“tarie TRANSMISSION INTRODUCTION THM 4180-E, We wish to thank General Motors Corp. for the information and illustrations that have made this booklet possible. This booklet contains general description and overhaul procedures necessary to repair, overhaul, or service the new THM 4T80-E electronic overdrive automatic transaxle. The THM 4780-E is a fully automatic Front Wheel Drive electronically controlled transaxle. It provides 4 forward ranges including overdrive and all shifts are freewheeling. Shift points are controlled by the PCM via two shift solenoids. Oil pressure is supplied by 3 gear type oil pumps. Oil pressure is regulated by the PCM via a force motor. Shift schedule and TCC apply rates are also controlled by the PCM and are influenced by many sensor inputs. ADAPT FUNCTION TRANSAXL the 47T80-E uses a line pressure control system which has the ability to continuously adapt the system’s line pressure (increase As Needed) to compensate for normal wear of clutch plates and bands. This "Learning" feature is similar to the A604. ‘The PCM maintains several adapt parameters for the transaxle. © UPSHIFT ADAPT - The PCM monitors the TIS Sensor and VSS during command shifts to determine if a shift is occurring too fast (Harsh) or too slow (Soft) and adjusts the transaxle Force Motor signal to maintain a set shift feel 0 STEADY STATE ADAPT - The PCM monitors the TIS Sensor and VSS after a shift and calculates the amount of slipping in that gear. The PCM then adjusts the Force Motor signal to maintain slippage below a set amount 0 GARAGE SHIFT ADAPT - The PCM monitors TIS Sensor during a shift into reverse or drive , and calculates if the engagement is occurring too fast (Harsh) or too slow (Soft), and the PCM adjusts the Force Motor signal to maintain a set (Desirable) garage shift feel. "Portions of materials contained herein have been reprinted with permission of General Motors Corp., Service Technology Group." Copyright © ATSG 1993 ROBERT D. CHERRNAY DALE ENGLAND TECHNICAL DIRECTOR FIELD SERVICE CONSULTANT. FRANK MIETUS WAYNE COLONNA TECHNICAL CONSULTANT TECHNICAL CONSULTANT WELDON BARNETT ED KRUSE TECHNICAL CONSULTANT LAY OUT 9200 SOUTH DADELAND BLVD. SUITE 720 MIAMI, FLORIDA 33156 (305) 661-4161LM ATSC]. 5 S < “ATIC TRANSMISSION SERVICE © INDEX POWERFLOW AND SOLENOID CHART. 4 SOLENOID LOCATIONS 5 ELECTRONIC CONTROLS DESCRIPTION 6 TROUBLE CODE CHART (ELDORADO/SEVILLE). nl ONBOARD DIAGNOSTIC (ELDORADO/SEVILLE). 12 WIRING SCHEMATICS (ELDORADO/SEVILLE) 4 CASE CONNECTOR PIN IDENTIFICATION. 16 LINE PRESSURE TEST 18 DIAGNOSTIC CHARTS. 20 OIL PASSAGE IDENTIFICATION, 29 CASE COVER CHECKBALL LOCATIONS. 33 LOWER VALVE BODY CHECKBALL LOCATIONS 35 ACCUMULATOR HOUSING CHECKBALL LOATIONS. 36 TRANSAXLE DISASSEMBLY. 38 COMPONENT SUB-ASSEMBLY. 53 TRANSAXLE REASSEMBLY. 1 INPUT SHAFT END PLAY MEASUREMENT. 85 FINAL DRIVE END PLAY MEASUREMENT 92 TORQUE SPECIFICATIONS. 102 BOLT LOCATIONS AND IDENTIFICATION 104 108 12 AIR CHECKING PROCEDURE! SPECIAL TOOL REQUIREMEN’ Automatic Transmission Service Group 9200 South Dadeland Blvd, Suite 720 Miami, FL 33156 (308) 661-4161Technical Service Information 4T80-E oer BUN 65 Se & PSY NO REVERSE 98D. FORWARD. Co~ST \ MSE cain BNGE allen "SUT? GGEh moter rbieliee ene minaret a Que ND AR SET oulex, cules ks, ew SMEs UH atin SCAG accutiaron slo scaunbaron ackBMon acd ton Figure 1 AUTOMATIC TRANSMISSION SERVICE GROUP 3Information RANGE REFERENCE AND SOLENOID’S STATE SRO. 4T80-E GEAR RATIOS CLUTCH COAST FIRST 2.96 SE Fonwaro SECOND 1.63 eure tonev THIRD. 1.00 FOURTH 0.68 REVERSE 2.13 a REVERSE at eth 2 res | cn] 8° ~ | 2 ow | wm | 0 | ae | rome oan const reves % autre | vtoe sino | ‘to | acter | soma | rae wm [x | on oa me fe [o os a mu | «| ov | om oa + [om | oF | wna remo | HENS rotons 2 [or | om | ano eo veuane | wen o 2 [a | om | wo roma | ano eau «| ov | om | onto nora | wn a + | on | oF | ammuco | arpueo | ‘armed | HOLOING WOLONG oo [a | om | om | mea | sno or vexone | ha.oNe 3 [om | ov | vemeo | araeo | aruto | sono e.oNG 7 | on | om | aman | amo rerio | HeNG NG a 2 | om | om | amen | amen a wna veiane | noone 1 [ow | of | waa | omen rento | ve.ONG voto ” 2 | om | om | wen | women oo wr rain | vow (ON « SOLENOID ENEGERIZEO Orr SOLENOID OEENEGER ZEO G the SOLENOIDS STATE FOLLOWS A SHIFT PATTERN WHICH DEFENOS UPON VEHICLE Sree and THAOTILE POSITION TT DOES NOT DEPEND UPON THe SELECTED GEAR Figure 2 AUTOMATIC TRANSMISSION SERVICE GROUP 4Technical Service Information "ANAL ppessune CONTROL SOLENOTD LOCATIONS TORQUE CONVERTER CLUTCH SOLENOID VEHICLE SPEED SENSOR 350 sy “ ‘TRANSAXLE PRESSURE SHIFT SOLENOIDS ‘SWITCH AaB ‘TRANSAXLE TEMPERATURE ‘SENSOR Figure 3 AUTOMATIC TRANSMISSION SERVICE GROUP 5Technical Service Information ‘The TCC solenoid i a three-pon assembly which uses negative (-) Duty Cycle, Pulse Width Modulation (Fised 32 Hz) to contol the rate of TCC apply-release, The solennd's ability 1 “ramp” apply and release pressures resull in a smoother apply and elease of TCC in all conditions ‘The TCC solenoid is a normally closed valve, mounted othe upper valve Body and used to contol the postion of the TCC apply valve ‘A Transaxle Pressure Coniral Solenoid (also known as a Force Motor) is a three-por. spool valve, electronic pressure regulator ‘that coniols pressure based on curen Mow though ils coil-winding ‘The Transaxle Pressure Coniol Solenoid is atached to the upper valve body and controls main line pressure by moving & pressure regulator vaive against spring pressure. The Transaxle Pressure Control Solenoid eliminates the need for a TV cable or vacuum modulate to aujust line pressure according to engine lod changes ‘The Transasle Pressure Control Solenoid position i contelled by & ‘combination of two methods: High side and Law side control. One terminal of the Transaxle Pressure Contra Solenoid receives a Fixed frequency (292.5 Ha) signal which varies in positive (4) Duty Cycle “This feed circuit othe Transaxle Pressure Contral Solenoid i called “Force HI". The opposite terminal ofthe Transaxle Pressure Control Solenoid is called "Force LO". Force LO is used to provide & {ground for the solenoid. Iti through this combination of "Force HI" and “Force LO” eirevitry that actual Transaxle Pressure Control Solenoid current i finely controlled, This advanced contra method assures instantaneous contzo of line pressure when changes in TPS and adoptive learning occur 0 Torque Converter Clutch Solenoid gS’ ‘TCC solenoid resistance should be 10-18 ohms when measured at 20°C (68°F), at 88°C (190°F) 11-25 ohms. Maximum solenold current flow should not exceed LS amps. (On the 6-way transaxle connector, measure resistance across Pins E and F Transaxle Pressure Control Solenoid (Force Motor) Forse High + 0% Duty Cycle + 40% Duty Cycle Fomelow = Line Pressure Amps 1 Amps @ 4.5 V Maximum Minium ‘Transaxle Pressure Control Solenold resistance should measure 3.5 - 4.6 ohms when measured at 20°C (68°F). ‘On the 6-way transaxle connector measure resistance aross Pins C and D. Shift Solenoids “A” and “B” ee» {shill solenoid iso two: port fed bled device which consists of coil/plunger-ball axsembly. The solenoid assembly works in eonjunetion wth an orifice 1 pressurize the shlt valve end chamber when voltage is applied to its coil, The eontolled pressure then moves the shifl valve against a spring causing a shift 10 occur ‘When voltage is na longer applied, the chamber is then opened to ‘exhaust and the opposite shill valve acion oscurs. Shift b=-f-7 SENSOR VOLTAGE —}——| oa ‘ABOVE 80°C 388 SENSOR VOLTAGE? BELOW A0"C — 40-20-16 4 7 19 31 43 65 67 79 91 109 115127 190 151 ‘Temperature °C Seessaskesseess NOTE ~ APCM INTERNAL SHUNT CIRCUIT WILL COME INTO PLAY AS TEMPERATURE INCREASES BEYOND 50°C. AS. ‘TEMPERATURE IS DECREASING, INTERNAL SHUNT COMES OUT AT 40°C. THERE IS A 10°C OVERLAP. Figure 6 AUTOMATIC TRANSMISSION SERVICE GROUP 8Technical Service Information INPUTS oUuTPUTS [INFORMATION SENSORS ELECTRONIC CONTROLLERS ELECTRONICALLY CONTROLLED | 1 Taansaxce pressure switex + Powearatn CONTROL MODULE FCM Perea 2. TRANSAXLE INPUT SPEED SENSOR une conTROLSOUNOD 5. TRANSAXLE VEHICLE SPEED SENSOR ‘A PRESSURE Co 01 8. SHIT SOLENOO “8 {TRANSAXLE TEMPERATURE SENSOR ©. SHFTSOLENOO "8" §.TRANSANLE RANGE STO . Tec cowtaot SOLENOID 6. THROTTLE POSITION TP SENSOR 1. ENGINE COOLANT TEMPERATURE ECT SENSOR «CRANKSHAFT POSITION SENSORS 6. TOROVE MANGEMENT BRAKE SWITCH 10,AR CONDITIONING inc SWITCH 11-CRUISE CONTROL OPERATION 12 MANFOCO ABSOLUTE PRESSURE MA seNsoR AUTOMATIC TRANSMISSION SERVICE GROUP °Technical Service Information PCM STATUS LIGHTS Displayed Whenever PCM System Is Selected, -1GG —E outsive ECON DE. AUTO nocwron | cow a0 «| SRF | wor [© aro | no0 wort on | enensizeo ages DisABLEO ENABLED. ENERGIZED ‘cx08e0 *~ |ENGROZED womow|oc-eerono | ormom | canco | osanco | oe-owrozo | orm | norem | oc-enroaso Function | ANSARESHPT] po operaring | TRANSAXLE SHIT eo NE CLUTON al on he oer gor ecaceemse [aaeesee | alike | eae "eae |e Figure 7 As soon as "PCM?" is selected (See Pages 11 and 12), the Climate Control Center(ccc) panel begins display of PCM Status Lights. PCM Status Lights will continue to be dis- played, as shown in Figure 7, until PCM diagnostic functions are exited. PCM Status Lights show the current state of certain discrete PCM inputs and outputs by turning on or off certain indicators on the CCC. (See Figure 7). NOTE: PAGES 9 THROUGH 14 APPLY TO ELDORADO/SEVILLE ONLY. AUTOMATIC TRANSMISSION SERVICE GROUP 10Technical Service Information -DORADO/SEVILLE PCM DIAGNOSTIC CODES cove | DESCRIPTION cove DESCRIPTION Trane Fe | ee ree Str eiceieuie) pos al | ees | Sete ental = Ventas Botte Say role] 8 : a) | eese| Scie conte Vaessonmeee 8 ors | Soo enpi Soot enue trtar A Beenie) pois | Soteumeisuucrousreorseressecon |_| ona | sure cane Soe oneronce (cue ¢ Soe we Paeones Bees | Sena ocowmen Toth feel & O20 | Open Fuel Pump Circuit 8 O67 | SeUCoast Or Resume/Accel Input Shorted {Cruise}... Pett | Stoned oe ontan 1) seror 0 Fe | eget cl Serres but é Were Bea eaoh a Pst 022 | Open Throtta Position (TP) Sensor |TCC, EGA] A 069 | Traction Contro! Active While n Cruise {Cruise} ¢ PoE | Geton'SenteGueoh bet nteeccasren AY | 98s | aston Convo Acie wie Ge : ese | We Sowwd Sonar Greck osen recy al | oT | itarmet eae roan : Le Oper: Throtie Post i (Py Seiten C wount (EGR) Rn | POTS | Intermittent Intake Air Temper ture (IAT) Sensor Cc Pe29 | Tansanle sui 8: Solna Foden a Perel ee ca q st ard, 4th Gear) ‘Maitunction (Trans. Pressure Control) 1020 | ae Ssteu Sema nst now oxo Range a se citunaion Cant Paw i PER | Sea Sieniog sages ar} Sanat A) | Se | Th gemeuge awn et op 4 eee 083 | 24X Reference Signal High A Pose | One anild masala Passe MAP Sensor A Poel iaameete ata tee teen = ‘ Sl eamiatnatelaie eet creed 086 | Uncetined Gear Ratio (Trans. Pressure Control PO33 | Eaterided Travel Brake Swntctiinout Cc ® 088 | Torque Converter Clutch (TCC) Not a | eee eee Disengaging (Trane. Adapts} oe lien tera ren aan *) | roo | ong sia cram Aaa A 035 | Ignition Ground Voltage Out of Range c f oe he jem {Cruise} 88 | Clnacm Ges Recreasnon ch) Ube Pir A) | page | Toc ore awe Cre Pre (oueed tehcan oor aaron eS reat 8 soar | srotes mse Ae tomcat IAD Sens | | ae : : Pe aero ‘ rch (1st, 310, 4th Gear) ee roos | eng si ovrce ¢ Fost | no Cam rene Bana from AL | BSBE | Bais Gavacrage tren aoge é a eee Fe | rise Corea Sars Roped Neti Gise uz | Front nanos Oeen grouse! 4] | Fce| Stoee Suis sane lace 600 5 Pees | Rear reales Onrten Senany Roce Ewes Sf) | A ‘Crise, TCC, Fue Tim, Transado Adapts) asl esnnceireses tas at oer 2] | ri | consent Gaius 2 ose | gone £105 | erake Boone: Vacuum (88¥) Too Low 8 fost | enc Sree itaten a] | 2198] Settsee’Saats ng creat broom z Fas | Pou toes tne hoy Bese 2] | pie] Pekistn? cua Uy eresien é FEES | S Sonsor Cour] : Fire | Sota EPROM Fale é rea eb Piar | Coovoaearrs um t TELLTALE STATUS 77 BERTGE ENGNE-SOON Values Indexer tame (ON 8 > Senvice venice SooN sesnys On DS & = “iuGrT SvSreke PROBLEM ~ CAR MAY NOT RESTART message E> ‘ReDUCeD ENGINE POWER mescege £2 (Barren nO Chane message t )) = BRACKETED SYSTEMS ARE OISABLED WHEN CODE IS CURRENT AUTOMATIC TRANSMISSION SERVICE GROUP uTechnical Service Information ELDORADO/SEVILLE | [gear ‘PCM?’ ‘STATUS. a UGHT, b--¥--p| “pom [LO »| crow. [vo Ley oispiay oxtare Inputs: Fo once a cela PARAMETER NUMBER PARAMETER POM INPUTS VO. P00) | Throws Poston INPUT Foes | Hantots Rosolne Prassu 7003 | Compuiea Baromate Pressure Poe | Engine Coos Temperature Cruise Bake Swicn Foes | ine ompereture FEC Brake Sic Poor | EGA Pate Penton ‘Throtie Patton Sten Po08 | Spark Advores, PardNeta Swen Foss | iter Sear votage tbe £010 Ws Pump Peedoacivotage Po | Engine 8 BDI2 | Yeble Spee Bower Stsing rosaure Sten P13 | EGA Fnte Postion Rescaec) Extanged ral Grace St Fors | Igiton't vo Coy Coolant Level Suen Pos | Hew Suto Eat Stats A 003 = GitLaver Ser Por | CM Output Feut Sats B 5003 Srp amas F530 | Front injector Puse Win 3 Pos: | Roarimector Puise Wictn 8: Po32 | Front Oxygen Sensor Votage oe ‘OTransaxle Pressure rat sire Se Costs 8 = HE | Mienigecond ‘Switch Code 35 gan Saraor rons Courts 8 2 Be | Amber secon ReESTaD) Pb38 | Front Gro term Puol em § nue O37 | Rear Shor Term Fue! Tim a - oe GEAR Poas | Front tong Term Pus ren 8 300 | eset Pb33 | Reorong Term Fue’ Tom 3: So | oe PBs | Seanchelara ave to Reock Sensor 3: Bro | Hega Poet | Knoek Sensor ° oy | Poa * vere Pore oe 381 | PaneNoura! Port Transaxle Prossure Swatch 00 - NO ot O72 ansaxie Turbine Speed (i mw oe ors | True Conver Sip Speed 3 Bore | Hater eo _ STE reread Pore | Transaxle Goar Rat 8: Port | Transale Tomporetare <9 = Pore | Trenaule Sn acest aig > Pors | Tranaale Stoncy Slate Acao! 0 PBs | TrensaxtePINTODIR Swit acest — | ~3.000 — Post | Torque Converter clutch Solnad 3 Pose | Taraase Sut Sime 32 £583 | Non-snve Wnee! Speed a: Pose | Brana Goostervacusm <1 = Popo | PCwPAGM ID = Transaxe ac £98 | Igntion Gyoie Counter at Pose __| Bw PAOM 10 Engine a PCM Output Fault Status Panam [STATUS A STATUS 8 saoigt | TCCSolkngine Temp ute | ShMATSHN'B a anddigt | EGREVAP Sener innit | — Inectors aed Digt | Cootng FansSevsce Beseieg Agama asain Engine Soon MiL Generator sro trereme amdigt | AC CiutehDelivered La To Decrement Torque/RSS Lit/Dive Not used, ‘VCE Han lana votage Cow Signal Vonage QQ" = Input Same Since Displayed "X" = Input Changed Since Displayed ° ‘PROM ID Code Number Ident An Individual ’caltraton And's Peroaloely Undated: Rolar To Latest Service| Publication For Correct 10 Number + Switch Crue ON Before TastingTechnical Service Information ELDORADO/SEVILLE a a ee 3 ourputsr | ovensiter} cuss | > coer] 4 HI ' ' \ Pow OUTPUTS mY = | (roe 10! ane pom cost tMeane |__| |snarshorr «9H TAS ISH oyu oureur secs) ey poo | NoOvovs 88 | aware emanora cra rae Booz | Sige Sohere Cues soenes 7 O03 | EGR Solenoid ‘SNAPSHOT Poe een roo asec) O08 08 1 Foro | Sansure Stina Soenad ' For | tareace sun Sonos Bon | Ae euteneny FOR | Tarsate iss Cons’ Soa Pom SUP sia NOT CYCLEABLE WITH ENGINE RUNNING on “Prot bata KEY wl ye ; ane Wi amwa pram Aenean jouw iyng met Tanta aroer eet toronto a dences Pe Ee ‘anes sarc Seton $6" erste aac ota Se sc ins Sop ioe sasted noe aro PCM codes POM SH NU ‘set and no Customer Snapshot (see page 16) has 5 , ‘been taken. Only the three most recent codes will cee Dovacoraed by Gave SuaPorT See Page 76 or wl y Saseianonet oO" Spare ate «son Engine Elo prormig 1 mi {i Duele oveton one orvrengnten cas wuts 1 Cruse sich mos bo PCM OVERRIDE mt outeut OVERRIDE ourpur VERRIDE| ‘ACTION ROMER OVERRIDE COOLER WARMER 300 | No Override PS01 | Torque Carvener Cluter So¥enoid on On 502 | EGA Soiencla Decrease Increase S03 | isc Motor Rett Ecend 508 | inoctor Disable (1 thr 6) Disable Select 50s | Fue! Pump Relay on On 806 | AIR Pump (not usec) P80? | Cruise Cental Sevoe Release Pullin S08 |Cooing Fan Relay Low Speed High Speed FanRelay Fan sag | Temporary Spark Advance Retard Advance Pst | imector Flow Select Tash esi | Traneauie Override Upsnt —Downanit S12 | Long Term Fug Tim Reset Reset No Action 7813 | TP Sensor & lee LearriGarage Shit Adapt Resel Reset Learn Reset Adapt sis | Tansaro Snit/Steady State Adapt Re Reset Shit Reset Steady Psi. Decrease Increase Ps20 Decresse Increase P21 Advance No Action Psze Rotars Advance e823 on on Psod Enable ___Disablo BVEHICLE SPEED SENSOR 130 [a] veo orvneo ] oo reser BW. 1290 BRN, 1200 TAN ovERsPeED ALERT MODULE (U04 ONLY) TRANSAXLE TEMPERATURE SENSOR athe 469 0K BL TRANSAXLE PRESSURE SWITCH rev switcH 1OLE SPEED CONTROL TSC) WOTOR TRANSAXLE PRESSURE CONTROL SOLENOID io 1239 OK GRNIVEL 120 a H sgt on 771 BLK —t— 1224 PNK, 585 TANIWHT 469 BLKIORN 772 WHT —t}— 1225 OK BLU mac —[Z}H_—@§ rane spss ice sso BLK WHT 427 PNK 426 OK BLU —_____ esirew 1330 1268 REDIBLK c 1229.7 BLUNWHT 1228 TORN 1229 0K GAN PCM raven sPeeo PUT 0 es [roe |rmasae seeeo rut 10 ms VEHICLE SPEED OUTPUT (2000 PULSES PER MILE) VEHICLE SPEEO INPUT Ki (PON) VEHICLE SPEED INPUT LO [PON2) a on TRANSAXLE RANGE SWITCH X INPUT (O71) Gn TRANSAXLE RANGE. ‘SWITCH INPUT (P07) Gn TRANSAXLE RANGE ‘SWITCH Z INPUT (PO71) THROTTLE POSITION SWITCH INPUT (PI72}, TRANSAXLE PRESSURE CONTROL SOLENOIO CONTROL (PO2s, PS20) TRANSAXLE PRESSURE CONTROL SOLENOID ENABLETechnical Service Information PCM TRANSAXLE SHIFT SOLENOID cxa9 581 ORN 122217 RN SHIFT A’ SOLENOID CONTROL (POT0) ‘SHIFT 8" SOLENOID 82 vEL CONTROL (PO11) reas veuaux oe] TRANSAXLE: SHIFT B SOLENOID ENGINE COMPARTMENT FUSE BLOCK ios IGN 750 PNKIBLK Fuse ot EVAPORATIVE EMISSION 428 DK GANYEL ‘GONTROL SOLENOIO EVAPORATIVEEMISSION JCONTACL (PORN) ‘CONTROL SOLENGID Power STEERING POWER STEERING mnswicn ereox sumer [AS | presse SWITCH INPUT ies) ENGINE COMPARTMENT 10 FUSE BLOCK 1725 ORN vas onn [207 | EXTENDED TRAVEL, ‘ona f (P88) | TORQUE CONVERTER a (Ech «orm: ~[o18| Siren foe) grax SWITCH INPUT (PI71) TOO RRARESHITCH 130 422 PNK PAARL score. i} TORGUE CONVERTER CLUTCH (TEC) SOLENOID | : TORQUE CONVERTER aa tanrsux [2e%9 | CCF SoueNon ‘CONTROL (F002, PSO1) earocegseewns wsneo [ma sneys GENERATOR "GENERATORTechnical Service Information CASE CONNECTOR LOCATION AND PIN IDENTIFICATION VIEW LOOKING INTO CASE CONNECTORS CONNECTOR NUMBER 130 CONNECTOR NUMBER 129 6 PIN CONNECTOR 8 PIN CONNECTOR cata rT c ‘A = TRANSAXLE INPUT SENSOR (HI) A = PSM SWITCH "X" CIRCUIT INPUT TO PCM B = TRANSAXLE INPUT SENSOR (LO) B = PSM SWITCH "Y" CIRCUIT INPUT TO PCM C = FORCE MOTOR C = TEMP SENSOR - SV RETURN D = FORCE MOTOR ENABLE D = TEMP SENSOR - INPUT E = TCC SOLENOID - 12V E = SHIFT SOLENOID "A" GROUND F = TCC SOLENOID - GROUND F = SHIFT SOLENOIDS - 12V G = SHIFT SOLENOID "B" GROUND H = PSM SWITCH "'Z" CIRCUIT INPUT TO PCM Figure 8 AUTOMATIC TRANSMISSION SERVICE GROUP 16Technical Service Information 1 CONNECTOR BODY, PIN 120479337 2 CONNECTOR BODY, P/N 12067951 3 TERMINAL P/N 12047581 4 TERMINAL P/N 12047767 ‘CONNECTOR BODY, PIN 12052848 CONNECTOR BODY, PIN 12052849 ‘TERMINAL PIN 12047581 ‘TERMINAL P/N 12047767 Figure 9 AUTOMATIC TRANSMISSION SERVICE GROUP 7Technical Service Information LINE PRESSURE TEST 1. Requires special line pressure fitting J-21867-93, as shown at left. 2. Remove the air cleaner assembly. 3, Raise vehicle and suitably support. 4. Install bar stock into pressure plug, and remove line pressure plug, as shown in Figure 10, Step 3. 5. Install line pressure fitting using a ratchet box wrench. Tighten adapter so the insert hole for the dowel rod is in a 1 O'Clock position. Refer to Figure 10, Step 4. 6. Lower vehicle and install dowel rod in Fitting as shown in Figure 10, Step 5. 7. Attach line pressure gage and hose to dowel rod fitting as shown in Figure 10, Step 6. 8. Secure hose in a safe position to avoid damage during line pressure test. 9. To remove the line pressure gage, reverse the steps above. Figure 10 AUTOMATIC TRANSMISSION SERVICE GROUP 18ATSG Technical Service Information . 1993 HYDRA-MATIC 4T80-E LINE PRESSURE CHECK PROCEDURE Line pressures are caitated for two sets of gear eanges = Drive-Patk:Neuirl, and Reverte, This allows the transaxle line pressure (0 be ppropriat fr diferent pressure needs in diferent gear ranges Gear Range Line Pressure Range Drive, Park or Neutral Minimum line S0-5S psi, Maximum line 230-280 psi Reverse Minimum line 90 psi, Maximum line 300 psi Before performing a line pressure check, verify that the tansaale pressure control solenoid is receiving the coect electrical signal from the vehicle computer: 1. Start the engine and set parking bake 2. Enter On-board diagnostics 3. Check fora stored tansale pressure conta solenoid malfunction code PO76, or her malfunction codes. 4. Repair veicle i necessary. Inspeet + Fluid level + Manual linkage a transaxle + tl line pressure gage 5. Put gear selector in Pak and set the parking brake 6. Sta engine and allow itt warm up at idle 7. Enter diagnosis and select “PCM output override” level 8. Access the “override” transasle pressure contol solenod west (PS20) 9. Increase TRANSAXLE PRESSURE CONTROL SOLENOID pressure signal and read the corresponding line pressure on the pressure gage. (Allow pressure to stabilize for 5 seconds ater each pressure change.) 10. Compare data tothe Drive-Park-Neutrl line pressure chart below NOTE: This ine pressure ts vad for TPC Solenoid overrides with vehicle stopped at Idle and In Park-Neutral. CAUTION sraies mus: be appies a all umes o prevent uneapected vehicle motion IT pressure readings die greatly from the line pressure chan, refer tothe Diagnosis Charts contained inthis section Dynamic Line Pressure Test The vehicle diagnostic overtides are designe ia contol the ransexle pressure contol solenoid in Park and Neutral with the vehicle stopped tile and in a dsnaniie mode during road tesing. Under dynunve Testing conditions the trance pressure control solenoid pressure signal can be overndden fo increase pressure (Fem noemal PCM commanded peesture. During road test conditions Nigh line pressures can be commanded 10 venfy line pressure system response. ‘To verity line pressure response in the dynamic mode, acess PCM output override transaxle pressure control solenoid test PS20 and drive the vehicle under normal road test conditions. While driving the vehicle. depress the warmer ution 10 gradually increase the transaxle pressure ontol solenoid signal. As the transaxle pressure control solenoid sign inereases transaxle upshifts should become progressively harsher. TAs fccurs because higher than required line preswures ae commanded in this test made UC pressure readings der greatly from the line pressure chan, refer tothe Diagnosis Chars contained inthis section "0010 2030 40 80 60 70 80 W100 1 Control Solenoid i (o) Tranaante Pre “Commended Reedout Slo + (4) Signa ume own i ncremens of 10 (Cooler Flow Rates: 1800+ RPM © 7.9 Lures at Min Line, 12-14 at Mas Line, Per Minute Figure 11 AUTOMATIC TRANSMISSION SERVICE GROUP 19CONDITION High Line Pressure (Harsh Shifts) Technical Service INSPECT + Press. Reg, Valve (211) + Pressure Control Solenoid (339) « Possible Codes: 56, 75, 76, 86, 89 + TPCS. Feed Valve + PR. Boost Valve (213) + PSM (936) + Transmission Hamess (12) + Checkballs (65) Information FOR CAUSE ‘Stuck at high torque signal due to under sized bore, sediment or TP.C.S. = Failed “off, intermittent short = Loose connector ‘Stuck ‘Stuck open Loose connector Loose connection at vehicle harness Missing ‘Second Gear Starts + Scavenge Pipe Seal (53) + Primary Pump Body (200) (Harsh Engagement) + Final Drive Internal Gear = Missing Snap Ring (135) + Actuator Feed Limit Valve (309) | - Stuck open Inadequate Lube or Low | + Scavenge Pump Body (225) Leakage at gasket or pump body Line Pressure + Scavenge Pipe (54) Restriction ‘Damaged, cut or leaking Leakage at gasket or pump body - Possible Codes: 29, 16, 94 + Transaxle Pressure Control Solenoid (339) + Starts At HI Line Only, Driven Sprocket Support (418) + Scavenge Screens (51 and $2) Clogged + PR.Valve (211) ‘Stuck due to sediment * Secondary Pump Body (203) = Leakage at gasket or pump body + Transaxle Flu = Low level * Cooler Lines = Clogged or restricted + “A” Shift Solenoid (909) = Stuck off inched wire to ground = Inoperative = Leakage = Pinched wire to ground = Staked checkball missing ‘Transaxle Slips in Reverse + Fluid Level + Line Pressure + Scavenge Pump (223, 224, 225) + Primary Pump (200, 201, 202) + Scavenge Pipe (54) + Scavenge Pipe Seal (53) + Rev. Clutch Seals (506, 507) + Plates (S11, 512, 513) + Reverse Band (13) + Rey. Servo Piston (928) + Rew. Servo Seals (929 and 930) Rev. Servo Pin (931) + Rev. Band Anchor Pins (9) = Too high or low = Too low = Gears worn or broken = Gears worn or broken = Debris in pipe = Cut or damaged ~ Cut, damaged or leaking = Damaged or bumed ~ Damaged, burned, slipping = Damaged or cracked = Cut, damaged or leaking = Binding, 0 short = Loose, missing Soft Shifts + Line Pressure + Transaxle Pressure Control Solenoid (339) + Transaxle Pressure Switch (PSM) (Clip) Clamp (340) = Possible Code: 28 + Calibration Prom = Broken clip causing leakage = Pinched wire to ground = Incorrect Figure 12 AUTOMATIC TRANSMISSION SERVICE GROUP 20Technical Service Information CONDITION INSPECT FOR CAUSE D2. D3, Ds + Checkbals = Missing from FWD/coast clutch No Fist Gear + LofRev Servo Apply Pin (931) | — Apply pin damage + 1-2 Shift Valve (919) = Stuck in up shifted position + FWDICC Support Seals (829) | - Damaged + FWDICC Studs (5) = Damaged, broken + Lo Roller Clutch (830) = Worn or damaged + "A" Shift Solenoid (909) = Debris, oF filed off + Possible Code 94 = Pinched or damaged wires, inoperative + Forward C. Piston (807) = Damaged or cracked + Forward C. Piston Seals = Rolled, cut or damages (08 and 809) + Support Housing Seal Rings (829) | ~ Leaking, damaged or cut + Forward Sprag (716) = Damaged, not holding + Checkball No. 8 = Missing D2, D3 No Second Gear Clutch Plates (431-435) Bumed or damaged Piston (430) Cracked or damaged Springs (428) Pision Seals on Piston (430) 2nd Sprag (517) “A™ Shift Solenoid (909) 1-2 Shift Valve (919 and 920) Broken, out of position Rolled, damaged or leaking Damaged, not holding Stuck on Stuck in Ist gear D3 + 3/4 Shift Valve Bore Plug (914) Misassembled No Third Gear Driven Sprocket Suppor (418) | ~ Exhaust valve cup plug or valve improperly installed Burned, splines damaged Cracked, damaged, checkball damage 3rd Clutch Plates (610-613) 3rd Clutch Piston (606) 3rd Clutch Seals on Piston (606) | ~ Cut or rolled Checkballs (437) = Missing, stuck 'B” Shift Solenoid (909) = Debris Possible Codes: 29, 117 = Wires pinched or damaged + "A" Shift Solenoid (909) = Inoperative + Code 94, 117 ‘No Fourth Gear + "A" Shift Solenoid (909) = Inoperative + possible code: 94 = Debris = Pinched wires + 4th Band (523) = Burned, slipping, missing + 4th Servo Pin (527) = Broken, seized + 4th Servo Piston (529) ~ Damaged + dth Servo Seals (525 and $32) | ~ Rolled, cut or damaged + 4th Servo Cover (524) = Cracked + 3/4 Shift Valve Bore Plug (914) | ~ Misassembled Figure 13 AUTOMATIC TRANSMISSION SERVICE GROUP 21Technical Service Information ‘CONDITION INSPECT FOR CAUSE No First Gear Inconsistent Shifts ‘Lo Roller Clutch (830) Forward Sprag (716) Oil Transfer Sleeve Forward Clutch Plate (815-817) ‘Seals (808 and 809) Detent Lever (17) FWD/Coast Housing (801) Piston (807) ‘A andlor (909) = Possible Codes; 16, 29, 94 "Shift Solenoid Manual Valve (916) ‘Checkball (437) in Housing “A” and "B” Shift Solenoids (909) ‘Worn or damaged Damaged, not holding Misaligned, damaged, leaking Burned, damaged Leaking, cut or rolled Misaligned Broken or spline damage Cracked or damaged Debris Pinched or damaged wires “A" and "B” Shift Solenoids Disabled Misaligned Leaking = Orting seal damage No compression ‘Third and Fourth Gear + “BY Shift Solenoid (909) = Stuck “on” Only «Possible Codes; 117 = Pinched wire to ground No Engine Braking * Oil Transfer Sleeve (824) = Misaligned + Drive Chain (414) = Broken, slipping. + Sprockets (407 and 415) = Damaged + Drive Axle, = Splines damaged No Overrun Braking in D3 | + Coast C. Plates (812-814) = Burned or damaged + Coast C. Seal/Checkball (810) | ~ Cut, wom or nicked + Forward Clutch Housing (801) | ~ Splines damaged = Housing cracked + Oil Level = Low = Stuck in upshift position + 3.4 Shift Valve (912) = Debris, stuck + "A" Shift Solenoid (909) + Possible Code: 94 No Overrun Braking in D2 | + 4th Band (523) ‘Slipping, bumed 4th Band Servo Pin (527) Stuck, broken ‘4th Servo Piston (529) 4th Servo Seals (525 and $32) Coast Clutch Plates(812-814) Coast Clutch Seal/Checkball (810) ‘Transaxle Pressure Switch Code 28 ‘Coast Clutch Support Seals (829) ieee Damaged, cracked Cut, rolled or damaged Burned, damaged Cut, wom or nicked Inoperative Damaged, missing No Engine Braking in D1 “Transaxle Pressure Switch (936) Possible Code: 28 ‘Coast Clutch Plates (812-814) Coast Clutch Seal/Checkball (810) Checkball No. 6 Lo/Rev Band (13) LofRev Servo. Piston (928) Seals (929 and 930) Inoperative Burned, damaged Cut, worn or nicked Missing Slipping, burned, damaged Damaged, seized Leaking, rolled Figure 14 AUTOMATIC TRANSMISSION SERVICE GROUP 2Technical Service Information CONDITION INSPECT FOR CAUSE Forward Motion in N + Manual Valve (916) = Mispositioned oF stuck ‘+ Forward Clutch Springs (820) — Jammed + Forward Clutch Piston (807) = Jammed + Forward Clutch Plates (815-817) | ~ Seized or jammed + Forward Clutch Housing (801) | ~ ‘Feed hole plugged. inspect tower + Sprocket Support Hub (622) = Holes plugged + Shift Linkage = Mispositioned = Disconnected Engine Stall + Tec = Stuek on or dragging + Converter Feed Valve (312) = Stuck open + TCC Solenoid (336) = Stuck on - Possible Code: 39 = Pinched wire to ground = Inoperative + Converter Feed Valve (312) = ‘Stuek open + Turbine Shaft (410) — Spline damaged Loss of Power = Low Avid = 2nd gear stans (909) = Possible Codes; 16, 29, 94 + TCC System = TCC stuck on or dragging + Torque Converter (1) ~ Debris + Turbine Shaft (610) = Bushing damage Loss of Drive * Torque Converter (1) + Scavenger. Primary Pumps (225 and 200) Pump Shatt (2) ‘Channel Plates (33, 900) Gaskets (228, 326, 328, 935) Scavenge Pipe Seal (53) Drive Sprockets (407 and 415) Drive Chain (414) Driven Sprocket Suppor (418) Final Drive ED. Pinions (103) + Rolle, Forward Sprag Forward/Coast Suppor (822) Manual Valve and Link (G15 and 916) + Turbine Shaft (410) ‘Broken lug, failed lug weld Sheared lug bolts Worn turbine shaft splines Low fluid Pump hub cracked or broken Internal failure ‘Closure weld failure Cover cracked at weld Seized, broken pump gears Broken Damaged Damaged Damaged or missing Broken Broken Damaged, porosity, leaking Damaged, splines worn Spalled pins or pinions Lack of lube ‘Wor, broken or locked No lube Not attached to detent lever Dislodged, stripped splines Figure 15 AUTOMATIC TRANSMISSION SERVICE GROUP 23Technical Service Information CONDITION INSPECT FOR CAUSE Engine Stars in Gear + Manual Valve (916) = Not engaged to detent lever = Stuck in wrong position + Transaxle Range Switch = Not working, mispositioned No Gear Selections * Detent Lever (17) = Nut loose oF missing + Manual Valve (916) = Stuck + Spacer Plate Gasket (935) = Blocked holes + Valve BodiewCase = Blocked channels ‘Shift Lever Indicates + Manual Valve (916) = Not engaged o detent lever ‘Wrong Gear + Detent Roller Pin (26) = Missing, damaged + Detent Roller (26) = Broken or disconnected + Spring (27) + Manual Detent Pivot (26) = Loose of missing + Manual Shaft (16) = Flats not parallel + Indicator Linkage = Misadjusted No TEC + TCC Solenoid (336) = Stuck off = Osring failed = No voluage to solenoid ~ Poor connection + PM = No signal to solenoid + Brake Switch = Contact corroded = Poor connection = Pinched wire = Misadjusted = No supply voltage + TCC Control Valve (317) = ‘Stuck off due to sediment or undersized bore + TCC Regulating Valve (318) = Stuck off due to sediment or undersized bore + TOC Feed Valve (312) = Stuck off due to sediment or undersized bore + Olt Pressure Sereen (342) = Clogged + O-Ring (612) = Damaged or leaking + Torque Converter (1) = Ballooning + O-Ring (412) = Wom + Possible Codes: 16,29, 88, 117 = 39, 90 = TCC not engaging fully or slipping Soft TCC Apply + Turbine Shaft Seal (612) = Wor or damaged + TCC Solenoid (336) = Malfunction + Transmission Fluid = Low + Cony, Clutch Feed Valve (312) | ~ Sticking Early TCC Engagement | + Trans Temp Sensor (350) = Shorted = Possible Codes: = 59 Open Circuit “TOC Not Disengaging + TCC Solencid (336) Stuck on due to debris + Converter Feed Valve (312) = Stuck on due 1 debris Convener Ballooning + Convener Feed Valve (312) ~ Stuck open due to sediment or undersized bore Figure 16 AUTOMATIC TRANSMISSION SERVICE GROUP 24ATSG Technical Service Information CONDITION INSPECT FOR CAUSE ‘No Torque Multiplication | + Drive Sprocket Suppor (400) = Broken or detached from case = Spline damage No Reverse + Reaction Carrier Shell (633) Missing, teeth damaged + LovReverse Anchor Pin (9) + Driven Sprocket Support (418) ‘Support Seals (422 and 423) Suppor Bolts + Reverse Band (13) + Reverse Band Apply Pin (931) ‘Anchor pin broken oF not positioned Porosity or broken Feed holes blocked Leaking. ‘Loose, not in grooves, mistocated Broken, worn not anchored ‘Too short or binding in case. Meee a mene ere Broken + Reverse Piston (505) Binding in case. + Seal (506 and 507) Leaking, damaged or worn + Checkball in Piston Missing ket (43 and 44) ‘Damaged or displaced + Case Cover (33) Damaged + Fluid Pressure Too low + Stee! Plates (511) Splines worn + Friction Plates (513) Splines or friction worn + Spring Assembly (508) Jammed + Housing (500) Cracked + Snap Ring (515) Out Will not stay in park + Deremt Spring (27) ~ Weak or broken + Detent Lever (17) = Mislocated or broken + Actuator Rod (21) ~ Bent = Guide damaged + Park Paw! Pivot Pin (23) = Missing + Parking Lock Gear (833) ~ Damaged teeth + Park Paw! (22) = Damaged (tooth) Manual Linkage Misadjusted or disconnected Exiended oF + Possible Codes: Delayed Upshifts +21, 22,24 = Transaxle Pressure Switch = Inoperative Code 28 Fi + Pressure Regulator Boost Valve | ~ Stuck in bushing. 213) ‘Transaxle Seized + Cooler Circuit Lines Blocked or leaking. *+ Cooler Fittings (3, 38) Blocked or leaking + Spacer Plate Gasket (328) Holes missing, off location + Scavenger Pipe (54) ‘Damaged, clogged Poor seal at pipe Valve Bodies (300 and 903) Filter (236) Filter Seal (209) Sereon Assemblies ($1 and $2) Loose, broken or missing bolts Sitting in side cover Cut damaged neck seal Clogged or not seated in case Noise * Torque Converter (1) = Loose lug bolts = Out of balance = Internal failure + Transaxle/Engine ~'Misaligned + Case Extension (134) =" Axle support bushing wom Figure 17 AUTOMATIC TRANSMISSION SERVICE GROUP 25Technical Service Information CONDITION INSPECT FOR CAUSE NOISE IN ALL RANGES for (A whine which may RPM load sensitive or ceases| when the TCC engages.) “Torque Converter (1) Verify noise internal to torque converter by placing left foot on brake with gear or selector in Drive and momentarily stall tengine. Torque converter noise increases ‘under load, ‘A High Pitch WHINE which will intensify with engine RPM or is Oil Pressure. sensitive, il Pump System Verify noise internal to oil pump during preliminary oil pressure check. An Increase in line pressure will vary an oil pump noise, ‘A Popping noise similar to Popcorn popping. Pump cavitation-indicated by bubbles on Aid level indicator. ‘Transaxle fluid strainer for filter seam leak. ‘Transaxle fluid strainer seal for proper positioning or cut seal ‘A BUZZ or High Frequency Rattle sound, “Trace cooler pipes and check for binding or contact at the at the Radiator other than the Cooler pipe connectors ‘Verify pressure buzz by watching for a needle vibration on the pressure gage (Road test may be necessary.) ‘A Whine or Grow! that inereases and fades with Vehicle speed and is most Noticeable under Light Acceleration Drive Link Assembly System Verify noise from sprockets and/or drive link assembly (chain) by placing left foot on brake and moving gear selector from Park or Reverse. If noise stops check items below: Drive Chain (414) Drive Sprocket and Driven Sprocket (407 and 415) Drive Sprocket Support and Driven Sprocket Support (400 and 418) ‘Suretched ‘Teeth broken or sheared = Bearing surfaces nicked or scored ‘Bearing race or roller bearing surfaces on ‘gear Support Inner Bearings rough or pitted. Bearing damage Bearing outer race support rough or nicked. ‘A Final Drive Noise or Hum, is most noticeable Under light throttle Acceleration and/or turns Final Drive Gear Set (100) Final Drive Internal Gear (120) Differential Carrier (110) Differential Side Gears (116) = Worn, planet pinions or washers = Worn, tooth damage Gears worn or pitted ‘Thrust washer damage Noise in Ist, 2nd, 3rd or Sth Final Drive Sun Gear (121) Final Drive Pinions (103) Gear wom or damage = Gears worn or damaged Figure 18 AUTOMATIC TRANSMISSION SERVICE GROUP 26Technical Service Information CONDITION INSPECT FOR CAUSE Vibration * Torque Converter (1) = Out of balance = Internal feilure + Transaxle/Engine = Misaligned + Case Extension (134) = Axle support bushing worn + Turbine Shaft (410) = Wor bushing + Output Shaft (57) = Out of balance Leaks at: Bottom Pan Fluid Fill Indicator Vehicle Speed Sensor Electrical Connector Cooler Connectors Bottom Pan (59) ‘Damaged or not flat + Gasket (61) = Damaged or off location + Case (6) = Porosity or cracked + Bolts (62) = Flange inside out, damage = High or low torque *+ Seal on Indicator (31) = Cut or nicked — Missing. + O-Ring Seal (130) Cut, nicked or missing * Electrical Connector (12) (O-Ring Seal + Case (6) Damaged or not seated Cut or nicked Missing, porosity Porosity or cracked *+ Cooler Connectors (3, 38) ) Stripped threads Damaged flare, seal damage High or low torque + Case (6) Stripped threads Porosity Debris in threads Case Extension + Case Extension (134) = Porosity or cracked + Case (6) ~ Porosity or cracked + Seal (126) = Cut or nicked = Missing + Bolts'(128 and 127) = Low torque = Missing. Manual Shaft * Seal (20) = Cut or nicked = Not seated + Linkage = Misadjusted Converter Seal + Seal (403) = Cut, nicked or worn = Missing garter spring + Torque Converter Bolt Low torque = Damaged hub Drive Axle Seal + Tri-Pot Joint = Corrosion on Tri-Pot housing at mating + surface Fluid Foaming + Fluid = Contaminated (antifreeze) = Transaxle overfilled + Engine ~ Overheated + Filter (236) ~ Cracked or not seated + Seal (209) = Damaged or not seated + Vehicle = Overloaded + Scavenger Screens (51, 52) = Clogged Figure 19 AUTOMATIC TRANSMISSION SERVICE GROUP 27Technical Service Information Q COOLER FITTING 1ExIT) LINE PRESSURE PLUG. EXTENSION GASKET GonvenTER Seat 8: i lin : 3 § MANUAL Shar SEAL FLUID CEVEL INDICATOR SEAL POSSIBLE LEAK POINTS Figure 20 AUTOMATIC TRANSMISSION SERVICE GROUP 28Technical Service Information LEFT SCAVENGE SUCTION RIGHT SCAVENGE SUCTION SCAVENGE OUTLET vow OIL PUMP PASSAGES SCAVENGER SIDE LEFT SCAVENGE SUCTION RIGHT SCAVENGE SUCTION SCAVENGE OUTLET UNE. voID OIL PUMP PASSAGES PRIMARY SIDE Figure 22 AUTOMATIC TRANSMISSION SERVICE GROUP 29Technical Service Information LEFT SCAVENGE SUCTION RIGHT SCAVENGE SUCTION SCAVENGE OUTLET MAIN PUMP SUCTION SUMP Sie AINE ‘SECONDARY LINE voIo PRIMARY PUMP BODY SCAVENGE PUMP SIDE LEFT SCAVENGE SUCTION RIGHT SCAVENGE SUCTION SCAVENGE OUTLET MAIN PUMP SUCTION SUMP. LINE SECONDARY LINE voIo PRIMARY PUMP BODY SECONDARY SIDE Figure 24 AUTOMATIC TRANSMISSION SERVICE GROUP 30ATSG Technical Service Information LEFT SCAVENGE SUCTION RIGHT SCAVENGE SUCTION MAIN PUMP SUCTON SUMP. uN SECONDARY LINE ‘CONVERTER FEED \upe 2 11 CONVERTER RELEASE 22. TORQUE SIGNAL 32 REVERSE 40 aR CLUTCH 58 VOID SECONDARY PUMP BODY CASE COVER SIDE LEFT SCAVENGE SUCTION RIGHT SCAVENGE SUCTION SCAVENGE OUTLET MAIN PUMP SUCTON UNE SECONDARY LINE voro SECONDARY PUMP BODY PRIMARY SIDE Figure 26 AUTOMATIC TRANSMISSION SERVICE GROUP 31ATSG Technical Service Information LEFT SCAVENGE SUCTION RIGHT SCAVENGE SUCTION MAIN PUMP SUCTON UNE CONVERTER FEED CUBE 2 TCC FEED LIMIT (CONVERTER RELEASE CONVERTER APPLY ‘TCC EXHAUST ENABLE ORIFICE TCC EXHAUST ENABLE To COOLER ACTUATOR FEED TORQUE SIGNAL PRIMARY ACCUMULATOR SECONDARY 2:3 ACCUMULATOR 2-3 ACCUMULATOR REVERSE 3AD CLUTCH FILTERED 3RO CLUTCH (ORFICEO 3AD CLUTCH REGULATED APPLY TCC CONTROL EXHAUST CHANNEL PLATE SPACER PASSAGES - UPPER Figure 27 10 n 2 3 “ 6 2 2 Fy 2 3 a a 6 rs 82 UNE ‘CONVERTER FEED Luge 2 Tec FEEO LIMIT CONVERTER RELEASE CONVERTER APPLY TCC EXHAUST ENABLE ORIFICE TCC EXHAUST ENABLE TO COOLER, ACTUATOR FEED TORQUE SIGNAL PRIMARY ACCUMULATOR. 1-2 ACCUMULATOR SECONDARY 2-3 ACCUMULATOR 2-3 ACCUMULATOR 3AD CLUTCH FILTERED 3RO CLUTCH ORIFICED 3D CLUTCH REGULATED APPLY Tec CONTROL EXHAUST ° #0] 45 (ls fe Ovo 0 ooh oO wl we & ao of 80@ U 2a CONTROL VALVE ASSEMBLY GASKET - UPPER Figure 28 AUTOMATIC TRANSMISSION SERVICE GROUP 32ATSG Technical Service Information 1 LEFT SCAVENGE SUCTION 2. RIGHT SCAVENGE SUCTION 4 MAIN PUMP SUCTON 5 SUMP 8 UNE 7 SECONDARY LINE 8 CONVERTER FEED 9 LUBE? 11 CONVERTER RELEASE 22 TORQUE SIGNAL SECONDARY PUMP BODY CASE COVER SIDE LEFT SCAVENGE SUCTION RIGHT SCAVENGE SUCTION SCAVENGE OUTLET MAIN PUMP SUCTON NE: SECONDARY LINE voio SECONDARY PUMP BODY PRIMARY SIDE Figure 26 AUTOMATIC TRANSMISSION SERVICE GROUP 31Technical Service Information 1 LEFT SCAVENGE SUCTION 2. RIGHT SCAVENGE SUCTION 3. SCAVENGE OUTLET 4 MAIN PUMP SUCTON 5 SUMP 6 8 9 UNE ‘CONVERTER FEED LUBE 2 ui 30 TCC FEED UMIT re 11 CONVERTER RELEASE 12 CONVERTER APPLY | 12 TCCEXHAUST ENABLE 18 TOCOOLER 20. ACTUATOR FEED } 22° TORQUE SIGNAL 30. SECONDARY 2-3, ACCUMULATOR 32 REVERSE 40 3RO CLUTCH 4) FILTERED 3AD CLUTCH 42 ORFICED 3RD CLUTCH 45 REGULATED APPLY 48 TCC CONTROL e es“. CASE COVER PASSAGES - V.B. SIDE Figure 29 LEFT SCAVENGE SUCTION RIGHT SCAVENGE SUCTION 55 OVERFLOW CASE COVER PASSAGES INTERNAL, Figure 30 AUTOMATIC TRANSMISSION SERVICE GROUP 33UNE CONVERTER FEED TCC FEEO LIMIT CONVERTER RELEASE CONVERTER APPLY TCC EXHAUST ENABLE TOCOOLER ACTUATOR FEED FICTERED ACTUATOR FEE TORQUE SIGNAL PRIMARY ACCUMULATOR SECONDARY 2-3 ACCUMULATOR 2.3 ACCUMULATOR RO CLUTCH FILTERED 3RO CLUTCH REGULATED APPLY TCC CONTROL, EXHAUST vor Technical Service Information LEFT SCAVENGE SUCTION RIGHT SCAVENGE SUTION UNE CuBe 2 cuBe. AUTOMATIC TRANSMISSION SERVICE GROUP Figure 32 34Technical Service Information 7 8 9 2 n 23 2 Fy 26 2 uM 8 36 a Fy 39 0 a “ a ry re 51 62 58 UNE PRN PRNDE PRNOKS ACTUATOR FEED FILTERED ACTUATOR FEED SOLENOID A SOLENOID 8. LO & REVERSE BAND APPLY REVERSE BAND REVERSE oRIve LoreeD to LO & REVERSE BAND REDUCE FORWARO CLUTCH 2ND CLUTCH 3RO CLUTCH 4TH BAND FEED 4TH BAND 32 COAST CLUTCH FEED COAST CLUTCH 02 bay EXHAUST vor LOWER CONTROL VALVE ASSEMBLY PASSAGES 7 20 2 2 2 2 a 2 3 ey 35 38 3 a a“ o e a 50 51 2 53 Figure 33 Ne PAN ACTUATOR FEED is FILTERED ACTUATOR FEED| SOLENOID A SOLENOID 8. REVERSE BAND 3:4 ACCUMULATOR 4-2 ACCUMULATOR REVERSE REVERSE CLUTCH RIVE LO FEED Lo. FORWARO CLUTCH 2ND CLUTCH RD CLUTCH ‘4TH BAND FEED 4TH BAND 0321 ‘COAST CLUTCH FEED COAST CLUTCH oat pay EXHAUST ORIFCED EXHAUST vor LOWER CHANNEL PLATE PASSAGES Figure 34 AUTOMATIC TRANSMISSION SERVICE GROUP 35ATSG Technical Service Information 1 LEFT SCAVENGE SUCTION 2. RIGHT SCAVENGE SUCTION 6 UNE 20. ACTUATOR FEED 27 PRIMARY ACCUMULATOR CASE PASSAGES BOTTOM 27 PRIMARY ACCUMULATOR 28 3-4 ACCUMULATOR 29 V2 ACCUMULATOR 33 REVERSE CLUTCH 38 FORWARD CLUTCH 46 ATHBAND, 56 voID FORWARD AND REVERSE ACCUMULATOR HOUSING PASSAGES Figure 36 AUTOMATIC TRANSMISSION SERVICE GROUP 36Technical Service Information 2. RIGHT SCAVENGE SUCTION IGHT SCAVENGE SUCTIOF 2 . iy CASE PASSAGES CONVERTER SIDE ©, ) —HO a 3 Figure 37 6 UNE 17 PRN 20. ACTUATOR FEED 21 FILTERED ACTUATOR FEED. 23. SOLENOIDA 24 SOLENOID 8 26 REVERSE BAND 27 PRIMARY ACCUMULATOR 28 3.4 ACCUMULATOR 32 REVERSE 33 REVERSE CLUTCH RIVE 35 LOFEED to 37 LO & REVERSE BAND REOUCE 38 FORWARD CLUTCH 38° 2NDCLUTCH 40. 3RO CLUTCH 43 CTH GAND FEED 44 TH BAND 470321 48 COAST CLUTCH FEED 43 COAST CLUTCH 53 ORIFICED EXHAUST voip LOWER CHANNEL PLATE PASSAGES Figure 38 AUTOMATIC TRANSMISSION SERVICE GROUP 37TRANSAXLE DISASSEMBLY GENERAL SERVICE INFORMATION Caution must be exercised when Lifting or rotating this transaxle due to its considerable weight (296 lbs). Utilize the bore located in the holding fixture whenever lifting the unit is necessary and lift with a chain hoist and/or appropriate lifting equipment. It may be necessary to place a counterweight fon the opposite side of your workbench for balance when you mount the 4T80-E transaxle in the bench fixture. Make sure the work area is adequate and CLEAN for the layout, inspection and cleaning of component parts. Do not over expand snap rings during disassembly or assembly process. 1, Install J-39050 support fixture onto the transaxle, as shown in Figure 39. CAUTION: TO AVOID THE POSSIBILITY OF PERSONAL INJURY AND DAMAGE TO THE TRANSAXLE, INSTALL ALL THE BOLTS FOR THE FIXTURE AND TORQUE TO 10 ft. ibs. 1. TORQUE CONVERTER ASSEMBLY 2. SHAFT, OlL PUMP DAIVEN 412. SEAL, O-RING Technical Service Information Install transaxle and fixture into the base fixture on bench, using suitable lifting device (See Figure 40) 3. Position transaxle with case extension pointing downward to allow fluid drain. 4, Insert pin into base to retain the transaxle in position to drain fluid. Rotate transaxle in fixture to position shown in Figure 40, after drainage. Remove one retaining bolt from speed sensor located in the case extension (See Figure 40). 7. Remove the speed sensor and seal. 8. Remove the cooler return line fitting using a 19mm wrench, from the case as shown in Figure 40. 9. Remove the oil pump drive shaft as shown in Figure 39. Remove the turbine shaft "0" ring as shown in Figure 39. Remove the three 10mm retaining bolts from the overdrive servo cover (See Figure 41). NOTE; HOLD THE SERVO COVER IN PLACE UNTIL ALL OF THE BOLTS ARE REMOVED. IF THIS IS NOT DONE, THE APPLY PIN WILL DAMAGE THE BORE IN THE CASE. Remove the servo cover and overdrive servo assembly as shown Figure 41. 10. ue 12. 3 COOLER CONNECTOR, RETURN (CASE) (1, 197mm) 4 CONNECTOR, O-RING COOLER (RETURN) 130 SENSOR, SPEED OUTPUT ASSEMBLY 131. BOLT, SPEED SENSOR TO CASE EXTENSION (1, 1mm) Figure 39 Figure 40 AUTOMATIC TRANSMISSION SERVICE GROUP 38Technical Service Information FLAT OF SPRING (2 MUST BE CENTERED TH SERVO, N'agSsEs ON Coven era Figure 41 ou 525 527 529 51 53 534 ‘COVER, «TH SERVO. RING, SNAP ‘SEAL, 4TH SERVO PISTON. ‘SPRING AND RETAINER ASSEMBLY, aTHSE BOLT, SERVO COVER TO CASE (3, 10mm) 534 AUTOMATIC TRANSMISSION SERVICE GROUP 39Technical Service Information 192 GEAR, DIFFERENTIAL SIDE (RIGHT) 133. WASHER, THRUST DIFFERENTIAL CARRIERICASE EXTENSION) (SELECTIVE) WASHER THICKNESS | COLOR] 3 8007-3 ‘on 1 28990-12 SELECTIVE Figure 42 FINAL DRIVE END PLAY MEASUREMENT 1. Install dial indicator J-26900-12 onto transaxle, as shown in Figure 42. 2. Position dial indicator with stem on output shaft as shown in Figure 42. 3. Zero out the dial indicator. 4, Insert J-28585 through output speed sensor bore and lift speed sensor rotor for measurement (See Figure 42). NOTE: PROTECT SPEED SENSOR BORE WITH ‘A PIECE OF WOOD OR USED FILLER TUBE SEAL, TO PREVENT DAMAGE. 5. Proper final drive end play should be .005"-.025" clearance. 6. Record measured specification and if necessary adjust with proper thick~ ness selective thrust washer upon reassembly. 7. Use the chart in Figure 42 for the proper selective thrust washer. 8. Remove the dial indicator from the transaxle. CASE EXTENSION AND SCAVENGE TUBE 1. Remove four 13mm bolts, one 10mm bolt, and one 15mm stud from'case extension as shown in Figure 43. 2. Remove the case extension and seal. Seal may remain in extension. 3. Remove thrust bearing and selective washer from final drive. 4, Remove the 8mm bolt that retains the scavenge tube in case (See Figure 43). 5. Remove scavenge tube by prying on the differential with screwdriver. (See Figure 43). 6. Remove and discard scavenge tube seal. (See Figure 43). AUTOMATIC TRANSMISSION SERVICE GROUP 40Technical Service Information 98 RING, SNAP (OUTPUT SHAFT) (3) 57 SHAFT, OUTPUT 18. BOLT, SCAVENGE TUBE (1, 8m) 100. CARRIER FINAL DRIVE 85. SEAL, SCAVENGE TUBE AND SCREENS 102 BEARING, THRUST (SUNGEARICARRIER) 54 TUBE, SCAVENGE 130 CARRIER, DIFFERENTIAL 126. SEAL, CASE EXTENSION TO CASE $31. WASHER, THRUST DIFFERENTIAL) (RIGHT) 127 STUG, CASE EXTENSION TO CASE (1, 15mm) M2. Gean, DIFFERENTIAL SIDE (RIGHT) 128. BOLT, CASE EXTENSION TO CASE («137m 117 WASHER, THRUST (OFFERENTIAL) LEFT) 129. BOLT CASE EXTENSION TO CASE 1. 10mm) M8 GEAR, DIFFERENTIAL SIDE LEFT) 132 BEARING, THRUST ME BOLT, DIFFERENTIAL CARRIER TO FINAL DRIVE (4, 15mm) 183. WASHER, THRUST (IFFERENTIAL CARRIERICASE 120. GEAR. FINAL ORI INTERNAL EXTENSION) (SELECTIVE! 42). Gean, FINAL ORIVE SUN. 136 EXTENSION, TRANSAXLE CASE 135_FING, SNAP Figure 43 Figure 44 FINAL DRIVE ASSEMBLY AND OUTPUT SHAFT 1, Transaxle MUST be in park with the 8. Remove the final drive carrier as shown differential locked in place. If the ‘n Figure 44, differential can rotate, turn the 9. Remove thrust bearing (102) as shown in manual shaft "counterclockwise" to Figure 44. the park position. Actuator rod will 19, Remove final drive sun gear. stick out of case. 11. Remove snap ring from case that retains 2. Remove the four 15mm differential final drive ring gear (See Figure 44). bolts (See Figure 44). 12. Remove final drive ring gear. 3, Remove the differential carrier(110) (See Figure 44). 4, Remove output shaft snap ring, as shown in Figure 44. 5. Remove the left side differential gear (See Figure 44). 6. NOTE: Output shaft can be removed Continued on next Page. through opposite end of case. 7. Remove thrust washer (117), as shown in Figure 44, AUTOMATIC TRANSMISSION SERVICE GROUPTechnical Service Information 51 SCREEN, SCAVENGE (LEFT) 52. SCREEN, SCAVENGE (RIGHT) 153. SEAL, SCAVENGE TUBE AND SCREENS 150 PAN, TRANSAXLE OIL 81. GASKET, O1L PAN, (62 BOLT, BOTTOM PAN TO CASE (16, 10mm) Figure 45 BOTTOM PAN, GASKET AND SCAVENGE SCREENS 1. Remove 16 bottom pan bolts using a 10mm socket (See Figure 45). 2. Remove bottom pan, and discard gasket. 3. Remove left scavenge screen and seal as shown in Figure 45. 4, Remove right scavenge screen and seal as shown in Figure 45. 5. A small screwdriver may be used to pry seals from the case using care not to damage the case bores. 6. Use a small screwdriver to disconnect shift solenoids A and B and transaxle Pressure switch connectors by prying back small tabs, shown in Figure 46. 7. Remove nine 10mm bolts from the oil transfer plate (See Figure 47). 8. Remove oil transfer plate. 9. Remove manual valve linkage clip using a small screwdriver as shown in Figure 46. 10. Remove two 10mm bolts(958) and two 10mm nuts(955) from lower valve body assembly as shown in Figure 47 915 MANUAL LINK AND CLIP ASSEMBLY Th 12. 13. Figure 46 Remove nine 10mm bolts from lower valve body assembly as shown in Figure 47. DO NOT remove the four bolts indicated in Figure 47 at this time. Lift lower channel plate, valve body assenbly and accumulator assembly from case as a single unit and set aside. (See Figure 47). AUTOMATIC TRANSMISSION SERVICE GROUPTechnical Service Information 09 nor Rewove TTS TIME | ation roo. XS SHOWN J 8001 on 524 BOLT. 18, 10m) 76900124 39686 903. CHANNEL PLATE TO CONTROL VALVE AND HOUSING ASSEMBLY 955 NUT. CHANNEL PLATE TO CASE (2, 10mm) 956. PLATE, OIL TRANSFER 968 BOLT, CHANNEL PLATE TO CASE (216mm) Figure 47 INPUT SHAFT END PLAY MEASUREMENT 1. Install end play tool J-39686 into the case barrel as shown in Figure 48. 2. Locate the "J" tab on end play tool on top of input shaft as shown in Figure 48. 3. Tool J-39686 must rest flat on case cee cover seal as shown in Figure 48. 4. Rotate threaded shaft clockwise until tight (See Figure 48). 5. Insert collar between flange and the handle of end play tool as shown in Figure 48. 6. Install dial indicator as shown in Figure 48, with tip of dial indicator [iwaSHen THICKNESS ] resting on top of tab. 227. 249 7. Zero the dial indicator. 258-260 2693.11 8. Push down on handle and check the end Su play measurement. 9. Proper end play is .004"-.033". 10. If the specification is out of range determine the proper selective washer using the chart in Figure 48. 11. Remove the dial indicator, end play tool, and post. 522 WASHER, THRUST [DRIVEN SPROCKET SUPPORT) (SELECTIVE) 04 HOUSING, THIRD CLUTCH Figure 48 AUTOMATIC TRANSMISSION SERVICE GROUP aATSG Technical Service Information 28 BOLT, SIDE COVER TO CASE COVER (@, 15mm 29 COVER, SIDE 30. GASKET, SIDE COVER TO CASE COVER 32. BOLT, SIDE COVER TO CASE COVER 11, 19mm) 209. SEAL, FLTER 238. FILTER, TRANSAXLE OIL 360 TEMPERATURE SENSOR (1, 17mm) 236 Figure 49 SIDE COVER AND RELATED PARTS 1, Remove nine side cover bolts, notice that one is larger than the others. (See Figure 49). 2. Remove the side cover and discard the side cover gasket. 3. Remove the main transaxle filter and filter seal (See Figure 49). 4, Seal may remain in secondary punp body, use small screwdriver to pry out (See Figure 49). 5. Use care not to damage seal bore in pump housing. 6. Use a small screwdriver to disconnect Temp Sensor, TCC Solenoid, and the Pressure Control Solenoid’ connectors by prying back tabs (See Figure 49). 7. Remove nineteen 8mm bolts located on the pump housings, and indicated in Figure 50. 8. Remove the scavenge, primary and the secondary pump assemblies as one unit as shown in Figure 51. 9. Remove the upper valve body bolts and remove the upper valve body, as shown in Figure 51. 10. Remove the spacer plate and gaskets. 11, Remove two checkballs from cover. AUTOMATIC TRANSMISSION SERVICE GROUP 44a e20 | ex ti m he © 2g & * : “7 PUMP ASSEMBLY "BY BOXT PUMP ASSEMBLY TO CASE (9, nm 231 BOLT, PUMP ASSEMBLY TO CASE (2. mm) 232 BOLT. PUMP ASSEMBLY TO CASE COVER (6, mm) 233. BOLT, PUMP ASSEMBLY TO CASE COVER(S, 8mm) 234 BOLT, SECONDARY PUMP TO CASE COVER (1, 8mm) 235. BOLT, SECONDARY PUMP TO CASE COVER (2, 8mm) 331 BOLT, SECONDARY PUMP TO CASE (1, &mm! UPPER CONTROL VALVE BODY (UCVB) ASSEMBLY 16. BOLT, PRESSURE CONTROL SOLENOID BRACKET TO Ucvs (3, 8mm) 229 BOLT, UCVB TO CASE (1, 8mm) 529. BOLT, UCVB TO CASE COVER 19, 8mm) 4350. BOLT, UCVB TO Case COVER (2 8mm) 351 BOLT, UCVS TO Case 9, 8mm) 331 BOLT, UCVB TO ORIVEN SPROCKET ‘SUPPORT (2, mm) Figure 50 200-238 228 300 3 328 PRIMARY, SECONDARY AND SCAVENGE PUMP ASW ‘GASKET, SECONDARY PUMP BODY TO SPACER PLATE BODY, UPPER CONTROL VALVE ASSEMBLY GASKET, VALVE BODY TO SPACER PLATE SPACER PLATE, CASE COVER ASSEMBLY GASKET, SPACER PLATE TO CASE COVER Figure 51 AUTOMATIC TRANSMISSION SERVICE GROUP