Oil Checks

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Line Pressures
Drive Min. 46-53 psi. Max. 150- 160 psi.
Reverse Min. 58-65 psi. Max. 180-200 psi

Line pressure tap

1
 Air Checks
Servo release
2nd clutch

Servo apply

To check servo apply, place separator plate on casting

3rd clutch 4th clutch and accum. and plug this hole in plate with thumb. Then blow
through small hole in plate at servo apply location.

2
 Trans ID
Adapter case
Case

Case tag

Main case oil pan Adapter case

oil pan
Vent 3-4 accumulator

Extension
housing

Converter housing
Range switch
3
 Trans ID

Converter housing

Extension
housing

4
Oil Pans & Filter
Adapter case oil pan

Torque bolts to 95-100 in lb

Main case oil pan

5
 Oil Pans & Filter

Oil Filter

6
 Valve Body
Torque VB bolts to 140 in lb

Main Valve Body Low band servo

Adapter case valve body

TCC solenoid

Band apply
solenoid
EPC solenoid
1-2/3-4 solenoid 2-3 solenoid

7
 .250” steel re-
OD Adapter Housing Valve Body verse shuttle ball
some models

Adapter case oil pan

Adapter case valve body

Models that use the reverse shuttle ball must

have the extra hole in the adapter housing sepa-
rator plate and must be used with a center sup-
port that has a reverse lockout control valve.
See next page for more. Adapter case
8
 Same as 4L80E early silver Bosch
type. Can be replaced with late Adapter case
Borg black type. Must use 4L80E valve body
bracket when this is done.
Cadillac Catera’s may shift too firm & plate
or through circuit codes with black
solenoid and will need to have a
Force motor EPC
Bosh replacement. 2000 up used
a small can silver Bosch type.

3-4 accum. 765” x .532” x .038”

3-4 accum. control

1.282”x .482” x .060”
Feed limit

Solenoid filter screen

Screen is available
separate from Honda.
It was used in the
Passport.
Must have o-ring
TCC sol. - on off type

Plates with a hole here must be used with a center support

TCC sol. PWM type that contains a reverse lockout control valve and will re-
used 2000 up quire a .250” steel check ball in the OD adapter housing.

9
 Main Valve Body

Main Valve Body

Main case oil pan

10
 Manual

PWM solenoid filter screen

Band control PWM solenoid

Wavy washer

1-2 accum. 1-2 accum. control

Some models may use a spring

11
 Main Valve Body

Install .250”
ball here

1-2 accumulator

Missing this check ball will cause a bind in 4th gear.

12
 Low pressure control
No upshift, has 1st gear
1.083” x .542” x .039” starts with wires off.
1-2/3-4 solenoid used at
this location
2-3 solenoid
Normally open
1.325” x .223” x .026”

Solenoids are different

2-3 shift even though they look
the same.
1-2 & 3-4 shift

1.325” x .223” x .026”

1-2/3-4 solenoid
Normally closed

13
 Main Case and Plate

“B” install .250” steel balls at these locations.

14
Low Band Servo

1.015” x .1.325” x .222

Apply pin

2.165” x 1.850” x .244”

Piston

Pin 2.943” x .283”

If this pin is missing
trans will slip in 1st &
2nd gear and be OK
in 3rd & 4th.

Cover

15
Pump Assembly

Push up this
direction.

Hub type pump alignment tool

must be used with this trans. Be
sure to push the pump up until it
bottoms out and then back off
slightly before tightening the bolts.

16
Front Seal and Drain Hole

Front seal partially cov-

ers the drain hole.
Relieve pocket with drill
for additional flow.

17
Front seal leaks are reduced when
the drain hole is expanded.

Converter housing

Enlarge drain hole

from this side of case
using 5/16” drill.

18
 2.232” x .778” x .072”
Pressure Reg.

Booster

19
 Pump Body
Pushing pump up during align-
ment moves crescent away
from the inner pump rear.

Dimples face up

Dimples face up

Dimples face up on pump gears as

shown. Make sure the pump gears
and the pump wear plate has no wear.
This trans likes a tight fitting pump
body bushing.

20
 .808” x .380” x .038”

Converter clutch control

21
 Bell Housing Types

Do not intermix any

of the ON-OFF with
PWM parts shown On-Off bell
on these pages or housing shown.
trans overheat and
failures will occur.
Note: Input shafts,
not shown, are also "A"
different.

If a wide bushing is
used make sure it
"R1" casting # does not touch wear
is On - Off plate and cut off
passage "A"

"EC3" casting #
is PWM

22
 Pump Wear Plate Types

On-Off pump body plate

PWM pump body plate

Scratch free plate is best for better pump

volume and a stronger lube circuit.

23
 Pump Body Types
On - Off pump body
PWM pump body

24
 TCC PWM Type Pump Assembly

TCC enable valve

Torque converter
clutch control valve

Pressure regulator valve Co

Iso nv
lat ert
or er
va clu
lve tch
reg
ula
tor
va
lve

TCC PWM Pump Assembly

Found on 2000 and later models

25
 Pump Body

Throttle signal accumulator piston

1.448” x .840” x .114”

26
 Center Support

Reverse lockout control valve here on mod-

els with check ball in OD adapter housing.

.808” x .380” x .038”

Overrun lockout valve

27
Center Support Plate

28
 Clutch Packs
4th clutch 2 frictions @ .089”
4 steels @ .083”

Piston
Return springs
Adapter case

Snap
ring

29
 Clutch Packs

Overrun clutch

Overrun clutch drum

.062” snap ring

.200” pressure plate .084” steels

.088” frictions
UP faces snap ring

Piston

Return spring
Retainer for return
OD clutch roller spring under roller
clutch not shown.

Snap ring

30
 Reverse clutch
Clutch Packs
.065” waved plate
Installs on piston 1st

Five .084” steel plates

Four .097” friction plates

Center support

Reverse clutch piston Return springs

Retainer
Snap
ring

31
 Clutch Packs

.065” waved plate installs on piston 1st

2nd clutch

Six .084” steel plates

Five .098” frictions

2nd clutch drum

2nd clutch piston

Return springs
Retainer
Snap
ring

32
 Clutch Packs

3rd clutch

.065” Bellville faces Five .083” steel plates

Install on piston 1st Four .098” frictions

3rd clutch drum 3rd clutch piston

& return springs
Retainer
Snap
ring

33
 Sprag

Hold inner race/gear. Outer

race must freewheel in the
direction of the arrow.

Snap
Input sun gear ring 3rd sprag race

3rd sprag & washers

34
 Adapter Case

OD lube oil restrictor

3-4 accum.
piston cover

2.695” x .1.220” x .118”

3-4 accum. piston

35
 Electronics

OD Adapter Housing Connector Earlier Style

E C Solenoid Firing Order

Gear Solenoids with volts
1st 2-3 sol
nd
2 2-3 & 1-2/3-4 sol
rd
3 1-2/3-4 sol
th
4 none
Rev 2-3 sol or none
Rev inhibited TCC sol

“A” TCC solenoid positive = normally closed / 17.6 ohms

“B” Force motor positive = normally open / 3.9 ohms
“C” Oil temp. sensor positive = 17.5K ohm @ 70°
“D” Oil temp. sensor negative
“E” Force motor negative

B D
A

36
 Electronics

Main Case Connector Earlier Style

C
D

B A

“A” 2-3 shift solenoid ground = normally open / 18.4 ohms

“B” Band apply solenoid ground = normally open / 9.7 ohms
“C” Common 12 volt positive
“D” 1-2/3-4 solenoid ground = normally closed / 17.8 ohms

37
 Electronics

BMW Type Single Main Case Connector

#2 sol
PCS
Temp
Temp
PCS

Common
ground

#1 sol

TCC Band sol

38
 Electronics

Later style GM Case Connectors

Main Case Connector

OD Adapter Housing
Connector Common
12 volt TFT sig
Common 2-3 sol
12 volt EPC sol neg
ground

TFT ground

TCC sol EPC sol pos

ground

Band apply
sol ground
1-2/3-4 sol ground
Not used

39
 Electronics
Mode Switch and Vehicle Speed Sensor

F G
H H

D C B A

Mode Switch
Pins with continuity
Park D to A&G + H to E
Reverse D to A,B&F
Neutral D to B&G + H to E
Drive D to B&C
3 D to A,B,C&G
2 D to A&C
1 D to C&G

Speed Sensor 3000 ohms

40
 Roller Bearings
OD ring gear

Roller bearing installs

black side up.

Note: Some models use a bear-

ing race on both top and bot-

Install .202” bearing race

3rd Clutch Drum

Then install roller bearing with inner lip facing

41
 Roller Bearings
Input Sun Gear

Then in-
stall .026” bear-

Install roller bearing onto sun gear first with inner lip facing up.

42
 Input Shaft

Input shaft may have a check ball and capsule assm.

Make sure it flows about like a .060” or greater hole.
This is the same as used on a T-700R4.

Blow this direction when checking

TCC exhaust ball and capsule.

43
Timed Planetary
Gears

Timed planetary gear sets need to be lined up to assemble. Align the lines
on the carrier to the punch on the gear. If this is not done, the sun gear will
not install. Not all models use this system.

44
 Band & Clutch Application
Gear Solenoids With Volts Apply Elements

1st 2/3 sol OD roller clutch, Overrun clutch, 3rd Sprag & Brake band

2nd 1-2/3-4 sol & 2/3 sol OD roller clutch, Overrun clutch, 2nd clutch & Brake band

3rd 1-2/3-4 sol OD roller clutch, Overrun clutch, 3rd clutch, 2nd clutch

4th none 2nd clutch, 3rd clutch, & 4th clutch

Rev. 2/3 sol or none OD roller clutch, Overrun clutch, Reverse clutch & 3rd Sprag

Rev. Inhibited TCC solenoid

Gear Ratios
1st 2.86
2nd 1.62
3rd 1.00
4th .72
Rev. 2.00

45
 Complaints
Complaint: Slips in 1st & 2nd gear. OK in 3rd & 4th.
Cause: Pin 2.943” x .283” missing from low servo band apply pin.
Solution: Reinstall pin into the band apply pin - see page 15

Complaint: 3rd clutch failure.

Cause: Low servo piston metal ring undersize.
Stock ring has .005 end gap. Some replacement ring will have .020 or more at end gap.
Solution: Reinstall old piston ring - see page 15

Complaint: 3rd clutch failure.

Cause: Bushing in center support worn or has sloppy fit on the 3rd clutch drum shaft.
This bushing seals 3rd oil and a loose bushing is a 3rd clutch oil leak. Some replace-
ment bushing come with too much clearance.
Center support 3rd clutch
bushing drum shaft

Solution: Use old bushing if not worn. New supports come with snug fitting bushings.

Complaint: 3rd clutch failure.

Cause: Low pressure due to EPC solenoid or plugged solenoid filter screen in the
adapter case valve body.
Solution: Repair or replace solenoids and screens as necessary.

46
 Complaints
Complaint: Blows oil out the vent.
Cause: Poor engine performance. Bad spark plug coils in Isuzu Troopers is common. Restricted
exhaust or poor engine tune causing throttle at higher seeds to be great enough to unlock con-
verter clutch resulting in trans overheat and blowing fluid out breather.
Solution: Repair and restore proper engine tune and performance.

Complaint: Rough 3 gear, particularly at light and medium throttle.

Cause: Using a Black Can EPC solenoid from a 4L80E instead of the Silver Can Bosch type.
Common on Cadillac's Catera and BMW cars
The Black Can type solenoid has a high initial setting "about 12 PSI higher" than the Silver Can
Bosch. This results in bumpy shift at lighter throttle. Isuzu Troopers with 4X4 don't seem to mind
the additional firmness.
Solution: Replace the $35.00 Black Can solenoid with the $325.00 Silver Can Bosh solenoid.

Complaint: Binds up going into 4th gear

Cause: Check ball missing from main valve body.
Solution: Reinstall a ball in main valve body - see page 12.

Complaint: No reverse, rough 2-3 and 3-2. On lift - tries to kill engine on 2-3 shift.
Cause: EPC and TCC solenoid connector plugged in 180◦ backwards into the OD housing
passthrough connnector. ◦
Solenoid connector rotated 180 OD Housing
Passthrough
Applies to models with reverse lockout connnector
valve located in the center support only.
If TCC solenoid is being fired in reverse
check speed sensor & lever switch. If
not and trans has reverse with wires off
connector - this is the problem.

Solution: Unplug solenoid connector and rotate 180◦ .

47
 Complaints

Complaint: 3rd gear slips, 2 -3 spin up or cut loose.

Cause: OD housing separator plate gaskets on wrong side of plate.
Solution: Reinstall gaskets to correct side of plate. Lay gaskets on top of the web areas, it is
clear which side is correct.

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