFT
SOLENOID
VALVE
N/C

(C)

45

32 SM/FDL
2345
LOW AND REVERSE CL

(B)

EX

45

EX

REVERSE

FDL

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

EX

EX

2345

345
2345

EX
EX

23 REGULATED

10h

FDL 44

22e

123
FEED LIMIT
32 SAFETY MODE

INTERMEDIATE CL

10
28a

COAST CLUTCH FEED


OVERDRIVE CLUTCH FEED 2
45

LINE
1-2 SIGNAL

LINE

#11
22a

23

19i

19g

26b

36a

25a

25b

24c

15a

13a

38a

36b

37b

D432

FDL

EX

33d

MANUAL VALVE

123
D432
37a

30a

30b

2d
30c

2e

54e

2m
30d

FDL

EX

FDL
EX

33e

32

LINE

23

OFF

4-5 SHIFT VLV CNTRL

GASKET (303)

FORWARD CLUTCH
COAST CLUTCH

SUCTION

123 REGULATED
123 BRAKING
345

TCC SIGNAL
REVERSE LOCKOUT
TCC SIGNAL
123 REGULATED
123 BRAKING
123 REGULATED
345

345

DIRECT CLUTCH
345
45
LINE SAFETY MODE

REGULATED APPLY
LINE

24b

TCC SIGNAL

12

Figure 96

(A)

35a
35b

EX
SECOND COAST CLUTCH
OVERDRIVE CLUTCH FEED 1
2345
2345
23 REGULATED
4-5 SIGNAL

LOW PRESSURE

GASKET (305)
BOTTOM CHANNEL PLATE (304)

45

FLUID FILTER
ASSEMBLY
(59)

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED

EX
EX

EX

EX

REGULATED APPLY

TCC SIGNAL
36f

36d

36e

23b

19

OVERDRIVE CLUTCH FEED 1

FLUID
PAN
(62)

10g

2345

REV

REAR CONTROL VALVE BODY (310)


GASKET (309)

345

REVERSE LOCKOUT
LINE
REGULATED APPLY
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2

THROTTLE SIGNAL

40a

26

44b

24

2345

44a
10f
27a

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH
23 REGULATED

345

345

X-4

44e
44d
28b

FDL

345
45

123
D432
345
DIRECT CLUTCH

EX

EX

345

23a

2345 OR REVERSE

FILTER
(308)

25

EX

EX

MEMORY
FEED LIMIT
LINE
EX

EX

EX

2345 OR REVERSE

EX

2345 OR REVERSE

REVERSE CLUTCH

REVERSE LOCKOUT

TCC SIGNAL

345

REVERSE CLUTCH

PRESSURES
INTAKE & DECREASE (SUCTION)
CONVERTER & LUBE
MAINLINE
REGULATED LINE
SOLENOID SIGNAL
ACCUMULATOR
FEED LIMIT
THROTTLE SIGNAL

15

17a

21

COAST CLUTCH

FORWARD CLUTCH

TCC PWM
SOLENOID
VALVE
N/C

23c

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

LINE

(214)

16a

REVERSE CLUTCH

32 SAFETY MODE

21

1
FLUID
PUMP
COVER
(202)

X-2

24a

REGULATED APPLY

SUCTION
2

LINE

16

#1

EX

FLUID PUMP
SCREEN
ASSEMBLY
(213)

16

25c
25e

2-3 SIGNAL
FEED LIMIT

REVERSE
LOCKOUT
VALVE

LINE

TCC REGULATOR VALVE

36c

345

15c

REVERSE LOCKOUT
LINE

CONVERTER
HOUSING
(224)

15b

15d

345

TCC
ENABLE
VALVE

FEED LIMIT VALVE

23

13

OVERDRIVE CLUTCH FEED 1


OVERDRIVE CLUTCH FEED 2

TCC SIGNAL
REGULATED APPLY

LINE

APPLY

FEED LIMIT
FEED LIMIT

10c
10

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

TCC
CONTROL
VALVE

10a

25d

1-2 SHIFT
SOLENOID
VALVE
N/C

1-2 SHIFT CONTROL VALVE

D432

20

FD LIMIT

RLO

CNTRL 3-4 SHIFT

10d

THROTTLE SIGNAL

RELEASE
TO COOLER

CONVERTER FEED

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REVERSE CLUTCH
FDL
2-3 SIGNAL
FDL
FEED LIMIT
1-2 SIGNAL

TCC SIGNAL

2-3 SIGNAL

D432

19f

19e

2-3 SHIFT VALVE

19j

DIRECT CLUTCH

14

LINE SAFETY MODE

1-2 SIGNAL

19h

33a

2345

123 REGULATED

10b

D432

SECOND CLUTCH

1-2 SHIFT VALVE

SAFETY MODE

28c

CONVERTER FDL
CONVERTER FEED

FORWARD CLUTCH

DECREASE

LINE

COAST CLUTCH

LINE

SECOND CLUTCH
D432

PRESSURE
CONTROL
SOLENOID
VALVE

EX

11a

EX

FILTER
(312)

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

11b

7a

PRESSURE
RELIEF
BALL
VALVE

EX

REVERSE CLUTCH

54g

54d

54b

MEMORY PILOT

DIRECT CLUTCH

46

20a

APPLY

36

12a

OVERDRIVE CL FD 1
OVERDRIVE CL FD 2
345
FEED LIMIT
LINE

EX

46

47b

32
1-2 SIGNAL
32 SAFETY MODE

DIRECT CLUTCH

DIRECT CLUTCH

30

27c

FEED LIMIT
MEMORY
MEMORY PILOT

EX

47a

AIR
BLEED
(233)

X-3

ACCUM

D432

32
32 SAFETY MODE

10e

AIR
BLEED
(203)

AIR
BLEED
(203)

21

SECOND CLUTCH

LINE

2b

ACCUMULATOR
INTERMEDIATE CLUTCH

32

42b

LINE
SECOND CLUTCH

19

32 SAFETY MODE

43a

INTERMEDIATE CLUTCH

ACCUM

DIRECT CLUTCH

37d

LINE

COAST CLUTCH

CASE (24)

CONVERTER FEED
DECREASE
PRESS REG VALVE

EX

SECOND
CLUTCH
ACCUMULATOR

OVERDRIVE CLUTCH FEED 2

40b

27b

AIR
BLEED
(203)

EX

INTERMEDIATE
CLUTCH
ACCUMULATOR

31

BOOST VALVE

OVERDRIVE CLUTCH FEED 1

ACCUMULATOR HOUSING (333)

COAST CLUTCH
123
123

39c
39b

LUBE

THROTTLE SIGNAL

OVERDRIVE CLUTCH FEED 2

41

32

EX

ACCUMULATOR

40c

DIRECT CLUTCH

FLUID
PRESSURE
TEST PLUG
(40)

54c

#12

COAST CLUTCH

AIR
BLEED
(233)

ACCUMULATOR

54a

5
2c

TO COOLER

LINE

OVERDRIVE
CLUTCH
ACCUMULATOR

ACCUM
OVERDRIVE CL FD 2 40d

2a

REVERSE CLUTCH
FORWARD CLUTCH

AIR
BLEED
(203)

EX

DIRECT
CLUTCH
ACCUMULATOR

GASKET (309)
FRONT CONTROL VALVE BODY (311)

ACCUMULATOR HOUSING (328)

EX

37c

COOLER

SPACER PLATE (307)

SECOND CLUTCH
REVERSE LOCKOUT

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (323)

DIRECT CL

OVERDRIVE CLUTCH

CO

R
OLE

BOTTOM CHANNEL PLATE (304)


GASKET (305)

LOW AND REV CL OR RLO


SECOND COAST CLUTCH

CENTER
SUPPORT
ASSEMBLY
(510535)

54f

APPLY

GASKET (303)

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH
LUBE

TO

100

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (317)
CASE (24)
TOP CHANNEL PLATE (301)

38e

LUBE

2-3 SIGNAL

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH

E
LUB

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

INTERMEDIATE CLUTCH

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

7b

NOTE:
PASSAGES AND
COMPONENTS
MARKED WITH
ARE USED FOR
THE 5L40-E ONLY

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

RELEASE

WWW.ALL-TRANS.BY

TORQUE
CONVERTER
ASSEMBLY
(1)

35d

OVERDRIVE RANGE FIFTH GEAR

OVERDRIVE RANGE FIFTH GEAR


(Torque Converter Clutch Released)

WWW.ALL-TRANS.BY

NO FIFTH GEAR

Overdrive Clutch Piston (487)


Leaking
Cracked or jammed

#12 Ball Check Valve


Stuck
Missing

4-5 Shift Solenoid Valve (376)


Stuck On

4-5 Shift Valve (374)


Stuck

4-5 Shift Control Valve (375)


Stuck

Overdrive Accumulator
Leaking

Fluid Passage Sleeve (39)


Leaking

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF OFF OFF APPLIED

APPLIED

APPLIED

APPLIED

APPLIED

LD = LOCKED IN DRIVE

100A

OVERDRIVE RANGE FIFTH GEAR


(Torque Converter Clutch Released)

WWW.ALL-TRANS.BY

PASSAGES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54

SUCTION
LINE
DECREASE
CONVERTER FEED
RELEASE
APPLY
REGULATED APPLY
TO COOLER
LUBE
FEED LIMIT
FILTERED FEED LIMIT
THROTTLE SIGNAL
LINE SAFETY MODE
REVERSE
REVERSE LOCK OUT (RLO)
REVERSE CLUTCH
LOW AND REVERSE CLUTCH
LOW AND REVERSE CLUTCH OR RLO
D432
123
FORWARD CLUTCH
2345
2345 OR REVERSE
TCC SIGNAL
123 REGULATED
123 BRAKING
1-2 SIGNAL
2-3 SIGNAL
4-5 SIGNAL
SECOND CLUTCH
COAST CLUTCH FEED
COAST CLUTCH
23 REGULATED
SECOND COAST CLUTCH
INTERMEDIATE CLUTCH
345
DIRECT CLUTCH
45
OVERDRIVE CLUTCH FEED 1
OVERDRIVE CLUTCH FEED 2
OVERDRIVE CLUTCH
32
32 SAFETY MODE
FDL
32 SAFETY MODE/FDL
MEMORY PILOT
MEMORY
EXHAUST
OIL RESERVOIR
TORQUE CONVERTER SEAL DRAINBACK
VENT
VOID
CONVERTER FDL
ACCUMULATOR

COMPONENTS ( )
(36)
(40)
(203)
(213)
(214)
(232)
(233)
(306)
(308)
(312)

100B

TRANSMISSION FLUID LEVEL HOLE PLUG


TRANSMISSION FLUID PRESSURE TEST PLUG
CHECK VALVE RETAINER AND BALL ASSEMBLY
TRANSMISSION FLUID PUMP SCREEN ASSEMBLY
BRASS ORIFICE INSERT
ORIFICE SLEEVE
ORIFICE CUP PLUG
CONTROL VALVE BODY BALL CHECK VALVE
(#1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
TCC PWM SOLENOID VALVE FILTER ASSEMBLY
PRESSURE CONTROL SOLENOID VALVE
FILTER ASSEMBLY

OVERDRIVE RANGE FIFTH GEAR

(Torque Converter Clutch Released)

WWW.ALL-TRANS.BY

(229)

51

4
53
48
7

(203)

52

FLUID PUMP COVER (202)


(Case Side)

48

48

48

12

27

48

24

21

48
32

10

48
48

FRONT

41

42

24
48

28

21

36
41

43
2

10
42

19
19

43

35 15
13

52

41

28

52

32

52

34

52

34

30

48

48

48
28

48

48
48

18
10

21

48

20
52

2
48

48
21

TOP CHANNEL PLATE (301)


(Bottom Channel Plate Side)

18
48
10

42

17

48

48

34
27

43
28

#10
10

BOTTOM CHANNEL PLATE (304)


(Top Channel Plate Side)

Figure 97

19

18

48
10 42

13

28
2

FOLDOUT 101

54b

20
19

36

37
54

47
52

47
10
2

46
13

52

37

36
40

36

52

52
54

48

48

52

40

42
43

39

38

FRONT CONTROL VALVE BODY (311)


(Bottom Channel Plate Side)

40d
54d
2c/54c

19h
15a

22g/23

48
10

#9

#8

48
30b

40a

22b
22d 22c

28

32a

22f
24

20

35a
22e

18

22

14

54f
30a
33a

25
26
25

35d

22a

24c
36a

48
30

19

15

19
14

52

19f

19e

38c

21c/31 27
20c
17
2h 20d

14

35c

25c

48

52
25

21

25b
19

38b

BOTTOM CHANNEL PLATE (304)


(Control Valve Body Side)

10

TOP CHANNEL PLATE (301)


(Case Side)

48

45

37c

47a

19i

38e

21

15

#6
43

44

38d

52

30

23

11b
10c

27c/46
10e

8
19j
2b
36c 25
13a
23a
37a
40c/41
40b
39c/41
36e
42b 52
36d 36b
43a
39b
38a
48 5
19g

14a/23 26b

#5

52

13
19

28

15

#4

34

27

27
52

20a

52
28

48

10

36f 26

25a

19

52

44
2
10

21

48
48

22

32

19

15
52

35

38

28

#11

38

20

35

X-5

24

19

52

38
52

31

30d

20b
26a

2m/54g

SPACER PLATE (307)


(Bottom Channel Plate Side)

32

38

52

15

19
2

10
48

52

44

34

52
2

10
48

48

27

43

44
10

28
48
10

52

30

33
17

52

30
33
54
25
25
17
30

28

33
13

35

22

44

26

21

42

35
22
35
39

20
20

22

36

52

35

40
2d/54e
25d
25e
17a 3
30c

35b
44e
28b 52
39a
#7
16
(Spring)
23 33e
52
2e
13b 33d
33c

21b/31
19c/21
44a 2
15e 33b 22
17b
19d/21
34a
15
21a
48a
27a 44b 10f
15f/18
17c/18
29 48b
44d
19b/21 19a 10i
43b
2f

43c/45
9
28a
11
42a
44c 10g
10
48
44f/45

48
10h

52

18

2
52

10
12

19

42 52

52 43

38
52 26 32

33

17

13

30

52

52

#3

22
22

20 21

15

23

36

25
30

27

23b

40
25

22 19

52

27b

10

48

12a
4
52
28c
48
47b 2a/54a

10d

38

39

2g

7b

FILTER
(308)

23

#2

35

38

15

35

30

X-1

19
15

22
35

19

48

19

24

7a

X-3

41

37b
10a

24a
48

X-4

36

10
48

40

48

36

24b

37
2

2
15b
48 11a/10b

23c

48
52

36
15

13

37d
23

48

16a

48

24

37

27
13

FRONT

19

19

#12

48

FRONT

2
41

13

11
12

48

20

42

20

43

10

27

47

12

27

48

48

27

48
48

24
7

36

24

48

48

48

20

13
48

48

16

37

48
48

48

16

48

28

37

FILTER
(312)

15c/16

37
7

32

21

48

48
15d/16

48

16

15

24

12
28

52

48
16

48
37

23
48

11

10

16

15

37

48

48

48

ARE USED FOR


23

48

16

48

48

FRONT

48

PASSAGES MARKED WITH


THE 5L40-E ONLY

X-2

48
32

CASE (24)
(Top Channel Plate Side)

EXHAUST FLUID NOT SHOWN


#1

16

(36)

DUAL PURPOSE PASSAGES HAVE


CHANNEL PLATE SIDE NUMBERS LISTED FIRST

FRONT

52

52

32

21

52

FRONT

12 (203)

TORQUE CONVERTER HOUSING (227)


(Fluid Pump Cover Side)

16

(203)

32

52

16

37

(203)

INDICATES BOLT HOLES

NON FUNCTIONAL HOLES HAVE BEEN


REMOVED FROM COMPONENT DRAWINGS
TO SIMPLIFY TRACING FLUID FLOW.

52

21

52
52

37

12

24

52
52

FRONT

NOTE:

32

15

18

CASE (24)
(Fluid Pump Cover Side)

12
21

52

52

34

30

52

48

52

48

32
9

37 16 21

52

48

37

16

24

52

48

52

(40)

12

48

35

FLUID PUMP COVER (202)


(Torque Converter Housing Side)

16

52

30

21

52

52

32

48

(213)
1

41

16

12

50

24
4
53
48
7

2/21

(214) 21

37

32

52

24

16

(233)
37

2
12

52

24
48

2
4

48

52

7
48

52

48
53

52

52

52

52

50

52

48

21

24

24

37

52

12

51

32

51

16

2
12

48

32 5
21 9

16

52

48

FRONT

53
5

31

52

52

52

TRANSMISSION
VENT
ASSEMBLY

48

(232)

48

48
4

(231)

51

(233)

44

48

48

REAR CONTROL VALVE BODY (310)


(Bottom Channel Plate Side)

(Torque Converter Clutch Applied)

FORWARD CLUTCH
COAST CLUTCH
LUBE

35c

45

48

29

EX

48a

2345
2345
2345
32 SM

22
33c

EX
EX

33b

#9

EX
EX
EX

22b

OFF

11
10i

43

LINE

13b
13

18

2345

LOW AND REV CL OR RLO

2-3 SIGNAL

EX

39a

22c

22

X-1

28
26a

32 SM

LINE

123 BRAKING
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2
45
OVERDRIVE CLUTCH FEED 1

123
D432

1-2 SIGNAL
123
FEED LIMIT

32 SAFETY MODE

32 SAFETY MODE
REVERSE LOCKOUT
D432

32

D432
32

2-3 SIGNAL

2-3 SIGNAL

TOP CHANNEL PLATE (301)


CASE (24)

REVERSE LOCKOUT
COAST CLUTCH

REVERSE LOCKOUT
COAST CLUTCH
FORWARD CLUTCH

REVERSE LOCKOUT
COAST CLUTCH

FEED LIMIT

1-2 SIGNAL

D432
2-3 SIGNAL

123 REGULATED

LINE

LINE SAFETY MODE

21

#6
19

15

19c

21

20b

31

#5

21c

31

17
21b

21a

#7

42a

16

19b

20d

20c

#4

19a

2f

2h

X-5

22f
43b

OVERDRIVE CL FD 2
OVERDRIVE CL FD 1
RLO

15e
22d

123 REGULATED
123 BRAKING

123
123
2345

32

18
15f

#8

2345
38d

27

17c

45
123
38

#3

38b

22g

14a

#2

38c

SPACER PLATE (307)

17b

45

45

19d

R N D 4 3 2

D432

LINE

EX

REV

32a

LINE

15

LOW AND REV CL OR RLO


REVERSE LOCKOUT
SECOND COAST CLUTCH

48b

LINE SAFETY MODE

COAST CLUTCH
FORWARD CLUTCH

2-3 SIGNAL

34a

EX

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
123
123

1-2 SIGNAL

32
2-3 SIGNAL

1-2 SIGNAL

EX

#10

D432
FEED LIMIT

45
43c

123 REGULATED
23 REGULATED

44c

44f

OFF

4-5 SHIFT
SOLENOID
VALVE
N/C

(C)

45

32 SM/FDL
2345
LOW AND REVERSE CL

(B)

EX

45

EX

REVERSE

FDL

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

EX

EX

2345

345
2345

EX
EX

23 REGULATED

10h

FDL 44

22e

123
FEED LIMIT
32 SAFETY MODE

INTERMEDIATE CL

10
28a

COAST CLUTCH FEED


OVERDRIVE CLUTCH FEED 2
45

LINE
1-2 SIGNAL

LINE

#11
22a

23

19i

19g

26b

36a

25a

25b

24c

15a

13a

38a

36b

37b

D432

FDL

EX

33d

MANUAL VALVE

123
D432
37a

30a

30b

2d
30c

2e

54e

2m
30d

FDL

EX

FDL
EX

33e

32

LINE

23

OFF

4-5 SHIFT VLV CNTRL

GASKET (303)

FORWARD CLUTCH
COAST CLUTCH

SUCTION

123 REGULATED
123 BRAKING
345

TCC SIGNAL
REVERSE LOCKOUT
TCC SIGNAL
123 REGULATED
123 BRAKING
123 REGULATED
345

345

DIRECT CLUTCH
345
45
LINE SAFETY MODE

REGULATED APPLY
LINE

24b

TCC SIGNAL

12

Figure 98

(A)

35a
35b

EX
SECOND COAST CLUTCH
OVERDRIVE CLUTCH FEED 1
2345
2345
23 REGULATED
4-5 SIGNAL

LOW PRESSURE

GASKET (305)
BOTTOM CHANNEL PLATE (304)

45

FLUID FILTER
ASSEMBLY
(59)

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED

EX
EX

EX

EX

REGULATED APPLY

TCC SIGNAL
36f

36d

36e

23b

19

OVERDRIVE CLUTCH FEED 1

FLUID
PAN
(62)

10g

2345

REV

REAR CONTROL VALVE BODY (310)


GASKET (309)

345

REVERSE LOCKOUT
LINE
REGULATED APPLY
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2

THROTTLE SIGNAL

40a

26

44b

24

2345

44a
10f
27a

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH
23 REGULATED

345

345

X-4

44e
44d
28b

FDL

345
45

123
D432
345
DIRECT CLUTCH

EX

EX

345

23a

2345 OR REVERSE

FILTER
(308)

25

EX

EX

MEMORY
FEED LIMIT
LINE
EX

EX

EX

2345 OR REVERSE

EX

2345 OR REVERSE

REVERSE CLUTCH

REVERSE LOCKOUT

TCC SIGNAL

345

REVERSE CLUTCH

PRESSURES
INTAKE & DECREASE (SUCTION)
CONVERTER & LUBE
MAINLINE
REGULATED LINE
SOLENOID SIGNAL
ACCUMULATOR
FEED LIMIT
THROTTLE SIGNAL

15

17a

21

COAST CLUTCH

FORWARD CLUTCH

TCC PWM
SOLENOID
VALVE
N/C

23c

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

LINE

(214)

16a

REVERSE CLUTCH

32 SAFETY MODE

21

1
FLUID
PUMP
COVER
(202)

X-2

24a

REGULATED APPLY

SUCTION
2

LINE

16

#1

EX

FLUID PUMP
SCREEN
ASSEMBLY
(213)

16

25c
25e

2-3 SIGNAL
FEED LIMIT

REVERSE
LOCKOUT
VALVE

LINE

TCC REGULATOR VALVE

36c

345

15c

REVERSE LOCKOUT
LINE

CONVERTER
HOUSING
(224)

15b

15d

345

TCC
ENABLE
VALVE

FEED LIMIT VALVE

23

13

OVERDRIVE CLUTCH FEED 1


OVERDRIVE CLUTCH FEED 2

TCC SIGNAL
REGULATED APPLY

LINE

APPLY

FEED LIMIT
FEED LIMIT

10c
10

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

TCC
CONTROL
VALVE

10a

25d

1-2 SHIFT
SOLENOID
VALVE
N/C

1-2 SHIFT CONTROL VALVE

D432

20

FD LIMIT

RLO

CNTRL 3-4 SHIFT

10d

THROTTLE SIGNAL

RELEASE
TO COOLER

CONVERTER FEED

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REVERSE CLUTCH
FDL
2-3 SIGNAL
FDL
FEED LIMIT
1-2 SIGNAL

TCC SIGNAL

2-3 SIGNAL

D432

19f

19e

2-3 SHIFT VALVE

19j

DIRECT CLUTCH

14

LINE SAFETY MODE

1-2 SIGNAL

19h

33a

2345

123 REGULATED

10b

D432

SECOND CLUTCH

1-2 SHIFT VALVE

SAFETY MODE

28c

CONVERTER FDL
CONVERTER FEED

FORWARD CLUTCH

DECREASE

LINE

COAST CLUTCH

LINE

SECOND CLUTCH
D432

PRESSURE
CONTROL
SOLENOID
VALVE

EX

11a

EX

FILTER
(312)

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

11b

7a

PRESSURE
RELIEF
BALL
VALVE

EX

REVERSE CLUTCH

54g

54d

54b

MEMORY PILOT

DIRECT CLUTCH

46

20a

APPLY

36

12a

OVERDRIVE CL FD 1
OVERDRIVE CL FD 2
345
FEED LIMIT
LINE

EX

46

47b

32
1-2 SIGNAL
32 SAFETY MODE

DIRECT CLUTCH

DIRECT CLUTCH

30

27c

FEED LIMIT
MEMORY
MEMORY PILOT

EX

47a

AIR
BLEED
(233)

X-3

ACCUM

D432

32
32 SAFETY MODE

10e

AIR
BLEED
(203)

AIR
BLEED
(203)

21

SECOND CLUTCH

LINE

2b

ACCUMULATOR
INTERMEDIATE CLUTCH

32

42b

LINE
SECOND CLUTCH

19

32 SAFETY MODE

43a

INTERMEDIATE CLUTCH

ACCUM

DIRECT CLUTCH

37d

LINE

COAST CLUTCH

CASE (24)

CONVERTER FEED
DECREASE
PRESS REG VALVE

EX

SECOND
CLUTCH
ACCUMULATOR

OVERDRIVE CLUTCH FEED 2

40b

27b

AIR
BLEED
(203)

EX

INTERMEDIATE
CLUTCH
ACCUMULATOR

31

BOOST VALVE

OVERDRIVE CLUTCH FEED 1

ACCUMULATOR HOUSING (333)

COAST CLUTCH
123
123

39c
39b

LUBE

THROTTLE SIGNAL

OVERDRIVE CLUTCH FEED 2

41

32

EX

ACCUMULATOR

40c

DIRECT CLUTCH

FLUID
PRESSURE
TEST PLUG
(40)

54c

#12

COAST CLUTCH

AIR
BLEED
(233)

ACCUMULATOR

54a

5
2c

TO COOLER

LINE

OVERDRIVE
CLUTCH
ACCUMULATOR

ACCUM
OVERDRIVE CL FD 2 40d

2a

REVERSE CLUTCH
FORWARD CLUTCH

AIR
BLEED
(203)

EX

DIRECT
CLUTCH
ACCUMULATOR

GASKET (309)
FRONT CONTROL VALVE BODY (311)

ACCUMULATOR HOUSING (328)

EX

37c

COOLER

SPACER PLATE (307)

SECOND CLUTCH
REVERSE LOCKOUT

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (323)

DIRECT CL

OVERDRIVE CLUTCH

CO

R
OLE

BOTTOM CHANNEL PLATE (304)


GASKET (305)

LOW AND REV CL OR RLO


SECOND COAST CLUTCH

CENTER
SUPPORT
ASSEMBLY
(510535)

54f

APPLY

GASKET (303)

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH
LUBE

TO

102

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (317)
CASE (24)
TOP CHANNEL PLATE (301)

38e

LUBE

2-3 SIGNAL

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH

E
LUB

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

INTERMEDIATE CLUTCH

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

7b

NOTE:
PASSAGES AND
COMPONENTS
MARKED WITH
ARE USED FOR
THE 5L40-E ONLY

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

RELEASE

WWW.ALL-TRANS.BY

TORQUE
CONVERTER
ASSEMBLY
(1)

35d

OVERDRIVE RANGE FIFTH GEAR

OVERDRIVE RANGE FIFTH GEAR


(Torque Converter Clutch Applied)

WWW.ALL-TRANS.BY

The torque converter clutch (TCC) applies during Fifth gear operation
when the transmission control module (TCM) receives the
appropriate input signals to energize (turn ON) the Torque Converter
Clutch Pulse Width Modulated (TCC PWM) solenoid valve.

NO TCC APPLY

TCC PWM Solenoid Valve (352)

Stuck Off
Leaking
No voltage to the solenoid
Poor connection

TCC Regulator Apply Valve (348)


Stuck

Input Shaft Fluid Seal (432)


Leaking

TCC Control Valve (235)


Stuck in Off position

TCC Enable Valve (237)


Stuck in Off position

#2 Ball Check Valve


Stuck
Missing
TCC STUCK ON

TCC PWM Solenoid Valve (352)


Stuck On

TCC Regulator Apply Valve (348)


Stuck

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF OFF OFF APPLIED

APPLIED

APPLIED

APPLIED

APPLIED

LD = LOCKED IN DRIVE

102A

OVERDRIVE RANGE FIFTH GEAR


(Torque Converter Clutch Applied)

WWW.ALL-TRANS.BY

PASSAGES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54

SUCTION
LINE
DECREASE
CONVERTER FEED
RELEASE
APPLY
REGULATED APPLY
TO COOLER
LUBE
FEED LIMIT
FILTERED FEED LIMIT
THROTTLE SIGNAL
LINE SAFETY MODE
REVERSE
REVERSE LOCK OUT (RLO)
REVERSE CLUTCH
LOW AND REVERSE CLUTCH
LOW AND REVERSE CLUTCH OR RLO
D432
123
FORWARD CLUTCH
2345
2345 OR REVERSE
TCC SIGNAL
123 REGULATED
123 BRAKING
1-2 SIGNAL
2-3 SIGNAL
4-5 SIGNAL
SECOND CLUTCH
COAST CLUTCH FEED
COAST CLUTCH
23 REGULATED
SECOND COAST CLUTCH
INTERMEDIATE CLUTCH
345
DIRECT CLUTCH
45
OVERDRIVE CLUTCH FEED 1
OVERDRIVE CLUTCH FEED 2
OVERDRIVE CLUTCH
32
32 SAFETY MODE
FDL
32 SAFETY MODE/FDL
MEMORY PILOT
MEMORY
EXHAUST
OIL RESERVOIR
TORQUE CONVERTER SEAL DRAINBACK
VENT
VOID
CONVERTER FDL
ACCUMULATOR

COMPONENTS ( )
(36)
(40)
(203)
(213)
(214)
(232)
(233)
(306)
(308)
(312)

102B

TRANSMISSION FLUID LEVEL HOLE PLUG


TRANSMISSION FLUID PRESSURE TEST PLUG
CHECK VALVE RETAINER AND BALL ASSEMBLY
TRANSMISSION FLUID PUMP SCREEN ASSEMBLY
BRASS ORIFICE INSERT
ORIFICE SLEEVE
ORIFICE CUP PLUG
CONTROL VALVE BODY BALL CHECK VALVE
(#1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
TCC PWM SOLENOID VALVE FILTER ASSEMBLY
PRESSURE CONTROL SOLENOID VALVE
FILTER ASSEMBLY

OVERDRIVE RANGE FIFTH GEAR

(Torque Converter Clutch Applied)

WWW.ALL-TRANS.BY

(229)

51

4
53
48
7

(203)

FLUID PUMP COVER (202)


(Case Side)
#1
48
48
48

24
48

12

27

48

24

21

48
32

10

48
48

FRONT

41

42

24
48

28

21

36

42

19
19

43

35 15
13

52

41

28

52

32

52

34

52

34

30

48

48

48
28

48

48
48

18
10

21

48

20
52

2
48

48
21

TOP CHANNEL PLATE (301)


(Bottom Channel Plate Side)

18
48
10

42

17

48

48

34
27

43
28

#10
10

BOTTOM CHANNEL PLATE (304)


(Top Channel Plate Side)

Figure 99

FOLDOUT 103

22g/23
38b

19

18

48
10 42

13

28
2

48
10

#9

#8

BOTTOM CHANNEL PLATE (304)


(Control Valve Body Side)

10

TOP CHANNEL PLATE (301)


(Case Side)

48

45

54b

20
19

36

37
54

47
52

47
10
2

46
13

52

37

36
40

36

52

52
54

48

48

52

40

42
43

39

38

FRONT CONTROL VALVE BODY (311)


(Bottom Channel Plate Side)

40d
54d
2c/54c

19h
15a

48
30b

40a

22b
22d 22c

28

32a

22f
24

20

35a
22e

18

22

14

54f
30a
33a

25
26
25

35d

22a

24c
36a

48
30

19

15

19
14

52

19f

19e

38c

21c/31 27
20c
17
2h 20d

14

35c

25c

48

52
25

21

25b
19

38e

21

15

#6
43

44

38d

52

30

37c

47a

19i

14a/23 26b

#5

52

13
19

28

15

#4

34

27

27

23

11b
10c

27c/46
10e

8
19j
2b
36c 25
13a
23a
37a
40c/41
40b
39c/41
36e
42b 52
36d 36b
43a
39b
38a
48 5
19g

25a

19

52

44
2
10

21

48
48

22

32

19

15
52

35

38

28

#11

38

20

35

X-5

24

19

52

38
52

31

30d

20b
26a

2m/54g

SPACER PLATE (307)


(Bottom Channel Plate Side)

32

38

52

15

19
2

10
48

52

44

34

52
2

10
48

48

27

43

44
10

28
48
10

52

30

33
17

52

30
33
54
25
25
17
30

28

33
13

35

22

44

26

21

42

35
22
35
39

20
20

22

36

52

35

40
2d/54e
25d
25e
17a 3
30c

35b
44e
28b 52
39a
#7
16
(Spring)
23 33e
52
2e
13b 33d
33c

21b/31
19c/21
44a 2
15e 33b 22
17b
19d/21
34a
15
21a
48a
27a 44b 10f
15f/18
17c/18
29 48b
44d
19b/21 19a 10i
43b
2f

43c/45
9
28a
11
42a
44c 10g
10
48
44f/45

48
10h

52

18

2
52

10
12

19

38
52 26 32

33

17

13
42 52

52 43

#3

22
22

30

30

52

23

36

25

20 21

15

40
25

22 19

52
27

52

39

10
52

20a

52
28

48

48

36f 26

38

#2

35

38

23b

15

35

30

X-1

19
15

22
35

19

48

19

24

27b

10
12

12a
4
52
28c
48
47b 2a/54a

10d

X-3

41

2g

7b

FILTER
(308)

23

48

36

7a
6

X-4

36

10
48

40

37b
10a

24a
48

37

2
15b
48 11a/10b

23c
24b

41

43

13

48
52

36

10

48

16a
37d

23

15

48

48

24

37

27
13

FRONT

19

19

11

FRONT

2
41

13
#12

48
48

24

48

10
20

42

20

43

27

47

12

27

48

48

24

FILTER
(312)

15c/16

36

37

27

48
15d/16

48

48

48

48

20

13
48

48

16

37

48
48

48

16

48

28

15

37
7

32

21

48

48

11

52

48
16

48
37

23

16

12
28

16

15

2
10

48

37

48

ARE USED FOR


23

48

16

48

48

FRONT

48

PASSAGES MARKED WITH


THE 5L40-E ONLY

X-2

48
16

CASE (24)
(Top Channel Plate Side)

EXHAUST FLUID NOT SHOWN

52

(36)

DUAL PURPOSE PASSAGES HAVE


CHANNEL PLATE SIDE NUMBERS LISTED FIRST

FRONT

32

21

52

12 (203)

52

FRONT

TORQUE CONVERTER HOUSING (227)


(Fluid Pump Cover Side)

16

(203)

32

52

INDICATES BOLT HOLES

52

52
16

52

NON FUNCTIONAL HOLES HAVE BEEN


REMOVED FROM COMPONENT DRAWINGS
TO SIMPLIFY TRACING FLUID FLOW.

52

21

37

(203)

52
52

37

32

NOTE:

24

12

32

21

52

12

52

52

15

18

CASE (24)
(Fluid Pump Cover Side)

37

48

52

48

34

30

52

48

32
9

37 16 21

16

24

48

52

(40)

12

48

52

16

35

FRONT

FLUID PUMP COVER (202)


(Torque Converter Housing Side)

41
52

30

21

52

52

48

(213)
1

50

24
4
53
48
7

32

2/21

16

12

32

(214) 21

37
16

52

2
12

24

(233)
37

52

24
48

2
4

52

7
48

48

52

52

5
8

52

21

52

52

48
53

52

48

50

37

24

24

12

51

32

52

51

16

2
12

48

32 5
21 9

48

52

16

FRONT

53
5

31

52

52

52

TRANSMISSION
VENT
ASSEMBLY

48

(232)

48

48
4

(231)

51

(233)

44

48

48

REAR CONTROL VALVE BODY (310)


(Bottom Channel Plate Side)

MANUAL FOURTH FOURTH GEAR

(from Overdrive Range Fifth Gear)

FORWARD CLUTCH
COAST CLUTCH
LUBE

30a

30b
35c

30c

2e

54e

29

EX

48b

2345
2345
2345
32 SM

22
33c

EX
EX

33b

#9

ON

11
10i

43

LINE

13b
13

18

2345

LOW AND REV CL OR RLO

2-3 SIGNAL

EX

39a

22c

22

X-1

28
26a

32 SM

LINE

123 BRAKING
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2
45
OVERDRIVE CLUTCH FEED 1

123
D432

32

1-2 SIGNAL
123
FEED LIMIT

32 SAFETY MODE

32 SAFETY MODE
REVERSE LOCKOUT
D432

32

D432
32

2-3 SIGNAL

2-3 SIGNAL

TOP CHANNEL PLATE (301)


CASE (24)

REVERSE LOCKOUT
COAST CLUTCH

REVERSE LOCKOUT
COAST CLUTCH
FORWARD CLUTCH

REVERSE LOCKOUT
COAST CLUTCH

1-2 SIGNAL

D432
FEED LIMIT

21

123 REGULATED

LINE

OVERDRIVE CL FD 2
OVERDRIVE CL FD 1
RLO

19

#6

19c

21

15
19d

20b

31

#5

21c

31

17
21b

21a

#7

42a

16

19b

20d

20c

#4

22f

123 REGULATED
123 BRAKING

123
123
2345

15e
22d
43b

19a

2f

2h

X-5

38d

27

18
15f

#8

2345
38

38c

#3

38b

22g

14a

#2

17c

45
123

23

19i

19g

26b

SPACER PLATE (307)

17b

45

45

32

D432

LINE

EX

REV

32a

LINE

15

EX
EX
EX

22b

LINE SAFETY MODE

COAST CLUTCH
FORWARD CLUTCH

2-3 SIGNAL

34a

EX

(C)

1-2 SIGNAL

32
2-3 SIGNAL

LOW AND REV CL OR RLO


REVERSE LOCKOUT
SECOND COAST CLUTCH

23 REGULATED

45

48
48a

1-2 SIGNAL

EX

#10

D432
FEED LIMIT

45
43c

OFF

4-5 SHIFT
SOLENOID
VALVE
N/C

EX

45

EX

REVERSE

44c

44f

123 REGULATED
23 REGULATED

(B)

EX

EX

2345

345
2345

EX
EX

123 REGULATED
123 BRAKING
345

FDL

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

45

22e

123
FEED LIMIT
32 SAFETY MODE

INTERMEDIATE CL

10h

FDL 44

COAST CLUTCH FEED


OVERDRIVE CLUTCH FEED 2
45

LINE
1-2 SIGNAL

LINE

10
28a

2-3 SIGNAL

D432

FDL

22a

32 SM/FDL
2345
LOW AND REVERSE CL

30d

FDL

EX

FDL
EX

EX

EX

#11

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
123
123

GASKET (303)

FORWARD CLUTCH
COAST CLUTCH

SUCTION

2d

54g
2m

TCC SIGNAL

LINE

33d

4-5 SHIFT VLV CNTRL

R N D 4 3 2

GASKET (305)
BOTTOM CHANNEL PLATE (304)

345

12

Figure 100

36a

19

25a

25b

24c

15a

13a

38a

36b

37b

26
37a

45

FLUID FILTER
ASSEMBLY
(59)

33e

OFF

EX
SECOND COAST CLUTCH
OVERDRIVE CLUTCH FEED 1
2345
2345
23 REGULATED
4-5 SIGNAL

LOW PRESSURE

REAR CONTROL VALVE BODY (310)


GASKET (309)

OVERDRIVE CLUTCH FEED 1

FLUID
PAN
(62)

23

LINE SAFETY MODE

THROTTLE SIGNAL

(A)

35a
35b

MANUAL VALVE

REVERSE LOCKOUT
LINE
REGULATED APPLY
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2

REVERSE CLUTCH

10g

2345
19j

24b

36f

36d

36e

23b

345

40a

345

X-4

44b

24

2345

REV

345

123
D432

LINE

345

25

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED

SECOND CLUTCH
D432
EX

TCC SIGNAL
REVERSE LOCKOUT
TCC SIGNAL
123 REGULATED
123 BRAKING
123 REGULATED
345

DIRECT CLUTCH
345
45
LINE SAFETY MODE

REGULATED APPLY

345

FILTER
(308)

44a
10f
27a

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH
23 REGULATED

EX
EX

EX

REGULATED APPLY

TCC SIGNAL

TCC SIGNAL

44e
44d
28b

FDL

345
45

123
D432
345
DIRECT CLUTCH

EX

EX

EX

EX

EX

EX

2345 OR REVERSE

EX

15

23a

REVERSE CLUTCH

2345 OR REVERSE

REVERSE LOCKOUT

REVERSE CLUTCH

REVERSE LOCKOUT
LINE

16a

17a

21

COAST CLUTCH

FORWARD CLUTCH

PRESSURES
INTAKE & DECREASE (SUCTION)
CONVERTER & LUBE
MAINLINE
REGULATED LINE
SOLENOID SIGNAL
ACCUMULATOR
FEED LIMIT
THROTTLE SIGNAL

X-2

TCC PWM
SOLENOID
VALVE
N/C

23c

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

LINE

(214)

16

#1

32 SAFETY MODE

21

1
FLUID
PUMP
COVER
(202)

16

25c
25e

2-3 SIGNAL
FEED LIMIT

REVERSE
LOCKOUT
VALVE

LINE

TCC REGULATOR VALVE

36c

345

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

15c

24a

REGULATED APPLY

SUCTION
2

LINE

15b

15d

EX

FLUID PUMP
SCREEN
ASSEMBLY
(213)

FEED LIMIT VALVE

23

13

OVERDRIVE CLUTCH FEED 1


OVERDRIVE CLUTCH FEED 2

CONVERTER
HOUSING
(224)

FEED LIMIT
FEED LIMIT

25d

1-2 SHIFT
SOLENOID
VALVE
N/C

1-2 SHIFT CONTROL VALVE

D432

20

FD LIMIT

2-3 SHIFT VALVE

10c
10

345

TCC
ENABLE
VALVE

THROTTLE SIGNAL

RELEASE
TO COOLER
APPLY

TCC SIGNAL
REGULATED APPLY

LINE

CONVERTER FDL
CONVERTER FEED

TCC
CONTROL
VALVE

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REVERSE CLUTCH
FDL
2-3 SIGNAL
FDL
FEED LIMIT
1-2 SIGNAL

LINE SAFETY MODE

10a

D432

19e

RLO

CNTRL 3-4 SHIFT

10d

2345 OR REVERSE

DECREASE

FORWARD CLUTCH

CONVERTER FEED

14
19f

TCC SIGNAL

2-3 SIGNAL

28c

DIRECT CLUTCH

COAST CLUTCH

LINE

LINE

MEMORY
FEED LIMIT
LINE

SAFETY MODE

1-2 SIGNAL

19h

33a

2345

123 REGULATED

10b

D432

SECOND CLUTCH

1-2 SHIFT VALVE


DIRECT CLUTCH

PRESSURE
CONTROL
SOLENOID
VALVE

EX

11a

EX

FILTER
(312)

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

11b

7a

PRESSURE
RELIEF
BALL
VALVE

EX

REVERSE CLUTCH

54f

54d

54b

MEMORY PILOT

EX

46

20a

APPLY

36

12a

OVERDRIVE CL FD 1
OVERDRIVE CL FD 2
345
FEED LIMIT
LINE

EX

46

47b

32
1-2 SIGNAL
32 SAFETY MODE

DIRECT CLUTCH

DIRECT CLUTCH

30

27c

FEED LIMIT
MEMORY
MEMORY PILOT

32
32 SAFETY MODE

47a

AIR
BLEED
(233)

LINE

COAST CLUTCH

CASE (24)

CONVERTER FEED
DECREASE
PRESS REG VALVE

10e

AIR
BLEED
(203)

AIR
BLEED
(203)

X-3

ACCUM

D432

LINE

2b

21

SECOND CLUTCH

32

42b

ACCUMULATOR
INTERMEDIATE CLUTCH

32 SAFETY MODE

43a

LINE
SECOND CLUTCH

19

DIRECT CLUTCH

37d

INTERMEDIATE CLUTCH

ACCUM

OVERDRIVE CLUTCH FEED 2

40b

27b

AIR
BLEED
(203)

EX

SECOND
CLUTCH
ACCUMULATOR

31

BOOST VALVE

OVERDRIVE CLUTCH FEED 1

EX

COAST CLUTCH
123
123

39c
39b

LUBE

THROTTLE SIGNAL

OVERDRIVE CLUTCH FEED 2

41

32

EX

ACCUMULATOR

40c

DIRECT CLUTCH

FLUID
PRESSURE
TEST PLUG
(40)

54c

#12

COAST CLUTCH

AIR
BLEED
(233)

ACCUMULATOR

54a

5
2c

SECOND CLUTCH
REVERSE LOCKOUT

ACCUMULATOR HOUSING (333)

INTERMEDIATE
CLUTCH
ACCUMULATOR

ACCUM
OVERDRIVE CL FD 2 40d

2a

TO COOLER

LINE

OVERDRIVE
CLUTCH
ACCUMULATOR

GASKET (309)
FRONT CONTROL VALVE BODY (311)

REVERSE CLUTCH
FORWARD CLUTCH

AIR
BLEED
(203)

EX

DIRECT
CLUTCH
ACCUMULATOR

37c

COOLER

SPACER PLATE (307)

ACCUMULATOR HOUSING (328)

EX

DIRECT CL

OVERDRIVE CLUTCH

CO

R
OLE

BOTTOM CHANNEL PLATE (304)


GASKET (305)

LOW AND REV CL OR RLO


SECOND COAST CLUTCH

CENTER
SUPPORT
ASSEMBLY
(510535)

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (323)

35d

APPLY

GASKET (303)

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH
LUBE

TO

104

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (317)
CASE (24)
TOP CHANNEL PLATE (301)

38e

LUBE

2-3 SIGNAL

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH

E
LUB

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

INTERMEDIATE CLUTCH

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

7b

NOTE:
PASSAGES AND
COMPONENTS
MARKED WITH
ARE USED FOR
THE 5L40-E ONLY

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

RELEASE

WWW.ALL-TRANS.BY

TORQUE
CONVERTER
ASSEMBLY
(1)

MANUAL FOURTH FOURTH GEAR


(from Overdrive Range Fifth Gear)

WWW.ALL-TRANS.BY

A manual 5-4 downshift can be accomplished by moving the gear


selector lever into the Manual Fourth position (4) when the
transmission is operating in Overdrive Range Fifth Gear D .

NO FOURTH GEAR

4-5 Shift Solenoid Valve (376)


Stuck Off
Leaking
No voltage to the solenoid

4-5 Shift Valve (374)


Stuck

4-5 Shift Control Valve (375)


Stuck

Coast Clutch Piston (438)


Leaking
Cracked or jammed

Coast Clutch Piston Ball Check Valve (437)


Leaking

Input Shaft Fluid Seal Ring (432)


Leaking

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF OFF ON APPLIED

APPLIED APPLIED

LD

APPLIED

APPLIED

LD = LOCKED IN DRIVE

104A

MANUAL FOURTH FOURTH GEAR


(from Overdrive Range Fifth Gear)

WWW.ALL-TRANS.BY

PASSAGES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54

SUCTION
LINE
DECREASE
CONVERTER FEED
RELEASE
APPLY
REGULATED APPLY
TO COOLER
LUBE
FEED LIMIT
FILTERED FEED LIMIT
THROTTLE SIGNAL
LINE SAFETY MODE
REVERSE
REVERSE LOCK OUT (RLO)
REVERSE CLUTCH
LOW AND REVERSE CLUTCH
LOW AND REVERSE CLUTCH OR RLO
D432
123
FORWARD CLUTCH
2345
2345 OR REVERSE
TCC SIGNAL
123 REGULATED
123 BRAKING
1-2 SIGNAL
2-3 SIGNAL
4-5 SIGNAL
SECOND CLUTCH
COAST CLUTCH FEED
COAST CLUTCH
23 REGULATED
SECOND COAST CLUTCH
INTERMEDIATE CLUTCH
345
DIRECT CLUTCH
45
OVERDRIVE CLUTCH FEED 1
OVERDRIVE CLUTCH FEED 2
OVERDRIVE CLUTCH
32
32 SAFETY MODE
FDL
32 SAFETY MODE/FDL
MEMORY PILOT
MEMORY
EXHAUST
OIL RESERVOIR
TORQUE CONVERTER SEAL DRAINBACK
VENT
VOID
CONVERTER FDL
ACCUMULATOR

COMPONENTS ( )
(36)
(40)
(203)
(213)
(214)
(232)
(233)
(306)
(308)
(312)

104B

TRANSMISSION FLUID LEVEL HOLE PLUG


TRANSMISSION FLUID PRESSURE TEST PLUG
CHECK VALVE RETAINER AND BALL ASSEMBLY
TRANSMISSION FLUID PUMP SCREEN ASSEMBLY
BRASS ORIFICE INSERT
ORIFICE SLEEVE
ORIFICE CUP PLUG
CONTROL VALVE BODY BALL CHECK VALVE
(#1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
TCC PWM SOLENOID VALVE FILTER ASSEMBLY
PRESSURE CONTROL SOLENOID VALVE
FILTER ASSEMBLY

MANUAL FOURTH FOURTH GEAR

(from Overdrive Range Fifth Gear)

WWW.ALL-TRANS.BY

(229)

51

48

32 5
21 9

4
53
48
7

(203)

52

48

48

12

21

48
27
32

10

48
48

FRONT

41

42

48

28

21

36

42

19
19

43

35 15
13

41

28

52

32

52

30

34

52

34

30

48

48

48
28

48

48
48

18
10

21

48

20
52

2
48

48
21

TOP CHANNEL PLATE (301)


(Bottom Channel Plate Side)

18
48
10

42

17

48

48

34
27

43
28

#10
10

TOP CHANNEL PLATE (301)


(Case Side)

BOTTOM CHANNEL PLATE (304)


(Top Channel Plate Side)

Figure 101

38b

48

19

18

48
10 42

13

28

45
2

48
10

#9

#8

BOTTOM CHANNEL PLATE (304)


(Control Valve Body Side)

10

FOLDOUT 105

22g/23

38e

21

15

#6
43

44

38d

52

30

54b

20
19

36

37
54

47
52

47
10
2

46
13

52

37

36
40

36

52

52
54

48

48

52

40

42
43

39

38

FRONT CONTROL VALVE BODY (311)


(Bottom Channel Plate Side)

40d
54d
2c/54c

19h
15a

48
30b

40a

22b
22d 22c

28

32a

22f
24

20

35a
22e

18

22

14

54f
30a
33a

25
26
25

35d

22a

24c
36a

48
30

19

15

19
14

52

19f

19e

38c

21c/31 27
20c
17
2h 20d

14

35c

25c

48

52
25

21

25b
19

14a/23 26b

#5

52

13
19

28

15

#4

34

27

37c

47a

19i

25a

19

52

44
2
10

21

48
48

22

32

19

15
52

35

38

28

#11

38

20

35

X-5

24

19

52

38
52

31

30d

20b
26a

2m/54g

SPACER PLATE (307)


(Bottom Channel Plate Side)

32

38

52

15

19
2

10
48

52

44

34

52
2

10
48

48

27

43

44
10

28
48
10

52

30

33
17

52

30
33
54
25
25
17
30

28

33
13

35

22

44

26

21

42

35
22
35
39

20
20

22

36

52

35

40
2d/54e
25d
25e
17a 3
30c

35b
44e
28b 52
39a
#7
16
(Spring)
23 33e
52
2e
13b 33d
33c

21b/31
19c/21
44a 2
15e 33b 22
17b
19d/21
34a
15
21a
48a
27a 44b 10f
15f/18
17c/18
29 48b
44d
19b/21 19a 10i
43b
2f

43c/45
9
28a
11
42a
44c 10g
10
48
44f/45

48
10h

52

18

2
52

10
12

19

42 52

52 43

38
52 26 32

33

17

13

30

52

#3

22
22

20 21

23

36

25

52
15

40
25

22 19

35

38

27
52

#2
39

23

11b
10c

27c/46
10e

8
19j
2b
36c 25
13a
23a
37a
40c/41
40b
39c/41
36e
42b 52
36d 36b
43a
39b
38a
48 5
19g

38

27
52

20a

52
28

48

10

36f 26

15

35

30

X-1

19
15

22
35

19

48

19

23b

52

24

27b

10

48

12a
4
52
28c
48
47b 2a/54a

10d

X-3

41

2g

7b

FILTER
(308)

23

48

36

7a
6

X-4

36

10
48

40

37b
10a

24a
48

37
2

2
15b
48 11a/10b

23c
24b

41

43

13

48
52

36

10

48

16a
37d

23

15

48

48

24

37

27

19

19

#12
42

13

FRONT

2
41

13

11
12

48

20

48
48

24
7

FRONT

24

20

43

10

27

47

12

27

48

27

48

24

FILTER
(312)

15c/16

36

37

48

48

48

20

13
48

48

16

37

48
48

48

16

48

28

48

24

48

48
15d/16

48

37
7

32

21

48

11

15

48
37

23

24

12
28

16

15

2
10

52

48
16

48

37

48

48

FRONT

48

ARE USED FOR


23

48

16

48

FRONT

48

16

PASSAGES MARKED WITH


THE 5L40-E ONLY

X-2

48
48

CASE (24)
(Top Channel Plate Side)

EXHAUST FLUID NOT SHOWN


#1

32

(36)

DUAL PURPOSE PASSAGES HAVE


CHANNEL PLATE SIDE NUMBERS LISTED FIRST

FLUID PUMP COVER (202)


(Case Side)

16

52

52

52

FRONT

32

21

12 (203)

TORQUE CONVERTER HOUSING (227)


(Fluid Pump Cover Side)

16

(203)

32

52

16

INDICATES BOLT HOLES

NON FUNCTIONAL HOLES HAVE BEEN


REMOVED FROM COMPONENT DRAWINGS
TO SIMPLIFY TRACING FLUID FLOW.

52

21

52
52

37

(203)

52
52

37

12

NOTE:

24

15

18

CASE (24)
(Fluid Pump Cover Side)

32

34

30

52

48

12
21

52

52

32
9

37 16 21

52

48

37

52

48

16

24

52

48

52

(40)

12

48

35

FLUID PUMP COVER (202)


(Torque Converter Housing Side)

16

52

30

41

21

FRONT

52

52

32

48

(213)
1

50

24
4
53
48
7

16

12

37
16

2/21

24
37

32

52

(233)

12

52

24

(214) 21

52

48

2
4

52

5
8

52

52

52

48

48

52

48
53

52

48

50

21

12

51

51

37

24

24

16

32

52

16

2
12

52

48

FRONT

53
5

31

52

52

52

TRANSMISSION
VENT
ASSEMBLY

48

(232)

48

48
4

(231)

51

(233)

44

48

48

REAR CONTROL VALVE BODY (310)


(Bottom Channel Plate Side)

MANUAL THIRD THIRD GEAR

(from Manual Fourth Fourth Gear)

FORWARD CLUTCH
COAST CLUTCH
LUBE

30a

30b
35c

30c

2e

54e

45
43c

OFF

EX

#10
45

48

29

EX

48a

2345
2345
2345
32 SM

22

EX
EX

33b

#9

EX
EX
EX

ON

11
10i

43

LINE

13b
13

18

2345

LOW AND REV CL OR RLO

EX

39a

2-3 SIGNAL

(C)

33c

22b

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
123
123

22c

22

X-1

28
26a

32 SM

LINE

123 BRAKING
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2
45
OVERDRIVE CLUTCH FEED 1

123
D432

32

1-2 SIGNAL
123
FEED LIMIT

32 SAFETY MODE

32 SAFETY MODE
REVERSE LOCKOUT
D432

32

D432
32

2-3 SIGNAL

2-3 SIGNAL

TOP CHANNEL PLATE (301)


CASE (24)

REVERSE LOCKOUT
COAST CLUTCH

REVERSE LOCKOUT
COAST CLUTCH
FORWARD CLUTCH

REVERSE LOCKOUT
COAST CLUTCH

FEED LIMIT

1-2 SIGNAL

D432
2-3 SIGNAL

123 REGULATED

LINE

OVERDRIVE CL FD 2
OVERDRIVE CL FD 1
RLO

21

#6
19

15

19c

21

20b

31

#5

21c

31

17
21b

21a

#7

42a

16

19b

20d

20c

#4

22f

123 REGULATED
123 BRAKING

123
123
2345

32

15e
22d
43b

19a

2f

2h

X-5

38d

27

18
15f

#8

2345
38

38c

#3

38b

22g

14a

#2

17c

45
123

23

19i

19g

26b

SPACER PLATE (307)

17b

45

45

19d

R N D 4 3 2

D432

LINE

EX

REV

32a

LINE

15

LOW AND REV CL OR RLO


REVERSE LOCKOUT
SECOND COAST CLUTCH

48b

LINE SAFETY MODE

COAST CLUTCH
FORWARD CLUTCH

2-3 SIGNAL

34a

EX

4-5 SHIFT
SOLENOID
VALVE
N/C

1-2 SIGNAL

32
2-3 SIGNAL

1-2 SIGNAL

(B)

44c

44f

D432
FEED LIMIT

FDL

45

123 REGULATED
23 REGULATED

FDL 44

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

EX

45

EX

REVERSE

23 REGULATED

10h
28a

22e

123
FEED LIMIT
32 SAFETY MODE

INTERMEDIATE CL

10

EX

EX

2345

345
2345

EX
EX

123 REGULATED
123 BRAKING
345

LINE

22a

COAST CLUTCH FEED


OVERDRIVE CLUTCH FEED 2
45

LINE
1-2 SIGNAL

FDL

EX

#11

32 SM/FDL
2345
LOW AND REVERSE CL

30d

FDL

EX

FDL
EX

33d

4-5 SHIFT VLV CNTRL

GASKET (303)

FORWARD CLUTCH
COAST CLUTCH

SUCTION

36a

25a

D432

12

Figure 102

33e

ON

MANUAL VALVE

GASKET (305)
BOTTOM CHANNEL PLATE (304)

TCC SIGNAL

LINE

23

EX
SECOND COAST CLUTCH
OVERDRIVE CLUTCH FEED 1
2345
2345
23 REGULATED
4-5 SIGNAL

LOW PRESSURE

123 REGULATED

TCC SIGNAL
REVERSE LOCKOUT
TCC SIGNAL
123 REGULATED
123 BRAKING
123 REGULATED
345
25b

24c

15a

19

345

45

FLUID FILTER
ASSEMBLY
(59)

(A)

35a
35b

2345

REV

REAR CONTROL VALVE BODY (310)


GASKET (309)

OVERDRIVE CLUTCH FEED 1

FLUID
PAN
(62)

10g

LINE SAFETY MODE

THROTTLE SIGNAL

2d

54g
2m

EX
13a

38a

36b

37b

26

REVERSE LOCKOUT
LINE
REGULATED APPLY
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2

REVERSE CLUTCH

EX

EX
EX

345

9
24

2345

44b

40a

37a

24b

36f

36d

36e

23b

X-4

44a
10f
27a

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH
23 REGULATED

345

345
25

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED

SECOND CLUTCH
D432
32
32 SAFETY MODE

345

DIRECT CLUTCH
345
45
LINE SAFETY MODE

REGULATED APPLY
LINE

345

44e
44d
28b

2-3 SIGNAL
FEED LIMIT

REVERSE
LOCKOUT
VALVE

EX

REGULATED APPLY

TCC SIGNAL

FILTER
(308)

17a

FDL

345
45

123
D432
345
DIRECT CLUTCH

EX

EX

EX

EX

EX

EX

2345 OR REVERSE

EX

TCC SIGNAL

23c

REVERSE CLUTCH

2345 OR REVERSE

15

23a

16a

REVERSE LOCKOUT

REVERSE CLUTCH

X-2

TCC PWM
SOLENOID
VALVE
N/C

25c
25e

21

COAST CLUTCH

FORWARD CLUTCH

PRESSURES
INTAKE & DECREASE (SUCTION)
CONVERTER & LUBE
MAINLINE
REGULATED LINE
SOLENOID SIGNAL
ACCUMULATOR
FEED LIMIT
THROTTLE SIGNAL

REVERSE LOCKOUT
LINE

OVERDRIVE CLUTCH FEED 1


OVERDRIVE CLUTCH FEED 2

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

LINE

(214)

16

#1

32 SAFETY MODE

21

1
FLUID
PUMP
COVER
(202)

16

25d

FD LIMIT

RLO

LINE

TCC REGULATOR VALVE

36c

345

15c

24a

REGULATED APPLY

SUCTION
2

LINE

15b

15d

EX

FLUID PUMP
SCREEN
ASSEMBLY
(213)

FEED LIMIT VALVE

23

13

345

CONVERTER
HOUSING
(224)

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

TCC SIGNAL
REGULATED APPLY

TCC
ENABLE
VALVE

THROTTLE SIGNAL

RELEASE
TO COOLER

CONVERTER FDL
CONVERTER FEED

LINE

APPLY

FEED LIMIT
FEED LIMIT

10c
10

1-2 SHIFT CONTROL VALVE

D432

20

1-2 SHIFT
SOLENOID
VALVE
N/C

TCC SIGNAL

3-4 SHIFT

10a

2345 OR REVERSE

DECREASE

FORWARD CLUTCH

TCC
CONTROL
VALVE

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REVERSE CLUTCH
FDL
2-3 SIGNAL
FDL
FEED LIMIT
1-2 SIGNAL

2-3 SHIFT VALVE

CNTRL

10d

D432

19f

19e

2345

2-3 SIGNAL

CONVERTER FEED

14

LINE SAFETY MODE

1-2 SIGNAL

28c

DIRECT CLUTCH

COAST CLUTCH

LINE

LINE

MEMORY
FEED LIMIT
LINE

SAFETY MODE
EX

10b

19h

33a

1-2 SHIFT VALVE


DIRECT CLUTCH

PRESSURE
CONTROL
SOLENOID
VALVE

EX

11a

EX

FILTER
(312)

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

11b

7a

PRESSURE
RELIEF
BALL
VALVE

EX

REVERSE CLUTCH

54f

54d

54b

MEMORY PILOT

123
D432

46

19j

APPLY

36

12a

OVERDRIVE CL FD 1
OVERDRIVE CL FD 2
345
FEED LIMIT
LINE

EX

46

47b

32
1-2 SIGNAL
32 SAFETY MODE

DIRECT CLUTCH

DIRECT CLUTCH

30

27c

FEED LIMIT
MEMORY
MEMORY PILOT

20a

47a

AIR
BLEED
(233)

LINE

COAST CLUTCH

CASE (24)

CONVERTER FEED
DECREASE
PRESS REG VALVE

10e

AIR
BLEED
(203)

AIR
BLEED
(203)

D432

SECOND CLUTCH

D432

LINE

2b

X-3

ACCUM

SECOND CLUTCH

32

42b

21

ACCUMULATOR
INTERMEDIATE CLUTCH

32 SAFETY MODE

43a

LINE
SECOND CLUTCH

19

DIRECT CLUTCH

37d

INTERMEDIATE CLUTCH

ACCUM

OVERDRIVE CLUTCH FEED 2

40b

27b

AIR
BLEED
(203)

EX

SECOND
CLUTCH
ACCUMULATOR

31

BOOST VALVE

OVERDRIVE CLUTCH FEED 1

EX

COAST CLUTCH
123
123

39c
39b

LUBE

THROTTLE SIGNAL

OVERDRIVE CLUTCH FEED 2

41

32

EX

ACCUMULATOR

40c

DIRECT CLUTCH

FLUID
PRESSURE
TEST PLUG
(40)

54c

#12

COAST CLUTCH

AIR
BLEED
(233)

ACCUMULATOR

54a

5
2c

SECOND CLUTCH
REVERSE LOCKOUT

ACCUMULATOR HOUSING (333)

INTERMEDIATE
CLUTCH
ACCUMULATOR

ACCUM
OVERDRIVE CL FD 2 40d

2a

TO COOLER

LINE

OVERDRIVE
CLUTCH
ACCUMULATOR

GASKET (309)
FRONT CONTROL VALVE BODY (311)

REVERSE CLUTCH
FORWARD CLUTCH

AIR
BLEED
(203)

EX

DIRECT
CLUTCH
ACCUMULATOR

37c

COOLER

SPACER PLATE (307)

ACCUMULATOR HOUSING (328)

EX

DIRECT CL

OVERDRIVE CLUTCH

CO

R
OLE

BOTTOM CHANNEL PLATE (304)


GASKET (305)

LOW AND REV CL OR RLO


SECOND COAST CLUTCH

CENTER
SUPPORT
ASSEMBLY
(510535)

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (323)

35d

APPLY

GASKET (303)

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH
LUBE

TO

106

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (317)
CASE (24)
TOP CHANNEL PLATE (301)

38e

LUBE

2-3 SIGNAL

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH

E
LUB

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

INTERMEDIATE CLUTCH

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

7b

NOTE:
PASSAGES AND
COMPONENTS
MARKED WITH
ARE USED FOR
THE 5L40-E ONLY

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

RELEASE

WWW.ALL-TRANS.BY

TORQUE
CONVERTER
ASSEMBLY
(1)

MANUAL THIRD THIRD GEAR


(from Manual Fourth Fourth Gear)

WWW.ALL-TRANS.BY

A manual 4-3 downshift can be accomplished by moving the gear


selector lever into the Manual Third (3) position when the
transmission is operating in Fourth gear. This causes the
transmission to shift into Third gear and prevents the transmission
from upshifting to either Fourth or Fifth gears.

NO THIRD GEAR

1-2 Shift Solenoid Valve (368)


Stuck Off
Leaking
No voltage to solenoid

3-4 Shift Valve (345)


Stuck
NO ENGINE BRAKING

4-5 Shift Solenoid Valve (376)


Leaking
No voltage to solenoid

Low Pressure Control Valve (383)


Stuck

#12 Ball Check Valve


Stuck
Missing

Fluid Passage Sleeve (39)


Leaking

Overdrive Clutch Piston (487)


Leaking
Cracked or jammed

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
ON OFF ON

APPLIED APPLIED

LD

APPLIED

LD

APPLIED

APPLIED

LD = LOCKED IN DRIVE

106A

MANUAL THIRD THIRD GEAR


(from Manual Fourth Fourth Gear)

WWW.ALL-TRANS.BY

PASSAGES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54

SUCTION
LINE
DECREASE
CONVERTER FEED
RELEASE
APPLY
REGULATED APPLY
TO COOLER
LUBE
FEED LIMIT
FILTERED FEED LIMIT
THROTTLE SIGNAL
LINE SAFETY MODE
REVERSE
REVERSE LOCK OUT (RLO)
REVERSE CLUTCH
LOW AND REVERSE CLUTCH
LOW AND REVERSE CLUTCH OR RLO
D432
123
FORWARD CLUTCH
2345
2345 OR REVERSE
TCC SIGNAL
123 REGULATED
123 BRAKING
1-2 SIGNAL
2-3 SIGNAL
4-5 SIGNAL
SECOND CLUTCH
COAST CLUTCH FEED
COAST CLUTCH
23 REGULATED
SECOND COAST CLUTCH
INTERMEDIATE CLUTCH
345
DIRECT CLUTCH
45
OVERDRIVE CLUTCH FEED 1
OVERDRIVE CLUTCH FEED 2
OVERDRIVE CLUTCH
32
32 SAFETY MODE
FDL
32 SAFETY MODE/FDL
MEMORY PILOT
MEMORY
EXHAUST
OIL RESERVOIR
TORQUE CONVERTER SEAL DRAINBACK
VENT
VOID
CONVERTER FDL
ACCUMULATOR

COMPONENTS ( )
(36)
(40)
(203)
(213)
(214)
(232)
(233)
(306)
(308)
(312)

106B

TRANSMISSION FLUID LEVEL HOLE PLUG


TRANSMISSION FLUID PRESSURE TEST PLUG
CHECK VALVE RETAINER AND BALL ASSEMBLY
TRANSMISSION FLUID PUMP SCREEN ASSEMBLY
BRASS ORIFICE INSERT
ORIFICE SLEEVE
ORIFICE CUP PLUG
CONTROL VALVE BODY BALL CHECK VALVE
(#1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
TCC PWM SOLENOID VALVE FILTER ASSEMBLY
PRESSURE CONTROL SOLENOID VALVE
FILTER ASSEMBLY

MANUAL THIRD THIRD GEAR

(from Manual Fourth Fourth Gear)

WWW.ALL-TRANS.BY

(229)

51

48

32 5
21 9

4
53
48
7

NOTE:

(203)

52

32

21

52

48
48
48

37

24
48

12

27

48

24

21

48
32

10

48
48

FRONT

41

42

24
48

28

21

36

42

19
19

43

35 15
13

52

41

28

52

32

52

34

52

34

30

48

48

48
28

48

48
48

18
10

21

48

20
52

2
48

48
21

TOP CHANNEL PLATE (301)


(Bottom Channel Plate Side)

18
48
10

42

17

48

48

34
27

43
28

#10
10

BOTTOM CHANNEL PLATE (304)


(Top Channel Plate Side)

Figure 103

FOLDOUT 107

22g/23
38b

19

18

48
10 42

13

28
2

48
10

#9

#8

BOTTOM CHANNEL PLATE (304)


(Control Valve Body Side)

10

TOP CHANNEL PLATE (301)


(Case Side)

48

45

54b

20
19

36

37
54

47
52

47
10
2

46
13

52

37

36
40

36

52

52
54

48

48

52

40

42
43

39

38

FRONT CONTROL VALVE BODY (311)


(Bottom Channel Plate Side)

40d
54d
2c/54c

19h
15a

48
30b

40a

22b
22d 22c

28

32a

22f
24

20

35a
22e

18

22

14

54f
30a
33a

25
26
25

35d

22a

24c
36a

48
30

19

15

19
14

52

19f

19e

38c

21c/31 27
20c
17
2h 20d

14

35c

25c

48

52
25

21

25b
19

38e

21

15

#6
43

44

38d

52

30

37c

47a

19i

14a/23 26b

#5

52

13
19

28

15

#4

34

27

27

23

11b
10c

27c/46
10e

8
19j
2b
36c 25
13a
23a
37a
40c/41
40b
39c/41
36e
42b 52
36d 36b
43a
39b
38a
48 5
19g

25a

19

52

44
2
10

21

48
48

22

32

19

15
52

35

38

28

#11

38

20

35

X-5

24

19

52

38
52

31

30d

20b
26a

2m/54g

SPACER PLATE (307)


(Bottom Channel Plate Side)

32

38

52

15

19
2

10
48

52

44

34

52
2

10
48

48

27

43

44
10

28
48
10

52

30

33
17

52

30
33
54
25
25
17
30

28

33
13

35

22

44

26

21

42

35
22
35
39

20
20

22

36

52

35

40
2d/54e
25d
25e
17a 3
30c

35b
44e
28b 52
39a
#7
16
(Spring)
23 33e
52
2e
13b 33d
33c

21b/31
19c/21
44a 2
15e 33b 22
17b
19d/21
34a
15
21a
48a
27a 44b 10f
15f/18
17c/18
29 48b
44d
19b/21 19a 10i
43b
2f

43c/45
9
28a
11
42a
44c 10g
10
48
44f/45

48
10h

52

18

2
52

10
12

19

38
52 26 32

33

17

13
42 52

52 43

#3

22
22

30

30

52

23

36

25

20 21

15

40
25

22 19

52
27

52

39

10
52

20a

52
28

48

48

36f 26

38

#2

35

38

23b

15

35

30

X-1

19
15

22
35

19

48

19

24

27b

10
12

12a
4
52
28c
48
47b 2a/54a

10d

X-3

41

2g

7b

FILTER
(308)

23

48

36

7a
6

X-4

36

10
48

40

37b
10a

24a
48

37

2
15b
48 11a/10b

23c
24b

41

43

13

48
52

36

10

48

16a
37d

23

15

48

48

24

37

27
13

FRONT

19

19

11

FRONT

2
41

13
#12

48
48

24

48

10
20

42

20

43

27

47

12

27

48

48

24

FILTER
(312)

15c/16

36

37

27

48
15d/16

48

48

48

48

20

13
48

48

16

37

48
48

48

16

48

28

15

37
7

32

21

48

52

48
16

48
37

23

16

12
28

16
48

11

10

48
23

15

48

ARE USED FOR

48

16

48

48

FRONT

48

PASSAGES MARKED WITH


THE 5L40-E ONLY

X-2

48
32

CASE (24)
(Top Channel Plate Side)

EXHAUST FLUID NOT SHOWN


#1

12

(36)

DUAL PURPOSE PASSAGES HAVE


CHANNEL PLATE SIDE NUMBERS LISTED FIRST

FLUID PUMP COVER (202)


(Case Side)

16

52

12 (203)

FRONT

TORQUE CONVERTER HOUSING (227)


(Fluid Pump Cover Side)

16

(203)

32

52

16

52

FRONT

37

(203)

52

21

INDICATES BOLT HOLES

52

37

52

NON FUNCTIONAL HOLES HAVE BEEN


REMOVED FROM COMPONENT DRAWINGS
TO SIMPLIFY TRACING FLUID FLOW.

24

52
52

21

32

52

12

52

52

15

18

CASE (24)
(Fluid Pump Cover Side)

37

48

34

30

52

48

52

48

32
9

37 16 21

16

24

52

48

52

(40)

12

48

FLUID PUMP COVER (202)


(Torque Converter Housing Side)

16

35

30

52

52

52

21

FRONT

48

(213)
1

50

24
4
53
48
7

32

2/21

41

16

12

32

(214) 21

37
16

37

12

52
52

24

24
48

2
4

52

(233)

52

52
7

48
53

52

52

7
48

48

52

21

50

52

48

12

51

51

37

24

24

16

32

52

16

2
12

52

48

FRONT

53
5

31

52

52

52

TRANSMISSION
VENT
ASSEMBLY

48

(232)

48

48
4

(231)

51

(233)

44

48

48

REAR CONTROL VALVE BODY (310)


(Bottom Channel Plate Side)

MANUAL SECOND SECOND GEAR

(from Manual Third Third Gear)

FORWARD CLUTCH
COAST CLUTCH
LUBE

30a

30b
35c

30c

2e

2d

54g

54e

2m

45

48

29

EX

48a

2345
2345
2345
32 SM

22
33c

EX
EX

33b

#9

EX
EX
EX

22b

ON

11
10i

43

LINE

13b
13

18

2345

LOW AND REV CL OR RLO

EX

39a

2-3 SIGNAL

(C)

22c

22

X-1

28
26a

45
32 SM

LINE

123 BRAKING
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2
45
OVERDRIVE CLUTCH FEED 1

123
D432

32

1-2 SIGNAL
123
FEED LIMIT

32 SAFETY MODE

32 SAFETY MODE
REVERSE LOCKOUT
D432

32

D432
32

2-3 SIGNAL

2-3 SIGNAL

TOP CHANNEL PLATE (301)


CASE (24)

REVERSE LOCKOUT
COAST CLUTCH

REVERSE LOCKOUT
COAST CLUTCH
FORWARD CLUTCH

REVERSE LOCKOUT
COAST CLUTCH

1-2 SIGNAL

D432
FEED LIMIT

21

123 REGULATED

LINE

123 REGULATED
123 BRAKING

19

#6

19c

21

15
19d

20b

31

#5

21c

31

17
21b

21a

#7

42a

16

19b

20d

20c

#4

22f

OVERDRIVE CL FD 2
OVERDRIVE CL FD 1
RLO

15e
22d
43b

19a

2f

2h

X-5

38d

27

18
15f

#8

2345
38

38c

#3

38b

22g

14a

#2

17c

45
123

23

19i

19g

26b

SPACER PLATE (307)

17b

123
123
2345

32

D432

LINE

EX

REV

32a

45

LINE

15

LOW AND REV CL OR RLO


REVERSE LOCKOUT
SECOND COAST CLUTCH

48b

LINE SAFETY MODE

COAST CLUTCH
FORWARD CLUTCH

2-3 SIGNAL

34a

EX

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
123
123

1-2 SIGNAL

32
2-3 SIGNAL

1-2 SIGNAL

EX

#10

22e

123
FEED LIMIT
32 SAFETY MODE

INTERMEDIATE CL

23 REGULATED

45
43c

D432
FEED LIMIT

44c

44f

ON

4-5 SHIFT
SOLENOID
VALVE
N/C

EX

45

EX

REVERSE

45

123 REGULATED
23 REGULATED

(B)

EX

EX

2345

345
2345

EX
EX

FDL

2-3 SHIFT
SOLENOID
VALVE
N/C

COAST CLUTCH FEED


OVERDRIVE CLUTCH FEED 2
45

LINE
1-2 SIGNAL

LINE

10h

FDL 44

2-3 SIGNAL

D432

FDL

10
28a

32 SM/FDL
2345
LOW AND REVERSE CL

30d

FDL

EX

FDL
EX

EX

EX

#11
22a

4-5 SHIFT VLV CNTRL

R N D 4 3 2

GASKET (305)
BOTTOM CHANNEL PLATE (304)

TCC SIGNAL

LINE

33d

CNTRL

GASKET (303)

FORWARD CLUTCH
COAST CLUTCH

SUCTION

36a

25a

25b

24c

15a

13a

38a

19

345

12

Figure 104

123 REGULATED
123 BRAKING
345

TCC SIGNAL
REVERSE LOCKOUT
TCC SIGNAL
123 REGULATED
123 BRAKING
123 REGULATED
345

345

DIRECT CLUTCH
345
45
LINE SAFETY MODE
36b

37b

26
37a

45

FLUID FILTER
ASSEMBLY
(59)

33e

ON

EX
SECOND COAST CLUTCH
OVERDRIVE CLUTCH FEED 1
2345
2345
23 REGULATED
4-5 SIGNAL

LOW PRESSURE

REAR CONTROL VALVE BODY (310)


GASKET (309)

OVERDRIVE CLUTCH FEED 1

FLUID
PAN
(62)

23

LINE SAFETY MODE

THROTTLE SIGNAL

(A)

35a
35b

MANUAL VALVE

REVERSE LOCKOUT
LINE
REGULATED APPLY
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2

REVERSE CLUTCH

10g

2345
19j

7a

24b

36f

36d

36e

23b

345

40a

345

X-4

44b

24

2345

REV

345

123
D432

LINE

345

25

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED

SECOND CLUTCH
D432
EX
EX
EX

EX

REGULATED APPLY

TCC SIGNAL

FILTER
(308)

44a
10f
27a

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH
23 REGULATED

345
45

123
D432
345
DIRECT CLUTCH

EX

EX

EX

EX

EX

EX

2345 OR REVERSE

EX

TCC SIGNAL

23c

REVERSE CLUTCH

2345 OR REVERSE

15

23a

16a

REVERSE LOCKOUT

REVERSE CLUTCH

X-2

TCC PWM
SOLENOID
VALVE
N/C

44e
44d
28b

21

COAST CLUTCH

FORWARD CLUTCH

PRESSURES
INTAKE & DECREASE (SUCTION)
CONVERTER & LUBE
MAINLINE
REGULATED LINE
SOLENOID SIGNAL
ACCUMULATOR
FEED LIMIT
THROTTLE SIGNAL

REVERSE LOCKOUT
LINE

OVERDRIVE CLUTCH FEED 1


OVERDRIVE CLUTCH FEED 2

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

LINE

(214)

16

#1

32 SAFETY MODE

21

1
FLUID
PUMP
COVER
(202)

16

17a

2-3 SIGNAL
FEED LIMIT

REVERSE
LOCKOUT
VALVE

LINE

TCC REGULATOR VALVE

36c

345

15c

24a

REGULATED APPLY

SUCTION
2

LINE

15b

15d

EX

FLUID PUMP
SCREEN
ASSEMBLY
(213)

FEED LIMIT VALVE

23

13

345

CONVERTER
HOUSING
(224)

10c
10

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

TCC SIGNAL
REGULATED APPLY

TCC
ENABLE
VALVE

THROTTLE SIGNAL

RELEASE
TO COOLER

CONVERTER FDL
CONVERTER FEED

LINE

APPLY

FEED LIMIT
FEED LIMIT

25c
25e

FDL

2-3 SHIFT VALVE

10a

25d

1-2 SHIFT
SOLENOID
VALVE
N/C

1-2 SHIFT CONTROL VALVE

D432

20

FD LIMIT

RLO

CNTRL 3-4 SHIFT

10d

2345 OR REVERSE

DECREASE

FORWARD CLUTCH

TCC
CONTROL
VALVE

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REVERSE CLUTCH
FDL
2-3 SIGNAL
FDL
FEED LIMIT
1-2 SIGNAL

TCC SIGNAL

2-3 SIGNAL

D432

19f

19e

LINE SAFETY MODE

1-2 SIGNAL

CONVERTER FEED

MEMORY
FEED LIMIT
LINE

SAFETY MODE

28c

DIRECT CLUTCH

COAST CLUTCH

LINE

LINE

14

2345

123 REGULATED

10b

19h

33a

1-2 SHIFT VALVE


DIRECT CLUTCH

PRESSURE
CONTROL
SOLENOID
VALVE

EX

11a

EX

FILTER
(312)

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

11b

REGULATED APPLY

PRESSURE
RELIEF
BALL
VALVE

EX

REVERSE CLUTCH

54f

54d

54b

MEMORY PILOT

EX

46

20a

APPLY

36

12a

OVERDRIVE CL FD 1
OVERDRIVE CL FD 2
345
FEED LIMIT
LINE

EX

46

47b

32
1-2 SIGNAL
32 SAFETY MODE

DIRECT CLUTCH

DIRECT CLUTCH

30

27c

FEED LIMIT
MEMORY
MEMORY PILOT

32
32 SAFETY MODE

47a

AIR
BLEED
(233)

LINE

COAST CLUTCH

CASE (24)

CONVERTER FEED
DECREASE
PRESS REG VALVE

10e

AIR
BLEED
(203)

AIR
BLEED
(203)

D432

SECOND CLUTCH

D432

LINE

2b

X-3

ACCUM

SECOND CLUTCH

32

42b

21

ACCUMULATOR
INTERMEDIATE CLUTCH

32 SAFETY MODE

43a

LINE
SECOND CLUTCH

19

DIRECT CLUTCH

37d

INTERMEDIATE CLUTCH

ACCUM

OVERDRIVE CLUTCH FEED 2

40b

27b

AIR
BLEED
(203)

EX

SECOND
CLUTCH
ACCUMULATOR

31

BOOST VALVE

OVERDRIVE CLUTCH FEED 1

EX

COAST CLUTCH
123
123

39c
39b

LUBE

THROTTLE SIGNAL

OVERDRIVE CLUTCH FEED 2

41

32

EX

ACCUMULATOR

40c

DIRECT CLUTCH

FLUID
PRESSURE
TEST PLUG
(40)

54c

#12

COAST CLUTCH

AIR
BLEED
(233)

ACCUMULATOR

54a

5
2c

SECOND CLUTCH
REVERSE LOCKOUT

ACCUMULATOR HOUSING (333)

INTERMEDIATE
CLUTCH
ACCUMULATOR

ACCUM
OVERDRIVE CL FD 2 40d

2a

TO COOLER

LINE

OVERDRIVE
CLUTCH
ACCUMULATOR

GASKET (309)
FRONT CONTROL VALVE BODY (311)

REVERSE CLUTCH
FORWARD CLUTCH

AIR
BLEED
(203)

EX

DIRECT
CLUTCH
ACCUMULATOR

37c

COOLER

SPACER PLATE (307)

ACCUMULATOR HOUSING (328)

EX

DIRECT CL

OVERDRIVE CLUTCH

CO

R
OLE

BOTTOM CHANNEL PLATE (304)


GASKET (305)

LOW AND REV CL OR RLO


SECOND COAST CLUTCH

CENTER
SUPPORT
ASSEMBLY
(510535)

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (323)

35d

APPLY

GASKET (303)

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH
LUBE

TO

108

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (317)
CASE (24)
TOP CHANNEL PLATE (301)

38e

LUBE

2-3 SIGNAL

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH

E
LUB

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

INTERMEDIATE CLUTCH

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

7b

NOTE:
PASSAGES AND
COMPONENTS
MARKED WITH
ARE USED FOR
THE 5L40-E ONLY

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

RELEASE

WWW.ALL-TRANS.BY

TORQUE
CONVERTER
ASSEMBLY
(1)

MANUAL SECOND SECOND GEAR


(from Manual Third Third Gear)

WWW.ALL-TRANS.BY

A manual 3-2 downshift can be accomplished by moving the gear


selector lever into the Manual Second (2) position when the
transmission is operating in Third gear. This causes the
transmission to shift into Second gear and prevents the
transmission from upshifting to Third, Fourth or Fifth gears.

NO SECOND GEAR

2-3 Shift Solenoid Valve (369)


Stuck Off
Leaking
No voltage to solenoid

2-3 Shift Valve (371)


Stuck

2-3 Shift Control Valve (370)


Stuck
NO ENGINE BRAKING

Center Support (518)


Cracked
Feed hole blocked

Fluid Passage Sleeve (38)


Leaking

Second Coast Clutch Piston (528)


Cracked or jammed
Leaking seals

4-5 Shift Solenoid Valve (376)


Leaking
No voltage to solenoid

Low Pressure Control Valve (383)


Stuck

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
ON ON ON

APPLIED APPLIED

LD

APPLIED

LD

APPLIED

LD = LOCKED IN DRIVE

108A

MANUAL SECOND SECOND GEAR


(from Manual Third Third Gear)

WWW.ALL-TRANS.BY

PASSAGES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54

SUCTION
LINE
DECREASE
CONVERTER FEED
RELEASE
APPLY
REGULATED APPLY
TO COOLER
LUBE
FEED LIMIT
FILTERED FEED LIMIT
THROTTLE SIGNAL
LINE SAFETY MODE
REVERSE
REVERSE LOCK OUT (RLO)
REVERSE CLUTCH
LOW AND REVERSE CLUTCH
LOW AND REVERSE CLUTCH OR RLO
D432
123
FORWARD CLUTCH
2345
2345 OR REVERSE
TCC SIGNAL
123 REGULATED
123 BRAKING
1-2 SIGNAL
2-3 SIGNAL
4-5 SIGNAL
SECOND CLUTCH
COAST CLUTCH FEED
COAST CLUTCH
23 REGULATED
SECOND COAST CLUTCH
INTERMEDIATE CLUTCH
345
DIRECT CLUTCH
45
OVERDRIVE CLUTCH FEED 1
OVERDRIVE CLUTCH FEED 2
OVERDRIVE CLUTCH
32
32 SAFETY MODE
FDL
32 SAFETY MODE/FDL
MEMORY PILOT
MEMORY
EXHAUST
OIL RESERVOIR
TORQUE CONVERTER SEAL DRAINBACK
VENT
VOID
CONVERTER FDL
ACCUMULATOR

COMPONENTS ( )
(36)
(40)
(203)
(213)
(214)
(232)
(233)
(306)
(308)
(312)

108B

TRANSMISSION FLUID LEVEL HOLE PLUG


TRANSMISSION FLUID PRESSURE TEST PLUG
CHECK VALVE RETAINER AND BALL ASSEMBLY
TRANSMISSION FLUID PUMP SCREEN ASSEMBLY
BRASS ORIFICE INSERT
ORIFICE SLEEVE
ORIFICE CUP PLUG
CONTROL VALVE BODY BALL CHECK VALVE
(#1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
TCC PWM SOLENOID VALVE FILTER ASSEMBLY
PRESSURE CONTROL SOLENOID VALVE
FILTER ASSEMBLY

MANUAL SECOND SECOND GEAR

(from Manual Third Third Gear)

WWW.ALL-TRANS.BY

(229)

51

48

32 5
21 9

4
53
48
7

NOTE:

(203)

52

32

21

52

48
48
48

37

24
48

12

27

48

24

21

48
32

10

48
48

FRONT

41

42

24
48

28

21

36

42

19
19

43

35 15
13

52

41

28

52

32

52

34

52

34

30

48

48

48
28

48

48
48

18
10

21

48

20
52

2
48

48
21

TOP CHANNEL PLATE (301)


(Bottom Channel Plate Side)

18
48
10

42

17

48

48

34
27

43
28

#10
10

BOTTOM CHANNEL PLATE (304)


(Top Channel Plate Side)

Figure 105

FOLDOUT 109

22g/23
38b

19

18

48
10 42

13

28
2

48
10

#9

#8

BOTTOM CHANNEL PLATE (304)


(Control Valve Body Side)

10

TOP CHANNEL PLATE (301)


(Case Side)

48

45

54b

20
19

36

37
54

47
52

47
10
2

46
13

52

37

36
40

36

52

52
54

48

48

52

40

42
43

39

38

FRONT CONTROL VALVE BODY (311)


(Bottom Channel Plate Side)

40d
54d
2c/54c

19h
15a

48
30b

40a

22b
22d 22c

28

32a

22f
24

20

35a
22e

18

22

14

54f
30a
33a

25
26
25

35d

22a

24c
36a

48
30

19

15

19
14

52

19f

19e

38c

21c/31 27
20c
17
2h 20d

14

35c

25c

48

52
25

21

25b
19

38e

21

15

#6
43

44

38d

52

30

37c

47a

19i

14a/23 26b

#5

52

13
19

28

15

#4

34

27

27

23

11b
10c

27c/46
10e

8
19j
2b
36c 25
13a
23a
37a
40c/41
40b
39c/41
36e
42b 52
36d 36b
43a
39b
38a
48 5
19g

25a

19

52

44
2
10

21

48
48

22

32

19

15
52

35

38

28

#11

38

20

35

X-5

24

19

52

38
52

31

30d

20b
26a

2m/54g

SPACER PLATE (307)


(Bottom Channel Plate Side)

32

38

52

15

19
2

10
48

52

44

34

52
2

10
48

48

27

43

44
10

28
48
10

52

30

33
17

52

30
33
54
25
25
17
30

28

33
13

35

22

44

26

21

42

35
22
35
39

20
20

22

36

52

35

40
2d/54e
25d
25e
17a 3
30c

35b
44e
28b 52
39a
#7
16
(Spring)
23 33e
52
2e
13b 33d
33c

21b/31
19c/21
44a 2
15e 33b 22
17b
19d/21
34a
15
21a
48a
27a 44b 10f
15f/18
17c/18
29 48b
44d
19b/21 19a 10i
43b
2f

43c/45
9
28a
11
42a
44c 10g
10
48
44f/45

48
10h

52

18

2
52

10
12

19

38
52 26 32

33

17

13
42 52

52 43

#3

22
22

30

30

52

23

36

25

20 21

15

40
25

22 19

52
27

52

39

10
52

20a

52
28

48

48

36f 26

38

#2

35

38

23b

15

35

30

X-1

19
15

22
35

19

48

19

24

27b

10
12

12a
4
52
28c
48
47b 2a/54a

10d

X-3

41

2g

7b

FILTER
(308)

23

48

36

7a
6

X-4

36

10
48

40

37b
10a

24a
48

37

2
15b
48 11a/10b

23c
24b

41

43

13

48
52

36

10

48

16a
37d

23

15

48

48

24

37

27
13

FRONT

19

19

11

FRONT

2
41

13
#12

48
48

24

48

10
20

42

20

43

27

47

12

27

48

48

24

FILTER
(312)

15c/16

36

37

27

48
15d/16

48

48

48

48

20

13
48

48

16

37

48
48

48

16

48

28

15

37
7

32

21

48

52

48
16

48
37

23

16

12
28

16
48

11

10

48
23

15

48

ARE USED FOR

48

16

48

48

FRONT

48

PASSAGES MARKED WITH


THE 5L40-E ONLY

X-2

48
32

CASE (24)
(Top Channel Plate Side)

EXHAUST FLUID NOT SHOWN


#1

12

(36)

DUAL PURPOSE PASSAGES HAVE


CHANNEL PLATE SIDE NUMBERS LISTED FIRST

FLUID PUMP COVER (202)


(Case Side)

16

52

12 (203)

FRONT

TORQUE CONVERTER HOUSING (227)


(Fluid Pump Cover Side)

16

(203)

32

52

16

52

FRONT

37

(203)

52

21

INDICATES BOLT HOLES

52

37

52

NON FUNCTIONAL HOLES HAVE BEEN


REMOVED FROM COMPONENT DRAWINGS
TO SIMPLIFY TRACING FLUID FLOW.

24

52
52

21

32

52

12

52

52

15

18

CASE (24)
(Fluid Pump Cover Side)

37

48

34

30

52

48

52

48

32
9

37 16 21

16

24

52

48

52

(40)

12

48

FLUID PUMP COVER (202)


(Torque Converter Housing Side)

16

35

30

52

52

52

21

FRONT

48

(213)
1

50

24
4
53
48
7

32

2/21

41

16

12

32

(214) 21

37
16

37

12

52
52

24

24
48

2
4

52

(233)

52

52
7

48
53

52

52

7
48

48

52

21

50

52

48

12

51

51

37

24

24

16

32

52

16

2
12

52

48

FRONT

53
5

31

52

52

52

TRANSMISSION
VENT
ASSEMBLY

48

(232)

48

48
4

(231)

51

(233)

44

48

48

REAR CONTROL VALVE BODY (310)


(Bottom Channel Plate Side)

(from Manual Second Second Gear)

FORWARD CLUTCH
COAST CLUTCH
LUBE

35c

30a

30b

2d
2e

30c

10h

45
43c

ON

#10

EX

EX
SECOND COAST CLUTCH
OVERDRIVE CLUTCH FEED 1
2345
2345
23 REGULATED
4-5 SIGNAL

45

48

29

EX

48a
34a

EX

48b

2345
2345
2345
32 SM

22

4-5 SHIFT
SOLENOID
VALVE
N/C

EX
EX

33b

#9

EX
EX
EX

ON

11
10i

43

LINE

13b
13

18

2345

LOW AND REV CL OR RLO

EX

39a

2-3 SIGNAL

(C)

33c

22b

FEED LIMIT
LINE SAFETY MODE
123 BRAKING
123
123

22c
22e
22

X-1

28
26a
32a

32 SM

123
D432

1-2 SIGNAL
123
FEED LIMIT

32 SAFETY MODE

32 SAFETY MODE
REVERSE LOCKOUT
D432

32

D432
32

2-3 SIGNAL

2-3 SIGNAL

TOP CHANNEL PLATE (301)


CASE (24)

REVERSE LOCKOUT
COAST CLUTCH

REVERSE LOCKOUT
COAST CLUTCH
FORWARD CLUTCH

REVERSE LOCKOUT
COAST CLUTCH

1-2 SIGNAL

D432
FEED LIMIT
2-3 SIGNAL

LINE

123 BRAKING
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2
45
OVERDRIVE CLUTCH FEED 1

LINE SAFETY MODE

123 REGULATED

LINE

OVERDRIVE CL FD 2
OVERDRIVE CL FD 1
RLO

21

#6
19

15

19c

21

20b

31

#5

21c

31

17
21b

21a

#7

42a

16

19b

20d

20c

#4

22f

123 REGULATED
123 BRAKING

123
123
2345

32

15e
22d
43b

19a

2f

2h

X-5

38d

27

18
15f

#8

2345
38

38b

#3

38c

22g

14a

#2

17c

45
123

23

19i

19g

26b

SPACER PLATE (307)

17b

45

45

19d

R N D 4 3 2

D432

LINE

REV

EX

MANUAL VALVE

LINE

15

1-2 SIGNAL

(B)

44c

44f

D432
FEED LIMIT

FDL

2-3 SHIFT
SOLENOID
VALVE
N/C

CNTRL

45

123 REGULATED
23 REGULATED

FDL 44

32 SM/FDL
2345
LOW AND REVERSE CL

28a

LINE SAFETY MODE

COAST CLUTCH
FORWARD CLUTCH

LOW AND REV CL OR RLO


REVERSE LOCKOUT
SECOND COAST CLUTCH

10

EX

45

REVERSE

23 REGULATED

#11
22a

1-2 SIGNAL

32
2-3 SIGNAL

2-3 SIGNAL

EX

33d

EX

EX

2345

345
2345

EX

EX

EX

FDL

33e

COAST CLUTCH FEED


OVERDRIVE CLUTCH FEED 2
45

123
FEED LIMIT
32 SAFETY MODE

INTERMEDIATE CL

23

OFF

4-5 SHIFT VLV CNTRL

LINE
1-2 SIGNAL

LINE

35a
35b

32

LINE

54e

2m
30d

FDL

EX

FDL
EX

(A)

GASKET (303)

FORWARD CLUTCH
COAST CLUTCH

SUCTION

36a

25a

25b

24c

15a

13a

38a

36b

37b

37a

D432

12

Figure 106

123 REGULATED
123 BRAKING
345

TCC SIGNAL
REVERSE LOCKOUT
TCC SIGNAL
123 REGULATED
123 BRAKING
123 REGULATED
345

345

DIRECT CLUTCH
345
45
LINE SAFETY MODE

REGULATED APPLY
LINE

7a

24b

TCC SIGNAL

45

FLUID FILTER
ASSEMBLY
(59)

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED

EX
EX

EX

EX

REGULATED APPLY

TCC SIGNAL
36f

36d

36e

23b

19

OVERDRIVE CLUTCH FEED 1

FLUID
PAN
(62)

10g

1-2 SHIFT
SOLENOID
VALVE
N/C

LOW PRESSURE

GASKET (305)
BOTTOM CHANNEL PLATE (304)

REVERSE LOCKOUT
LINE
REGULATED APPLY
2345 OR REVERSE
OVERDRIVE CLUTCH FEED 2

THROTTLE SIGNAL

2345

REV

REAR CONTROL VALVE BODY (310)


GASKET (309)

345

44b

40a

26

44a
10f
27a

24

2345

44e
44d
28b

INTERMEDIATE CLUTCH
INTERMEDIATE CLUTCH
23 REGULATED

345

345

X-4

17a

FDL

345
45

123
D432
345
DIRECT CLUTCH

EX

EX

345

23a

2345 OR REVERSE

FILTER
(308)

25

EX

EX

MEMORY
FEED LIMIT
LINE
EX

EX

EX

2345 OR REVERSE

EX

2345 OR REVERSE

REVERSE CLUTCH

REVERSE LOCKOUT
LINE

REVERSE LOCKOUT

TCC SIGNAL

345

REVERSE CLUTCH

PRESSURES
INTAKE & DECREASE (SUCTION)
CONVERTER & LUBE
MAINLINE
REGULATED LINE
SOLENOID SIGNAL
ACCUMULATOR
FEED LIMIT
THROTTLE SIGNAL

15

25c
25e

21

COAST CLUTCH

FORWARD CLUTCH

TCC PWM
SOLENOID
VALVE
N/C

23c

FEED LIMIT
2-3 SIGNAL
32
1-2 SIGNAL

LINE

(214)

16a

REVERSE CLUTCH

32 SAFETY MODE

21

1
FLUID
PUMP
COVER
(202)

X-2

24a

REGULATED APPLY

SUCTION
2

LINE

16

#1

EX

FLUID PUMP
SCREEN
ASSEMBLY
(213)

16

25d

2-3 SIGNAL
FEED LIMIT

REVERSE
LOCKOUT
VALVE

LINE

TCC REGULATOR VALVE

36c

345

15c

OVERDRIVE CLUTCH FEED 1


OVERDRIVE CLUTCH FEED 2

CONVERTER
HOUSING
(224)

15b

15d

345

TCC
ENABLE
VALVE

FEED LIMIT VALVE

23

13

32
1-2 SIGNAL

TCC SIGNAL
REGULATED APPLY

LINE

APPLY

FEED LIMIT
FEED LIMIT

10c
10

FEED LIMIT
2-3 SIGNAL

TCC
CONTROL
VALVE

10a

20

FD LIMIT

2-3 SHIFT VALVE

CNTRL 3-4 SHIFT

10d

THROTTLE SIGNAL

RELEASE
TO COOLER

CONVERTER FEED

D432
SECOND CLUTCH
23 REGULATED
123 REGULATED
123 REGULATED
LOW AND REVERSE CLUTCH
FDL
2-3 SIGNAL
FDL
FEED LIMIT
1-2 SIGNAL

1-2 SHIFT CONTROL VALVE

D432

19e

RLO

2-3 SIGNAL

D432

19f

TCC SIGNAL

123
D432

DIRECT CLUTCH

14

LINE SAFETY MODE

1-2 SIGNAL

19h

33a

2345

123 REGULATED

10b

D432

SECOND CLUTCH

1-2 SHIFT VALVE

SAFETY MODE

28c

CONVERTER FDL
CONVERTER FEED

FORWARD CLUTCH

DECREASE

LINE

COAST CLUTCH

LINE

SECOND CLUTCH
D432

PRESSURE
CONTROL
SOLENOID
VALVE

EX

11a

EX

FILTER
(312)

MEMORY

THROTTLE SIGNAL
FILTERED FEED LIMIT

11b

19j

PRESSURE
RELIEF
BALL
VALVE

EX

REVERSE CLUTCH

54g

54d

54b

MEMORY PILOT

DIRECT CLUTCH

46

20a

APPLY

36

12a

OVERDRIVE CL FD 1
OVERDRIVE CL FD 2
345
FEED LIMIT
LINE

EX

46

47b

32
1-2 SIGNAL
32 SAFETY MODE

DIRECT CLUTCH

DIRECT CLUTCH

30

27c

FEED LIMIT
MEMORY
MEMORY PILOT

EX

47a

AIR
BLEED
(233)

X-3

ACCUM

D432

32
32 SAFETY MODE

10e

AIR
BLEED
(203)

AIR
BLEED
(203)

21

SECOND CLUTCH

LINE

2b

ACCUMULATOR
INTERMEDIATE CLUTCH

32

42b

LINE
SECOND CLUTCH

19

32 SAFETY MODE

43a

INTERMEDIATE CLUTCH

ACCUM

DIRECT CLUTCH

37d

LINE

COAST CLUTCH

CASE (24)

CONVERTER FEED
DECREASE
PRESS REG VALVE

EX

SECOND
CLUTCH
ACCUMULATOR

OVERDRIVE CLUTCH FEED 2

40b

27b

AIR
BLEED
(203)

EX

INTERMEDIATE
CLUTCH
ACCUMULATOR

31

BOOST VALVE

OVERDRIVE CLUTCH FEED 1

ACCUMULATOR HOUSING (333)

COAST CLUTCH
123
123

39c
39b

LUBE

THROTTLE SIGNAL

OVERDRIVE CLUTCH FEED 2

41

32

EX

ACCUMULATOR

40c

DIRECT CLUTCH

FLUID
PRESSURE
TEST PLUG
(40)

54c

#12

COAST CLUTCH

AIR
BLEED
(233)

ACCUMULATOR

54a

5
2c

TO COOLER

LINE

OVERDRIVE
CLUTCH
ACCUMULATOR

ACCUM
OVERDRIVE CL FD 2 40d

2a

REVERSE CLUTCH
FORWARD CLUTCH

AIR
BLEED
(203)

EX

DIRECT
CLUTCH
ACCUMULATOR

GASKET (309)
FRONT CONTROL VALVE BODY (311)

ACCUMULATOR HOUSING (328)

EX

37c

COOLER

SPACER PLATE (307)

SECOND CLUTCH
REVERSE LOCKOUT

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (323)

DIRECT CL

OVERDRIVE CLUTCH

CO

R
OLE

BOTTOM CHANNEL PLATE (304)


GASKET (305)

LOW AND REV CL OR RLO


SECOND COAST CLUTCH

CENTER
SUPPORT
ASSEMBLY
(510535)

54f

APPLY

GASKET (303)

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH
LUBE

TO

110

OVERDRIVE CLUTCH
ACCUMULATOR HOUSING (317)
CASE (24)
TOP CHANNEL PLATE (301)

38e

LUBE

2-3 SIGNAL

REVERSE CLUTCH
DIRECT CLUTCH
FORWARD CLUTCH
COAST CLUTCH

E
LUB

OVERDRIVE
AND
INTERMEDIATE
CLUTCH
ASSEMBLY
(480497)

INTERMEDIATE CLUTCH

FORWARD
AND COAST
CLUTCH
ASSEMBLY
(430451)

7b

NOTE:
PASSAGES AND
COMPONENTS
MARKED WITH
ARE USED FOR
THE 5L40-E ONLY

DIRECT
AND REVERSE
CLUTCH
ASSEMBLY
(400420)

RELEASE

WWW.ALL-TRANS.BY

TORQUE
CONVERTER
ASSEMBLY
(1)

35d

MANUAL SECOND FIRST GEAR

MANUAL SECOND FIRST GEAR


(from Manual Second Second Gear)

WWW.ALL-TRANS.BY

In Manual Second range, a 2-1 downshift can be commanded by


the TCM, if the vehicle speed is low enough not to overrev the
engine (calibratable in the TCM). Manual Second First Gear is
commanded in order to achieve maximum engine compression
braking for slowing the vehicle.

NO FIRST GEAR

1-2 Shift Solenoid Valve (368)


Stuck On

1-2 Shift Control Valve (366)


Stuck

1-2 Shift Valve (387)


Stuck
NO ENGINE BRAKING

#8 Ball Check Valve (518)


Stuck
Missing

Fluid Passage Sleeve (38)


Leaking

Low and Reverse Clutch Piston (517)


Leaking
Jammed or cracked

Center Support (518)


Broken
Leaking

4-5 Shift Solenoid Valve (376)


Leaking
No voltage to solenoid

Low Pressure Control Valve (383)


Stuck

SOLENOID
FORWARD OVER- INTERM. INTER- LOW LOW AND
SECOND SECOND
DIRECT REVERSE COAST FORWARD SPRAG DRIVE SPRAG MEDIATE SPRAG REVERSE SECOND SPRAG COAST
1-2 2-3 4-5 CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OFF ON ON

APPLIED APPLIED

LD

LD

APPLIED

LD = LOCKED IN DRIVE

110A

MANUAL SECOND FIRST GEAR


(from Manual Second Second Gear)

WWW.ALL-TRANS.BY

PASSAGES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54

SUCTION
LINE
DECREASE
CONVERTER FEED
RELEASE
APPLY
REGULATED APPLY
TO COOLER
LUBE
FEED LIMIT
FILTERED FEED LIMIT
THROTTLE SIGNAL
LINE SAFETY MODE
REVERSE
REVERSE LOCK OUT (RLO)
REVERSE CLUTCH
LOW AND REVERSE CLUTCH
LOW AND REVERSE CLUTCH OR RLO
D432
123
FORWARD CLUTCH
2345
2345 OR REVERSE
TCC SIGNAL
123 REGULATED
123 BRAKING
1-2 SIGNAL
2-3 SIGNAL
4-5 SIGNAL
SECOND CLUTCH
COAST CLUTCH FEED
COAST CLUTCH
23 REGULATED
SECOND COAST CLUTCH
INTERMEDIATE CLUTCH
345
DIRECT CLUTCH
45
OVERDRIVE CLUTCH FEED 1
OVERDRIVE CLUTCH FEED 2
OVERDRIVE CLUTCH
32
32 SAFETY MODE
FDL
32 SAFETY MODE/FDL
MEMORY PILOT
MEMORY
EXHAUST
OIL RESERVOIR
TORQUE CONVERTER SEAL DRAINBACK
VENT
VOID
CONVERTER FDL
ACCUMULATOR

COMPONENTS ( )
(36)
(40)
(203)
(213)
(214)
(232)
(233)
(306)
(308)
(312)

110B

TRANSMISSION FLUID LEVEL HOLE PLUG


TRANSMISSION FLUID PRESSURE TEST PLUG
CHECK VALVE RETAINER AND BALL ASSEMBLY
TRANSMISSION FLUID PUMP SCREEN ASSEMBLY
BRASS ORIFICE INSERT
ORIFICE SLEEVE
ORIFICE CUP PLUG
CONTROL VALVE BODY BALL CHECK VALVE
(#1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
TCC PWM SOLENOID VALVE FILTER ASSEMBLY
PRESSURE CONTROL SOLENOID VALVE
FILTER ASSEMBLY

MANUAL SECOND FIRST GEAR

(from Manual Second Second Gear)

WWW.ALL-TRANS.BY

(229)

51

48

32 5
21 9

4
53
48
7

NOTE:

(203)

52

32

21

52

48
48
48

37

24
48

12

27

48

24

21

48
32

10

48
48

FRONT

41

42

24
48

28

21

36

42

19
19

43

35 15
13

52

41

28

52

32

52

34

52

34

30

48

48

48
28

48

48
48

18
10

21

48

20
52

2
48

48
21

TOP CHANNEL PLATE (301)


(Bottom Channel Plate Side)

18
48
10

42

17

48

48

34
27

43
28

#10
10

BOTTOM CHANNEL PLATE (304)


(Top Channel Plate Side)

Figure 107

FOLDOUT 111

22g/23
38b

19

18

48
10 42

13

28
2

48
10

#9

#8

BOTTOM CHANNEL PLATE (304)


(Control Valve Body Side)

10

TOP CHANNEL PLATE (301)


(Case Side)

48

45

54b

20
19

36

37
54

47
52

47
10
2

46
13

52

37

36
40

36

52

52
54

48

48

52

40

42
43

39

38

FRONT CONTROL VALVE BODY (311)


(Bottom Channel Plate Side)

40d
54d
2c/54c

19h
15a

48
30b

40a

22b
22d 22c

28

32a

22f
24

20

35a
22e

18

22

14

54f
30a
33a

25
26
25

35d

22a

24c
36a

48
30

19

15

19
14

52

19f

19e

38c

21c/31 27
20c
17
2h 20d

14

35c

25c

48

52
25

21

25b
19

38e

21

15

#6
43

44

38d

52

30

37c

47a

19i

14a/23 26b

#5

52

13
19

28

15

#4

34

27

27

23

11b
10c

27c/46
10e

8
19j
2b
36c 25
13a
23a
37a
40c/41
40b
39c/41
36e
42b 52
36d 36b
43a
39b
38a
48 5
19g

25a

19

52

44
2
10

21

48
48

22

32

19

15
52

35

38

28

#11

38

20

35

X-5

24

19

52

38
52

31

30d

20b
26a

2m/54g

SPACER PLATE (307)


(Bottom Channel Plate Side)

32

38

52

15

19
2

10
48

52

44

34

52
2

10
48

48

27

43

44
10

28
48
10

52

30

33
17

52

30
33
54
25
25
17
30

28

33
13

35

22

44

26

21

42

35
22
35
39

20
20

22

36

52

35

40
2d/54e
25d
25e
17a 3
30c

35b
44e
28b 52
39a
#7
16
(Spring)
23 33e
52
2e
13b 33d
33c

21b/31
19c/21
44a 2
15e 33b 22
17b
19d/21
34a
15
21a
48a
27a 44b 10f
15f/18
17c/18
29 48b
44d
19b/21 19a 10i
43b
2f

43c/45
9
28a
11
42a
44c 10g
10
48
44f/45

48
10h

52

18

2
52

10
12

19

38
52 26 32

33

17

13
42 52

52 43

#3

22
22

30

30

52

23

36

25

20 21

15

40
25

22 19

52
27

52

39

10
52

20a

52
28

48

48

36f 26

38

#2

35

38

23b

15

35

30

X-1

19
15

22
35

19

48

19

24

27b

10
12

12a
4
52
28c
48
47b 2a/54a

10d

X-3

41

2g

7b

FILTER
(308)

23

48

36

7a
6

X-4

36

10
48

40

37b
10a

24a
48

37

2
15b
48 11a/10b

23c
24b

41

43

13

48
52

36

10

48

16a
37d

23

15

48

48

24

37

27
13

FRONT

19

19

11

FRONT

2
41

13
#12

48
48

24

48

10
20

42

20

43

27

47

12

27

48

48

24

FILTER
(312)

15c/16

36

37

27

48
15d/16

48

48

48

48

20

13
48

48

16

37

48
48

48

16

48

28

15

37
7

32

21

48

52

48
16

48
37

23

16

12
28

16
48

11

10

48
23

15

48

ARE USED FOR

48

16

48

48

FRONT

48

PASSAGES MARKED WITH


THE 5L40-E ONLY

X-2

48
32

CASE (24)
(Top Channel Plate Side)

EXHAUST FLUID NOT SHOWN


#1

12

(36)

DUAL PURPOSE PASSAGES HAVE


CHANNEL PLATE SIDE NUMBERS LISTED FIRST

FLUID PUMP COVER (202)


(Case Side)

16

52

12 (203)

FRONT

TORQUE CONVERTER HOUSING (227)


(Fluid Pump Cover Side)

16

(203)

32

52

16

52

FRONT

37

(203)

52

21

INDICATES BOLT HOLES

52

37

52

NON FUNCTIONAL HOLES HAVE BEEN


REMOVED FROM COMPONENT DRAWINGS
TO SIMPLIFY TRACING FLUID FLOW.

24

52
52

21

32

52

12

52

52

15

18

CASE (24)
(Fluid Pump Cover Side)

37

48

34

30

52

48

52

48

32
9

37 16 21

16

24

52

48

52

(40)

12

48

FLUID PUMP COVER (202)


(Torque Converter Housing Side)

16

35

30

52

52

52

21

FRONT

48

(213)
1

50

24
4
53
48
7

32

2/21

41

16

12

32

(214) 21

37
16

37

12

52
52

24

24
48

2
4

52

(233)

52

52
7

48
53

52

52

7
48

48

52

21

50

52

48

12

51

51

37

24

24

16

32

52

16

2
12

52

48

FRONT

53
5

31

52

52

52

TRANSMISSION
VENT
ASSEMBLY

48

(232)

48

48
4

(231)

51

(233)

44

48

48

REAR CONTROL VALVE BODY (310)


(Bottom Channel Plate Side)

LUBRICATION POINTS
WWW.ALL-TRANS.BY

COOLER AND LUBRICATION CIRCUITS


COOLER CIRCUIT:

LUBE FLUID
FROM COOLER

Line pressure from the fluid pump assembly is


directed to the pressure regulator valve (210)
located in the fluid pump cover assembly (202).
Line pressure passes through the pressure regulator
valve (210) and enters the converter feed passage.
Converter feed fluid is routed to the TCC control
valve (235) where it passes through the valve into
the release circuit.
Note: In TCC apply mode, converter feed fluid is
routed directly from the TCC control valve (235) into
the cooler circuit and does not enter the torque converter.

Release fluid passes through the fluid pump cover


assembly (202) and flows between the stator shaft
and the turbine shaft (433).
Release fluid enters a passage in the turbine shaft
(433) and flows to the release side of the torque
converter clutch pressure plate, passes around the
pressure plate and enters the apply side of the plate.
Apply fluid from the torque converter assembly
(1) is then routed back to the TCC control valve
(235) where it passes through the valve and enters
the cooler circuit.
The cooler passage is routed through the fluid pump
cover assembly (202), into the case (24) and is sent
to the transmission cooler located inside the radiator.

LUBRICATION CIRCUITS:

112

Figure 108

Fluid leaving the transmission cooler


enters the lube circuit at the case (24)
and is routed to the fluid pump cover
assembly (202).
Lube passes through the fluid pump
cover assembly (202) and enters the
input shaft (433).
Lube then passes through the input
shaft (433) and flows throughout the
transmission.

Bushing and Bearing Locations


WWW.ALL-TRANS.BY

503

476

473

461

400

17

547

542

23

20

28

561

5L40-E
ONLY

215

226

201

435

456

465

552

519

552
541

465

554

548
5L40-E
ONLY

26

17

LOW CLUTCH ROLLER THRUST BEARING

473

INTERMEDIATE CLUTCH SPRAG ASSEMBLY

20

INPUT AND REACTION CARRIER THRUST BEARING

476

INTERMEDIATE CLUTCH ROLLER THRUST BEARING


ASSEMBLY

23

INPUT AND REACTION CARRIER THRUST BEARING


503

LOW CLUTCH SPRAG ASSEMBLY

26

OUTPUT SHAFT BEARING


519

INPUT AND REACTION BEARING ASSEMBLY

28

OUTPUT SHAFT BEARING


541

INPUT AND REACTION BEARING ASSEMBLY

542

2ND CLUTCH ROLLER INNER RACE BEARING


ASSEMBLY

201

INPUT SHAFT BEARING ASSEMBLY

215

TURBINE SHAFT BUSHING

226

TORQUE CONVERTER BUSHING

547

2ND CLUTCH SPRAG ASSEMBLY

400

REVERSE CLUTCH HOUSING BUSHING

548

INPUT AND REACTION CARRIER BUSHING

435

FORWARD CLUTCH BUSHING

552

REACTION CARRIER BUSHING

456

FORWARD CLUTCH ROLLER INNER BEARING

554

INPUT AND REACTION BEARING ASSEMBLY

461

FORWARD CLUTCH SPRAG ASSEMBLY

561

INPUT AND REACTION CARRIER BUSHING

465

INPUT AND REACTION CARRIER BUSHING ASSEMBLY

bushbrngloc

Figure 109

113

Seal Locations
WWW.ALL-TRANS.BY

229

200

404

406

436

487

438

495

517

528

520
5L40-E
ONLY

29

32

316

56

314

430

38

432

TORQUE CONVERTER HOUSING FLUID SEAL ASSEMBLY

402

REVERSE CLUTCH PISTON INNER SEAL

29

TRANSMISSION PROP SHAFT FLANGE SEAL

404

REVERSE CLUTCH PISTON

32

TRANSMISSION PROP SHAFT FLANGE (O-RING) SEAL

406

DIRECT CLUTCH PISTON ASSEMBLY

38

CENTER SUPPORT FLUID PASSAGE SLEEVE

430

INPUT SHAFT (O-RING) SEAL

39

OVERDRIVE CLUTCH FLUID PASSAGE SLEEVE

431

INPUT SHAFT FLUID SEAL RING

56

A/TRANSMISSION WIRING HARNESS (O-RING) SEAL (2)

432

INPUT SHAFT FLUID SEAL RING

57

TRANSMISSION FILTER SEAL (2)

436

FORWARD CLUTCH PISTON ASSEMBLY

64

A/TRANS FLUID PAN DRAIN PLUG SEAL

438

COAST CLUTCH PISTON ASSEMBLY

200

REVERSE CLUTCH HOUSING FLUID SEAL RING

487

OVERDRIVE CLUTCH PISTON ASSEMBLY

218

A/TRANS FLUID PUMP SLIDE SEAL

495

INTERMEDIATE CLUTCH PISTON ASSEMBLY

220

A/TRANS FLUID PUMP SLIDE RING

517

LOW AND REVERSE CLUTCH PISTON

229

TORQUE CONVERTER HOUSING SEAL

520

2ND CLUTCH PISTON

242

A/TRANS FLUID PUMP SLIDE O-RING SEAL

528

2ND COAST CLUTCH PISTON ASSEMBLY

314

CLUTCH ACCUMULATOR PISTON FLUID


SEAL RING

605

MANUAL SHIFT SHAFT SEAL

316

CLUTCH ACCUMULATOR PISTON FLUID


SEAL RING

242

218

57

39

431

220

402

605

64

sealloc

114

Figure 110

WWW.ALL-TRANS.BY

ILLUSTRATED PARTS LIST

115

WWW.ALL-TRANS.BY

116

27

7
6

29

30

34

26

24

28

25

33
31 32

5
35

37
36

42
45

43

40
38
4L40-E
ONLY

39

12

38

11

Figure 111

4L40-E
ONLY

47

10
9

52

8
51
49

21

22

47

53

50
55 56
54

23

57

20
19

58

57

5L40-E
SOME
MODELS

18
15

16

17

14

59

19

4L40-E
ONLY

59
60

60

61

61

assmpart_explode

62
62

65

64
63

65

64
63

Case and Associated Parts

66
41
5L40-E
ONLY

44

46

Case and Associated Parts Legend


WWW.ALL-TRANS.BY

TORQUE CONVERTER ASSEMBLY

33

TRANSMISSION PROP SHAFT THRUST WASHER

TORQUE CONVERTER HOUSING TO MAIN CASE BOLT

34

PROP SHAFT FLANGE NUT

TORQUE CONVERTER HOUSING ASSEMBLY

35

A/T CASE EXTENSION BOLT

TORQUE CONVERTER HOUSING FLUID SEAL ASSEMBLY

36

TRANSMISSION LEVEL HOLE PLUG

REVERSE CLUTCH HOUSING THRUST WASHER


(SELECTIVE)

37

TRANSMISSION FLUID LEVEL HOLE PLUG O-RING

38

CENTER SUPPORT FLUID PASSAGE SLEEVE

DIRECT AND REVERSE CLUTCH ASSEMBLY


39

OVERDRIVE CLUTCH FLUID PASSAGE SLEEVE

FORWARD AND COAST (W/CLUTCH ASSEMBLY)


40

TRANSMISSION PRESSURE TEST PLUG

INPUT SUN GEAR (W/FORWARD CLUTCH ROLLER


INNER RACE) SHAFT

41

OUTPUT SPEED SENSOR SPACER

DIRECT CLUTCH HUB THRUST WASHER

42

OUTPUT SPEED SENSOR

10

DIRECT CLUTCH (W/INPUT AND REACTION CARRIER IN)


HUB

43

OUTPUT SPEED SENSOR BOLT

44

INPUT SPEED SENSOR

11

INPUT AND REACTION CARRIER INNER SHAFT


THRUST WASHER

45

INPUT SPEED SENSOR BOLT

12

INTERMEDIATE CLUTCH SPRAG ASSEMBLY

46

TRANSMISSION FLUID PUMP COVER GASKET

14

INTERMEDIATE AND OVERDRIVE CLUTCH HOUSING


RETAINER RING (SELECTIVE)

47

CONTROL VALVE BODY AND ACCUMULATOR ASSEMBLY

15

OVERDRIVE CLUTCH HOUSING

49

CONTROL VALVE BODY BOLT

16

LOW CLUTCH SPRAG

50

CONTROL VALVE BODY BOLT

17

LOW CLUTCH ROLLER THRUST BEARING

51

CONTROL VALVE BODY BOLT

18

CENTER SUPPORT

52

MANUAL SHAFT DETENT ASSEMBLY

19

INPUT AND REACTION CARRIER

53

CONTROL VALVE BODY BOLT

20

INPUT AND REACTION CARRIER THRUST BEARING

54

WIRING HARNESS CLIP

21

OUTPUT SHAFT ASSEMBLY (W/REAR INTERNAL GEAR)

55

A/TRANSMISSION WIRING HARNESS

22

INPUT AND REACTION CARRIER WASHER (SELECTIVE)

56

A/TRANSMISSION WIRING HARNESS (O-RING) SEAL (2)

23

INPUT AND REACTION CARRIER THRUST BEARING

57

TRANSMISSION FILTER SEAL (2)

24

A/TRANSMISSION CASE

58

TRANSMISSION FILTER SPACER

25

A/T CASE EXTENSION GASKET

59

A/TRANSMISSION FLUID FILTER

26

OUTPUT SHAFT BEARING

60

A/TRANS FLUID PAN GASKET

27

TRANSMISSION CASE EXTENSION

61

A/TRANS FLUID PAN MAGNET

28

OUTPUT SHAFT BEARING

62

A/TRANS FLUID PAN ASSEMBLY

29

TRANSMISSION PROP SHAFT FLANGE SEAL

63

A/TRANS FLUID PAN DRAIN PLUG

30

OUTPUT SHAFT ASSEMBLY RETAINER

64

A/TRANS FLUID PAN DRAIN PLUG SEAL

31

TRANSMISSION PROP SHAFT FLANGE

65

A/TRANS FLUID PAN BOLT

32

TRANSMISSION PROP SHAFT FLANGE (O-RING) SEAL

66

TRANSMISSION PRESSURE TEST PLUG O-RING SEAL

117

Fluid Pump Assembly


WWW.ALL-TRANS.BY

203
200

233
241

240

211

203

201

238

207

206

205

239
204

202

210
236

209

237

208

234
211
204

214

233
234

212

215

232

235

213

217

216

231

218

219
242
220
221

222

223

224
225
226
227

229
228

118

Figure 112

conv_hous_expl

Fluid Pump Assembly Legend


WWW.ALL-TRANS.BY

200

REVERSE CLUTCH HOUSING FLUID SEAL RING

222

A/TRANS FLUID PUMP VANE

201

INPUT SHAFT BEARING ASSEMBLY

223

A/TRANS FLUID PUMP ROTOR (SELECTIVE)

202

A/TRANS FLUID PUMP COVER ASSEMBLY

224

A/TRANS FLUID PUMP ROTOR GUIDE

203

CHECK VALVE RETAINER AND BALL ASSEMBLY

225

A/TRANS FLUID PUMP VANE RING

204

VALVE BUSHING/SPRING RETAINER

226

TORQUE CONVERTER BUSHING

205

LINE BOOST VALVE BUSHING SEAL

227

TORQUE CONVERTER HOUSING

206

LINE BOOST VALVE BUSHING

228

TORQUE CONVERTER HOUSING SEAL BOLT

207

LINE BOOST VALVE

229

TORQUE CONVERTER HOUSING SEAL

208

LINE BOOST VALVE SPRING

231

A/TRANS FLUID PUMP SLIDE PIN ASSEMBLY

209

PRESSURE REGULATOR VALVE SPRING

232

ORIFICE SLEEVE

210

PRESSURE REGULATOR VALVE

233

ORIFICE CUP PLUG

211

A/TRANS FLUID PUMP RETAINER PIN

234

TCC CONTROL VALVE SPRING

212

A/TRANS FLUID PUMP COVER SEAL

235

TCC CONTROL VALVE

213

A/TRANS FLUID PUMP SCREEN ASSEMBLY

236

A/TRANS FLUID PUMP RETAINER PIN

214

BRASS ORIFICE INSERT

237

TCC ENABLE VALVE

215

TURBINE SHAFT BUSHING

238

PRESSURE RELIEF BALL VALVE SPRING

216

A/TRANS FLUID PUMP SLIDE (SELECTIVE)

239

PRESSURE RELIEF BALL VALVE

217

A/TRANS FLUID PUMP SLIDE SEAL SUPPORT

240

A/TRANS FLUID PUMP BOLT

218

A/TRANS FLUID PUMP SLIDE SEAL

241

A/TRANS FLUID PUMP BOLT

219

A/TRANS FLUID PUMP SLIDE SPRING

242

A/TRANS FLUID PUMP SLIDE O-RING SEAL

220

A/TRANS FLUID PUMP SLIDE RING

221

A/TRANS FLUID PUMP VANE RING

119

Control Valve Body and Accumulator Assembly


WWW.ALL-TRANS.BY

5L40-E
318 ONLY

300

318

318

301

318
333
332

302

331

303

328
323
317

327

322
326

316
304

321

330

315

325
329

320
324

314

305

319

313
5L40-E
ONLY

306

307

305
308

309
4L40-E
ONLY
312
307

310

311

120

Figure 113

vb_explode

Control Valve Body and Accumulator Assembly Legend


WWW.ALL-TRANS.BY

300

CONTROL VALVE BODY BOLT

318

ACCUMULATOR HOUSING BOLT

301

CONTROL VALVE TOP CHANNEL PLATE

319

OVERDRIVE CLUTCH ACCUMULATOR PISTON SPRING

302

CONTROL VALVE CHANNEL PLATE BALL CHECK SPRING

320

OVERDRIVE CLUTCH ACCUMULATOR PISTON FLUID


SEAL RING

303

CONTROL VALVE CHANNEL PLATE GASKET


321

OVERDRIVE CLUTCH ACCUMULATOR PISTON

304

CONTROL VALVE BOTTOM CHANNEL PLATE


322

305

CONTROL VALVE BODY GASKET

OVERDRIVE CLUTCH ACCUMULATOR PISTON FLUID


SEAL RING

306

CONTROL VALVE BODY BALL CHECK VALVE

323

OVERDRIVE CLUTCH ACCUMULATOR HOUSING

307

CONTROL VALVE BODY SPACER PLATE

324

INTERMEDIATE CLUTCH ACCUMULATOR PISTON


SPRING

308

TCC PWM SOLENOID VALVE FILTER ASSEMBLY


325

309

CONTROL VALVE BODY SPACER PLATE GASKET

INTERMEDIATE CLUTCH ACCUMULATOR PISTON


FLUID RING

310

CONTROL VALVE REAR BODY

326

INTERMEDIATE CLUTCH ACCUMULATOR PISTON

311

CONTROL VALVE FRONT BODY

327

INTERMEDIATE CLUTCH ACCUMULATOR PISTON FLUID


SEAL RING

312

PRESSURE CONTROL SOLENOID VALVE FILTER


ASSEMBLY

328

INTERMEDIATE CLUTCH ACCUMULATOR HOUSING

313

DIRECT CLUTCH ACCUMULATOR PISTON SPRING

329

2ND CLUTCH ACCUMULATOR PISTON SPRING

314

DIRECT CLUTCH ACCUMULATOR PISTON FLUID


SEAL RING

330

2ND CLUTCH ACCUMULATOR PISTON RING

331

2ND CLUTCH ACCUMULATOR PISTON

315

DIRECT CLUTCH ACCUMULATOR PISTON


332

2ND CLUTCH ACCUMULATOR PISTON RING

316

DIRECT CLUTCH ACCUMULATOR PISTON FLUID


SEAL RING

333

2ND CLUTCH ACCUMULATOR HOUSING

317

DIRECT CLUTCH ACCUMULATOR HOUSING

121

Front Control Valve Body


WWW.ALL-TRANS.BY

343
342

343

341
344

340

345
346

357

355
356

351
353
347

354
348

343

349
350
352

351

340

CONTROL VALVE FRONT BODY

349

SOLENOID VALVE (O-RING) SEAL

341

SAFETY MODE VALVE

350

SOLENOID VALVE (O-RING) SEAL

342

SAFETY MODE VALVE SPRING

351

SOLENOID VALVE RETAINER

343

VALVE SPRING RETAINER

352

TCC PWM SOLENOID VALVE

344

3-4 SHIFT VALVE SPRING

353

FEED LIMIT VALVE

345

3-4 SHIFT VALVE

354

FEED LIMIT VALVE SPRING

346

3-4 SHIFT CONTROL VALVE

355

PRESSURE CONTROL SOLENOID (O-RING) SEAL

347

TCC REGULATOR APPLY VALVE SPRING

356

PRESSURE CONTROL SOLENOID (O-RING) SEAL

348

TCC REGULATOR APPLY VALVE

357

PRESSURE CONTROL SOLENOID ASSEMBLY

vb2_disassembly

122

Figure 114

Rear Control Valve Body


WWW.ALL-TRANS.BY

368

343
350
367

369

351

366
349

376

370
371

351

365

350
372

349

375

349

350
351

374
387

373

388
384
385
383

386
343

343

382

381

377
378
380

379

343

VALVE SPRING RETAINER

375

4-5 SHIFT CONTROL VALVE

349

SOLENOID VALVE (O-RING) SEAL

376

4-5 SHIFT SOLENOID VALVE ASSEMBLY

350

SOLENOID VALVE (O-RING) SEAL

377

MANUAL VALVE

351

SOLENOID VALVE RETAINER

378

MANUAL VALVE LINK WASHER (WAVED)

365

CONTROL VALVE REAR BODY

379

MANUAL VALVE LINK

366

1-2 SHIFT CONTROL VALVE

380

MANUAL VALVE LINK RETAINER

367

1-2 SHIFT CONTROL VALVE SPRING

381

LOW PRESSURE CONTROL VALVE BORE PLUG

368

1-2 SHIFT SOLENOID VALVE ASSEMBLY

382

LOW PRESSURE CONTROL VALVE SPRING

369

2-3 SHIFT SOLENOID VALVE ASSEMBLY

383

LOW PRESSURE CONTROL VALVE

370

2-3 SHIFT CONTROL VALVE

384

LOW PRESSURE CONTROL VALVE BORE RETAINER

371

2-3 SHIFT VALVE

385

REVERSE LOCKOUT VALVE

372

2-3 SHIFT VALVE SPRING

386

REVERSE LOCKOUT VALVE SPRING

373

4-5 SHIFT VALVE SPRING

387

1-2 SHIFT VALVE

374

4-5 SHIFT VALVE

388

1-2 SHIFT VALVE SPRING


vb1_disassembly

Figure 115

123

Direct and Reverse Clutch Assembly


WWW.ALL-TRANS.BY

409
408
407
406
405
404
402
401
400

414
413
403

412
411
410

420
419

418
417
416
415

124

400

REVERSE CLUTCH HOUSING BUSHING

401

REVERSE CLUTCH (W/INPUT HOUSING ASSEMBLY)

402

REVERSE CLUTCH PISTON INNER SEAL

403

REVERSE CLUTCH HOUSING BALL CHECK VALVE

404

REVERSE CLUTCH PISTON

405

DIRECT CLUTCH HOUSING BALL CHECK VALVE

406

DIRECT CLUTCH PISTON ASSEMBLY

407

DIRECT AND REVERSE CLUTCH SPRING

408

DIRECT AND REVERSE CLUTCH SPRING RETAINER

409

DIRECT AND REVERSE CLUTCH SPRING RETAINER RING

410

DIRECT CLUTCH APPLY PLATE

411

DIRECT CLUTCH PLATE ASSEMBLY (OUTER SPLINE)

412

DIRECT CLUTCH PLATE ASSEMBLY (INNER SPLINE)

413

DIRECT CLUTCH BACKING PLATE

414

DIRECT CLUTCH BACKING PLATE RETAINER RING


(SELECTIVE)

415

REVERSE CLUTCH SPACER

416

REVERSE CLUTCH APPLY PLATE

417

REVERSE CLUTCH PLATE ASSEMBLY (OUTER SPLINE)

418

REVERSE CLUTCH PLATE ASSEMBLY (INNER SPLINE)

419

REVERSE CLUTCH BACKING PLATE

420

REVERSE CLUTCH BACKING PLATE RETAINER RING


(SELECTIVE)

Partlist_A

Figure 116

Forward and Coast Clutch Assembly


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440
439
438
436
434

437

435

433

430 431

432

446
445

444
443
442
441

451
450

449
448
447

440

FORWARD AND COAST CLUTCH SPRING


RETAINER RING

441

COAST CLUTCH SPACER PLATE (SELECTIVE)

442

COAST CLUTCH APPLY PLATE

443

COAST CLUTCH PLATE ASSEMBLY (OUTER SPLINE)

444

COAST CLUTCH PLATE ASSEMBLY (INNER SPLINE)

430

INPUT SHAFT (O-RING) SEAL

431

INPUT SHAFT FLUID SEAL RING

432

INPUT SHAFT FLUID SEAL RING

433

FORWARD CLUTCH (W/INPUT HOUSING ASSEMBLY)


445

COAST CLUTCH BACKING PLATE

434

FORWARD CLUTCH HOUSING BALL CHECK VALVE


ASSEMBLY

446

COAST CLUTCH HOUSING

435

FORWARD CLUTCH BUSHING

447

FORWARD CLUTCH APPLY PLATE

436

FORWARD CLUTCH PISTON ASSEMBLY

448

FORWARD CLUTCH PLATE ASSEMBLY (OUTER SPLINE)

437

COAST CLUTCH PISTON BALL CHECK VALVE


ASSEMBLY

449

FORWARD CLUTCH PLATE ASSEMBLY (INNER SPLINE)

450

FORWARD CLUTCH BACKING PLATE

438

COAST CLUTCH PISTON ASSEMBLY

451

439

FORWARD AND COAST CLUTCH SPRING

FORWARD CLUTCH BACKING PLATE


RETAINER RING (SELECTIVE)
Partlist_B

Figure 117

125

Input Sun Gear Shaft and Forward Sprag Clutch Assembly


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462

457

456

455

460
461
460

459
458

458

FORWARD CLUTCH ROLLER OUTER RACE WASHER

459

FORWARD CLUTCH SPRAG OUTER RACE

460

FORWARD CLUTCH SPRAG ASSEMBLY RETAINER


RINGS

455

FORWARD CLUTCH ROLLER INNER RACE THRUST RING

456

FORWARD CLUTCH ROLLER INNER BEARING

461

FORWARD CLUTCH SPRAG ASSEMBLY

457

INPUT SUN GEAR SHAFT ASSEMBLY

462

ORIFICED CUP PLUG (LUBE)

Partlist_C

Figure 118

Direct Clutch Drum and Shaft Assembly


465

466

465

465

INPUT AND REACTION CARRIER BUSHING ASSEMBLY

466

DIRECT CLUTCH (W/INPUT AND HUB ASSEMBLY)


Partlist_D

126

Figure 119

Intermediate Sprag Clutch Assembly


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470

474

472
473
472
471

477
476
475
470

OVERDRIVE AND REVERSE CLUTCH (W/HUB


ASSEMBLY)

471

INTERMEDIATE CLUTCH ROLLER THRUST WASHER

472

INTERMEDIATE CLUTCH SPRAG ASSEMBLY


RETAINER RINGS

473

INTERMEDIATE CLUTCH SPRAG ASSEMBLY

474

INTERMEDIATE CLUTCH SPRAG OUTER RACE

475

INTERMEDIATE CLUTCH ROLLER THRUST WASHER

476

INTERMEDIATE CLUTCH ROLLER THRUST BEARING


ASSEMBLY

477

INTERMEDIATE CLUTCH ROLLER THRUST BEARING


ASSEMBLY RETAINER

Partlist_E

Figure 120

127

Overdrive and Intermediate Clutch Assembly


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483
482
481
480

487
486
485
484

492

491
490
489
488

497
496
495
494
493

Partlist_F

128

Figure 121

Overdrive and Intermediate Clutch Assembly Legend


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480

OVERDRIVE CLUTCH BACKING PLATE


RETAINER RING (SELECTIVE)

489

INTERMEDIATE CLUTCH BACKING PLATE

481

OVERDRIVE CLUTCH BACKING PLATE

490

INTERMEDIATE CLUTCH PLATE ASSEMBLY


(INNER SPLINE)

482

OVERDRIVE CLUTCH PLATE ASSEMBLY


(INNER SPLINE)

491

INTERMEDIATE CLUTCH PLATE ASSEMBLY


(OUTER SPLINE)

483

OVERDRIVE CLUTCH PLATE ASSEMBLY


(OUTER SPLINE)

492

INTERMEDIATE CLUTCH APPLY PLATE

493

OVERDRIVE CLUTCH HOUSING

484

OVERDRIVE CLUTCH SPACER


494

INTERMEDIATE CLUTCH SPRING

485

OVERDRIVE CLUTCH SPRING RETAINER RING


495

INTERMEDIATE CLUTCH PISTON ASSEMBLY

486

OVERDRIVE CLUTCH SPRING


496

INTERMEDIATE CLUTCH (W/HOUSING ASSEMBLY)

487

OVERDRIVE CLUTCH PISTON ASSEMBLY


497

INTERMEDIATE CLUTCH HOUSING RETAINER RING

488

INTERMEDIATE CLUTCH BACKING PLATE


RETAINER RING (SELECTIVE)

Low Clutch Sprag Assembly


505

501
504
502
503
502
501
500

500

LOW CLUTCH ROLLER RETAINER

503

LOW CLUTCH SPRAG ASSEMBLY

501

LOW CLUTCH ROLLER THRUST WASHER

504

LOW CLUTCH SPRAG OUTER RACE

502

LOW CLUTCH SPRAG ASSEMBLY RETAINER RINGS

505

LOW CLUTCH SPRAG INNER RACE

Figure 122

Partlist_G

129

Center Support Assembly


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514

513
512
511
510

5L40-E
ONLY
521

522

520
519
518
517
516

515
528
527
526

525
524
523
535
534

533
532
531
530
529

Partlist_H

130

Figure 123

Center Support Assembly Legend


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510

LOW AND REVERSE CLUTCH PLATE


RETAINER RING (SELECTIVE)

511

LOW AND REVERSE CLUTCH BACKING PLATE

512

LOW AND REVERSE CLUTCH PLATE ASSEMBLY


(INNER SPLINE)

513

LOW AND REVERSE CLUTCH PLATE ASSEMBLY


(OUTER SPLINE)

514

LOW AND REVERSE CLUTCH APPLY PLATE

515

LOW AND REVERSE CLUTCH SPRING RETAINER RING

516

LOW AND REVERSE CLUTCH SPRING

517

LOW AND REVERSE CLUTCH PISTON

518

CENTER SUPPORT

519

INPUT AND REACTION BEARING ASSEMBLY

520

2ND CLUTCH PISTON

521

2ND CLUTCH SPRING

522

2ND CLUTCH SPRING RETAINER RING

523

2ND CLUTCH APPLY PLATE

524

2ND CLUTCH PLATE ASSEMBLY (OUTER SPLINE)

525

2ND CLUTCH PLATE ASSEMBLY (INNER SPLINE)

526

2ND CLUTCH BACKING PLATE

527

2ND CLUTCH BACKING PLATE


RETAINER RING (SELECTIVE)

528

2ND COAST CLUTCH PISTON ASSEMBLY

529

2ND COAST CLUTCH SPRING

530

2ND COAST CLUTCH SPRING RETAINER RING

531

2ND COAST CLUTCH SPACER

532

2ND COAST CLUTCH PLATE ASSEMBLY (OUTER SPLINE)

533

2ND COAST CLUTCH PLATE ASSEMBLY (INNER SPLINE)

534

2ND COAST CLUTCH BACKING PLATE

535

2ND COAST CLUTCH PLATE (BACKING PLATE)


RETAINER RING (SELECTIVE)

131

Planetary Carrier Assembly


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544
546
547
546
545
544
543
542
541
540
554
552
553
552
551
550
549
548

4L40-E
ONLY
553

5L40-E
ONLY

540

INPUT AND REACTION CARRIER OUTER RING

547

2ND CLUTCH SPRAG ASSEMBLY

541

INPUT AND REACTION BEARING ASSEMBLY

548

INPUT AND REACTION CARRIER BUSHING

542

2ND CLUTCH ROLLER INNER RACE BEARING


ASSEMBLY

549

2ND CLUTCH SPRAG INNER (W/RACE)

550

REACTION INTERNAL GEAR

543

2ND CLUTCH SPRAG RETAINER


551

REACTION INTERNAL GEAR FLANGE WASHER

544

2ND CLUTCH ROLLER OUTER RACE WASHER


552

REACTION CARRIER BUSHING (2)

545

2ND CLUTCH SPRAG OUTER RACE


553

INPUT AND REACTION CARRIER

546

2ND CLUTCH SPRAG ASSEMBLY RETAINER


554

INPUT AND REACTION BEARING ASSEMBLY

Partlist_J

132

Figure 124

Rear Internal Gear Output Shaft Assembly (4L40-E)


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563

562

564
561
560

562

OUTPUT SHAFT ASSEMBLY

560

REAR INTERNAL GEAR

563

REAR INTERNAL RETAINER RING

561

INPUT AND REACTION CARRIER BUSHING

564

CUP PLUG

Partlist_K4L40-E

Figure 125

Rear Internal Gear Output Shaft Assembly (5L40-E)


563
562

564
561
560

562

OUTPUT SHAFT ASSEMBLY

560

REAR INTERNAL GEAR

563

REAR INTERNAL RETAINER RING

561

INPUT AND REACTION CARRIER BUSHING

564

CUP PLUG

Figure 126

Partlist_K

133

Park Pawl Assembly A


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601

600

615
602

613

606
612

604

605

614

611
610

607
608
609

600

MANUAL SHAFT DETENT LEVER

609

PARK PAWL ACTUATOR BRACKET BOLT

601

MANUAL SHAFT DETENT LEVER PIN

610

PARK PAWL SHAFT

602

TRANSMISSION MANUAL SHIFT SHAFT SWITCH


ASSEMBLY

611

PARK PAWL SPRING

612

PARK PAWL

604

TRANSMISSION CASE ASSEMBLY


613

PARK PAWL ACTUATOR ASSEMBLY

605

MANUAL SHIFT SHAFT SEAL


614

CUP PLUG

606

MANUAL SHIFT SHAFT


615

607

PARK PAWL ACTUATOR BRACKET

TRANSMISSION MANUAL SHIFT SHAFT ASSEMBLY


SPACER

608

PARK PAWL ACTUATOR BRACKET


shift_assmA

134

Figure 127

Park Pawl Assembly B


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601

600

602

613

603
612

604

605

611

606

610

607
608
609

600

MANUAL SHAFT DETENT LEVER

608

PARK PAWL ACTUATOR BRACKET

601

MANUAL SHAFT DETENT LEVER PIN

609

PARK PAWL ACTUATOR BRACKET BOLT

602

TRANSMISSION MANUAL SHIFT SHAFT SWITCH


ASSEMBLY

610

PARK PAWL SHAFT

611

PARK PAWL SPRING

603

MANUAL SHAFT DETENT LEVER PIN


612

PARK PAWL

604

TRANSMISSION CASE ASSEMBLY


613

PARK PAWL ACTUATOR ASSEMBLY

605

MANUAL SHIFT SHAFT SEAL

606

MANUAL SHIFT SHAFT

607

PARK PAWL ACTUATOR BRACKET


shift_assmB

Figure 128

135

BASIC SPECIFICATIONS
WWW.ALL-TRANS.BY

HYDRA-MATIC 4L40-E TRANSMISSION


Produced at: Strasbourg,
France

HYDRA-MATIC 4L40-E
(FOUR-SPEED)

Transmission Drive
Rear Wheel Drive
All Wheel Drive

Transmission Fluid Capacity (Approximate)


245 mm Converter (Dry): 8.5 L (9.0 qt)

Transmission Type
4L40-E = 4: Four Speed
L: Longitudinal Mount
40: Product Series
E: Electronically Controlled

Transmission Weight
245 mm Converter (Dry): 66.5 kg (146.6 lb)
(Wet): 74.0 kg (163.1 lb)
Converter Sizes Available
245 mm

Automatic Overdrive with a Torque Converter Clutch Assembly.

Current Engine Range


1.9 L Gasoline
Control Systems
Shift Pattern (3) Two-way on/off solenoids
Shift Quality Pressure Control Solenoid
Torque Converter Clutch Pulse Width Modulated
solenoid control
Gear Ratios
1st
2nd
3rd
4th
Rev

2.82
1.54
1.00
0.70
2.38

Maximum Engine Torque


180 Nm (133 lb ft)
Maximum Gearbox Torque
430 Nm (317 lb ft)
Maximum Shift Speed
Output: 8,500 RPM
Shift: 6,500 RPM
Maximum Gross Vehicle Weight
3,500 kg (7,716 lb)
Transmission Fluid Type
Dexron III
136

Converter Bolt Circle Diameters


For 245 mm Converter 228.0 mm to 247.7 mm
Converter Stall Torque Ratio Range
For 245 mm Converter 1.60 to 2.70
Converter K Factor Range
For 245 mm Converter 122 to 260
Not all K Factors are applicable across the range of Converter Stall Torque Ratios.

Transmission Packaging Information*


Overall Length
723.0 mm with 245 mm Converter
(2 Wheel Drive)
*All dimensions shown are nominal.

Driver Shift Control Only


Pressure Taps Available
Line Pressure
Information may vary with application. All information, illustrations
and specifications contained in this book are based on the latest product
information available at the time of publication. The right is reserved to
make changes at any time without notice.

BASIC SPECIFICATIONS
WWW.ALL-TRANS.BY

HYDRA-MATIC 5L40-E TRANSMISSION


Produced at: Strasbourg,
France

HYDRA-MATIC 5L40-E
(FIVE-SPEED)

Transmission Fluid Capacity (Approximate)


245 mm Converter (Dry): 8.5 L (9.0 qt)

Transmission Drive
Rear Wheel Drive
All Wheel Drive
Transmission Type
5L40-E = 5: Five Speed
L: Longitudinal Mount
40: Product Series
E: Electronically Controlled
Automatic Overdrive with a Torque Converter Clutch Assembly.

Current Engine Range


2.2 L to 3.2 L Gasoline
2.0 L to 3.0 L Diesel
Control Systems
Shift Pattern (3) Two-way on/off solenoids
Shift Quality Pressure Control Solenoid
Torque Converter Clutch Pulse Width Modulated
solenoid control
Gear Ratios
1st
2nd
3rd
4th
5th
Rev

3.42
2.21
1.60
1.00
0.75
3.03

Maximum Engine Torque


390 Nm (288 lb ft)
Maximum Gearbox Torque
670 Nm (494 lb ft)
Maximum Shift Speed
Output: 8,500 RPM
Shift: 6,500 RPM
Maximum Gross Vehicle Weight
3,500 kg (7,716 lb)
Transmission Fluid Type
Dexron III

Transmission Weight
245 mm Converter (Dry): 73.0 kg (161.0 lb)
(Wet): 80.5 kg (177.5 lb)
Converter Sizes Available
245 mm
245 mm Hybrid Converter (Option for applications
above approximately 280 Nm (207 lb ft)
258 mm Converter (Option for applications above
approximately 350 Nm (258 lb ft)
Converter Bolt Circle Diameters
For 245 mm Converter 228.0 mm to 247.7 mm
For 245 mm Hybrid Converter 234.0 mm (Reference)
For 258 mm Converter 234.0 mm (Reference)
Converter Stall Torque Ratio Range
For 245 mm Converter 1.60 to 2.70
For 245 mm Hybrid Converter 2.0 (Reference)
For 258 mm Converter 1.60 to 2.10
Converter K Factor Range
For 245 mm Converter 122 to 260
For 245 mm Hybrid Converter 140 (Reference)
For 258 mm Converter 106 to 164
Not all K Factors are applicable across the range of Converter Stall Torque Ratios.

Transmission Packaging Information*


Overall Length
711.0 to 723.0 mm with 245 mm Converter
(2 Wheel Drive)
728.0 mm with 258 mm Converter
(2 Wheel Drive)
*All dimensions shown are nominal.

Seven Position Quadrant or Driver Shift Control


(P, R, N, D , 4, 3, 2)
Pressure Taps Available
Line Pressure
Information may vary with application. All information, illustrations
and specifications contained in this book are based on the latest product
information available at the time of publication. The right is reserved to
make changes at any time without notice.

137

HYDRA-MATIC PRODUCT DESIGNATION SYSTEM


WWW.ALL-TRANS.BY

The product designation system used for all Hydra-matic


transaxles and transmissions consists of a series of numbers
and letters that correspond with the special features incorporated
in that product line. The first character is a number that
designates the number of forward gear ranges available in that
unit. For example: 4 = four forward gear ranges.
The second character is a letter that designates how the unit is
mounted in the vehicle. When the letter T is used, it
designates that the unit is transversely mounted and is used
primarily for front wheel drive vehicles. The letter L
designates that it is longitudinally mounted in the vehicle and
it is used primarily for rear wheel drive vehicles. The letter
M designates that the unit is a manual transaxle or
transmission but not specific to a front or rear wheel drive
vehicle application.

The third and fourth characters consists of a set of numbers,


(i.e. 40), that designate the transaxle or transmission Series
number. This number signifies the relative torque capacity of
the unit.
The fifth character designates the major features incorporated
into this unit. For example, the letter E designates that the
unit has electronic controls.
By using this method of classification, the HYDRA-MATIC
4L40-E is a 4-speed, longitudinally mounted, 40 series unit,
with electronic controls.

HYDRA-MATIC 4L40-E
HYDRA-MATIC

138

40

Number of
Speeds:
3
4
5
V (CVT)

Type:
T - Transverse
L - Longitudinal
M - Manual

Series:
Based on
Relative
Torque
Capacity

Major Features:
E - Electronic Controls
A - All Wheel Drive
HD - Heavy Duty

HYDRA-MATIC PRODUCT DESIGNATION SYSTEM


WWW.ALL-TRANS.BY

The product designation system used for all Hydra-matic


transaxles and transmissions consists of a series of numbers
and letters that correspond with the special features incorporated
in that product line. The first character is a number that
designates the number of forward gear ranges available in that
unit. For example: 5 = five forward gear ranges.
The second character is a letter that designates how the unit is
mounted in the vehicle. When the letter T is used, it
designates that the unit is transversely mounted and is used
primarily for front wheel drive vehicles. The letter L
designates that it is longitudinally mounted in the vehicle and
it is used primarily for rear wheel drive vehicles. The letter
M designates that the unit is a manual transaxle or
transmission but not specific to a front or rear wheel drive
vehicle application.

The third and fourth characters consists of a set of numbers,


(i.e. 40), that designate the transaxle or transmission Series
number. This number signifies the relative torque capacity of
the unit.
The fifth character designates the major features incorporated
into this unit. For example, the letter E designates that the
unit has electronic controls.
By using this method of classification, the HYDRA-MATIC
5L40-E is a 5-speed, longitudinally mounted, 40 series unit,
with electronic controls.

HYDRA-MATIC 5L40-E
HYDRA-MATIC

40

Number of
Speeds:
3
4
5
V (CVT)

Type:
T - Transverse
L - Longitudinal
M - Manual

Series:
Based on
Relative
Torque
Capacity

Major Features:
E - Electronic Controls
A - All Wheel Drive
HD - Heavy Duty

139

GLOSSARY OF TECHNICAL TERMS


WWW.ALL-TRANS.BY

Accumulator: A component of the transmission that


absorbs hydraulic pressure during the apply of clutch
or band. Accumulators are designed to control the
quality of a shift from one gear range to another.
Adaptive Learning: Programming within the TCM
that automatically adjusts hydraulic pressures in order
to compensate for changes in the transmission (i.e.
component wear).
Applied: An apply component that is holding another
component to which it is splined or assembled with.
Also referred to as engaged.

Apply Components: Hydraulically operated clutches,


servos, bands, and mechanical one-way roller or sprag
clutches that drive or hold members of a planetary
gear set.
Apply Plate: A steel clutch plate in a clutch pack
located next to the (apply) piston.
Backing Plate: A steel plate in a clutch pack that is
usually the last plate in that clutch assembly (farthest
from the clutch piston).

De-energize(d): To interrupt the electrical current that


flows to an electronically controlled device making it
electrically inoperable.
Direct Drive: A condition in a gear set where the
input speed and input torque equals the output speed
and torque. The gear ratio through the gear set is 1:1.
Downshift: A change in a gear ratio where input
speed and torque increases.
Driver Shift Control: A selector system variant which
is configured to be shifted only manually, and allows for
engine braking in first, second, third and fourth gears.
Duty Cycle: In reference to an electronically controlled
solenoid, it is the amount of time (expressed as a
percentage) that current flows through the solenoid coil.
Engine Control Module (ECM): An electronic device
that manages the electrical system of the engine.

Ball Check Valve: A spherical hydraulically controlled


component (usually made of steel) that either seals or
opens fluid circuits. It is also referred to as a check
valve or checkball.

Energize(d): To supply a current to an electronically


controlled device enabling it to perform its designed
function.

Band: An apply component that consists of a flexible


strip of steel and friction material that wraps around a
drum. When applied, it tightens around the drum and
prevents the drum from rotating.

Engine Compression Braking: A condition where


compression from the engine is used with the
transmission to decrease vehicle speed. Braking
(slowing of the vehicle) occurs when a lower gear ratio
is manually selected by moving the gear selector lever.

Brake Switch: An electrical device that provides


signals to the Transmission Control Module (TCM)
based on the position of the brake pedal. The TCM
uses this information to apply or release the torque
converter clutch (TCC).
Centrifugal Force: A force that is imparted on an
object (due to rotation) that increases as that object
moves further away from a center/point of rotation.
Clutch Pack: An assembly of components generally
consisting of clutch plates, an apply plate and a
backing plate.
Clutch Plate: A hydraulically activated component
that has two basic designs: (1) all steel, or (2) a steel
core with friction material bonded to one or two sides
of the plate.

140

Coupling Speed: The speed at which a vehicle is


traveling and no longer requires torque multiplication
through the torque converter. At this point the stator
free wheels to allow fluid leaving the turbine to flow
directly to the pump. (See torque converter)

Exhaust: The release of fluid pressure from a hydraulic


circuit. (The words exhausts and exhausting are also
used and have the same intended meaning.)
Fluid: Generally considered a liquid or gas. In this
publication fluid refers primarily to transmission fluid.
Fluid Pressure: A pressure (in this textbook usually
transmission fluid) that is consistent throughout its circuit.
Force: A measurable effort that is exerted on an object
(component).
Freewheeling: A condition where power is lost through
a driving or holding device (i.e. roller or sprag clutches).
Friction Material: A heat and wear resistant fibrous
material bonded to clutch plates and bands.

Component: Any physical part of the transmission.

Gear: A round, toothed device that is used for


transmitting torque through other components.

Control Valve Body: A machined metal casting that


contains valve trains and other hydraulically controlled
components that shift the transmission.

Gear Range: A specific speed to torque ratio at


which the transmission is operating (i.e. 1st gear,
2nd gear etc.).

GLOSSARY OF TECHNICAL TERMS


WWW.ALL-TRANS.BY

Gear Ratio: Revolutions of an input gear as compared


to the revolutions of an output gear. It can also be
expressed as the number of teeth on a gear as compared
to the number of teeth on a gear that it is in mesh with.

Pulse Width Modulated (PWM): An electronic signal


that continuously cycles the ON and OFF time of a
device (such as a solenoid) while varying the amount
of ON time.

Hydraulic Circuit: A fluid passage which often


includes the mechanical components in that circuit
designed to perform a specific function.

Race (Inner or Outer): A highly polished steel surface


that contacts bearings or sprag or roller elements.

Input: A starting point for torque, revolutions or energy


into another component of the transmission.
Internal Gear: The outermost member of a gear set
that has gear teeth in constant mesh with planetary
pinion gears of the gear set.
Internal Leak: Loss of fluid pressure in a hydraulic
circuit.
Land (Valve Land): The larger diameters of a spool
valve that contact the valve bore or bushing.
Line Pressure: The main fluid pressure in a hydraulic
system created by the pump and pressure regulator
valve.
Manual Valve: A spool valve that distributes fluid to
various hydraulic circuits and is mechanically linked
to the gear selector lever.
Orifice: A restricting device (usually a hole in the
spacer plate) for controlling pressure build up into
another circuit.
Overdrive: An operating condition in the gear set
allowing output speed to be higher than input speed
and output torque to be lower than input torque.
Overrunning: The function of a one-way mechanical
clutch that allows the clutch to freewheel during certain
operating conditions of the transmission.
Pinion Gear: A small toothed gear that meshes with a
larger gear.
Planet Pinion Gears: Pinion gears (housed in a carrier)
that are in constant mesh with a circumferential internal
gear and centralized sun gear.

Reduction (Gear Reduction): An operating condition


in the gear set allowing output speed to be lower
than input speed and output torque to be higher than
input torque.
Residual Fluid Pressure: Excess pressure contained
within an area after the supply pressure has been
terminated.
Roller Clutch: A mechanical clutch (holding device)
consisting of roller bearings assembled between inner
and outer races.
Safety Mode: A condition whereby a component (i.e.
engine or transmission) will partially function even if
its electrical system is disabled.
Servo: A spring loaded device consisting of a piston
in a bore that is operated (stroked) by hydraulic pressure
to apply or release a band.
Solenoid Valve: An electronic device used to control
transmission shift patterns or regulate fluid pressure.
Spool Valve: A cylindrical hydraulic control device
having a variety of land and valley diameters, used to
control fluid flow.
Sprag Clutch: A mechanical clutch (holding device)
consisting of figure eight like elements assembled
between inner and outer races.
Throttle Position: The travel of the throttle plate that
is expressed in percentages and measured by the throttle
position (TP) sensor.
Torque: A measurable twisting force expressed in
terms of Newton-meters (Nm), pounds feet (lbs ft) or
pounds inches (lbs in).

Planetary Gear Set: An assembly of gears that consists


of an internal gear, planet pinion gears with a carrier,
and a sun gear.

Torque Converter: A component of an automatic


transmission, (attached to the engine flywheel) that
transfers torque from the engine to the transmission
through a fluid coupling.

Powertrain Control Module (PCM): An electronic


device that manages most of the electrical systems
throughout the vehicle.

Transmission Control Module (TCM): An electronic


device that manages the electrical system of the
transmission.

Pressure: A measurable force that is exerted on an


area and expressed as kilopascals (kPa) or pounds per
square inch (psi).

Variable Capacity Pump: The device that provides


fluid for operating the hydraulic circuits in the
transmission. The amount of fluid supplied varies
depending on vehicle operating conditions.
141

ABBREVIATIONS
WWW.ALL-TRANS.BY

AC - Alternating Current
A/C - Air Conditioning
ACC or ACCUM - Accumulator
AFL - Actuator Feed Limit
ALDL - Assembly Line Diagnostic Link
AMP - Amperage
ASM - Assembly
AT - Automatic Transmission

N - Neutral
NC - Normally Closed
N.m - Newton Meters
NO - Normally Open

C - Degrees Celsius

P - Park
PCM - Powertrain Control Module
PC - Pressure Control (solenoid)
PR - Park Reverse (circuit)
PRESS REG - Pressure Regulator
PSI - Pounds per Square Inch
PWM - Pulse Width Modulated

CC - Converter Clutch
CL - Clutch
CONT - Control
CONV - Converter
DC - Direct Current
D.C. - Duty Cycle
DLC - Diagnostic Link Connector
DRAC - Digital Ratio Adaptor Converter
DSC - Driver Shift Control
DTC - Diagnostic Trouble Code
D2 - Drive 2 (circuit)
D3 - Drive 3 (circuit)
D4 - Drive 4 (circuit)
D432 - Drive 432 (circuit)
ECM - Engine Control Module
ECT - Engine Coolant Temperature
EX - Exhaust

F - Degrees Fahrenheit
FD - Feed
FWD - Forward
Hz - Hertz
ISS - Input Speed Sensor
KM/H - Kilometers per Hour
kPa - KiloPascals
MAP - Manifold Absolute Pressure
MPH - Miles per Hour

142

ORF - Orificed
ORUN - Overrun
OSS - Output Speed Sensor

R - Reverse
REV - Reverse
RPM - Revolutions per Minute
SEL - Selective
SIG - Signal
SOL - Solenoid
SS - Shift Solenoid
TCC - Torque Converter Clutch
TCM - Transmission Control Module
TFP - Transmission Fluid Pressure
TFT - Transmission Fluid Temperature
TP - Throttle Position (sensor)
TRANS - Transmission or Transaxle
V - Volts
VSS - Vehicle Speed Sensor
2WD - 2 Wheel Drive
4WD - 4 Wheel Drive

INDEX
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A
Abbreviations ........................................................................... 142
Accumulators ......................................................................... 40-41
direct clutch accumulator ................................................ 41
overdrive clutch accumulator .......................................... 41
intermediate clutch accumulator ..................................... 41
second clutch accumulator .............................................. 41
Apply Components ................................................................ 15-28
direct clutch ..................................................................... 16
reverse clutch .................................................................. 17
coast clutch ...................................................................... 18
forward clutch ................................................................. 19
forward clutch sprag ....................................................... 20
overdrive clutch ............................................................... 21
intermediate clutch sprag ................................................ 22
intermediate clutch .......................................................... 23
low clutch sprag .............................................................. 24
low and reverse clutch .................................................... 25
second clutch ................................................................... 26
second clutch sprag ......................................................... 27
second coast clutch ......................................................... 28

D
Direct Clutch .............................................................................. 16
Direct Clutch Accumulator ........................................................ 41
Direct Clutch Drum and Shaft Assembly ................................ 126
Direct and Reverse Clutch Assembly ...................................... 124
Direct Drive .............................................................................. 30B
Driver Shift Control Gear Ranges ............................................. 9A
E
Electrical Components .......................................................... 45-52
component locations ....................................................... 45
safety mode ..................................................................... 45
transmission manual shift shaft switch assembly ........... 46
transmission output speed sensor .................................... 47
transmission input speed sensor ...................................... 47
transmission fluid temperature sensor ............................ 48
shift solenoid valves ........................................................ 49
TCC PWM solenoid valve .............................................. 50
pressure control solenoid valve ....................................... 51
components external to the transmission ........................ 52
Explanation of Gear Ranges ................................................... 9-9A

B
F
Ball Check Valves Location and Function ........................... 42-43
Basic Specifications .......................................................... 136-137
Bushing and Bearing Locations ............................................... 113
C
Case and Associated Parts ................................................. 116-117
Center Support Assembly .................................................. 130-131
Coast Clutch ............................................................................... 18
Color Legend ....................................................................... 10A-B
Complete Hydraulic Circuits ............................................... 85-112
park ............................................................................. 86-87
reverse ........................................................................ 88-89
neutral ......................................................................... 90-91
overdrive range first gear ........................................ 92-93
overdrive range second gear ................................... 94-95
overdrive range third gear ....................................... 96-97
overdrive range fourth gear .................................... 98-99
overdrive range fifth gear (TCC released) .......... 100-101
overdrive range fifth gear (TCC applied) ........... 102-103
manual fourth fourth gear ................................... 104-105
manual third third gear ........................................ 106-107
manual second second gear ................................ 108-109
manual second first gear ..................................... 110-111
lubrication points .......................................................... 112
Contents, Table of ........................................................................ 2
Control Valve Body and Accumulator Assembly ............ 120-121
Cross Sectional Views ............................................................ 8-8A

Feed Limit Valve ........................................................................ 36


Fluid Pump Assembly ................................................. 33, 118-119
First Gear (overdrive) ................................................ 62-65, 92-93
Forward Clutch ........................................................................... 19
Forward Clutch Sprag ................................................................ 20
Forward and Coast Clutch Assembly ....................................... 125
Front Control Valve Body ........................................................ 122
G
General Description ...................................................................... 9
Glossary Of Technical Terms ........................................... 140-141
H
How To Use This Book ............................................................ 4-5
Hydra-matic Product Designation System ........................ 138-139
Hydraulic Control Components ............................................ 32-44
location of major components ......................................... 32
fluid pump assembly ....................................................... 33
pressure regulation .......................................................... 34
valves located in the fluid pump cover assembly ........... 35
valves located in the front control valve body .......... 36-37
valves located in the rear control valve body ............ 38-39
accumulators .............................................................. 40-41
ball check valves location and function ..................... 42-43

143

INDEX
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Illustrated Parts List .......................................................... 115-135


case and associated parts ........................................ 116-117
fluid pump assembly .............................................. 118-119
control valve body and accumulator assembly ...... 120-121
front control valve body ................................................ 122
rear control valve body ................................................. 123
direct and reverse clutch assembly ............................... 124
forward and coast clutch assembly ............................... 125
input sun gear shaft and forward sprag clutch assembly . 126
direct clutch drum and shaft assembly ......................... 126
intermediate sprag clutch assembly .............................. 127
overdrive and intermediate clutch assembly.......... 128-129
low clutch sprag assembly ............................................ 129
center support assembly ......................................... 130-131
planetary carrier assembly ............................................ 132
rear internal gear output shaft assembly ....................... 133
park pawl assembly ................................................ 134-135
Input Speed Sensor ..................................................................... 47
Input Sun Gear Shaft and Forward Sprag Clutch Assembly ... 126
Intermediate Clutch .................................................................... 23
Intermediate Clutch Accumulator .............................................. 41
Intermediate Clutch Sprag .......................................................... 22
Intermediate Sprag Clutch Assembly ....................................... 127
Introduction .................................................................................. 3
L
Line Boost Valve ........................................................................ 35
Low and Reverse Clutch ............................................................ 25
Low Clutch Sprag ....................................................................... 24
Low Clutch Sprag Assembly ................................................... 129
Low Pressure Control Valve ...................................................... 38
Lubrication Points .................................................................... 112
M
Major Mechanical Components ................................................. 10
Manual Fourth Fourth Gear ............................... 76-77, 104-105
Manual Second First Gear .................................. 82-83, 110-111
Manual Second Second Gear ............................. 80-81, 108-109
Manual Third Third Gear ................................... 76-79, 106-107
Manual Valve ............................................................................. 39
N
Neutral .................................................................... 60-61, 90-91

144

O
Operating Conditions - Range Reference Chart ........................ 84
Output Speed Sensor .................................................................. 47
Overdrive .................................................................................. 30B
Overdrive and Intermediate Clutch Assembly .................. 128-129
Overdrive Clutch ........................................................................ 21
Overdrive Clutch Accumulator .................................................. 41
Overdrive Range First Gear ................................... 62-65, 92-93
Overdrive Range Fifth Gear ............................................... 72-73
Overdrive Range Fifth Gear (TCC Applied) ... 74B-75, 102-103
Overdrive Range Fifth Gear (TCC Released) .. 74-74A, 100-101
Overdrive Range Fourth Gear ................................ 70-71, 98-99
Overdrive Range Second Gear ............................... 66-67, 94-95
Overdrive Range Third Gear .................................. 68-69, 96-97
P
Park ............................................................................ 56-57, 86-87
Park Pawl Assembly .......................................................... 134-135
Planetary Carrier Assembly ..................................................... 132
Planetary Gear Sets ............................................................... 29-31
description ....................................................................... 29
reduction ....................................................................... 30A
direct drive .................................................................... 30B
overdrive ....................................................................... 30B
reverse direction of rotation .......................................... 30B
Power Flow ............................................................................ 53-84
mechanical powerflow from TCC .......................... 54-54A
common hydraulic functions................................... 54B-55
park ............................................................................. 56-57
reverse ........................................................................ 58-59
neutral ......................................................................... 60-61
overdrive range first gear ........................................ 62-65
overdrive range second gear ................................... 66-67
overdrive range third gear ....................................... 68-69
overdrive range fourth gear .................................... 70-71
overdrive range fifth gear ....................................... 72-73
overdrive fifth, TCC released to applied ................ 74-74A
overdrive fifth, TCC applied to released ................ 74B-75
manual fourth fourth gear ....................................... 76-77
manual third third gear ............................................ 78-79
manual second second gear .................................... 80-81
manual second first gear ......................................... 82-83
Preface ....................................................................................... 1
Pressure Control Solenoid Valve ......................................... 36, 51
Pressure Regulation .................................................................... 34
Pressure Regulator Valve ........................................................... 35
Pressure Relief Ball Valve ......................................................... 35
Principles of Operation ......................................................... 9A-52
major mechanical components ........................................ 10
color legend .............................................................. 10A-B
range reference chart ....................................................... 11
torque converter ......................................................... 12-14
apply components ...................................................... 15-28
planetary gear sets ...................................................... 29-31
hydraulic control components .................................... 32-44
electrical components ................................................. 45-52

INDEX
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R
Range Reference Charts ....................................................... 11, 84
Ravigneaux Planetary Gear Set .................................................. 29
Rear Control Valve Body ......................................................... 123
Rear Internal Gear Output Shaft Assembly ............................. 133
Reduction ................................................................................. 30A
Reverse ............................................................ 30B, 58-59, 88-89
Reverse Clutch ........................................................................... 17
Reverse Lockout Valve .............................................................. 38
S
Safety Mode ............................................................................... 45
Safety Mode Valve ..................................................................... 37
Seal Locations .......................................................................... 114
Second Clutch ............................................................................. 26
Second Clutch Accumulator ....................................................... 41
Second Clutch Sprag .................................................................. 27
Second Coast Clutch .................................................................. 28
Second Gear (overdrive) ........................................... 66-67, 94-95
Shift Solenoid Valve (1-2) ......................................................... 38
Shift Solenoid Valve (2-3) ......................................................... 38
Shift Solenoid Valve (4-5) ......................................................... 39
Shift Solenoid Valves ................................................................. 49
Shift Control Valve (1-2) ........................................................... 38
Shift Control Valve (2-3) ........................................................... 38
Shift Control Valve (3-4) ........................................................... 36
Shift Control Valve (4-5) ........................................................... 39
Shift Valve (1-2) ......................................................................... 38
Shift Valve (2-3) ......................................................................... 38
Shift Valve (3-4) ......................................................................... 36
Shift Valve (4-5) ......................................................................... 39
Speed Sensors ............................................................................. 47
Stator Assembly ......................................................................... 13

U
Understanding The Graphics .................................................. 6-8A
V
Valves Located In The Front Control Valve Body ............... 36-37
pressure control solenoid valve ....................................... 36
feed limit valve ............................................................... 36
TCC PWM solenoid valve .............................................. 36
TCC regulator apply valve .............................................. 36
3-4 shift valve ................................................................. 36
3-4 shift control valve ..................................................... 36
safety mode valve ........................................................... 37
Valves Located In The Rear Control Valve Body ................ 38-39
reverse lockout valve ...................................................... 38
low pressure control valve .............................................. 38
1-2 shift solenoid valve ................................................... 38
1-2 shift control valve ..................................................... 38
1-2 shift valve ................................................................. 38
2-3 shift solenoid valve ................................................... 38
2-3 shift control valve ..................................................... 38
2-3 shift valve ................................................................. 38
4-5 shift solenoid valve ................................................... 39
4-5 shift control valve ..................................................... 39
4-5 shift valve ................................................................. 39
manual valve ................................................................... 39
Valves Located In The Fluid Pump Cover Assembly ............... 35
pressure regulator valve .................................................. 35
line boost valve ............................................................... 35
pressure relief ball valve ................................................. 35
torque converter clutch control valve ............................. 35
torque converter clutch enable valve .............................. 35
check valve retainer and ball assemblies ........................ 35
orifice cup plugs .............................................................. 35

T
Table of Contents ......................................................................... 2
TCC PWM Solenoid Valve .................................................. 36, 50
Torque Converter Clutch Control Valve .................................... 35
Torque Converter Clutch Enable Valve ..................................... 35
Torque Converter Clutch Regulator Apply Valve ..................... 36
Transmission Manual Shift Shaft Switch Assembly ................. 46
Third Gear (overdrive) .............................................. 68-69, 96-97
Torque Converter Clutch ....................................................... 12-14
converter pump and turbine ............................................ 12
pressure plate ................................................................... 12
stator assembly ................................................................ 13
torque converter apply and release ................................. 14
Torque Converter Clutch Applied ................. 14, 74B-75, 102-103
Torque Converter Clutch Released .............................. 14, 74-74A
Transmission Fluid Temperature Sensor ................................... 48
Transmission Adapt Function .................................................... 51

145

NOTES
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146