HY D R A -MATI C 4L40-E/5L40- E

INDEX
GO TO PAGE

PREVIOUS MENU

5L40-E IDENTIFICATION TAG INFORMATION .......................................................................................... 3 CUT-AWAY VIEW AND COOLER LINE IDENTIFICATION ........................................................................ 4 COMPONENT APPLICATION CHART .......................................................................................................... 5 SOLENOID APPLICATION AND RESISTANCE CHARTS ........................................................................... 6 INTERNAL WIRE SCHEMATIC ..................................................................................................................... 7 TCM LOCATION, CONNECTOR I.D. AND UNDERHOOD FUSE BLOCK I.D. ........................................ 8 ELECTRONIC COMPONENT LOCATER ....................................................................................................... 10 INTERNAL MODE SWITCH DESCRIPTION ............. ................................................................................... 11 DIAGNOSTIC TROUBLE CODES AND DESCRIPTION ............................................................................... 12 GENERAL OPERATION AND DESCRIPTION ............. ................................................................................. 14 FLUID LEVEL CHECKING PROCEDURE .................................................................................................... 15 LINE PRESSURE TESTS .................................................................................................................................. 16 OIL PRESSURE PASSAGE IDENTIFICATIONS ........................................................................................... 17 CHECK BALL DESCRIPTIONS ....................................................................................................................... 24 TRANSMISSION DISASSEMBLY .................................................................................................................... 27 TRANSMISSION EXPLODED VIEW .............................................................................................................. 30 COMPONENT REBUILD SECTION......... CASE ASSEMBLY .......................................................................................................................................... 41 OIL PUMP ASSEMBLY .................................................................................................................................. 45 DIRECT AND REVERSE CLUTCH HOUSING ........................................................................................... 51 FORWARD AND COAST CLUTCH HOUSING ........................................................................................... 59 FORWARD SPRAG ASSEMBLY ................................................................................................................... 67 INTERMEDIATE SPRAG ASSEMBLY ........................................................................................................ 69 INTERMEDIATE AND OVERDRIVE CLUTCH HOUSING ...................................................................... 76 LOW SPRAG ASSEMBLY .............................................................................................................................. 81 CENTER SUPPORT ASSEMBLY ................................................................................................................. 84 5L40-E PLANETARY CARRIER ASSEMBLY .............................................................................................. 96 4L40-E PLANETARY CARRIER ASSEMBLY .............................................................................................. 99 VALVE BODY ASSEMBLY ............................................................................................................................ 102 CHECKBALL LOCATIONS .......................................................................................................................... 105 FINAL TRANSMISSION ASSEMBLY ............................................................................................................ 108 BOLT IDENTIFICATION CHART ................................................................................................................. 126 TORQUE SPECIFICATIONS .......................................................................................................................... 127

"Portions of materials contained herein have been reprinted with permission of General Motors Corporation, Service Operations."

AUTOMATIC TRANSMISSION SERVICE GROUP 9200 S. DADELAND BLVD. SUITE 720 MIAMI, FLORIDA 33156 (305) 670-4161
Copyright © ATSG 2002

2

INTRODUCTION
HYDRA-MATIC 4/5L40-E

Published July, 2002

Beginning at the start of production for some 1999 models, BMW has introduced a new 5 speed automatic transmission that is designed and manufactured by General Motors Powertrain division in Strasbourg, France and is illustrated in Figure 1. This new transmission is designated as follows: GM Designation - 5L40-E BMW Designation - A5S 360R Model year 1999 applications are as follows: 3 Series BMW, with 2.5L Gasoline Engine, Used in USA and Japan. 3 Series BMW, with 2.8L Gasoline Engine, Used in USA and Japan. 5 Series BMW, with 3.0L Diesel Engine, Used Worldwide. Model year 2003 applications are as follows: Cadillac CTS model, Gasoline Engine, Used Worldwide No part of any ATSG 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 written permission of Automatic Transmission Service Group. This includes all text illustrations, tables and charts. "Portions of materials contained herein have been reprinted with permission of General Motors Corporation, Service Operations." The information and part numbers contained in this booklet have been carefully compiled from industry sources known for their reliability, but ATSG does not guarantee its accuracy. Copyright © ATSG 2002

DALE ENGLAND
FIELD SERVICE CONSULTANT

JIM DIAL
TECHNICAL CONSULTANT

WAYNE COLONNA
TECHNICAL SUPERVISOR

ED KRUSE
TECHNICAL CONSULTANT

PETER LUBAN
TECHNICAL CONSULTANT

GREGORY LIPNICK
TECHNICAL CONSULTANT

JON GLATSTEIN
TECHNICAL CONSULTANT

DAVID CHALKER
TECHNICAL CONSULTANT

GERALD CAMPBELL
TECHNICAL CONSULTANT

JERRY GOTT
TECHNICAL CONSULTANT

ROLAND ALVAREZ
TECHNICAL CONSULTANT

STANTON ANDERSON
TECHNICAL CONSULTANT

AUTOMATIC TRANSMISSION SERVICE GROUP 9200 S. DADELAND BLVD. SUITE 720 MIAMI, FLORIDA 33156 (305) 670-4161

1

Technical Service Information
5 L 4 0 E = 5 Forward Speeds = Longitudinal (Rear Drive) = Electronic Controls

}= Relative Torque Capacity

GM

ATIC RAM G HYD SBOUR 96 STRA ANCE FR

02

32 2 8

*013

9781

RVO

*

CUSTOMER PART NUMBER

MADE IN FRANCE
CAL. TCM

1 423 875 HYDRAMATIC PART NO. STRASBOURG 96022832

GM
P08

VO
HYDRAMATIC PART NUMBER SERIAL NUMBER

_ _

SERIAL NO.

0139781

CALIBRATION

Production Location = Strasbourg, France Torque Converter Size = 245mm and 258mm (Model Sensitive) Pressure Taps = Line Pressure Only Transmission Fluid Type = Dexronä III Transmission Fluid Capacity (Approx.) = Complete Overhaul: Dry 8.5L (9.0 Qt)

Figure 1

AUTOMATIC TRANSMISSION SERVICE GROUP

9 2/9 18/14 18:5

971 019

GM
P08

142

387

5

VO
2832
9781

9602

0139

BROADCAST CODE

Copyright © 2002 ATSG

3

D. Clutch Clutch Clutch Int.Technical Service Information 5L40-E CUT-AWAY VIEW AND COMPONENT LOCATIONS Direct Coast O. Clutch Sprag Sprag Low Sprag 2nd Clutch 5L40-E ONLY Sprag GM ATIC RAM G HYD SBOUR 96 STRA ANCE FR 022 832 * RVO 9781 *013 To Cooler Figure 2 4 AUTOMATIC TRANSMISSION SERVICE GROUP 9 2/9 18/14 18:5 971 019 GM P08 5 387 142 VO 2832 9602 9781 0139 From Cooler Copyright © 2002 ATSG . Clutch Low/Rev Clutch 2nd Coast Clutch 5L40-E ONLY 2nd Clutch 5L40-E ONLY Reverse Clutch Forward Clutch Forward Int.

75 GEAR Engine Braking Low/ 2nd Fwd. 4. 2.21 1. Low Clutch Clutch Sprag Sprag Int.00 0.D.03 3. Clutch Gear Sprag Ratio * Engine braking is electronically controlled by the TCM. 4L40-E COMPONENT APPLICATION CHART RANGE Park/Neutral Reverse R 1st 1st 2nd D. Direct Coast Reverse Fwd. 4.00 0. 3. and is available as calibrated for each model and application.D.54 1.60 1.03 2. On = Clutch Applied. 2nd 3rd 3rd 4th 5th Yes No* Yes No* Yes No* Yes Yes Yes On On On On On On On On On On On On On On On On On On On On On On On On On On On On On On On On On Hold Hold Hold Hold Hold Hold Hold Hold Hold Hold Hold Hold Hold 3.82 1. 2nd 3rd 3rd 4th Yes No* Yes No* Yes No* Yes Yes On On On On On On On On On On On On On On On On On On On On On On Hold Hold Hold Hold Hold Hold Hold Hold Hold Hold Hold 3.21 2. Reverse Clutch Clutch Clutch Fwd. Low 2nd Int.42 2.00 1. and is available as calibrated for each model and application.70 GEAR Engine Braking Direct Coast Reverse Fwd. On = Clutch Applied. Copyright © 2002 ATSG Figure 3 AUTOMATIC TRANSMISSION SERVICE GROUP 5 . O. O. 3. 2nd Int. Clutch Clutch Clutch Clutch Low/ Int. Reverse Coast Clutch Clutch Clutch Clutch Gear Clutch Clutch Clutch Clutch Clutch Clutch Clutch Clutch Clutch Sprag Sprag Sprag Sprag Ratio * Engine braking is electronically controlled by the TCM.82 2.60 1.42 3.54 1. 2.Technical Service Information COMPONENT APPLICATION CHARTS 5L40-E COMPONENT APPLICATION CHART RANGE Park/Neutral Reverse R 1st 1st 2nd D.

*** Calibrated for particular model and spplication.N/C) 4-5 Shift Solenoid "C" (On/Off .6 Ohms 325-485 Ohms 325-485 Ohms See Chart Below See Chart TFT Sensor Resistance Chart 19 18 15 11 12 10 6 7 4 8 14 9 16 13 20 17 Temperature C° (F°) -30C (-22F) -20C (-8F) -10C (14F) 0C (32F) 10C (50F) 20C (68F) 30C (86F) 40C (104F) 50C (122F) 60C (140F) 70C (158F) 80C (176F) 90C (194F) 100C (212F) 110C (230F) 120C (248F) 130C (266F) Minimum 50264 27439 15540 9097 5493 3418 2185 1430 958 656 459 327 237 174 130 98 75 3 1 5 2 View Looking Into Transmission Case Connector Resistance In Ohms Nominal 52594 28582 16120 9399 5658 3511 2240 1465 980 671 469 334 242 178 133 101 78 Maximum 54924 29725 16700 9701 5823 3604 2295 1500 1002 686 479 341 247 182 136 104 80 Figure 4 6 AUTOMATIC TRANSMISSION SERVICE GROUP .42 3. 2nd 3rd 3rd 4th 5th Yes No* Yes No* Yes No* Yes Yes Yes On On On On On On On On On On On On On On On On On On On On On On On On On On On On On On On On On GEAR Engine Braking Low/ 2nd 1-2 Direct Coast Reverse Fwd. 2.N/C) TCC Solenoid (PWM .N/C) 2-3 Shift Solenoid "B" (On/Off .42 2. Off = Solenoid De-Energized. Off Off Off Off On** On** On** On** On** On** 3.Technical Service Information 5L40-E SOLENOID APPLICATION CHART RANGE Park/Neutral Reverse R 1st 1st 2nd D. On = Clutch Applied.5 Ohms 3.5-4.60 1.21 1. 4. *** 4-5 Shift Sol. *** On Off Off On On On On Off Off On On On On Off Off Off Off Off On Off On Off On On Off 2-3 Shift Sol. On = Solenoid Energized.00 0.N/C) Input Speed Sensor Output Speed Sensor Transmission Fluid Temperature Sensor Internal Mode Switch CASE CONN TERMINALS 14 And 17 9 And 17 5 And 17 20 And 17 8 And 13 18 And 15 1 And 3 10 And 6 See Wire Schematic RESISTANCE @ 20°C (68°F) 15-17 Ohms 15-17 Ohms 15-17 Ohms 10.60 1.21 2. *** TCC Sol. and is available as calibrated for each model and application.75 Gear Ratio * Engine braking is electronically controlled by the TCM. 2nd Int. 3.03 3. O.N/C) Pressure Control Solenoid (PWM .0-11. 5L40-E COMPONENT RESISTANCE CHART COMPONENT 1-2 Shift Solenoid "A" (On/Off . Reverse Coast Shift Clutch Clutch Clutch Clutch Clutch Clutch Clutch Clutch Clutch Sol. ** Dependant upon various sensors including vehicle speed and throttle position.D.

14. Fuse No. Description 1 Output Speed Sensor (OSS) (+) 2 3 4 5 6 7 8 9 Internal Mode Switch Signal "N" Output Speed Sensor (OSS) (-) Internal Mode Switch Supply 4-5 Shift Solenoid (C) Ground Trans Fluid Temp (TFT) Sensor (-) Internal Mode Switch Signal "B" Pressure Control Solenoid (-) 2-3 Shift Solenoid (B) Ground Trans Fluid Temp (TFT) Sensor (+) Pin No. 40. BLUE/WHITE YELLOW PURPLE ORANGE/BLACK DK. BLUE/WHITE ORANGE/BLACK WHITE YELLOW TAN/WHITE GRAY BLACK/WHITE 17 14 9 5 20 13 8 1 3 18 15 2 11 7 16 19 4 12 WHITE BLACK BLUE GRAY YELLOW GREEN WHITE ORANGE WHITE YELLOW WHITE BROWN GRAY BLACK RED BLUE GREEN "NOT USED" RED WHITE WHITE WHITE WHITE 4-5 Shift 2-3 Shift 1-2 Shift Solenoid (A) Solenoid (B) Solenoid (C) BLACK BLUE GRAY TCC Solenoid Pressure Control Solenoid YELLOW GREEN WHITE BLACK/WHITE BLACK/WHITE 7 6 3 29 1 2 10 11 Output Sensor Turbine Sensor N P B A C TO ECM A B C D E F 37 RED/WHITE 27 5 9 BATTERY VOLTAGE ACCESSORY VOLTAGE IGNITION VOLTAGE 24 36 25 YELLOW PINK 15 YELLOW/BLACK TAN 10 6 TCM 21 TFT Sensor (Resistor in Wire) G100 PINK YELLOW RED/WHITE 5L40-E TRANSMISSION 12 19 26 TCM/IPC. (10A) UNDERHOOD FUSE BLOCK (See Page 8) Case Connector Terminal Identification 19 18 15 11 12 10 6 7 4 8 14 9 16 13 20 17 Pin No. Description 11 Internal Mode Switch Signal "P" 12 13 14 15 16 17 18 19 20 "Not Used" Pressure Control Solenoid (+) 1-2 Shift Solenoid (A) Ground Input Speed Sensor (ISS) (-) Internal Mode Switch Signal "A" Solenoid Power In Input Speed Sensor (ISS) (+) Internal Mode Switch Signal "C" TCC/PWM Solenoid Ground 3 1 5 2 View Looking Into Trans Case Connector 10 Copyright © 2002 ATSG Figure 5 Supply Internal Mode Switch AUTOMATIC TRANSMISSION SERVICE GROUP 7 . GREEN YELLOW/BLACK PURPLE TAN/BLACK ORANGE/BLACK LT.Technical Service Information CADILLAC/BMW INTERNAL WIRE SCHEMATIC TCM G100 8 30 18 19 4 RED LT. Fuse No. 6.5A) B+ ECM/TCM. Fuse No. (15A) THEFT. (7.

6.5A 68 67 47 51 50 49 48 46 66 65 45 40 64 63 39 37 38 71 44 43 70 42 PCM LOCATION RIGHT FRONT ENGINE COMPARTMENT 41 TCM LOCATION RIGHT FRONT ENGINE COMPARTMENT 72 62 36 35 61 60 59 58 34 30 27 26 24 22 20 14 11 9 57 56 33 29 32 28 UNDERHOOD FUSE BLOCK LOCATION RIGHT FRONT ENGINE COMPARTMENT 31 4 55 25 23 21 15 54 53 52 19 13 10 8 6 18 12 17 16 3 7 69 5 TCM/IPC. 10A Copyright © 2002 ATSG Figure 6 8 AUTOMATIC TRANSMISSION SERVICE GROUP . Fuse No. 14. Fuse No. Fuse No.Technical Service Information TRANSMISSION CONTROL MODULE (TCM) CONNECTOR IDENTIFICATION 34 22 42 33 10 1 9 21 UNDERHOOD FUSE BLOCK LOCATIONS AND IDENTIFICATION THEFT. 40. 7. 15A 2 1 ECM/TCM.

34. 20. 23. 1 2 3 4 5 6 7 8 9 10 11 13 15 18 19 21 24 25 27 29 30 32 33 36 37 38 WIRE COLOR CIRCUIT NO. 31. 39. Copyright © 2002 ATSG Figure 7 AUTOMATIC TRANSMISSION SERVICE GROUP 9 . 28. 26. 40.(CAN) Transmission Range Switch Signal "A" Transmission Range Switch Signal "P" TCC Brake Switch Signal Special Note: Pins 12. 16. Blue/White 1229 Lt. 17. 41. Yellow 400 Purple 401 Orange/Black 1228 Tan/Black 422 Yellow 343A Black/White 1551E Black/White 1551C Orange 1525 Pink 239C Orange/Black 1230 Dk.Technical Service Information TRANSMISSION CONTROL MODULE (TCM) CONNECTOR IDENTIFICATION PIN NO. Green 1222 White 2500 Green 2501 Tan/White 771 White 776 Purple 420E FUNCTION Output Shaft Speed (OSS) Sensor High Signal Output Shaft Speed (OSS) Sensor Low Signal Pressure Control Solenoid High Control Torque Converter Clutch Solenoid Ground Control Signal Accessory Voltage Ground Ground Solenoid Power Feed Ignition Switch Voltage Transmission Input Shaft (ISS) High Signal Transmission Input Shaft (ISS) Low Signal Serial Data Transmission Fluid Temperature (TFT) High Signal 2-3 Shift Solenoid "B" Ground Signal 4-5 Shift Solenoid "C" Ground Signal Transmission Fluid Temperature (TFT) Low Signal Transmission Range Switch Signal "B" Transmission Range Switch Signal "C" Battery Positive Voltage Pressure Control Solenoid Low Control 1-2 Shift Solenoid "A" Ground Signal High Speed GMLAN Serial Data Bus + (CAN) High Speed GMLAN Serial Data Bus . 35. 22. Blue/White 1231 White/Black 5043B Yellow/Black 1227 Yellow/Black 1223 Purple 898 Tan 2762 Yellow 772 Gray 773 Red/White 1440D Lt. 42 are "Not Used". 14.

Technical Service Information ELECTRICAL COMPONENTS Electrical signals from various sensors provide information to the TCM or PCM. TCC BRAKE SWITCH ELECTRONIC CONTROLLERS * TRANSMISSION CONTROL MODULE (TCM) SOME MODELS * POWERTRAIN CONTROL MODULE (PCM) * ENGINE CONTROL MODULE (ECM) SOME MODELS * BODY CONTROL MODULE (BCM) * DIAGNOSTIC LINK CONNECTOR (DLC) TRANSMISSION COMPONENTS 1. engine speed and converter turbine speed. Note: Some models use an Engine Control Module (ECM) and a Transmission Control Module (TCM) and some models use a Powertrain Control Module (PCM) for both engine and transmission management. INTERNAL MODE SWITCH (IMS) J. 1-2 SHIFT SOLENOID 4. 2-3 SHIFT SOLENOID 5. OUTPUT SPEED SENSOR (OSS) H. THROTTLE POSITION SENSOR (TPS) B. the pressure control solenoid is turned off which will increase line pressure to the maximum. engine coolant temp. about vehicle speed. Also. range selector position. INPUT SPEED SENSOR (ISS) G. This type of control provides consistent shift points and shift quality based on the operating conditions of the vehicle. This "Safety Mode" operating state forces the transmission to operate in 5th gear when the range selector is in any forward range. TCC/PWM SOLENOID 3. PRESSURE CONTROL SOLENOID 2. ACCELERATOR PEDAL POSITION (APP) SENSOR K. INFORMATION SENSORS A. The TCM or PCM uses this information to determine upshift and downshift speeds. ENGINE COOLANT TEMPERATURE (ECT) SENSOR F. TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR I. all three shift solenoids will be turned off. If for any reason the entire electronic control system of the transmission becomes disabled. MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR C. MANIFOLD AIR TEMPERATURE (MAT) SENSOR E. ENGINE SPEED SENSOR D. throttle position. 4-5 SHIFT SOLENOID Copyright © 2002 ATSG Figure 8 10 AUTOMATIC TRANSMISSION SERVICE GROUP . apply or release of the TCC and what fluid pressure is needed to apply the clutch packs.

Technical Service Information INTERNAL MODE SWITCH The Internal Mode Switch supplies the Transmission Control Module or Powertrain Control Module with input regarding the selector lever position (P. The mode switch is located inside the transmission. R. N. Power In C A B P P/N P 3 R N D 4 2 RANGE SELECTED Park Reverse Neutral Overdrive Manual 4 Manual 3 Manual 2 1 = Switch Closed 0 = Switch Open A 1 1 0 0 1 1 0 CIRCUIT B C P 0 0 1 1 0 0 1 0 1 1 0 0 1 1 1 0 1 0 0 1 1 P/N 1 0 1 0 0 0 0 Internal Mode Switch + N P B A C Copyright © 2002 ATSG Figure 9 AUTOMATIC TRANSMISSION SERVICE GROUP 11 . 4. The selector position is indicated by the state of five different On/Off switches. 3. as shown below. D. 2). on the manual shaft and is fixed in rotation to the main case by the dentent lever spring and no adjustment is ever necessary.

2nd Gear Gear Ratio Error. 4th Gear Gear Ratio Error. 1st Gear Gear Ratio Error. -40°F indicated Input Shaft Speed (ISS) signal drops 1000 RPM or greater for 4 seconds No Input Shaft Speed (ISS) signal TCC Brake Switch stuck "ON" (Open) No Output Shaft Speed (OSS) signal Output Shaft Speed (OSS) signal drops 1300 RPM or greater for 3 seconds TCC Brake Switch stuck "OFF" (Closed) Invalid engine speed Gear Ratio Error. open or shorted to ground 1-2 Shift Solenoid "A" stuck "ON" 1-2 Shift Solenoid "A" stuck "OFF" 2-3 Shift Solenoid "B" stuck "OFF" 2-3 Shift Solenoid "B" stuck "ON" 4-5 Shift Solenoid "C" stuck "OFF" 4-5 Shift Solenoid "C" stuck "ON" Park/Neutral switch circuit low (0 Volts) or high (12 Volts) TCM detects checksum error between RAM and EEPROM test data BMW CODE 61 96 96 80 81 34 34 34 33 33 151 32 32 151 150 50 52 53 54 55 48 0 60 80 Copyright © 2002 ATSG Figure 10 12 AUTOMATIC TRANSMISSION SERVICE GROUP . 5th Gear Torque Converter Clutch (TCC) slippage detected Torque Converter Clutch (TCC) stuck "ON" Pressure Control Solenoid circuit.Technical Service Information DIAGNOSTIC TROUBLE CODES (DTC) AND DESCRIPTION DTC P0218 P0500 P0562 P0563 P0601 P0602 P0603 P0604 P0711 P0712 P0713 P0716 P0717 P0719 P0722 P0723 P0724 P0727 P0731 P0732 P0733 P0734 P0735 P0741 P0742 P0748 P0751 P0752 P0756 P0757 P0761 P0762 P0850 P1621 DESCRIPTION Transmission Fluid Temp is 132°C (270°F) or greater for 10 minutes Vehicle Speed is less than 5 km/h (3mph) for a total of 50 seconds System Voltage is less than 11 Volts for 10 seconds System Voltage is greater than 18 Volts for 10 seconds TCM EEPROM checksums do not match TCM detects an unlocked calibration memory range TCM NVRAM checksums do not match The data read from RAM does not match data written to RAM Erratic Transmission Fluid Temperature (TFT) signal Transmission Fluid Temperature (TFT) shorted to ground. 3rd Gear Gear Ratio Error. 315°F indicated Transmission Fluid Temperature (TFT) open circuit.

gear ratio indicates Reverse Internal Mode Switch (IMS) signal "A" shorted to ground Internal Mode Switch (IMS) D2 and D3 transitional error Internal Mode Switch (IMS) Neut and D5 transitional error Internal Mode Switch (IMS).Technical Service Information DIAGNOSTIC TROUBLE CODES (DTC) AND DESCRIPTION DTC P1779 P1780 P1791 P1792 P1793 P1795 P1815 P1818 P1820 P1822 P1823 P1825 P1826 P1831 P1832 P1833 P1834 P1842 P1843 P1845 P1847 P1864 P1865 P1866 P1867 P1868 U2105 DESCRIPTION Invalid Engine Torque Signal Engine Torque Reduction request has failed Invalid Accelerator Pedal Position (APP) sensor signal Engine Coolant Temperature (ECT) sensor circuit Invalid Wheel Speed data from the ECM Invalid Throttle Plate Position (TPP) sensor signal from the ECM Invalid Internal Mode Switch (IMS) state while engine is being started IMS signal indicates forward range. combination of switch inputs invalid Internal Mode Switch (IMS) signal "C" is high while in a forward gear Pressure Control Solenoid circuit shorted to ground Pressure Control Solenoid circuit shorted to voltage Shift Solenoid power wire circuit shorted to ground Shift Solenoid power wire circuit shorted to voltage 1-2 Shift Solenoid "A" circuit open or shorted to ground 1-2 Shift Solenoid "A" circuit shorted to voltage 2-3 Shift Solenoid "B" circuit open or shorted to ground 2-3 Shift Solenoid "B" circuit shorted to voltage 4-5 Shift Solenoid "C" circuit open or shorted to ground 4-5 Shift Solenoid "C" circuit shorted to voltage TCC/PWM Solenoid circuit open or shorted to ground TCC/PWM Solenoid circuit shorted to voltage Calculated transmission fluid life remaining is 10% or less TCM has not recieved ECM data within the preset time parameters BMW CODE 146 145 147 148 149 147 60 60 60 60 60 60 60 0 0 84 16 17 18 4 Copyright © 2002 ATSG Figure 11 AUTOMATIC TRANSMISSION SERVICE GROUP 13 .

The IMS operation is illustrated and explained in Figure 9. Manual downshifts are controlled by the TCM. Park position should not be selected until the vehicle has come to a complete stop. as illustrated in Figure 8.Technical Service Information GENERAL OPERATION AND DESCRIPTION The 5L40-E transmission is a completely new design rear wheel drive unit and was designed to be a four or five speed transmission. The hydraulic system primarily consists of a 13 vane pump. This range also helps for engine braking when descending grades. Upshifts and downshifts all occur automatically. except 4th and 5th is prohibited. The TCM controls shift feel through the Pressure Control Solenoid. the four mechanical sprag clutches and a component application chart in Figures 2 and 3. 14 AUTOMATIC TRANSMISSION SERVICE GROUP .Manual Fourth can be used for conditions where it may be desirable to use only 4 gear ratios. For safety reasons. 4 . converter housing and transmission case. and description of each gear range is explained in this section. If necessary. not the manual valve location. not the manual valve. rear wheel drive. Refer to Figure 4 for the solenoid application chart for each gear. The TCM commands three on/off Shift Solenoids to control shift timing. this position should be selected to restart the engine while the vehicle is moving. R N . The same case and components are used for both applications with the exclusion of the 2nd clutch. 2nd coast clutch and the 2nd sprag clutch.Overdrive range should be used for all normal driving conditions for maximum efficiency and fuel economy. four mechanical sprag clutches and a hydraulic pressurization and control system. STANDARD SHIFT QUADRANT With the "Standard" range indicator. Refer to Figure 5 for the internal wiring schematic. and the use of a smaller ravigneaux planetary carrier assembly in the 4 speed version. It consists primarily of a four element (Lock-Up) torque converter. . two channel plates.Neutral position enables the engine to start and operate without driving the vehicle. one ravigneaux planetary gear set. Upshifts and downshifts all occur automatically. nine multiple-disc friction clutch packs. Downshifts to a lower gear are possible for safe passing by depressing the accelerator. Changing gear ratios is fully automatic and is accomplished through the use of a Transmission Control Module (TCM). P . Notice also in Figure 5 that this transmission uses an Internal Mode Switch (IMS). The TCM recieves and monitors various electronic sensor inputs and uses this information to shift the transmission at the optimum time.Reverse position enables the vehicle to be operated in a rearward direction. with a maximum torque rating of 360 Nm. the transmission may be operated in any one of the seven different positions shown on the shift quadrant as follows. Manual downshifts are controlled by the TCM. such as trailer towing or hilly terrain. The pump maintains the working pressures needed to stroke the clutch pistons that apply or release the friction components. Manual Fourth can be selected at any vehicle speed but will downshift into 4th gear only if vehicle speed is low enough not to over-rev the engine. Overdrive range allows the transmission to upshift automatically into each of the 5 forward gear ratios. D . or by manually selecting a lower gear with the shift selector. five forward speed. as illustrated in Figure 12. the vehicles parking brake should always be used in addition to the "Park" position. along with case connector pin identification and a resistance chart for the internal components. The TCM also controls the apply and release of the torque converter clutch through a TCC/PWM Solenoid. except 5th gear is prohibited. two control valve bodies. such as trailer towing or hilly terrain. fully electronic controlled transmission. This range is also helpful for engine braking when descending slight grades. The Hydra-matic 5L40-E is a fully automatic.Park position enables the engine to be started while preventing the vehicle from rolling either forward or backward.Manual Third can be used for conditions where it is desirable to use only 3 gear ratios. Manual 3rd can be selected at any vehicle speed but will downshift to 3rd only if vehicle speed is low enough not to over-rev the engine. The ravigneaux planetary gear set provides the five forward speeds and reverse. We have provided you with an illustration to identify the location of the nine different clutch packs. 3 .

Have a container ready to capture any lost fluid.Technical Service Information "STANDARD" RANGE INDICATOR Caution: The engine must be running when Check/Fill plug is removed. The fluid should trickle from the plugs opening. Use Figure 13 for the locations as they differ from gasoline models to diesel models. The vehicle must be level with the engine running and the shift lever in the PARK range.lb. or excessive fluid loss will occur. Add Dexron® III automatic transmission fluid in increments of 0. pausing a few seconds in each range. Raise the vehicle on a hoist. Depress the brake pedal and move the shift lever through all of the gear ranges.5 L (0.5 quart) until the fluid drains from the threaded opening. stand clear and take precautions with protective clothing when removing the plug. and since the actual fluid level is unknown. Transmission fluid may be hot. FLUID LEVEL CHECK AND FILL PLUG LOCATIONS GM ATIC RAM G HYD SBOUR 96 STRA ANCE FR 022 832 *013 9781 RVO * Pressure Test Plug Figure 13 AUTOMATIC TRANSMISSION SERVICE GROUP 9 2/9 18/14 18:5 971 019 GM P08 142 387 5 VO 2832 9781 9602 0139 Fluid Level Check And Fill Plug (Gas Engines) Location For Check And Fill Plug On Diesel Applications Copyright © 2002 ATSG 15 . Return the shift lever to the PARK range. Remove the transmission fill plug with care as described above. Do not turn the engine off with the fill plug removed as you can be injured by hot transmission fluid being expelled from the Check/Fill plug opening. P R N D 4 3 2 Copyright © 2002 ATSG Figure 12 FLUID LEVEL CHECKING PROCEDURE Start the engine as it must be running to properly check the fluid level. Let the transmission fluid temperature rise until it has reached a temperature of 90-125°F (30-50°C). Torque specification for the Check/Fill plug is 15 ft.

D.Technical Service Information LINE PRESSURE TEST GM ATIC RAM G HYD SBOUR 96 STRA ANCE FR 022 832 *013 9781 RVO * To Cooler Pressure Test Plug llllllll ll llll GM 142 387 5 VO 2832 9781 9602 0139 GM ATIC RAM G HYD SBOUR 96 STRA ANCE FR 022 832 P08 *013 9781 RVO * RANGE P.8 95-119 PSI 0.7 117-140 PSI 0. M2 REVERSE LINE PRESSURE Minimum Maximum 48 psi 180 psi 60 psi 232 psi Figure 14 PCS AMPS PRESSURE 0.3 162-188 PSI 0.1 42-64 PSI ENGINE AT 1300 RPM Copyright © 2002 ATSG 16 AUTOMATIC TRANSMISSION SERVICE GROUP lll lll 9 2/9 18/14 18:5 971 019 9 2/9 18/14 18:5 971 019 GM P08 142 387 5 VO 2832 9781 9602 0139 Fluid Level Check And Fill Plug From Cooler lllllllllll llll llllllllll llll . M4.1 173-197 PSI 0. M3. N.5 145-169 PSI 0.9 63-89 PSI 1.

TCC SIGNAL 32. TO COOLER 9. FORWARD CLUTCH 24. DECREASE OIL 4. CONVERTER SEAL DRAIN 51.Technical Service Information BELL HOUSING OIL PASSAGES 51 51 50 53 5 52 6 4 3 48 48 52 2 4 2 52 7 24 53 50 48 52 8 7 16 2 48 48 48 37 2 52 2 21 12 32 52 12 52 1. CONVERTER RELEASE 6. SUCTION 2. LUBE FROM COOLER 12. VENT 52. CONVERTER FEED 5. COAST CLUTCH 37. REVERSE CLUTCH 21. REGULATED APPLY 8. CONVERTER APPLY 7. CONVERTER FEED LIMIT Copyright © 2002 ATSG Figure 15 AUTOMATIC TRANSMISSION SERVICE GROUP 17 . LINE PRESSURE 3. THROTTLE SIGNAL 16. VOID 53. EXHAUST 50. DIRECT CLUTCH 48.

REGULATED APPLY 8. CONVERTER APPLY 7. CONVERTER SEAL DRAIN 51. LINE PRESSURE 3. VENT 52. THROTTLE SIGNAL 16. LUBE FROM COOLER 12. THROTTLE SIGNAL 16. TO COOLER 9. DECREASE OIL 4. LINE PRESSURE 3. FORWARD CLUTCH 24. CONVERTER RELEASE 6. REGULATED APPLY 8. DIRECT CLUTCH 48. EXHAUST 50. VENT 52. REVERSE CLUTCH 21. DECREASE OIL 4. TCC SIGNAL 32. VOID 53. CONVERTER FEED LIMIT PUMP COVER OIL PASSAGES CASE SIDE 3 (233) 52 2. CONVERTER APPLY 7. TCC SIGNAL 32. VOID 53. CONVERTER FEED LIMIT 48 8 52 7 9 24 37 16 37 (203) 52 2 16 (203) 52 52 21 32 12 32 (203) 32 (203) GM 52 (203) AIR BLEED BALL CAPSULE (233) ORIFICED CUP PLUG Copyright © 2002 ATSG Figure 16 18 AUTOMATIC TRANSMISSION SERVICE GROUP . CONVERTER RELEASE 6. LUBE FROM COOLER 12. CONVERTER SEAL DRAIN 51. FORWARD CLUTCH 24. CONVERTER FEED 5. REVERSE CLUTCH 21. DIRECT CLUTCH 48. TO COOLER 9. CONVERTER FEED 5. COAST CLUTCH 37.Technical Service Information PUMP COVER OIL PASSAGES BELL HOUSING SIDE 51 51 48 2 52 2 3 48 50 24 53 16 2 12 3 1 7 48 48 52 12 32 48 2 37 24 2 21 16 48 8 6 7 4 48 3 2 48 4 6 5 52 53 1. SUCTION 2. COAST CLUTCH 37. EXHAUST 50.

REGULATED APPLY 8. FORWARD CLUTCH 24. TO COOLER 9. THROTTLE SIGNAL 16.Technical Service Information MAIN CASE "FRONT" OIL PASSAGES TRANSMISSION COOLER 8 7 24 37 12 16 32 21 2 9 2. LUBE FROM COOLER 12. COAST CLUTCH 37. LINE PRESSURE 7. REVERSE CLUTCH 21. DIRECT CLUTCH Copyright © 2002 ATSG Figure 17 AUTOMATIC TRANSMISSION SERVICE GROUP 19 . TCC SIGNAL 32.

REVERSE LOCK OUT 16. REVERSE CLUTCH 18. LOW/REV CLUTCH OR RLO 21. DIRECT CLUTCH 41. LINE PRESSURE 7. FORWARD CLUTCH 24. 2ND COAST CLUTCH 35. SECOND CLUTCH 32. TCC SIGNAL 30. OVERDRIVE CLUTCH Copyright © 2002 ATSG Figure 18 20 AUTOMATIC TRANSMISSION SERVICE GROUP . REGULATED APPLY 12. COAST CLUTCH 34. THROTTLE SIGNAL 15. INTERMEDIATE CLUTCH 37.Technical Service Information MAIN CASE "BOTTOM" OIL PASSAGES 2 12 32 21 16 37 24 7 41 35 30 34 18 15 2.

Technical Service Information "FRONT" VALVE BODY OIL PASSAGES 48 16 23 15 48 24 7 2 7 52 23 36 36 40 36 38 48 52 37 40 39 42 43 48 52 54 40 2 48 10 27 20 13 46 13 48 37 10 12 28 47 47 10 2 52 52 52 54 37 48 52 48 11 "REAR" VALVE BODY OIL PASSAGES 48 25 48 14 25 26 14 38 36 38 32 20 20 2 21 15 19 42 2 20 2 48 10 48 17 26 33 13 33 48 48 43 28 44 48 34 44 10 27 44 10 35 22 35 39 22 40 22 52 44 30 28 2 52 25 24 52 15 35 19 22 52 30 33 25 25 17 30 54 52 19 19 48 30 52 35 52 31 2. 23. CONVERTER RELEASE 6. 21. 31. REVERSE CLUTCH 17. LUBE FROM COOLER 10. THROTTLE SIGNAL 13. 29. CONVERTER FEED 5. 25. 46. 30. 35. 44. CONVERTER APPLY 7. 54. 40. 39. 52. 51. REGULATED APPLY 8. REVERSE LOCK OUT (RLO) 16. LINE PRESSURE 3. 45. 37. 42. FEED LIMIT 11. DECREASE OIL 4. 43. 53. 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 VENT VOID CONVERTER FDL ACCUMULATOR Copyright © 2002 ATSG Figure 19 AUTOMATIC TRANSMISSION SERVICE GROUP 21 . 22. FILTERED FEED LIMIT 12. 20. REVERSE 15. 48. 38. TO COOLER 9. 47. LINE SAFETY MODE 14. 41. 32. 26. LOW/REV CLUTCH OR RLO 19. 34. LOW AND REVERSE CLUTCH 18. D432 123 FORWARD CLUTCH 2345 2345 OR REVERSE TCC SIGNAL 123 REGUL ATED 123 BRAKING 1-2 SIGNAL 2-3 SIGNAL 4-5 SIGNAL SECOND CLUTCH COAST FEED CLUTCH COAST CLUTCH 23 REGUL ATED SECOND COAST CLUTCH INTERMEDIATE CLUTCH 36. 28. 24. 27. 33.

Technical Service Information "TYPICAL" SPACER PLATE 13 27 17 16 Copyright © 2002 ATSG Figure 20 22 AUTOMATIC TRANSMISSION SERVICE GROUP .

48. REVERSE 15. LINE SAFETY MODE 14. 53. LOW AND REVERSE CLUTCH 18. 44. 51. 28. 21. 54. DECREASE OIL 4. LINE PRESSURE 3. 37. 43. 29. 31.Technical Service Information "TOP" CHANNEL PLATE OIL PASSAGES "CASE" SIDE 16 37 48 12 28 48 48 48 48 10 48 27 13 42 41 32 21 48 48 36 48 48 48 24 7 2 21 32 12 12 48 "BOTTOM" CHANNEL PLATE SIDE 48 32 21 48 2 16 48 16 37 48 7 24 21 48 10 43 19 27 48 41 2 41 35 35 52 52 19 52 52 52 27 18 52 34 30 30 34 52 43 42 52 2 52 48 48 48 48 28 48 48 19 48 48 48 18 48 10 48 21 15 13 20 22 35 38 52 52 52 15 2. TO COOLER 9. REVERSE CLUTCH 17. 38. 34. 39. 47. 33. 42. 22. 24. REGULATED APPLY 8. FILTERED FEED LIMIT 12. 35. 23. 46. 41. 30. CONVERTER FEED 5. 40. 32. REVERSE LOCK OUT (RLO) 16. LUBE FROM COOLER 10. D432 123 FORWARD CLUTCH 2345 2345 OR REVERSE TCC SIGNAL 123 REGUL ATED 123 BRAKING 1-2 SIGNAL 2-3 SIGNAL 4-5 SIGNAL SECOND CLUTCH COAST FEED CLUTCH COAST CLUTCH 23 REGUL ATED SECOND COAST CLUTCH INTERMEDIATE CLUTCH 36. THROTTLE SIGNAL 13. 20. 26. LOW/REV CLUTCH OR RLO 19. 45. CONVERTER RELEASE 6. 25. 27. 52. 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 VENT VOID CONVERTER FDL ACCUMULATOR Copyright © 2002 ATSG Figure 21 AUTOMATIC TRANSMISSION SERVICE GROUP 23 . CONVERTER APPLY 7. FEED LIMIT 11.

Check Ball No. and into the reverse clutch circuit to help control the apply rate of the reverse clutch.Technical Service Information Check Ball No. 3: Seats to force four five fluid through orifice 27 in the spacer plate and into the overdrive clutch feed circuit to help control the apply rate of the overdrive clutch. 9: Seats to force two-three regulated fluid through orifice 22 in the spacer plate and into the overdrive clutch feed 1 circuit to help control the apply rate of the overdrive clutch when in a 3rd gear coast condition. Note: This Check Ball not used in 4L40-E models. while blocking the other fluid circuit. 4: Seats to force 123 fluid through orifice 16 in the spacer plate and into the coast clutch feed circuit to help control the apply rate of the coast clutch. and 5th) to enter the reverse or 2345 circuit. 11: Seats to force two-three regulated fluid through orifice 23 in the spacer plate and into the second coast clutch circuit to help control the apply rate of the 2nd coast clutch when in a 2nd gear coast condition. 10: Seats to allow either three-two safety mode fluid (Safety Mode Operation Only) or FDL fluid (In 1st Gear) to enter the 3-2 safety mode or FDL fluid circuit while blocking the other. Check Ball No. Check Ball No. 5: Seats to force forward clutch fluid through orifice 17 in the spacer plate to help control the apply rate of the coast clutch. Check Ball No. Check Ball No. Check Ball No. Check Ball No. 1: Seats to force reverse lockout fluid through orifice 13 in the spacer plate. while blocking the other fluid circuit. Copyright © 2002 ATSG Figure 22 24 AUTOMATIC TRANSMISSION SERVICE GROUP . 2: Seats to allow either reverse fluid (In Reverse) or 2345 fluid (In 2nd. 12: Seats to allow either overdrive clutch feed 1 fluid (In a 3rd Gear Coast condition) or overdrive clutch feed 2 fluid (In 5th Gear) to enter the overdrive clutch circuit while blocking the other fluid circuit. 6: Seats to force forward clutch fluid through orifice 15 in the spacer plate and into the forward clutch circuit to help control the apply rate of the forward clutch. Check Ball No. 4th. Check Ball No. Check Ball No. 3rd. 7: Seated by a calibrated spring that goes in channel plate before the check ball and provides extra D432 fluid in the forward and coast clutch circuits to reduce garage shift response time. 8: Seats to allow either low/reverse clutch fluid (In 1st gear coast condition) or reverse lockout (RLO) fluid (In Reverse) to enter the low/reverse clutch or reverse lockout circuit. Check Ball No.

Technical Service Information CHECK BALL LOCATIONS AND DESCRIPTION No. NO. 3 No. 1 No. 8 No. 11 (5L40-E Only) "TYPICAL" 5L40-E SPACER PLATE 23 22 13 16 15 27 17 Copyright © 2002 ATSG Figure 23 AUTOMATIC TRANSMISSION SERVICE GROUP 25 . 302 No. 10 No. 7 No. 5 No. 2 No. 4 No. 6 SPRING ILLUS. 9 No. 12 No.

47. 53. LINE SAFETY MODE 14. 42. 43. REVERSE LOCK OUT (RLO) 16. 52. LOW AND REVERSE CLUTCH 18. 21. 29. 31. REVERSE CLUTCH 17. 24. 23. 41. REVERSE 15. THROTTLE SIGNAL 13. 33. 20. TO COOLER 9. CONVERTER RELEASE 6. LINE PRESSURE 3. 46. CONVERTER FEED 5. 30. 38. 25. LOW/REV CLUTCH OR RLO 19. REGULATED APPLY 8. CONVERTER APPLY 7. 45. D432 123 FORWARD CLUTCH 2345 2345 OR REVERSE TCC SIGNAL 123 REGUL ATED 123 BRAKING 1-2 SIGNAL 2-3 SIGNAL 4-5 SIGNAL SECOND CLUTCH COAST FEED CLUTCH COAST CLUTCH 23 REGUL ATED SECOND COAST CLUTCH INTERMEDIATE CLUTCH 36. 39. 28. 22. LUBE FROM COOLER 10. 40. 48. FILTERED FEED LIMIT 12.Technical Service Information "BOTTOM" CHANNEL PLATE OIL PASSAGES "TOP" CHANNEL PLATE SIDE 48 16 48 37 48 7 48 27 20 13 36 42 41 43 48 19 15 19 35 19 35 40 39 30 19 38 32 35 22 2 25 22 30 17 21 2 20 52 13 48 43 28 10 34 27 10 10 44 45 2 10 "VALVE BODY" SIDE 48 48 48 10 12 28 48 48 16 23 48 48 37 48 10 7 7 48 24 48 23 36 52 2 24 16 2 2 11 15 24 2 48 12 28 37 48 27 27 10 47 10 2 42 43 27 20 19 37 36 24 36 40 13 23 41 48 19 26 25 19 23 38 38 52 32 19 35 20 21 2 17 15 13 36 22 22 19 33 15 52 28 30 28 44 44 2 34 27 52 52 19 21 48 42 10 18 48 48 43 18 13 28 10 48 19 48 42 21 2. 27. 26. 44. 54. 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 VENT VOID CONVERTER FDL ACCUMULATOR Copyright © 2002 ATSG Figure 24 26 AUTOMATIC TRANSMISSION SERVICE GROUP . DECREASE OIL 4. FEED LIMIT 11. 34. 32. 37. 51. 35.

Technical Service Information TRANSMISSION DISASSEMBLY EXTERNAL COMPONENTS 1. Caution: The Torque Converter weighs approximately 26 pounds. 2. using a small screwdriver. 1 3 Continued on Page 28 1 TORQUE CONVERTER ASSEMBLY 3 TRANSMISSION ASSEMBLY Copyright © 2002 ATSG Figure 26 HOLDING FIXTURE J-8763-02 TEC KPA K FIT Z-A LL GM ATIC AM G HYDR BOUR 96 AS STR ANCE FR 022 832 *013 9781 RVO* Copyright © 2002 ATSG Figure 25 AUTOMATIC TRANSMISSION SERVICE GROUP 2/99 18/14 18:5 71 0199 VO GM P08 1423 875 960 228 32 81 997 013 Copyright © 2002 ATSG Figure 27 27 . Remove the torque converter assembly from transmission as shown in Figure 26. as shown in Figure 25. Install transmission Holding Fixture J-8763-02 or equivalent that will allow you to mount the transmission in a bench fixture and rotate it to a desired position for disassembly. by pulling straight out and rotating until dis-engaged from the transmission. Remove and discard the "O" ring from turbine shaft. as shown in Figure 27. 3.

DRIVESHAFT YOKE DRIVESHAFT YOKE "O" RING SEAL DRIVESHAFT YOKE WASHER DRIVESHAFT YOKE RETAINING NUT 96 Copyright © 2002 ATSG Figure 29 Figure 30 28 AUTOMATIC TRANSMISSION SERVICE GROUP G 02 M 30 1 "O" Ring Groove M22 X 1. and allow fluid to drain. Rotate the transmission in fixture so extension housing is facing up. as shown in Figure 30. 34. GM ATIC AM G HYDR BOUR 96 AS STR ANCE FR 022 832 *013 9781 RVO* 64 63 32 63 BOTTOM PAN DRAIN PLUG 64 BOTTOM PAN DRAIN PLUG WASHER Copyright © 2002 ATSG Figure 28 32. as shown in Figure 29. 5. Put transmission into Park and remove the prop shaft flange nut and washer (See Figure 30) 7. Remove and discard the "O" ring seal from the inside groove of the driveshaft yoke. 6. 35.Technical Service Information Continued From Page 27 4. 8.5 X 10 Copyright © 2002 ATSG 7 2/99 18/14 18:5 71 0199 VO GM P08 1423 875 960 228 32 81 997 013 35 34 33 . Remove the driveshaft yoke from transmission output shaft. 33. Remove the drain plug from the bottom pan. as shown in Figure 30. as shown in Figure 28.

Note: This thrust washer is selective. to drain any access fluid. as shown in Figure 31 15. Continued on Page 32 36 96 G 02 M 30 1 7 29 27 25 28 26 29 27 31 26 27 28 29 31 EXTENSION HOUSING FR ONT CAGED NEEDLE BEARING ASM. 14. as shown in Figure 32. Remove the seven extension housing to case retaining bolts. Remove the thrust bearing which is hand pressed into the extension housing. 12. Set extension housing aside for sub-assembly and rotate transmission slowly so that output shaft is facing down. Remove and discard the extension housing gasket. or stuck to the extension housing thrust bearing. Remove and discard the extension housing driveshaft yoke seal. 11. as shown in Figure 32.Technical Service Information 9. Refer to Figures 31 and 32. Remove the output shaft to extension housing thrust washer (27) that may be on the output shaft. OUTPUT SHAFT BEARING THRUST WASHER (SELECTIVE) OUTPUT SHAFT TO EXTENSION HO USING THRUST BEARING EXTENSION HOUSING ASSEMBLY EXTENSION HOUSING YOKE METAL CLAD SEAL ASSEMBLY 25 EXTENSION HOUSING TO MAIN CASE GASKET 27 OUTPUT SHAFT BEARING THRUST WASHER (SELECTIVE) 29 EXTENSION HOUSING ASSEMBLY Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 31 Figure 32 AUTOMATIC TRANSMISSION SERVICE GROUP 29 . Remove the extension housing assembly. 13. as shown in Figure 31. as shown in Figure 32. 10.

Technical Service Information TRANSMISSION GEAR TRAIN EXPLODED VIEW 1 3 4 5 2 10 9 11 12 14 15 24 23 22 25 37 46 40 44 45 43 42 41 5L40-E Only 38 4L40-E 39 Only 38 Copyright © 2002 ATSG Figure 33 30 AUTOMATIC TRANSMISSION SERVICE GROUP .

Technical Service Information TRANSMISSION GEAR TRAIN EXPLODED VIEW 6 7 8 16 17 18 19 20 21 21 29 27 28 26 36 32 33 34 35 22 30 31 23 36 4L40-E Only Copyright © 2002 ATSG Figure 34 AUTOMATIC TRANSMISSION SERVICE GROUP 31 .

Rotate transmission in fixture so that bottom pan is facing up. 18. and remove oil pan. as shown in Figure 35.Technical Service Information Legend For Figures 33 and 34 1 2 3 4 5 6 7 8 9 10 11 12 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 TORQUE CONVERTER ASSEMBLY (MODEL SENSITIVE) TORQUE CONVERTER HOU SING TO MAIN CASE BOLTS (7) CONVERTER HOUSING AND OIL PUMP ASSEMBLY CONVERTER HOUSING TO MAIN CASE "D" RING SEAL REVERSE CLUTCH HOUSING THRUST WASHER (SELECTIVE) DIRECT AND REVERSE CLUTCH HOUSING ASSEMBLY FORWARD AND COAST CLUTCH HOUSING ASSEMBLY FORWARD SPRAG ASSEMBLY AND INPUT SUN GEAR SHAFT DIRECT CLUTCH HUB THRUST WASHER DIRECT CLUTCH HUB AND SHAFT ASSEMBLY DIRECT CLUTCH HUB TO O. IC 78 IAL AT SER 39 AM RG DR OU CE 01 HY SBFRAN _ TCM RA _ ST DE IN . 19.D. CLUTCH HUB THRUST WASHER O. Remove and discard bottom oil pan gasket. BEARING WASHER (SELECTIVE) OUTPUT SHAFT TO EXTENSION HO USING THRUST BEARING EXTENSION HOUSING ASSEMBLY REAR CAGED NEEDLE BEARING IN EXTENSION HOUSING EXTENSION HOUSING YOKE SEAL ASSEMBLY DRIVESHAFT YOKE ASSEMBLY OUTPUT SHAFT TO YOKE "O" RING SEAL DRIVESHAFT YOKE RETAINING WASHER DRIVESHAFT YOKE RETAINING NUT EXTENSION HOUSING RE TAINING BOLTS (7) TRANSMISSION FILL PLUG AND "O" RING CENTER SUPPORT OIL PASSAGE SLEEVE AND SEAL ASSEMBLY O. CLUTCH HOUSING SNAP RING (SELECTIVE) INTERMEDIATE AND OVERDRIVE CLUTCH HOUSING ASSEMBLY LOW SPRAG ASSEMBLY LOW SPRAG TO CENTER SUPPORT THRUST BEARING CENTER SUPPORT ASSEMBLY 2ND CLUTCH SPRAG AND HUB ASSEMBLY (5L40-E ONLY) 2ND CLUTCH SPRAG THRUST WASHER (5L40-E ONLY) PL ANETARY CARRIER ASSEMBLY PL ANETARY CARRIER TO OUTPUT SHAFT THRUST BEARING OUTPUT SHAFT AND INTERNAL RING GEAR ASSEMBLY TRANSMISSION MAIN CASE ASSEMBLY EXTENSION HOUSING TO MAIN CASE GASKET FRONT CAGED NEEDLE BEARING IN EXTENSION HOUSING OUTPUT SHAFT TO EXT. 28 42 T NO 1 02 PAR 1 9 6 NO. Ensure that bottom pan magnet is stuck in position in bottom pan (See Figure 35). 17. as shown in Figure 35. as shown in Figure 35.D. HSG. CAL 8 P0 VO . Remove the 20 bottom pan retaining bolts. 65 62 61 60 96 02 04 73 60 61 62 65 BOTTOM OIL PAN GASKET BOTTOM OIL PAN MAGNET BOTTOM OIL PAN BOTTOM OIL PAN BOLTS (20 REQUIRED) Copyright © 2002 ATSG Figures 33 and 34 Legend Figure 35 32 AUTOMATIC TRANSMISSION SERVICE GROUP 30 7 96 02 05 66 Y N AN RA LT RM FI E S G IB IN E AD M GM MA 5 32 87 3 .D. CLUTCH HUB AND INTERMEDIATE SPRAG ASSEMBLY INTERM./INTERMEDIATE OIL PASSAGE SLEEVE AND SEAL ASSEMBLY TRANSMISSION PRESSURE TEST PLUG OUTPUT SPEED SENSOR SPACER OUTPUT SPEED SENSOR OUTPUT SPEED SENSOR RETAINING BOLT INPUT SPEED SENSOR INPUT SPEED SENSOR RETAINING BOLT PUMP COVER TO MAIN CASE MOLDED GASKET TRANSMISSION DISASSEMBLY (CONT'D) BOTTOM PAN COMPONENTS 16.D. AND O.

Continued on Page 34 59 Y N AN A TR RM FIL E S G IB IN E AD M 58 57 96 02 04 73 30 7 57 BOTTOM PAN OIL FILTER SEALS 58 BOTTOM PAN OIL FILTER SPACER (SOME MODELS) 59 BOTTOM PAN OIL FILTER ASSEMBLY Copyright © 2002 ATSG Figure 36 AUTOMATIC TRANSMISSION SERVICE GROUP 96 02 05 66 55 54 GM 5 32 87 3 . if used. 28 42 T NO 02 1 PAR 1 9 6IAL NO.Technical Service Information 20. as shown in Figure 36. The oil filter seals. will remain in the oil pump cover and will probably have to be removed with a slide hammer and attachment. as shown in Figure 36. Notice that there are two filter seals used with this unit. Remove transmission case connector retainer with a screwdriver and push case connector back into the transmission case to make ready for wiring harness removal (See Figure 37). IC 78 AT SER 39 AM RG DR OU CE 01 HY SBFRAN _ TCM RA _ ST DE IN MA . Remove and discard the two oil filter seals at this time. 25. and store in a safe place for transmission re-assembly (See Figure 36). 21. CAL 8 P0 VO 54 TRANSMISSION CASE CONNECTOR RETAINER 55 TRANSMISSION CASE CONNECTOR Copyright © 2002 ATSG Figure 37 33 . 24. Remove the oil filter spacer. using the proper tools. 23. Remove and discard the bottom pan oil filter. 22.

Using a small screwdriver. Continued on Page 36 Internal Wiring Harness Assembly TFT Sensor (Part Of Harness) TFT Sensor Retaining Bracket 1-2 Shift Solenoid (A) Input Shaft Speed Sensor Pressure Control Solenoid TCC/PWM Solenoid Output Shaft Speed Sensor 960 204 73 2-3 Shift Solenoid (B) 4-5 Shift Solenoid (C) 8 P0 30 7 Figure 38 34 AUTOMATIC TRANSMISSION SERVICE GROUP 960 205 66 GM 5 32 87 . 28. Remove the valve body assembly from the case as shown in Figure 39.Technical Service Information TRANSMISSION DISASSEMBLY (CONT'D) BOTTOM PAN COMPONENTS 26. 3 28 42 RT NO 02 1 PA 1 9 6 L NO. and set aside for the component rebuild section. 29. as shown in Figure 40. and set aside for component rebuild. Remove and discard the valve body seals from the case. Remove the Internal Wiring Harness assembly from the transmission. Remove only the nine valve body bolts that are called out in Figure 41. carefully remove the wire harness connectors from all of the following components: (See Figure 38) o Pressure Control Solenoid o TCC/PWM Solenoid o Input Shaft Speed Sensor o 1-2 Shift Solenoid o 2-3 Shift Solenoid o 4-5 Shift Solenoid o Output Shaft Speed Sensor o Internal Mode Switch o TFT Sensor from Bracket 27. as shown in Figure 38. CA VO Internal Mode Switch Copyright © 2002 ATSG . 30. IC 78 AT G RIA SE 39 RAM UR CE 01 HYDASBO AN FR TCM _ _ R _ ST E IN MAD L.

00 X 50 (4 TOTAL) 53 DETENT SPRING TO CASE M6 X 1.00 X 68 (1) 38 CENTER SUPPORT SEAL AND SLEEVE ASSEMBLY 39 OVERDRIVE CLUTCH SEAL AND SLEEVE ASSEMBLY Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 39 Figure 40 8 30 Remove These Four Bolts A 96020473 L-2 B 30 7 L-1 C Remove This Bolt Copyright © 2002 ATSG Figure 41 AUTOMATIC TRANSMISSION SERVICE GROUP M 3 5 87 28 3 NO.00 X 50 (4 TOTAL) 51 FRONT VALVE BODY TO CASE M6 X 1. CA AD 8 P0 VO 2 96020566 96022748 GM MA 5 32 87 3 . 28 42 T NO 1 02 PAR 1 9 6IAL NO. 2 42 RT 0 1 1 PA 6 NO. CAL 8 P0 VO Remove These Four Bolts 78 9 35 .Technical Service Information 49 53 39 38 96 02 05 66 51 96 02 04 73 30 7 49 REAR VALVE BODY TO CASE M6 X 1. 7 8 9 AL 9 C RI 3 ATI G SE 01 AM UR E DR BO C HY AS FRANM _ TC _ IN STRE GM L. IC 78 AT SER 39 AM RG DR OU CE 01 HY SBFRAN _ TCM RA _ ST DE IN .

Remove output speed sensor retaining bolt. as shown in Figure 43. 32.Technical Service Information 45 TRANSMISSION DISASSEMBLY (CONT'D) BOTTOM PAN COMPONENTS 31. output speed sensor spacer and output speed sensor. 44 2 44 INPUT SHAFT SPEED SENSOR 45 INPUT SPEED SENSOR RETAINING BOLT 3 Copyright © 2002 ATSG Figure 42 43 42 46 4 41 41 OUTPUT SPEED SENSOR SPACER 42 OUTPUT SHAFT SPEED SENSOR 43 OUTPUT SPEED SENSOR RETAINING BOLT 2 BELL HOUSING RETAINING BOLTS (7 REQUIRED) 3 BELL HOUSING AND PUMP ASSEMBLY 4 BELL HOUSING TO CASE SEAL Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 43 Figure 44 36 AUTOMATIC TRANSMISSION SERVICE GROUP . as shown in Figure 42. Remove input speed sensor retaining bolt and input speed sensor.

Seperate the reverse clutch housing from the forward clutch housing. as shown in Figure 44. Remove and discard the bell housing to case seal and the pump cover to case gasket. as shown in Figure 44 and set aside for the component rebuild process. Continued on Page 38 Forward And Reverse Drums Removed As An Assembly 6 7 6 DIRECT AND REVERSE CLUTCH HOUSING ASSEMBLY 7 FORWARD AND COAST CLUTCH HOUSING ASSEMBLY Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 45 Figure 46 AUTOMATIC TRANSMISSION SERVICE GROUP 37 . Remove bell housing and oil pump assembly. 37. and set aside for component rebuild process. 36. Remove the forward clutch housing and reverse clutch housing as an assembly by grasping the turbine shaft and lifting straight up. 34. as shown in Figure 46. as shown in Figure 44. as shown in Figure 45. Remove the 7 bell housing to case retaining bolts.Technical Service Information TRANSMISSION DISASSEMBLY (CONT'D) INTERNAL COMPONENTS 33. 35.

40. 43. as shown in Figure 50. Remove the input sun gear shaft and forward sprag assembly by lifting straight up. as shown in Figure 49. 39. and set the assembly aside for the component rebuild section. as shown in Figure 50.Technical Service Information TRANSMISSION DISASSEMBLY (CONT'D) INTERNAL COMPONENTS 38. Remove the overdrive clutch housing from the case. as shown in Figure 48. Use caution when removing or installing this snap ring. and set aside for the component rebuild section. using the Snap Ring Pliers J-45126 (See Figure 50). Remove the direct clutch hub and the thrust washer from the case. Note: These snap ring pliers are required to remove or install this snap ring as they have long handles and are locking. as the snap ring is very thick and very strong. Remove the overdrive clutch hub and thrust washer from the case. Continued on Page 40 9 8 10 8 FORWARD SPRAG ASSEMBLY AND INPUT SUN GEAR SHAFT Copyright © 2002 ATSG 9 DIRECT CLUTCH HUB THRUST WASHER 10 DIRECT CLUTCH HUB AND SHAFT ASSEMBLY Copyright © 2002 ATSG Figure 47 Figure 48 38 AUTOMATIC TRANSMISSION SERVICE GROUP . 42. 41. Ensure that you have the J-45126 snap ring pliers engaged properly. Remove the "Selective" snap ring retaining the overdrive clutch housing in the case. as shown in Figure 47.

CLUTCH HUB THRUST WASHER 12 O.D. CLUTCH HOUSING SNAP RING (SELECTIVE) 15 INTERMEDIATE/OVERDRIVE CLUTCH HOUSING ASSEMBLY Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 49 Figure 50 AUTOMATIC TRANSMISSION SERVICE GROUP 39 . CLUTCH HUB AND INTERMEDIATE SPRAG ASSEMBLY 14 INTERM/O.D.D.Technical Service Information Snap Ring Pliers J-45126 Are "Required" To Remove Or Replace This Snap Ring Snap Ring Pliers J-45126 are long handled for leverage and locking J-45126 11 14 12 15 11 DIRECT CLUTCH HUB TO O.

46. 17 4L40-E ONLY 5L40-E ONLY 21 16 LOW SPRAG ASSEMBLY 17 LOW SPRAG TO CENTER SUPPORT THRUST WASHER 21 Copyright © 2002 ATSG Figure 51 18 18 CENTER SUPPORT ASSEMBLY 21 PL ANETARY CARRIER ASSEMBLY Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 52 Figure 53 40 AUTOMATIC TRANSMISSION SERVICE GROUP . as shown in Figure 51. and set aside for component rebuild section. and set aside for the component rebuild section. as shown in Figure 53. as shown in Figure 52.Technical Service Information TRANSMISSION DISASSEMBLY (CONT'D) 16 INTERNAL COMPONENTS 44. Remove the low sprag assembly and the thrust bearing. We have illustrated both the 4L40-E and the 5L40-E in Figure 53. 45. Remove the center support assembly from the case. and set aside for the component rebuild section. Remove the planetary gear set from the case.

as shown in Figure 54.Technical Service Information COMPONENT REBUILD SECTION CASE ASSEMBLY 47. This transmission has 2 different manual shaft configurations. o Pressure test plug threads for damage. Remove the planetary internal ring gear and output shaft along with the thrust bearing. 5. Use Figure 55 or Figure 56. o Fluid level plug threads for damage. We have illustrated both the 4L40-E and the 5L40-E in Figure 54. Clean the transmission case thoroughly and dry with compressed air. o Damaged or porous fluid passages. Re-install the transmission case into the fixture and rotate so that the case front is facing up. 4. 3. o Gasket sealing surfaces for damage. as a guide to remove the manual shaft to replace the manual shaft seal. 6. Inspect the transmission case for the following: o Damaged threads that may need Heli-Coil®. depending on the model you are working. Component Rebuild Continued on Page 45 4L40-E ONLY 5L40-E ONLY 22 23 22 23 22 PL ANETARY CARRIER TO OUTPUT SHAFT THRUST BEARING 23 OUTPUT SHAFT AND INTERNAL RING GEAR ASSEMBLY Copyright © 2002 ATSG Figure 54 AUTOMATIC TRANSMISSION SERVICE GROUP 41 . 1. 2. as shown in Figures 55 and 56. Rotate the transmission so that the pan surface is facing up to prepare for removing manual shaft and manual shaft seal. 48. The models shown in Figure 55 is for right hand drive vehicles and the models shown in Figure 56 is for left hand drive vehicles. o Snap ring grooves for damage. Install a new manual shaft seal using the proper seal driver and re-install the manual linkage using Figure 55 or Figure 56.

Technical Service Information MANUAL SHAFT ASSEMBLY "A" 600 615 602 601 613 606 605 612 604 614 610 607 609 608 600 601 602 604 605 606 607 608 MANUAL SHAFT DETENT LEVER MANUAL SHAFT DETENT LEVER RETAINING PIN INTERNAL MODE SWITCH TRANSMISSION MAIN CASE ASSEMBLY MANUAL SHAFT SEAL ASSEMBLY MANUAL SHIFT SHAFT PARKING PAWL ACTUATOR BRACKET PARKING PAWL ACTUATOR BRACKET 609 610 611 612 613 614 615 PARKING PAWL ACTUATOR BRACKET BOLTS (2) PARKING PAWL PIVOT PIN PARKING PAWL RETURN SPRING PARKING PAWL PARKING PAWL ACTUATOR ROD ASSEMBLY CUP PLUG MANUAL SHAFT SPACER ASSEMBLY Figure 55 42 AUTOMATIC TRANSMISSION SERVICE GROUP VO 2 611 STDE A M AL. 2 42 RT N 0 1 1 PA 6 NO. 7 8 9 IAL 9 IC AT G SER 1 3 0 AM UR E DR BO NC _ HY AS FRA M _ R IN TC _ GM C 8 P0 Copyright © 2002 ATSG . 3 5 87 28 3 O.

2 42 RT N 0 1 1 PA 6 NO.Technical Service Information MANUAL SHAFT ASSEMBLY "B" 600 601 602 613 603 612 604 610 607 609 608 600 601 602 603 604 605 606 MANUAL SHAFT DETENT LEVER MANUAL SHAFT DETENT LEVER RETAINING PIN INTERNAL MODE SWITCH MANUAL SHAFT DETENT LEVER RETAINING PIN TRANSMISSION MAIN CASE ASSEMBLY MANUAL SHAFT SEAL ASSEMBLY MANUAL SHIFT SHAFT Figure 56 AUTOMATIC TRANSMISSION SERVICE GROUP VO 2 611 607 608 609 610 611 612 613 PARKING PAWL ACTUATOR BRACKET PARKING PAWL ACTUATOR BRACKET PARKING PAWL ACTUATOR BRACKET BOLTS (2) PARKING PAWL PIVOT PIN PARKING PAWL RETURN SPRING PARKING PAWL PARKING PAWL ACTUATOR ROD ASSEMBLY S DE A M AL. 3 5 87 28 3 O. 7 8 9 IAL 9 IC AT G SER 1 3 0 AM UR E DR BO NC HY AS FRA M _ TC _ TR IN GM C 8 P0 605 606 Copyright © 2002 ATSG 43 .

Technical Service Information OIL PUMP COVER ASSEMBLY EXPLODED VIEW 199 233 200 203 240 211 238 239 241 201 203 207 206 205 204 237 204 22 6 2.25 X 40 (6) OIL PUMP COVER RETAINING BOLT 8 X 1.1 234 235 233 232 215 202 214 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 PUMP COVER TO REVERSE DRUM THRUST WASHER (SELECTIVE) REVERSE CLUTCH SCARF-CUT SEAL RINGS CAGED NEEDLE BEARING (PUMP COVER TO INPUT SHAFT) OIL PUMP COVER ASSEMBLY BALL CAPSULE ASSE MBLY (4) VALVE BUSHING RETAINER LINE PRESSURE BOOST VALVE BUSHING "O" RING SEAL LINE PRESSURE BOOST VALVE BUSHING LINE PRESSURE BOO ST VALVE LINE PRESSURE BOOST VALVE SPRING PRESSURE REGUL ATOR VALVE SPRING PRESSURE REGUL ATOR VALVE OIL PUMP COVER RETAINING PIN OIL PUMP COVER SCREEN ASSEMBLY "O" RING SEAL OIL PUMP COVER SCREEN ASSEMBLY BRASS ORIFICE CUP PLUG STATOR SHAFT TO INPUT SHAFT BUSHING OIL PUMP SLIDE (SELECTIVE) OIL PUMP SLIDE SEAL SUPPORT OIL PUMP SLIDE "TEFLON" SEAL OIL PUMP SLIDE RETURN SPRING OIL PUMP SLIDE "TEFLON" SEAL RING 44 AUTOMATIC TRANSMISSION SERVICE GROUP nat 234 TO FIGURE 58 221 222 223 224 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 Figure 57 1/8 236 6 6 210 209 208 213 212 211 OIL PUMP VANE RINGS (2) OIL PUMP VANES (13) OIL PUMP ROTOR (SELECTIVE) OIL PUMP ROTOR GUIDE TORQUE CONVERTER HUB BUSH ING TORQUE CONVERTER HOUSING TORQUE CONVERTER HUB METAL CLAD SEAL TORQUE CONVERTER METAL CLAD SEAL RETAINING BOLTS (2) TORQUE CONVERTER HOUSING TO MAIN CASE "O" RING SEAL OIL PUMP SLIDE PIVOT PIN AND SPRING ASSEMBLY ORIFICED SLEEVE ASSEMBLY ORIFICED CUP PLUG (2) TCC CONTROL/ENABLE VALVE SPRINGS (2 SAME) TCC CONTROL VALVE TCC ENABLE VALVE RETAINING PIN TCC ENABLE VALVE LINE PRESSURE RELIEF B ALL SPRING LINE PRESSURE RELIEF BALL OIL PUMP COVER RETAINING BOLT 6 X 1.25 X 40 (5) OIL PUMP SLIDE SEAL BACK-UP "O" RING Copyright © 2002 ATSG .

Install a new pump screen and "O" ring seal in pump cover as shown in Figure 57. The bushing is not serviced and if necessary will require a complete pump cover. 2.Technical Service Information OIL PUMP AND BELL HOUSING ASSEMBLY EXPLODED VIEW FROM FIGURE 57 COMPONENT REBUILD SECTION OIL PUMP ASSEMBLY 1. Clean all converter housing and oil pump parts thoroughly and dry with compressed air. 8. 231 216 217 218 219 242 220 221 222 223 224 221 226 Continued on Page 46 227 230 COMPLETED PUMP COVER ASSEMBLY 832 HYDRAMATIC STRASBURG FRANCE 96 022 *0139781RVO* GM 229 228 Copyright © 2002 ATSG 22 6 2. Install the selective thrust washer on the pump cover and retain with Trans-Jel®. The caged needle bearing can be serviced as necessary with the proper puller and driver.1 Copyright © 2002 ATSG Figure 58 Figure 59 AUTOMATIC TRANSMISSION SERVICE GROUP 1/8 6 6 n at 45 . Lubricate all valves and sleeves with clean transmission fluid and install the valve line-ups exactly as shown in Figure 57. 4. 6. Ensure that orifice cup plugs and ball capsules are in place and functional. Use Figure 57 and 58 as a guide to disassemble the converter housing and oil pump assembly. 5. as shown in Figure 59. 3. 9. Set the completed pump cover aside for final oil pump and converter housing assembly. 10. 7. Inspect all converter housing and pump parts thoroughly and replace as necessary.

Technical Service Information COMPONENT REBUILD (CONT'D) OIL PUMP ASSEMBLY (CONT'D) 11. 17. The clearance should be . 13. Lay a straight edge across the surface over the slide and rotor. Ensure that the slide seals are left out.0015 SLIDE .001"-. The clearance should be .001 . Note: These measurements may also be done with a depth micrometer. Measure the clearance between the slide and the straight edge. use the chart in Figure 63 to make your selections based on the clearance recorded and the thickness of the current slide and rotor. as shown in Figure 62. using proper size bushing driver. 15. as shown in Figure 61.. HYDRAMATIC STRASBURG FRANCE 96 022 832 GM *0139781RVO* Copyright © 2002 ATSG Figure 60 ROTOR .0025 226 227 832 022 HYDRAMATIC STRASBURG FRANCE 96 022 832 *0139781RVO* GM Copyright © 2002 ATSG 226 TORQUE CONVERTER HOUSING B USHING 227 TORQUE CONVERTER HOUSING ASSEMBLY GM *0139781RVO* HYDRAMATIC STRASBURG FRANCE 96 Copyright © 2002 ATSG Figure 61 Figure 62 46 AUTOMATIC TRANSMISSION SERVICE GROUP .. as shown in Figure 64. 16. as shown in Figure 61. 12.0015". If replacements are needed. Place the converter housing on a flat surface with the worm track side facing up and install the current slide and rotor (See Figure 60).0025" with no seals in the slide. Install the pump slide pivot pin and spring. as shown in Figure 61. 14.002"-. 18. Measure the clearance between the rotor and the straight edge. Install new bushing as necessary in converter housing.002 .

17.7071 0.7086 0.7076 0. and retain with a small amount of Trans-Jel®.7076 0.975 .17. using a screwdriver or installation tool. 23.974 17.948 .988 .987 17.0.948 .7065 .0.0.974 17. 21. as shown in Figure 64.17.013 THICKNESS (In) 0.18.013 THICKNESS (In) 0.18. Install oil pump slide back-up "O" ring (242) and pump slide "Teflon" seal ring (220) into groove in slide.0.000 18.18.7076 .0.Technical Service Information 19. as shown in Figure 64.961 17.7076 .988 .17.7065 .7081 0. with the "Teflon" seal (220) facing down.7071 0. 20.7086 0.0.962 .0.961 17.7081 .7081 0.7086 .17.18.17.7091 022 HYDRAMATIC STRASBURG FRANCE 96 832 216 217 218 219 220 231 242 OIL PUMP SLIDE (SELECTIVE) OIL PUMP SLIDE SEAL SUPPORT OIL PUMP SLIDE "TEFLON" SEAL OIL PUMP SLIDE RETURN SPRING OIL PUMP SLIDE "TEFLON" SEAL RING OIL PUMP SLIDE PIVOT PIN AND SPRING ASSEMBLY OIL PUMP SLIDE BACK-UP "O" RING GM *0139781RVO* Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 63 Figure 64 AUTOMATIC TRANSMISSION SERVICE GROUP 47 .7081 .001 . Install the oil pump slide into the pump pocket as shown in Figure 64.7091 220 242 242 217 220 218 231 216 217 218 219 OIL PUMP SLIDE SELECTION CHART THICKNESS (mm) 17. Continued on Page 48 OIL PUMP ROTOR SELECTION CHART THICKNESS (mm) 17. Install the oil pump slide "Teflon" seal (218) by pulling the slide towards the pump pivot pin and sliding the seal down between slide seal support (217) and converter housing.7086 .001 .7071 .975 . 22. Install the oil pump slide spring.0. Install oil pump slide seal support (217) into slide.0.962 .000 18.7071 . as shown in Figure 64. as shown in Figure 64.0.987 17.

Continued on Page 50 221 222 223 224 221 222 223 224 221 HYDRAMATIC STRASBURG FRANCE 96 022 832 OIL PUMP VANE RINGS (2) OIL PUMP VANES (13) OIL PUMP ROTOR (SELECTIVE) OIL PUMP ROTOR GUIDE FINISHED INSTALLATION 224 223 HYDRAMATIC STRASBURG FRANCE 96 022 832 GM GM 223 OIL PUMP ROTOR (SELECTIVE) 224 OIL PUMP ROTOR GUIDE Copyright © 2002 ATSG *0139781RVO* *0139781RVO* Copyright © 2002 ATSG Figure 65 Figure 66 48 AUTOMATIC TRANSMISSION SERVICE GROUP . Install one of the oil pump vane rings into the pump pocket. as shown in Figure 69. and hand tighten only.). Install the pre-assembled oil pump cover onto the converter housing. 29. Install the 13 oil pump vanes into their slots in the rotor. 31. 27. 33.lb. Install the oil pump rotor guide into the rotor in the direction shown in Figure 65. as shown in Figure 66. and retain with a small amount of Trans-Jel®.). Install the proper pump cover to converter housing retaining bolts in their proper locations as shown in Figure 68. 26. as shown in Figure 66. Install the other oil pump vane ring on top of the rotor and inside of the oil pump vanes. 25. as shown in Figure 69. Torque five pump cover retaining bolts (241) to 22 Nm (16 ft.Technical Service Information COMPONENT REBUILD (CONT'D) OIL PUMP ASSEMBLY (CONT'D) 24. Install the J-21368 pump alignment band and tighten. Torque six pump cover retaining bolts (240) to 11 Nm (8 ft. The finished assembly should look like illustration in Figure 66. 34. 28. as shown in Figure 69. 32. Install the previously assembled rotor guide and rotor assembly into the pump pocket and ensure that it is properly seated.lb. as shown in Figure 67. Remove J-21368 pump alignment band. 30.

25 X 40 (6 REQUIRED) PUMP COVER RETAINING BOLT 8 X 1.Technical Service Information 240 241 240 nat 226 2.25 X 40 (6 REQUIRED) 241 PUMP COVER RETAINING BOLT 8 X 1.) TORQUE LARGE BOLTS (241) TO 22 Nm (16 FT.25 X 40 (5 REQUIRED) Copyright © 2002 ATSG GM *0139781RVO* 22 6 2.25 X 40 (5 REQUIRED) 22 6 2.) J-21368 6 6 Sn ap -O n 49 . PUMP COVER RETAINING BOLT 6 X 1.LB.1 241 9/9 1/8 202 240 6 6 GM 241 240 PUMP COVER RETAINING BOLT 6 X 1.LB.1 227 HYDRAMATIC STRASBURG FRANCE 96 022 832 GM *0139781RVO* HYDRAMATIC STRASBURG FRANCE 96 022 832 202 227 240 241 COMPLETED OIL PUMP COVER ASSEMBLY COMPLETED CONVERTER HO USING AND OIL PUMP ASM.1 Copyright © 2002 ATSG Figure 67 Figure 69 AUTOMATIC TRANSMISSION SERVICE GROUP 1/8 n at 1/8 nat Copyright © 2002 ATSG Figure 68 TORQUE SMALL BOLTS (240) TO 11 Nm (8 FT.

1 Copyright © 2002 ATSG Figure 70 50 AUTOMATIC TRANSMISSION SERVICE GROUP 1/8 6 6 n at J-44766 SEAL INSTALLER 229 228 6 6 n at 228 TORQUE CONVERTER SEAL RETAINING BOLTS (2 REQUIRED) 229 TORQUE CONVERTER METAL CLAD SEAL ASSEMBLY Copyright © 2002 ATSG Figure 71 . 22 6 2. align the converter seal with the bolt holes. as shown in Figure 72. 37.). Set the completed converter housing and pump assembly aside for the final assembly process.6 Nm (31 in.1 HYDRAMATIC STRASBURG FRANCE 96 022 832 GM *0139781RVO* 230 CONVERTER HOUSING TO MAIN CASE "O" RING SEAL ENSURE THAT SEAL IS FULLY SEATED 1/8 HYDRAMATIC STRASBURG FRANCE 96 022 832 GM *0139781RVO* 22 6 2. and ensure that it is fully seated. and then install the converter seal in the housing (See Figure 71). Install converter housing to case "O" ring seal. 38. Install new converter seal onto the installation tool J-44766. 36.lb. as shown in Figure 70.Technical Service Information 230 COMPONENT REBUILD (CONT'D) OIL PUMP ASSEMBLY (CONT'D) 35. Install the two seal retaining bolts and torque to 3.

Technical Service Information COMPONENT REBUILD DIRECT AND REVERSE CLUTCH HOUSING 1. 5. Inspect thoroughly all direct and reverse clutch parts for any wear and/or damage. 4. as shown in Figure 73. as shown in Figure 73. 3. Inspect the reverse clutch housing ball capsule for proper operation. Using Figure 74 as a guide dis-assemble the direct and reverse clutch housing. Continued on Page 53 Sn ap -O n DIRECT CLUTCH PISTON INSPECT BALL CAPSULE FOR PROPER OPERATION Copyright © 2002 ATSG Figure 72 INSPECT BALL CAPSULE FOR PROPER OPERATION REVERSE CLUTCH HOUSING Copyright © 2002 ATSG Figure 73 AUTOMATIC TRANSMISSION SERVICE GROUP 51 . 2. Clean thoroughly all direct and reverse clutch parts and dry with compressed air. Inspect the direct clutch piston ball capsule for proper operation.

Technical Service Information REVERSE AND DIRECT CLUTCH HOUSING ASSEMBLY 401 402 400 404 405 406 407 408 409 403 410 411 413 414 412 415 416 417 419 420 418 400 401 402 403 404 405 406 407 408 409 410 REVERSE CLUTCH HOUSING BUSHING REVERSE CLUTCH HOUSING ASSEMBLY REVERSE CLUTCH HOUSING INNER "O" RING SEAL REVERSE CLUTCH HOUSING BALL CAPSULE ASSEMBLY REVERSE CLUTCH PISTON/DIRECT CLUTCH HOUSING DIRECT CLUTCH PISTON BALL CAPSULE ASSEMBLY DIRECT CLUTCH PISTON ASSEMBLY DIRECT AND REVERSE CLUTCH BELLVILLE RETURN SPRING DIRECT AND REVERSE CLUTCH RETURN SPRING RETAINER RETURN SPRING RETAINER SNAP RING DIRECT CLUTCH "WAVE" PLATE 411 412 413 414 415 416 417 418 419 420 DIRECT CLUTCH "OUTER SPLINE" SINGLE SIDED PLATES (4) DIRECT CLUTCH "INNER SPLINE" SINGLE SIDED PLATES (4) DIRECT CLUTCH BACKING PLATE DIRECT CLUTCH BACKING PLATE SNAP RING (SELECTIVE) REVERSE CLUTCH APPLY PLATE REVERSE CLUTCH "WAVE" PLATE REVERSE CLUTCH "OUTER SPLINE" SINGLE SIDED PLATES (2) REVERSE CLUTCH "INNER SPLINE" SINGLE SIDED PLATES (2) REVERSE CLUTCH BACKING PLATE REVERSE CLUTCH BACKING PLATE SNAP RING (SELECTIVE) Copyright © 2002 ATSG Figure 74 52 AUTOMATIC TRANSMISSION SERVICE GROUP .

10. The direct clutch housing (404) also serves as the reverse clutch piston and has a molded seal as shown in Figure 75. as shown in Figure 76. Continued on Page 54 406 402 404 MOLDED SEAL 401 J-45133 401 401 REVERSE CLUTCH HOUSING ASSEMBLY 402 REVERSE CLUTCH HOUSING "O" RING 404 REVERSE PISTON/DIRECT CLUTCH HOUSING ASSEMBLY 401 REVERSE CLUTCH HOUSING ASSEMBLY 406 DIRECT CLUTCH PISTON ASSEMBLY Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 75 Figure 76 AUTOMATIC TRANSMISSION SERVICE GROUP 53 . Lubricate the inside diameter of the direct clutch housing and install the direct clutch housing into the reverse clutch housing. by rotating into position.Technical Service Information COMPONENT REBUILD DIRECT AND REVERSE CLUTCH HOUSING 6. as shown in Figure 75. 7. Lubricate the molded seals with a small amount of Trans-Jel® and install direct clutch piston by rotating into position (See Figure 76). Install J-45133 seal protector onto the reverse housing. Install new "O" ring seal into groove in the reverse clutch housing and lubricate with a small amount of Trans-Jel® (See Figure 75). 8. 9.

Note: GM recommends a "New" snap ring for this location. as shown in Figure 77. Continued on Page 55 409 408 407 410 401 401 401 407 408 409 REVERSE CLUTCH HOUSING ASSEMBLY DIRECT/REVERSE BELLVILLE RETURN SPRING ASSEMBLY DIRECT/REVERSE CLUTCH SPRING RETAINER RETURN SPRING RETAINER SNAP RING 401 REVERSE CLUTCH HOUSING ASSEMBLY 410 DIRECT CLUTCH "WAVE" PLATE Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 77 Figure 78 54 AUTOMATIC TRANSMISSION SERVICE GROUP . as shown in Figure 77.Technical Service Information COMPONENT REBUILD DIRECT AND REVERSE CLUTCH HOUSING (CONT'D) 11. compress the bellville spring and install the snap ring (See Figures 77 and 78). Install the direct clutch "Wave" plate. Using a universal spring compressor or a foot press. 13. 14. 12. as shown in Figure 78. Install the direct/reverse bellville return spring on top of the direct clutch piston. Install the bellville return spring retainer.

Note: Lined side must be installed facing up as shown.06 mm (. and ensure that the snap ring is fully seated against the top of the snap ring groove in housing. Install the direct clutch "single sided" plates beginning with an outside spline plate first and alternating with inside spline plates until you have installed 4 of each. Change the "Selective" backing plate snap ring as necessary to achieve proper clutch clearance.073").042") to 1. Install the direct clutch backing plate on top of the last inside spline plate (See Figure 79).Technical Service Information "Selective" Snap Ring 414 413 15. Continued on Page 56 411 412 CHECKING DIRECT CLUTCH CLEARANCE CLEARANCE SHOULD BE . 19. Clutch plate amounts may vary by model. 16.042"-. Direct clutch clearance should be: 1. as shown in Figure 80. and zero the dial indicator.073" 401 10 20 30 40 50 0 50 0 10 20 30 40 401 411 412 413 414 REVERSE/DIRECT CLUTCH HOUSING ASSEMBLY DIRECT CLUTCH "OUTSIDE SPLINE" SINGLE SIDED PLATES (4) DIRECT CLUTCH "INSIDE SPLINE" SINGLE SIDED PLATES (4) DIRECT CLUTCH BACKING PLATE DIRECT CLUTCH BACKING PLATE SNAP RING (SELECTIVE) Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 79 Figure 80 AUTOMATIC TRANSMISSION SERVICE GROUP 55 . 18.86 mm (. as shown in Figure 79. as shown in Figure 79. 17. Install dial indicator on top of the direct clutch backing plate. Install the "Selective" backing plate snap ring.

23. 25. 27.Technical Service Information COMPONENT REBUILD DIRECT AND REVERSE CLUTCH HOUSING (CONT'D) 20. Note: Lined side must be installed facing up as shown in Figure 82. 24. 21. Install dial indicator on top of reverse clutch backing plate.039") to 1. 26.98 mm (. Clutch plate amounts may vary by model. and ensure that the snap ring is fully seated against the top of the snap ring groove in reverse housing. Change the "Selective" backing plate snap ring as necessary to achieve proper clutch clearance. and zero the dial indicator. Install the "Selective" backing plate snap ring as shown in Figure 82. Set the completed Direct/Reverse Clutch Housing aside for the final assembly process.43 mm (.056"). as shown in Figure 82. 22. Install the reverse clutch backing plate on top of the last inside spline plate. as shown in Figure 81. as shown in Figure 81. as shown in Figure 83. Install the reverse clutch "single sided" plates beginning with an outside spline plate first and alternating with inside plates until you have installed 2 of each. Install the reverse clutch "Wave" plate on top of the apply plate. Reverse clutch clearance should be: 0. Install the reverse clutch apply plate with the lip facing up. as shown in Figure 82. 416 415 401 Component Rebuild Section Continued on Page 59 401 REVERSE/DIRECT CLUTCH HOUSING ASSEMBLY 415 REVERSE CLUTCH APPLY PLATE (LIP FACING UP) 416 REVERSE CLUTCH "WAVE" PLATE Copyright © 2002 ATSG Figure 81 56 AUTOMATIC TRANSMISSION SERVICE GROUP .

039"-.Technical Service Information "Selective" Snap Ring 420 419 418 417 CHECKING REVERSE CLUTCH CLEARANCE CLEARANCE SHOULD BE .056" 0 10 20 10 20 30 40 401 30 40 50 0 50 401 417 418 419 420 REVERSE/DIRECT CLUTCH HOUSING ASSEMBLY REVERSE CLUTCH "OUTSIDE SPLINE" SINGLE SIDED PLATES (2) REVERSE CLUTCH "INSIDE SPLINE" SINGLE SIDED PLATES (2) REVERSE CLUTCH BACKNIG PLATE REVERSE CLUTCH BACKING PLATE SNAP RING (SELECTIVE) Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 82 Figure 83 AUTOMATIC TRANSMISSION SERVICE GROUP 57 .

Technical Service Information FORWARD AND COAST CLUTCH HOUSING ASSEMBLY 433 431 430 432 434 436 437 438 435 439 440 441 442 443 445 446 444 448 447 450 451 449 430 431 432 433 434 435 436 437 438 439 440 INPUT SHAFT "O" RING SEAL INPUT SHAFT "SOLID" TEFLON SEAL RING (1 REQUIRED) INPUT SHAFT "SCARF-CUT" SEAL RING (3 REQUIRED) INPUT HOUSING ASSEMBLY FORWARD CLUTCH BALL CAPSULE ASSEMBLY INPUT HOUSING BUSHING FORWARD CLUTCH MOLDED PISTON ASSEMBLY COAST CLUTCH BALL CAPSULE ASSEMBLY COAST CLUTCH PISTON ASSEMBLY FORWARD AND COAST CLUTCH RETURN SPRING ASM. RETURN SPRING RETAINING SNAP RING 441 442 443 444 445 446 447 448 449 450 451 COAST CLUTCH APPLY PLATE. "SELECTIVE" COAST CLUTCH "WAVE" PLATE SINGLE SIDED "OUTSIDE S PLINE" COAST CLUTCH PLATE (3) SINGLE SIDED "INSIDE SP LINE" COAST CLUTCH PLATE (3) COAST CLUTCH BACKING PLATE COAST CLUTCH HOUSING FORWARD CLUTCH "WAVE" PLATE SINGLE SIDED "OUTSIDE S PLINE" FORWARD CLUTCH PLATE (4) SINGLE SIDED "INSIDE SP LINE" FORWARD CLUTCH PLATE (4) FORWARD CLUTCH BACKING PLATE FORWARD CLUTCH BACKING PLATE SNAP RING "SELECTIVE" Copyright © 2002 ATSG Figure 84 58 AUTOMATIC TRANSMISSION SERVICE GROUP .

Thoroughly clean all forward and coast clutch parts and dry with compressed air. Continued on Page 60 INSPECT BALL CAPSULE FOR PROPER OPERATION 436 COAST CLUTCH PISTON J-45134 433 FORWARD/COAST CLUTCH HOUSING INSPECT BALL CAPSULE FOR PROPER OPERATION 433 INPUT HOUSING ASSEMBLY 436 FORWARD CLUTCH MOLDED PISTON ASSEMBLY J-45134 FORWARD CLUTCH PISTON LIP SEAL PROTECTOR Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 85 Figure 86 AUTOMATIC TRANSMISSION SERVICE GROUP 59 . Remove J-45134 seal protector. as shown in Figure 85. 5. 4. 8. 9. by rotating into position. Thoroughly inspect all forward and coast clutch parts for any wear and/or damage. Lubricate the molded seals of the new forward clutch piston with small amount of Trans-Jel®. 3. as shown in Figure 86. 2. 7.Technical Service Information COMPONENT REBUILD FORWARD AND COAST CLUTCH HOUSING 1. as shown in Figure 86. Install the forward clutch piston. Dis-assemble the forward/coast clutch housing using Figure 84 as a guide. Inspect the coast clutch piston ball capsule for proper operation. Place forward clutch housing on a foot press and install J-45134 seal ptotector on forward clutch housing. 6. Inspect the forward/coast clutch housing ball capsule for proper operation (See Figure 85).

Note: GM recommends a "New" snap ring in this location. Ensure that the snap ring is fully seated and release the foot press (See Figures 87 and 88). as shown in Figure 89. Lubricate the molded inner seal and the inside diameter of the coast clutch piston with small amount of Trans-Jel®. as shown in Figure 87. Install J-45132 seal protector on forward clutch housing. 13.Technical Service Information COMPONENT REBUILD FORWARD AND COAST CLUTCH HOUSING (CONT'D) 10. Notice: Record dimension "A". Install the forward/coast clutch return spring and retainer assembly. Notice: Record this as dimension "C". Subtract dimension "C" from dimension "B". Measure from the top of the forward clutch housing to the top of the coast clutch piston. (See Figure 87). 440 RETURN SPRING RETAINING SNAP RING J-45132 COAST CLUTCH PISTON LIP SEAL PROTECTOR Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 87 Figure 88 60 AUTOMATIC TRANSMISSION SERVICE GROUP . Notice: Record this as dimension "B". as shown in Figure 89. 17. 18. 440 439 438 J-45132 433 433 INPUT HOUSING ASSEMBLY 438 COAST CLUTCH PISTON ASSEMBLY 439 FORWARD AND COAST CLUTCH RETURN SPRING ASM. as shown in Figure 87. 15. 16. 14. 11. compress return spring and install the snap ring. Remove J-45132 seal protector. Install the coast clutch piston. Measure from the top of the forward clutch housing to the top of the forward clutch piston. This answer is now dimension "A". 19. by rotating and pushing down into position. Using the foot press. 12. as shown in Figure 87.

"SELECTIVE" COAST CLUTCH "WAVE" PLATE SINGLE SIDED "OUTSIDE S PLINE" COAST CLUTCH PLATE (3) SINGLE SIDED "INSIDE SP LINE" COAST CLUTCH PLATE (3) COAST CLUTCH BACKING PLATE COAST CLUTCH HOUSING Copyright © 2002 ATSG Figure 89 Figure 90 AUTOMATIC TRANSMISSION SERVICE GROUP 61 . Note: In this procedure. Install the coast clutch "Wave" plate on top of the last outside spline plate in the coast clutch housing. "C" from Dim "B". Install the coast clutch backing plate into the coast clutch housing. as shown in Figure 90. 23. Install the coast clutch "single sided" plates beginning with an inside spline plate first and alternating with outside spline plates until you have installed 3 of each. lined side must be installed facing down. Lay the coast clutch housing on a flat surface in the direction shown in Figure 90. 22. This equals Dimension "A". Continued on Page 62 441 442 CALCULATING COAST CLUTCH CLEARANCE 443 444 0 1 2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 mm/in 0 AUTO POWER-O FF 1 1 2 3 4 5 6 7 8 9 2 1 2 3 4 5 6 7 8 9 3 IN 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 02. Clutch plate amounts may vary by model. 6 mm in ELECTRONIC DIGITAL C ALIPER 446 B C Copyright © 2002 ATSG 441 442 443 444 445 446 COAST CLUTCH APPLY PLATE.Technical Service Information 20. as shown in Figure 90. as shown in Figure 90. as shown in Figure 90. 21.5044 5 90 100 110 120 130 140 150 445 Subtract Dim.

While holding it in position. 29. Dimension "A" = 0. as shown in Figure 92. Notice: Record this as dimension "D". turn the assembly over and place it back on the foot press as shown in Figure 94. all the way.030") to 1. Measure the distance from the top of the coast clutch housing to the top of the coast clutch apply plate. EXAMPLE: Dimension "B" = 2. 26. The coast clutch housing is now complete and should look like the illustration in Figure 91.504" Dimension "C" = 2. This is where we will need the pre-recorded dimensions. Note: The "Selective" apply plate usually has a number stamped on it for I. Change the "Selective" coast clutch apply plate as necessary to obtain proper clearance. This is the coast clutch pack travel.375" Subtract dimension "C" from dimension "B" and this = dimension "A".170" Subtract dimension "A" from dimension "D" and this = clutch pack travel. We are now ready to check for proper coast clutch clearance. Figure 91 CALCULATING COAST CLUTCH CLEARANCE 0 IN 1 2 3 4 5 6 7 8 9 10 20 mm/in mm/in 0 0 AUTO POWER-O FF 1 2 00.041". 27. as shown in Figure 90.D. Install the forward clutch "Wave" plate on top of the coast clutch housing (See Figure 94). 28.170 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 30 40 50 60 70 "D" 3 80 90 100 110 120 130 140 150 mm 1 2 3 4 5 6 7 8 9 4 1 2 3 4 5 6 7 8 9 5 1 2 3 4 5 6 7 8 9 6 in ELECTRONIC DIGITAL C ALIPER Continued on Page 64 Figure 92 62 AUTOMATIC TRANSMISSION SERVICE GROUP .Technical Service Information COMPLETED COAST CLUTCH HOUSING COMPONENT REBUILD FORWARD AND COAST CLUTCH HOUSING (CONT'D) 24. Clutch travel in this example is 0. 32. Subtract pre-recorded dimension "A" from dimension "D".129" Dimension "D" = 0. Install the "Selective" apply plate on top of the wave plate. as shown in Figure 93. Holding the completed coast clutch housing in your left hand and grasping the turbine shaft with your right hand.77 mm (.060"). 31. and travel shoud be as follows: 0. index and install the coast clutch housing up into the forward clutch housing.67 mm (. 25. 30.

Technical Service Information FORWARD CLUTCH "WAVE" PLATE Copyright © 2002 ATSG Figure 93 AUTOMATIC TRANSMISSION SERVICE GROUP .1 1.1 FL 842 Copyright © 2002 ATSG Figure 94 63 .

450 449 448 CHECKING FORWARD CLUTCH CLEARANCE CLEARANCE SHOULD BE .1 1.1 . and ensure that the snap ring is fully seated against the top of the snap ring groove in forward clutch housing. Install the "Selective" backing plate snap ring as shown in Figure 95. 36. as shown in Figure 95.1 FL 842 FL 842 Copyright © 2002 ATSG Figure 96 . Install forward clutch backing plate on top of the last inside spline plate (See Figure 95)..073" 10 20 30 40 50 0 10 20 30 40 0 50 448 449 450 451 SINGLE SIDED "OUTSIDE S PLINE" FORWARD CLUTCH PLATE (4) SINGLE SIDED "INSIDE SP LINE" FORWARD CLUTCH PLATE (4) FORWARD CLUTCH BACKING PLATE FORWARD CLUTCH BACKING PLATE SNAP RING "SELECTIVE" Copyright © 2002 ATSG Figure 95 64 AUTOMATIC TRANSMISSION SERVICE GROUP . and zero the dial indicator.Technical Service Information 451 COMPONENT REBUILD FORWARD AND COAST CLUTCH HOUSING (CONT'D) 33.042" . 35. as shown in Figure 95. Install dial indicator on top of forward clutch backing plate. Note: Lined side must be facing up.1 1. Install the forward clutch "single sided" plates beginning with an outside spline plate first and alternating with inside spline plates until you have installed 4 of each. Clutch plate amounts may vary by model. as shown in Figure 96. 34.

Change the "Selective" backing plate snap ring as necessary to achieve proper clutch clearance. ensuring that the scarfs are not overlapped.073"). SOLID SEAL (431) REQUIRES J-45130-2 INSTALL TOOL 431 432 J-45130-3 RE-SIZING TOOL 433 431 INPUT SHAFT "SOLID" TEFLON SEAL RING (1 REQUIRED) 432 INPUT SHAFT "SCARF-CUT" SEAL RING (3 REQUIRED) 433 INPUT HOUSING ASSEMBLY Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 97 Figure 98 AUTOMATIC TRANSMISSION SERVICE GROUP 65 .042") to 1.Technical Service Information 37. as shown in Figure 97. Set completed forward/coast clutch housing aside for the final assembly process. Install the one solid seal ring on the turbine shaft using J-45130 installation tool. Install the J-45130-3 re-sizing tool. 38. 41. Refer to Figure 98.06 mm (. Install the three remaining scarf-cut seal rings as shown in Figure 98. 39. Note: Leave the re-sizing tool in place until ready to install in transmission. 40.86 mm (. Forward clutch clearance should be: 1.

Technical Service Information FORWARD SPRAG AND DIRECT DRUM AND SHAFT ASSEMBLY 456 455 457 462 458 459 460 461 460 U FWEB 446271 SKF FRANCE 464 465 465 455 456 457 458 459 460 FORWARD SPRAG INNER RACE THRUST BEARING SNAP RING FORWARD SPRAG INNER RACE THRUST BEARING INPUT SUN GEAR SHAFT ASSEMBLY FORWARD SPRAG OUTER RACE THRUST WASHER FORWARD SPRAG OUTER RACE ASSEMBLY FORWARD SPRAG END BEARINGS (2) 461 462 464 465 466 Figure 99 66 AUTOMATIC TRANSMISSION SERVICE GROUP ENT ED PAT 466 FORWARD SPRAG AND CAGE ASSEMBLY ORIFICED CUP PLUG FOR LUBRICATION OUTER RACE TO DIRECT DRUM THRUST WASHER DIRECT DRUM AND SHAFT BUSHING S (2) DIRECT DRUM AND SHAFT ASSEMBLY Copyright © 2002 ATSG .

with the "windows" to the left. as shown in Figure 100. Replace as necessary. Continued on Page 68 460 458 FORWARD SPRAG OUTER RACE 457 457 INPUT SUN GEAR SHAFT ASSEMBLY 458 FORWARD SPRAG OUTER RACE THRUST WASHER 460 FORWARD SPRAG END BEARING (2) "WINDOWS" TO LEFT AS SHOWN FORWARD SPRAG AND CAGE ASSEMBLY Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 100 Figure 101 AUTOMATIC TRANSMISSION SERVICE GROUP 67 . 4. 5. Stand sun gear shaft up on the hub as shown in Figure 100. Clean all forward sprag parts thoroughly and dry with compressed air. 7. Inspect all forward sprag parts thoroughly for any wear and/or damage. Dis-assemble the forward sprag assembly using Figure 99 as a guide. on a flat work surface. 3. Install one forward sprag end bearing on sun gear hub and shaft. 2.Technical Service Information COMPONENT REBUILD FORWARD SPRAG ASSEMBLY 1. as shown in Figure 100. and ensure that the outer race is arranged as shown. Refer to Figure 101. 6. Install thrust washer (458) on sun gear hub and shaft. Install the forward sprag cage assembly into the outer race exactly as shown in Figure 101.

Install the pre-assembled forward sprag cage and outer race onto the inner race in direction shown in Figure 102. with the smooth side facing up. ENT ED PAT U ENT ED PAT FORWARD SPRAG OUTER RACE SHOULD FREEWHEEL CLOCKWISE AND LOCK COUNTER-CLOCKWISE WHILE HOLDING HUB AND SHAFT Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 102 Figure 103 68 AUTOMATIC TRANSMISSION SERVICE GROUP SKF FRANCE SKF FRANCE FORWARD SPRAG AND OUTER RACE ASSEMBLY FWEB 446271 U FREEWHEEL . Note: Forward Sprag Outer Race should freewheel clockwise and lock counterclockwise. Check the forward sprag for proper operation as shown in Figure 103. FORWARD SPRAG END BEARING FWEB 446271 9.Technical Service Information COMPONENT REBUILD FORWARD SPRAG ASSEMBLY (CONT'D) 8. 10. 11. as shown in Figure 103. Install the other forward sprag end bearing in the direction shown in Figure 102. Set the completed forward sprag and sun gear shaft assembly aside for final assembly. by rotating in a clockwise motion.

2. COMPONENT REBUILD O. Set the completed assembly aside for the final transmission assembly process. 3. Clean all intermediate sprag parts thoroughly and dry with compressed air. Inspect all intermediate sprag parts thoroughly for any wear and/or damage.D. Install the direct clutch hub to forward sprag outer race thrust washer into the direct clutch hub and shaft assembly in the direction shown in Figure 104. CLUTCH HUB/INTERMEDIATE SPRAG 1. 4.Technical Service Information COMPONENT REBUILD DIRECT CLUTCH HUB AND WASHER 1. and retain with a small amount of Trans-Jel®. After removing the metal retainer dis-assemble the remainder of the intermediate sprag using Figure 106 as a guide. The intermediate sprag outer race is held on with a pressed on metal retainer. as shown in Figure 105. as shown in Figure 105. 2. and can be removed easily with 2 screwdrivers as shown in Figure 105. 5. Continued on Page 70 466 464 REMOVING INTERMEDIATE SPRAG ASSEMBLY THRUST BEARING RETAINER FWEB 446273 ENT ED PAT U 464 OUTER RACE TO DIRECT DRUM THRUST WASHER 466 DIRECT CLUTCH HUB AND SHAFT ASSEMBLY Copyright © 2002 ATSG Figure 104 Figure 105 AUTOMATIC TRANSMISSION SERVICE GROUP SKF FRANCE Copyright © 2002 ATSG 69 . Place the overdrive clutch hub and intermediate sprag assembly on flat work surface.

Technical Service Information INTERMEDIATE SPRAG ASSEMBLY 470 469 471 472 473 472 474 475 476 477 U FWEB 446273 SKF FRANCE 469 470 471 472 473 474 475 476 477 DIRECT CLUTCH HUB TO OVERDRIVE/REVERSE CLUTCH HUB THRUST WASHER OVERDRIVE AND REVERSE CLUTCH HUB ASSEMBLY INTERMEDIATE SPRAG FRONT THRUST WASHER INTERMEDIATE SPRAG END BEARINGS INTERMEDIATE SPRAG AND CAGE ASSEMBLY INTERMEDIATE SPRAG OUTER RACE ASSEMBLY INTERMEDIATE SPRAG REAR THRUST WASHER INTERMEDIATE SPRAG THRUST BEARING ASSEMBLY INTERMEDIATE SPRAG THRUST BEARING RETAINER 70 ENT ED PAT Copyright © 2002 ATSG Figure 106 AUTOMATIC TRANSMISSION SERVICE GROUP .

Continued on Page 72 472 471 INTERMEDIATE SPRAG OUTER RACE 470 "WINDOWS" TO LEFT AS SHOWN 470 OVERDRIVE CLUTCH HUB ASSEMBLY 471 INTERMEDIATE SPRAG FRONT THRUST WASHER 472 INTERMEDIATE SPRAG END BEARINGS (2 REQUIRED) INTERMEDIATE SPRAG AND CAGE ASSEMBLY Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 107 Figure 108 AUTOMATIC TRANSMISSION SERVICE GROUP 71 . 9. with the "windows" to the left. and ensure that the outer race is arranged as shown. Install one intermediate sprag end bearing on top of the thrust washer in the direction shown in Figure 107. Refer to Figure 108. Install intermediate sprag outer race thrust washer. Install the intermediate sprag cage assembly in the outer sprag race exactly as shown in Figure 108. as shown in Figure 107. CLUTCH HUB/INTERMEDIATE SPRAG (CONT'D) 6. Place the overdrive clutch hub on a flat surface with shaft facing up. 7. 8. as shown in Figure 107.Technical Service Information O.D.

Install the pre-assembled intermediate sprag cage and outer race assembly onto the inner race.D. in the direction shown in Figure 109. Ensure now that the outer race freewheels in a clockwise direction and holds in the counter clockwise direction. INTERMEDIATE SPRAG AND OUTER RACE ASSEMBLY FREEWHEEL Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 109 Figure 110 72 AUTOMATIC TRANSMISSION SERVICE GROUP . by rotating with a clockwise motion. CLUTCH HUB/INTERMEDIATE SPRAG (CONT'D) 10. 11. as shown in Figure 110.Technical Service Information O.

13.Technical Service Information 12. Install a "New" retainer (477) on top of thrust bearing. with the smooth side facing up. Continued on Page 74 475 477 476 472 FWEB 446273 ENT ED PAT U ENT ED PAT 470 OVERDRIVE CLUTCH HUB ASSEMBLY 472 INTERMEDIATE SPRAG END BEARINGS (2 REQUIRED) 475 INTERMEDIATE SPRAG FRONT THRUST WASHER 476 INTERMEDIATE SPRAG THRUST BEARING ASSEMBLY 477 INTERMEDIATE SPRAG THRUST BEARING RETAINER Copyright © 2002 ATSG Figure 111 Figure 112 AUTOMATIC TRANSMISSION SERVICE GROUP SKF FRANCE SKF FRANCE 470 FWEB 446273 Copyright © 2002 ATSG U 73 . 14. 15. on top of the thrust washer. as shown in Figure 112 with the lip facing up. Install the intermediate sprag thrust bearing. Install another intermediate sprag thrust washer on top of the end bearing (See Figure 111). Install the other intermediate sprag end bearing in the direction shown in Figure 111. as shown in Figure 112.

Turn the assembly over and install the thrust washer. 19. CLUTCH HUB/INTERMEDIATE SPRAG (CONT'D) 16. Check for proper sprag freewheel one more time referring to Figure 110. Ensure that the "New" retainer is fully seated.D. 18. 17. Retain the thrust washer with small amount of Trans-Jel®. shown in Figure 113. THRUST WASHER ENSURE THAT RETAINER IS FULLY SEATED FWEB 446273 ENT ED PAT U 74 SKF FRANCE Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 113 Figure 114 AUTOMATIC TRANSMISSION SERVICE GROUP . as shown in Figure 114.Technical Service Information O. Set the completed overdrive clutch hub and intermediate sprag assembly aside for the final transmission assembly process.

D./O. HOUSING TO MAIN CASE SNAP RING (SELECTIVE) OVERDRIVE CLUTCH BACKING PLATE SNAP RING (SELECTIVE) OVERDRIVE CLUTCH BACKING PLATE OVERDRIVE CLUTCH "INSIDE SPLINE" SINGLE SIDED PLATES (2) OVERDRIVE CLUTCH "OUTSIDE SPLINE" SINGLE SIDED PLATES (2) OVERDRIVE CLUTCH APPLY RING SPACER OVERDRIVE CLUTCH BELLVILLE RETURN SPRING SNAP RING OVERDRIVE CLUTCH BELLVILLE RETURN SPRING OVERDRIVE CLUTCH PISTON ASSEMBLY INTERMEDIATE CLUTCH BACKING PLATE SNAP RING (SELECTIVE) 489 490 491 492 493 494 495 496 497 INTERMEDIATE CLUTCH BACKING PLATE INTERMEDIATE CLUTCH "INSIDE SPLINE" SINGLE SIDED PLATES (3) INTERMEDIATE CLUTCH "OUTSIDE SPLINE" SINGLE SIDED PLATES (3) INTERMEDIATE CLUTCH "WAVE" PLATE INTERMEDIATE/OVERDRIVE CLUTCH HOUSING INTERMEDIATE CLUTCH RETURN SPRING ASSEMBLY INTERMEDIATE CLUTCH PISTON ASSEMBLY INTERMEDIATE CLUTCH PISTON HOUSING INTERMEDIATE CLUTCH PISTON HOUSING RETAINING RING Copyright © 2002 ATSG Figure 115 AUTOMATIC TRANSMISSION SERVICE GROUP 75 .Technical Service Information INTERMEDIATE AND OVERDRIVE CLUTCH HOUSING ASSEMBLY 480 481 482 484 485 486 487 483 488 489 490 492 14 491 493 494 495 496 497 14 480 481 482 483 484 485 486 487 488 INT.

Dis-assemble the overdrive and intermediate clutch housing assembly. 2. Inspect all overdrive and intermediate clutch parts thoroughly for the following: o Plugged feed passages o Worn or damaged splines o Damaged or worn springs o Damaged or worn pistons o Damaged or worn clutch plates 4. as shown in Figure 116. using Figure 115 as a guide.Technical Service Information COMPONENT REBUILD O. 3.D. Clean all overdrive and intermediate clutch parts thoroughly and dry with compressed air. 497 496 495 494 493 496 495 INTERMEDIATE CLUTCH MOLDED PISTON ASSEMBLY 496 INTERMEDIATE CLUTCH PISTON HOUSING 493 494 496 497 INTERMEDIATE/OVERDRIVE CLUTCH HOUSING INTERMEDIATE CLUTCH RETURN SPRING ASSEMBLY PRE-ASSEMBLED INTERMEDIATE CLUTCH PISTON HOUSING INTERMEDIATE CLUTCH PISTON HOUSING RETAINING RING Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 116 Figure 117 76 AUTOMATIC TRANSMISSION SERVICE GROUP . Lubricate molded intermediate clutch piston with small amount of Trans-Jel® and install it into intermediate clutch housing with rotating motion. AND INTERMEDIATE CLUTCH HOUSING 1.

Install the intermediate clutch return spring assembly into housing.S. 7. PLATES (3) INTERMEDIATE/OVERDRIVE CLUTCH HOUSING Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 118 Figure 119 AUTOMATIC TRANSMISSION SERVICE GROUP 77 . 10. as shown in Figure 117. Compress intermediate housing and the return spring using a foot press.S. as shown in Figure 119. CLUTCH BACKING PLATE SNAP RING (SELECTIVE) INTERMEDIATE CLUTCH BACKING PLATE INTERMED. as shown in Figure 118. and install snap ring. as shown in Figure 117. CLUTCH "INSIDE SPLINE" S. Turn overdrive housing over and install "Wave" plate. Clutch plate amounts may vary by model. 8. 6. Install the intermediate clutch "single sided" plates beginning with an outside spline plate first and alternating with inside spline plates until you have installed 3 of each. Note: Lined side must be installed facing up as shown in Figure 119. as shown in Figure 119. PLATES (3) INTERMED.Technical Service Information 5. CLUTCH "OUTSIDE SPLINE" S. 9. Install pre-assembled intermediate clutch piston and housing assembly on top of return spring in direction shown in Figure 117. Install the intermediate clutch backing plate. Continued on Page 78 492 490 491 488 489 493 493 492 INTERMEDIATE CLUTCH "WAVE" PLATE 493 INTERMEDIATE/OVERDRIVE CLUTCH HOUSING 488 489 490 491 493 INTERMED.

12. Install J-45135 lip seal protector.D.031"-. 13. 14. and zero the dial indicator.Technical Service Information COMPONENT REBUILD O. as shown in Figure 121 to install overdrive clutch piston. Change the "Selective" backing plate snap ring as necessary to achieve proper clutch clearance. Continued on Page 79 J-45135 LIP SEAL PROTECTOR "MANDATORY" TOOL Copyright © 2002 ATSG Figure 121 OVERDRIVE CLUTCH PISTON CHECKING INTERMEDIATE CLUTCH CLEARANCE CLEARANCE SHOULD BE . as shown in Figure 122. Remove the J-45135 lip seal protector. 16. Install dial indicator on top of the intermediate clutch backing plate.D. 15. Install the "Selective" backing plate snap ring as shown in Figure 119. piston seals.062" 10 20 30 40 50 0 10 20 30 40 0 50 Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 120 Figure 122 78 AUTOMATIC TRANSMISSION SERVICE GROUP . AND INTERMEDIATE CLUTCH HOUSING CONT'D) 11. Lubricate molded overdrive clutch piston seals with small amount of Trans-Jel® and install the overdrive clutch piston into the housing. and ensure that snap ring is fully seated against the top of snap ring groove in the housing.78 mm (.062").031") to 1.58 mm (. as shown in Figure 120. Note: This tool is mandatory to prevent damage to the O. Intermediate clutch clearance should be: 0.

D. as shown in Figure 123. Install the "Bellville" overdrive clutch piston return spring (486). as shown in Figure 124. 19. 18. Install the overdrive clutch apply ring spacer. Using your foot press and J-44764 spring compressor adapter. Continued on Page 80 J-44764 SPRING COMPRESSOR "MANDATORY" TOOL 485 Copyright © 2002 ATSG Figure 124 484 486 493 493 485 OVERDRIVE CLUTCH BELLVILLE RETURN SPRING SNAP RING 486 OVERDRIVE CLUTCH BELLVILLE RETURN SPRING 493 INTERMEDIATE/OVERDRIVE CLUTCH HOUSING 484 OVERDRIVE CLUTCH APPLY RING SPACER 493 INTERMEDIATE/OVERDRIVE CLUTCH HOUSING Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 123 Figure 125 AUTOMATIC TRANSMISSION SERVICE GROUP 79 .Technical Service Information O. as shown in Figure 125. compress the return spring and install the snap ring. AND INTERMEDIATE CLUTCH HOUSING (CONT'D) 17.

25. 23. 481 482 483 CHECKING OVERDRIVE CLUTCH CLEARANCE CLEARANCE SHOULD BE . as shown in Figure 126. 24. Note: Lined side must be installed facing up as shown in Figure 126. as shown in Figure 126. and ensure that snap ring is fully seated against the top of snap ring groove in the housing. Clutch plate amounts may vary by model. Install the overdrive clutch backing plate.Technical Service Information 480 O. Overdrive clutch clearance should be: 0.037"-. 22. Install dial indicator on top of the overdrive clutch backing plate. as shown in Figure 127.037") to 1. Change the "Selective" backing plate snap ring as necessary to achieve proper clutch clearance.79 mm (.070").94 mm (. Install the overdrive clutch "single sided" plates beginning with an outside spline plate first and alternating with inside spline plates until you have installed 2 of each (See Figure 126). PLATES (2) INTERMEDIATE/OVERDRIVE CLUTCH HOUSING Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 126 Figure 127 80 AUTOMATIC TRANSMISSION SERVICE GROUP . 21.070" 493 10 20 30 40 50 0 50 0 10 20 30 40 480 481 482 483 493 OVERDRIVE CLUTCH BACKING PLATE SNAP RING (SELECTIVE) OVERDRIVE CLUTCH BACKING PLATE OVERDRIVE CLUTCH "INSIDE SPLINE" S.D.S. AND INTERMEDIATE CLUTCH HOUSING (CONT'D) 20. and zero the dial indicator. PLATES (2) OVERDRIVE CLUTCH "OUTSIDE SPLINE" S. Set the completed overdrive clutch housing aside for transmission final assembly process.S. Install the "Selective" backing plate snap ring.

3. Inspect the low sprag assembly for proper hold and freewheel operation (See Figure 128). 2.Technical Service Information COMPONENT REBUILD LOW SPRAG ASSEMBLY 1. "SPECIAL NOTE" LOW SPRAG CANNOT BE DIS-ASSEMBLED IF SERVICE IS NECESSARY. If replacement is necessary. and then set aside for the transmission final assembly process. low sprag must be serviced as a complete assembly. EXPLODED VIEW IS FOR REFERENCE ONLY! Reference Only Serviced As Complete Assembly 500 501 502 FWEB 446273 ENT ED PAT U LOW SPRAG OUTER RACE 502 FREEWHEEL HOLD LOW SPRAG OUTER RACE SHOULD FREEWHEEL COUNTER-CLOCKWISE AND LOCK CLOCKWISE WHILE HOLDING HUB AS SHOWN ABOVE Copyright © 2002 ATSG Figure 128 Serviced As Complete Assembly 500 501 502 503 504 505 LOW SPRAG ASSEMBLY RETAINER (CRIMPED IN PLACE) LOW SPRAG THRUST WASHER (2) LOW SPRAG END BEARINGS (2) LOW SPRAG AND CAGE ASSEMBLY LOW SPRAG OUTER RACE LOW SPRAG INNER RACE Figure 129 legend Figure 129 AUTOMATIC TRANSMISSION SERVICE GROUP SKF FRANCE 503 504 501 505 Copyright © 2002 ATSG 81 . Inspect the low sprag assembly for any visable wear and/or damage. IT MUST BE REPLACED AS A SERVICE PACKAGE.

Technical Service Information CENTER SUPPORT "FRONT SIDE" EXPLODED VIEW 510 511 512 514 513 518 516 536 515 517 519 Installed During Final Assembly 510 511 512 513 514 515 516 517 518 519 520 521 522 523 LOW/REVERSE CLUTCH BACKING PLATE SNAP RING (SELECTIVE) LOW/REVERSE CLUTCH BACKING PLATE LOW/REVERSE CLUTCH "INNER SPLINE" SINGLE SIDED PLATE (5) LOW/REVERSE CLUTCH "OUTER SPLINE" SINGLE SIDED PLATE (5) LOW/REVERSE CLUTCH "WAVE" PLATE LOW/REVERSE CLUTCH BELLVILLE RETURN PLATE SNAP RING LOW/REVERSE CLUTCH BELLVILLE RETURN SPRING LOW/REVERSE CLUTCH PISTON ASSEMBLY CENTER SUPPORT ASSEMBLY CAGED NEEDLE BEARING ASSEMBLY 2ND CLUTCH PISTON ASSEMBLY 2ND CLUTCH PISTON RETURN SPRING ASSEMBLY 2ND CLUTCH RETURN SPRING RETAINER SNAP RING 2ND CLUTCH "WAVE" PLATE 524 525 526 527 528 529 530 531 532 533 534 535 536 537 2ND CLUTCH "OUTER SPLINE" SINGLE SIDED PLATE (5) 2ND CLUTCH "INNER SPLINE" SINGLE SIDED PLATE (5) 2ND CLUTCH BACKING PLATE 2ND CLUTCH BACKING PLATE SNAP RING (SELECTIVE) 2ND COAST CLUTCH PISTON ASSEMBLY 2ND COAST CLUTCH PISTON BELLVILLE RETURN SPRING 2ND COAST CLUTCH BELLVILLE RETURN SPRING SNAP RING 2ND COAST CLUTCH APPLY/SPACER RING 2ND COAST CLUTCH "OUTER SPLINE" SINGLE SIDED PLATE (3) 2ND COAST CLUTCH "INNER SPLINE" SINGLE SIDED PLATE (3) 2ND COAST CLUTCH BACKING PLATE 2ND COAST CLUTCH BACKING PLATE SNAP RING (SELECTIVE) LOW SPRAG TO CENTER SUPPORT THRUST BEARING 2ND CLUTCH PISTON RETURN SPRING RETAINER Copyright © 2002 ATSG Figure 130 82 AUTOMATIC TRANSMISSION SERVICE GROUP .

1 1 FL Legend For This Illustration Is Found In Figure 130 Copyright © 2002 ATSG Figure 131 96 02 29 71 99 AUTOMATIC TRANSMISSION SERVICE GROUP 83 .Technical Service Information CENTER SUPPORT "REAR SIDE" EXPLODED VIEW 535 534 533 531 532 530 529 528 527 526 525 524 518 523 522 537 521 520 12 .1 .

Lubricate the low/reverse clutch piston seals with small amount of Trans-Jel® and install the low/reverse clutch piston in the center support. 7. using the proper puller and proper diameter installer (See Figure 132). 8. 6. as shown in Figure 134.1 . Clean all center support parts thoroughly and dry with compressed air. as shown in Figure 134. on low/reverse side. 5.1 1 FL 99 518 CENTER SUPPORT ASSEMBLY 519 CAGED NEEDLE BEARING ASSEMBLY Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 132 Figure 133 84 AUTOMATIC TRANSMISSION SERVICE GROUP . Install J-45136 and J-45140 lip seal protectors. Dis-assemble the center support using Figures 130 and 131 as a guide. 2. Install the low/reverse clutch "Bellville" return spring.Technical Service Information COMPONENT REBUILD CENTER SUPPORT 1. Remove the lip seal protectors. Replace the caged needle bearing as necessary. 3. "MANDATORY" TOOLS J-45140 J-45136 519 518 96 02 29 71 12 . Note: These tools are mandatory to prevent damage to the L/R piston seals. Inspect all center support parts thoroughly for the following: o Plugged feed passages o Damaged or worn splines o Damaged or worn springs o Damaged or worn pistons o Damaged or worn clutch plates 4. as shown in Figure 133.

Place the assembly on foot press. compress the return spring and install the retaining snap ring (See Figure 134). as shown in Figure 135. Continued on Page 86 516 515 517 514 518 518 515 516 517 518 LOW/REVERSE BELLVILLE RETURN SPRING SNAP RING LOW/REVERSE CLUTCH BELLVILLE RETURN SPRING LOW/REVERSE CLUTCH PISTON ASSEMBLY CENTER SUPPORT ASSEMBLY 514 LOW/REVERSE "WAVE" PLATE 518 CENTER SUPPORT ASSEMBLY Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 134 Figure 135 AUTOMATIC TRANSMISSION SERVICE GROUP 85 . Install the low/reverse clutch "Wave" plate into center support. 10.Technical Service Information 9.

Technical Service Information
CENTER SUPPORT (CONT'D)
11. Install low/reverse clutch "single sided" plates beginning with an outside spline plate first and alternating with inside spline plates until you have installed 5 of each (See Figure 136). Note: Lined side must be installed facing up, as shown in Figure 136. Clutch plate amounts may vary by model. 12. Install the low/reverse backing plate, as shown in Figure 137. 13. Install the "Selective" backing plate snap ring, as shown in Figure 137, and ensure that snap ring is fully seated against the top of snap ring groove in the center support.

510

513

512

511

518 518

512 LOW/REVERSE CLUTCH "INNER SPLINE" PLATE (5) 513 LOW/REVERSE CLUTCH "OUTER SPLINE" PLATE (5) 518 CENTER SUPPORT ASSEMBLY

510 LOW/REVERSE CLUTCH BACKING PLATE SNAP RING 511 LOW/REVERSE CLUTCH BACKING PLATE 518 CENTER SUPPORT ASSEMBLY

Copyright © 2002 ATSG

Copyright © 2002 ATSG

Figure 136

Figure 137

86

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information
14. Install dial indicator on top of the low/reverse clutch backing plate, as shown in Figure 138, and zero the dial indicator. 15. Low/Reverse clutch clearance shoud be: 1.32 mm (.052") to 2.17 mm (.085"). Change the "Selective" backing plate snap ring as necessary to achieve proper clutch clearance. 16. Turn the center support over, install J-45137 and J-45145 lip seal protectors, as shown in Figure 139. Note: These tools are mandatory to prevent damage to the 2nd clutch piston seals.

"MANDATORY" TOOLS FOR 2ND CLUTCH PISTON

J-45137

Continued on Page 88

J-45145

CHECKING LOW/REVERSE CLUTCH CLEARANCE CLEARANCE SHOULD BE .052"-.085"

10 20 30 40 50

0

10 20 30 40

0

50

96

02

29

71

12

.1 .1 1

FL

99

Copyright © 2002 ATSG

Copyright © 2002 ATSG

Figure 138

Figure 139

AUTOMATIC TRANSMISSION SERVICE GROUP

87

Technical Service Information
CENTER SUPPORT (CONT'D)
522

537

521

520

518

17. Lubricate the 2nd clutch piston seals with a small amount of Trans-Jel® and install the 2nd clutch piston into the center support, as shown in Figure 140. 18. Remove the lip seal protectors. 19. Install the 2nd clutch return spring assembly, as shown in Figure 140. 20. Install the return spring retainer and snap ring on top of the return spring (See Figure 140). 21. Place center support on foot press, compress return spring and retainer, and install the snap ring ensuring that it is fully seated. 22. Install the 2nd clutch "Wave" plate into center support, as shown in Figure 141. 23. Install the 2nd clutch "single sided" plates beginning with an outside spline plate first and alternating with inside spline plates until you have installed 5 of each (See Figure 141). Note: Lined side must be installed facing up, as shown in Figure 141. Clutch plate amounts may vary by model. This set of clutch plates are not used at all in the "4L40-E" models. 24. Install the 2nd clutch backing plate, as shown in Figure 142. 25. Install the "Selective" backing plate snap ring, as shown in Figure 141, and ensure that snap ring is fully seated against the top of snap ring groove in the center support.

Continued on Page 90

96

02

29

71

12

.1 .1 1

FL

99

518 520 521 522 537

CENTER SUPPORT ASSEMBLY 2ND CLUTCH PISTON ASSEMBLY 2ND CLUTCH PISTON RETURN SPRING ASSEMBLY 2ND CLUTCH RETURN SPRING RETAINER SNAP RING 2ND CLUTCH RETURN SPRING RETAINER

Copyright © 2002 ATSG

Figure 140

88

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

525 524

527

523

526

518

518

96

02

29

71

12

.1 .1 1

FL

96

99

02

29

71

12

.1 .1 1

FL

99

518 523 524 525

CENTER SUPPORT ASSEMBLY 2ND CLUTCH "WAVE" PLATE 2ND CLUTCH "OUTER SPLINE" SINGLE SIDED PLATE (5) 2ND CLUTCH "INNER SPLINE" SINGLE SIDED PLATE (5)

518 CENTER SUPPORT ASSEMBLY 526 2ND CLUTCH BACKING PLATE 527 2ND CLUTCH BACKING PLATE SNAP RING (SELECTIVE)

Copyright © 2002 ATSG

Copyright © 2002 ATSG

Figure 141

Figure 142

AUTOMATIC TRANSMISSION SERVICE GROUP

89

as shown in Figure 143.1 . Install J-45136 lip seal protector.1 1 FL 96 02 29 99 71 12 . as shown in Figure 144.1 1 FL 99 Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 143 Figure 144 90 AUTOMATIC TRANSMISSION SERVICE GROUP . Change the "Selective" backing plate snap ring as necessary to achieve proper clutch clearance.1 . Compress return spring and install the return spring snap ring as shown in Figure 146. Note: This is a mandatory tool to prevent any damage to 2nd coast clutch piston seals. 32. Lubricate the 2nd coast clutch piston seals with small amount of Trans-Jel® and install the 2nd coast clutch piston into the center support using the J-45145 installation tool (See Figure 145). Install dial indicator on top of the 2nd clutch backing plate.076"). 28. and zero the dial indicator. Continued on Page 93 "MANDATORY" TOOL J-45136 CHECKING 2ND CLUTCH CLEARANCE CLEARANCE SHOULD BE . as shown in Figure 146. Install the 2nd coast clutch "Bellville" return spring. 2nd Clutch clearance should be: 1. 27.Technical Service Information CENTER SUPPORT (CONT'D) 26. Remove the J-45136 lip seal protector.052"-.052") to 1. 29. 30.076" 10 20 30 40 50 0 10 20 30 40 0 50 96 02 29 71 12 .92 mm (.32 mm (. 31.

Technical Service Information J-45145 PISTON INSTALLER 530 529 528 518 518 96 02 29 71 12 .1 .1 .1 1 FL 96 02 29 71 12 .1 1 FL 99 99 518 CENTER SUPPORT ASSEMBLY 528 2ND COAST CLUTCH PISTON ASSEMBLY 518 CENTER SUPPORT ASSEMBLY 529 2ND COAST CLUTCH PISTON RETURN SPRING 530 2ND COAST CLUTCH RETURN SPRING SNAP RING Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 145 Figure 146 AUTOMATIC TRANSMISSION SERVICE GROUP 91 .

1 .Technical Service Information 535 533 532 534 531 518 518 96 02 29 71 12 .S.S.1 1 FL 96 02 29 99 71 12 .1 1 FL 99 518 531 532 533 CENTER SUPPORT ASSEMBLY 2ND COAST CLUTCH APPLY RING SPACER 2ND COAST CLUTCH "OUTER SPLINE" S. PLATES (3) 2ND COAST CLUTCH "INNER SPLINE" S.1 . PLATES (3) 518 CENTER SUPPORT ASSEMBLY 534 2ND COAST CLUTCH BACKING PLATE 535 2ND COAST CLUTCH BACKING PLATE SNAP RING (SELECTIVE) Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 147 Figure 148 92 AUTOMATIC TRANSMISSION SERVICE GROUP .

1 1 FL 99 Copyright © 2002 ATSG Figure 149 AUTOMATIC TRANSMISSION SERVICE GROUP 93 .6 mm (.80 mm (. as shown in Figure 148. Install dial indicator on top of 2nd coast clutch backing plate.063" 10 20 30 40 50 0 10 20 30 40 0 50 96 02 29 71 12 . Set the completed Center Support Assembly aside for final transmission assembly. 38. Change the "Selective" backing plate snap ring as necessary to achieve proper clutch clearance. and zero the dial indicator.1 . Install the 2nd coast clutch backing plate. as shown in Figure 149. CHECKING 2ND COAST CLUTCH CLEARANCE CLEARANCE SHOULD BE . as shown in Figure 147. Install 2nd coast clutch "single sided" plates beginning with an outside spline plate first and alternating with inside spline plates until you have installed 3 of each (See Figure 147). Clutch plate amounts may vary by model.031") to 1. and ensure that snap ring is fully seated against the top of snap ring groove in the center support. 36. ensuring that slots are installed over return spring legs. 2nd Coast Clutch clearance should be: 0. as shown in Figure 147. Note: Lined side must be installed facing up. Install the 2nd coast clutch apply ring spacer. This set of clutch plates are not used at all in the "4L40-E" models.063"). 35. 34. 39.031"-. as shown in Figure 148. 37.Technical Service Information CENTER SUPPORT (CONT'D) 33. Install the "Selective" backing plate snap ring.

EXPLODED VIEW IS FOR REFERENCE ONLY! Figure 150 94 AUTOMATIC TRANSMISSION SERVICE GROUP ENT ED PAT 553 563 29 33 34 Copyright © 2002 ATSG . IT MUST BE REPLACED AS A SERVICE PACKAGE. IF SERVICE IS NECESSARY.Technical Service Information 5L40-E "ONLY" 2ND SPRAG AND PLANETARY SYSTEM EXPLODED VIEW 540 541 542 543 544 545 546 547 546 544 U FWEB 446273 SKF FRANCE 549 548 550 551 552 552 554 560 559 562 561 564 "SPECIAL NOTE" 2ND SPRAG CANNOT BE DIS-ASSEMBLED.

Technical Service Information 4L40-E "ONLY" PLANETARY SYSTEM EXPLODED VIEW (2ND SPRAG NOT USED) 553 540 541 552 552 554 560 559 562 563 30 33 34 561 564 29 33 34 540 541 542 543 544 545 546 547 548 OUTPUT SHAFT TO DRIVESHAFT YOKE SPACER DRIVESHAFT YOKE WASHER DRIVESHAFT YOKE RETAINING NUT THRUST BEARING RETAINING SNAP RING PL ANETARY CARRIER THRUST BEARING 2ND SPRAG ASSEMBLY THRUST BEARING 2ND CLUTCH SPRAG RETAINER (CRIMPED IN PLACE) 2ND CLUTCH SPRAG OUTER RACE THRUST WASHER (2) 2ND CLUTCH SPRAG OUTER RACE 2ND CLUTCH SPRAG END BEARING (2) 2ND CLUTCH SPRAG AND CAGE ASSEMBLY 2ND CLUTCH SPRAG INNER RACE AND HUB BUSHING 549 550 551 552 553 554 559 560 561 562 563 564 2ND CLUTCH SPRAG INNER RACE AND HUB ASSEMBLY REACTION INTERNAL RING GEAR PL ANETARY TO 2ND SPRAG/HUB THRUST WASHER PL ANETARY CARRIER BUSHING (2) PL ANETARY CARRIER ASSEMBLY PL ANETARY CARRIER CAGED NEEDLE BEARING OUTPUT SHAFT TO PL ANETARY CARRIER THRUST BEARING REAR INTERNAL RING GEAR OUTPUT SHAFT BUSHING OUTPUT SHAFT ASSEMBLY OUTPUT SHAFT TO REAR RING GEAR RETAINING SNAP RING OUTPUT SHAFT CUP PLUG Copyright © 2002 ATSG Figure 151 AUTOMATIC TRANSMISSION SERVICE GROUP 95 .

IT MUST BE REPLACED AS A SERVICE PACKAGE. Install thrust bearing (542) on top of 2nd sprag assembly. as shown in Figure 156 Continued on Page 97 5L40-E PLANETARY CARRIER "SPECIAL NOTE" 2ND SPRAG CANNOT BE DIS-ASSEMBLED IF SERVICE IS NECESSARY. as shown in Figure 153. 3. Install 2nd sprag and hub assembly on 5L40-E carrier. Exploded view is for reference only. as shown in Figure 156. Clean all planetary system parts thoroughly and dry with compressed air. 8. 9. Install thrust washer (551) on 5L40-E carrier as ahown in Figure 153. 4. If replacement is necessary. EXPLODED VIEW IS FOR REFERENCE ONLY! 549 551 2ND SPRAG OUTER RACE FREEWHEEL 553 HOLD 2ND SPRAG OUTER RACE SHOULD FREEWHEEL COUNTER-CLOCKWISE AND LOCK CLOCKWISE WHILE HOLDING HUB AS SHOWN ABOVE Copyright © 2002 ATSG 549 COMPLETE 2ND SPRAG AND HUB ASSEMBLY (5L40-E ONLY) 551 2ND SPRAG TO PLANETARY THRUST WASHER (5L40-E ONLY) 553 5L40-E PL ANETARY CARRIER ASSEMBLY Copyright © 2002 ATSG Figure 152 Figure 153 96 AUTOMATIC TRANSMISSION SERVICE GROUP . Note: The 2nd Sprag Assembly cannot be dis-assembled. Inspect the Sprag Assembly for proper hold and freewheel operation (See Figure 152). 2. 5. Inspect all planetary system parts thoroughly for any wear and/or damage.Technical Service Information COMPONENT REBUILD "5L40-E" PLANETARY SYSTEM 1. 7. 6. Install thrust bearing (541) on top of thrust bearing 542. Dis-assemble the planetary carrier system using Figures 150 and 151 as a guide. 2nd sprag must be serviced as a complete assembly.

as shown in Figure 155. Install the retaining snap ring. and ensure that it is fully seated. 12. 11. aside for the final transmission assembly process. Thrust bearing identification for these two bearings is provided in Figure 154. Continued on Page 98 541 542 540 540 PL ANETARY THRUST BEARING RETAINING SNAP RING 541 PL ANETARY CARRIER THRUST BEARING 542 2ND SPRAG ASSEMBLY THRUST BEARING (5L40-E ONLY) 541 Copyright © 2002 ATSG Figure 154 542 COMPLETED 5L40-E REAR PLANETARY 553 540 541 542 553 PL ANETARY THRUST BEARING RETAINING SNAP RING PL ANETARY CARRIER THRUST BEARING 2ND SPRAG ASSEMBLY THRUST BEARING (5L40-E ONLY) 5L40-E PL ANETARY CARRIER/2ND SPRAG ASSEMBLY Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 155 Figure 156 AUTOMATIC TRANSMISSION SERVICE GROUP 97 . as shown in Figure 156.Technical Service Information PLANETARY THRUST BEARING IDENTIFICATION 540 "5L40-E" PLANETARY SYSTEM (CONT'D) 10. Set the completed 5L40-E planetary carrier assembly.

Set the completed 5L40-E output shaft. Install the internal ring gear snap ring into the groove in ring gear.Technical Service Information "5L40-E" PLANETARY SYSTEM (CONT'D) 13. and retain with small amount of Trans-Jel®. 5L40-E OUTPUT SHAFT EXPLODED VIEW 559 560 562 COMPLETED 5L40-E OUTPUT SHAFT 563 30 30 559 560 562 563 DRIVESHAFT YOKE TO OUTPUT SHAFT SPACER OUTPUT SHAFT TO PL ANETARY CARRIER THRUST BEARING 5L40-E REAR INTERNAL RING GEAR 5L40-E OUTPUT SHAFT ASSEMBLY OUTPUT SHAFT TO RING GEAR RETAINING SNAP RING Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 157 Figure 158 98 AUTOMATIC TRANSMISSION SERVICE GROUP . Install output shaft into the output internal ring gear. 15. 14. as shown in Figure 158. and ensure that it is fully seated. 17. 16. as shown in Figure 157. Install driveshaft yoke spacer onto output shaft against the flat surface (See Figure 158). as shown in Figure 158. Install thrust bearing (559) onto output shaft. as shown in Figure 158. aside for the final transmission assembly process.

4. Install the retaining snap ring onto planetary carrier. 5. Set the completed 4L40-E planetary carrier. aside for the final transmission assembly process. as shown in Figure 162. as shown in Figure 160. 2. Set the completed 4L40-E output shaft. Install thrust bearing (559) onto output shaft. as shown in Figure 162. 8. and ensure that it is fully seated. Install output shaft into the output internal ring gear. as shown in Figure 159. Install the internal ring gear snap ring into the groove in ring gear. 3. Install thrust bearing (541) onto the 4L40-E planetary carrier. and retain with small amount of Trans-Jel®. as shown in Figure 161. 541 553 540 PL ANETARY THRUST BEARING RETAINING SNAP RING 541 PL ANETARY CARRIER THRUST BEARING 553 4L40-E PL ANETARY CARRIER ASSEMBLY Copyright © 2002 ATSG Figure 159 COMPLETED 4L40-E PLANETARY CARRIER COMPLETED 4L40-E OUTPUT SHAFT Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 160 Figure 161 AUTOMATIC TRANSMISSION SERVICE GROUP 99 . as shown in Figure 162. and down flush on step. 7.Technical Service Information 4L40-E PLANETARY CARRIER EXPLODED VIEW 540 COMPONENT REBUILD "4L40-E" PLANETARY SYSTEM 1. 6. for final assembly. and ensure that it is fully seated. as shown in Figure 159. Install driveshaft yoke spacer onto output shaft against the flat surface (See Figure 162).

CLUTCH ACCUMULATOR PISTON LARGE SEAL RING INTERMEDIATE CLUTCH ACCUMULATOR PISTON INTERM. CLUTCH ACCUMULATOR PISTON LARGE SEAL RING OVERDRIVE CLUTCH ACCUMULATOR PISTON O.D.D. CLUTCH ACCUMULATOR PISTON SMALL SEAL RING INTERMEDIATE CLUTCH ACCUMULATOR HOUSING 2ND CLUTCH ACCUMULATOR PISTON SPRING 2ND CLUTCH ACCUMULATOR PISTON LARGE SEAL RING 2ND CLUTCH ACCUMULATOR PISTON 2ND CLUTCH ACCUMULATOR PISTON SMALL SEAL RING 2ND CLUTCH ACCUMULATOR HOUSING 560 562 563 30 30 559 560 562 563 DRIVESHAFT YOKE TO OUTPUT SHAFT SPACER OUTPUT SHAFT TO PL ANETARY CARRIER THRUST BEARING 4L40-E REAR INTERNAL RING GEAR 4L40-E OUTPUT SHAFT ASSEMBLY OUTPUT SHAFT TO RING GEAR RETAINING SNAP RING Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 162 Figure 163 Legend 100 AUTOMATIC TRANSMISSION SERVICE GROUP . CLUTCH ACCUMULATOR PISTON SMALL SEAL RING OVERDRIVE CLUTCH ACCUMULATOR HOUSING INTERMEDIATE CLUTCH ACCUMULATOR PISTON SPRING INTERM.Technical Service Information 4L40-E OUTPUT SHAFT EXPLODED VIEW 559 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 TOP CHANNEL PL ATE TO VALVE BODY BOLTS (7) TOP CHANNEL PL ATE ASSEMBLY NUMBER 7 CHECKBALL SPRING TOP CHANNEL PL ATE TO BOTTOM CHANNEL PLATE GASKET BOTTOM CHANNEL PL ATE ASSEMBLY UPPER SPACER PLATE GASKET NUMBER 7 CHECKBALL VALVE BODY SPACER PLATE TCC/PWM SOLENOID SCREEN ASSEMBLY LOWER SPACER PLATE GASKET REAR VALVE BODY ASSEMBLY FRONT VALVE BODY ASSEMBLY PRESSURE CONTROL SOLENOID SCREEN ASSEMBLY DIRECT CLUTCH ACCUMULATOR PISTON SPRING DIRECT CLUTCH ACCUMULATOR PISTON LARGE SEAL RING DIRECT CLUTCH ACCUMULATOR PISTON DIRECT CLUTCH ACCUMULATOR PISTON SMALL SEAL RING DIRECT CLUTCH ACCUMULATOR HOUSING ACCUMULATOR HOUSING BOLTS (3 PER HOUSING) OVERDRIVE CLUTCH ACCUMULATOR PISTON SPRING O.

Technical Service Information VALVE BODY ASSEMBLY EXPLODED VIEW 318 318 318 318 333 332 328 323 317 322 326 316 321 315 330 325 320 314 319 313 5L40-E ONLY 324 305 329 304 327 331 302 5L40-E ONLY 300 301 303 306 307 305 308 4L40-E ONLY 312 307 309 310 311 Copyright © 2002 ATSG Figure 163 AUTOMATIC TRANSMISSION SERVICE GROUP 101 .

3. lubricating them with Dexron III® as they are installed. Inspect each valve. valve spring. 11. Clean all valve body parts thoroughly and dry with compressed air. 10. Install each valve train back into their bores exactly as shown in Figure 164. 4. Dis-assemble complete valve body assembly using Figure 163 as a guide.Technical Service Information COMPONENT REBUILD VALVE BODY ASSEMBLY 1. 2. Remove and discard both valve body gaskets. 14. Extra care here will eliminate some of the troublesome problems encountered later. FRONT VALVE BODY ASSEMBLY EXPLODED VIEW 343 342 341 340 346 357 344 345 343 355 356 351 354 343 353 347 348 349 350 352 351 340 341 342 343 344 345 346 347 348 FRONT VALVE BODY CASTING ASSEMBLY SAFETY MODE VALVE SAFETY MODE VALVE SPRING VALVE SPRING RETAINER 3-4 SHIFT VALVE SPRING 3-4 SHIFT VALVE 3-4 SHIFT CONTROL VALVE TCC REGULATOR APPLY VALVE SPRING TCC REGULATOR APPLY VALVE 349 350 351 352 353 354 355 356 357 SOLENOID ASSEMBLY SMALL "O" RING SEAL SOLENOID ASSEMBLY LARGE "O" RING SEAL SOLENOID ASSEMBLY RETAINER TCC/PWM SOLENOID ASSEMBLY FEED LIMIT VALVE FEED LIMIT VALVE SPRING PRESSURE CONTROL SOLENOID SMALL "O" RING SEAL PRESSURE CONTROL SOLENOID L ARGE "O" RING SEAL PRESSURE CONTROL SOLENOID ASSEMBLY Copyright © 2002 ATSG Figure 164 102 AUTOMATIC TRANSMISSION SERVICE GROUP . Install new "O" ring seals on the TCC/PWM Solenoid and the Pressure Control Solenoid as they are installed (See Figure 164). Clean all front valve body parts thoroughly and dry with compressed air. 9. 5. Dis-assemble the front valve body assembly using Figure 164 as a guide. bore plug and retainers for any wear and/or damage. 6. valve spring. Inspect each valve. Lay each valve line-up out in order as you remove them from the valve body casting. Lay each valve line-up out in order as you remove them from the valve body casting. 8. 12. Inspect all valve body parts thoroughly for any wear and/or damage. Refer to Figure 163. Dis-assemble the rear valve body assembly using Figure 165 as a guide. bore plug and retainers for any wear and/or damage. 7. 13.

lubricating them with Dexron III® as they are installed. Install new "O" ring seals on all three of the Shift Solenoids as they are installed.Technical Service Information VALVE BODY ASSEMBLY (CONT'D) 15. Clean all front valve body parts thoroughly and dry with compressed air. Extra care here will eliminate some of the troublesome problems encountered later. Install each valve train back into their bores exactly as shown in Figure 165. Continued on Page 104 REAR VALVE BODY ASSEMBLY EXPLODED VIEW 343 350 367 366 349 371 372 349 350 351 370 351 376 368 369 365 375 374 373 350 349 351 387 388 384 385 343 343 386 381 377 383 382 378 380 343 349 350 351 365 366 367 368 369 370 371 372 373 374 379 375 376 377 378 379 380 381 382 383 384 385 386 387 388 4-5 SHIFT CONTROL VALVE 4-5 SHIFT SOLENOID ASSEMBLY MANUAL VALVE MANUAL VALVE LINK "WAVED" WASHER MANUAL VALVE LINK MANUAL VALVE LINK "E" CLIP RETAINER LOW PRESSURE CONTROL VALVE BORE PLUG LOW PRESSURE CONTROL VALVE SPRING LOW PRESSURE CONTROL VALVE LOW PRESSURE CONTROL VALVE BORE PLUG RETAINER REVERSE LOCKOUT VALVE REVERSE LOCKOUT VALVE SPRING 1-2 SHIFT VALVE 1-2 SHIFT VALVE SPRING VALVE SPRING RETAINER SOLENOID ASSEMBLY SMALL "O" RING SEAL SOLENOID ASSEMBLY LARGE "O" RING SEAL SOLENOID ASSEMBLY RETAINER REAR VALVE BODY CASTING ASSEMBLY 1-2 SHIFT CONTROL VALVE 1-2 SHIFT CONTROL VALVE SPRING 1-2 SHIFT SOLENOID ASSEMBLY 2-3 SHIFT SOLENOID ASSEMBLY 2-3 SHIFT CONTROL VALVE 2-3 SHIFT VALVE 2-3 SHIFT VALVE SPRING 4-5 SHIFT VALVE SPRING 4-5 SHIFT VALVE Copyright © 2002 ATSG Figure 165 AUTOMATIC TRANSMISSION SERVICE GROUP 103 . 18. as shown in Figure 165. 17. 16.

Install the four J-39068 guide pins in locations shown in Figure 166. 25. as shown in Figure 167. Install upper spacer plate gasket over the guide pins. Note: Retain the checkballs in channel plate with "Small" amount of Trans-Jel®. 26. 24. as shown in Figure 168. 21. Install lower spacer plate gasket over the guide pins as shown in Figure 166. Continued on Page 107 307 308 304 312 309 305 310 311 307 308 309 310 311 312 J-39068 VALVE BODY GUIDE PINS (4 REQUIRED) VALVE BODY SPACER PLATE TCC PWM SOLENOID SCREEN ASSEMBLY LOWER SPACER PLATE GASKET REAR VALVE BODY ASSEMBLY FRONT VALVE BODY ASSEMBLY PRESSURE CONTROL SOLENOID SCREEN ASSEMBLY 304 BOTTOM CHANNEL PL ATE WITH CHECKBALLS INSTALLED 305 UPPER SPACER PLATE GASKET Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 166 Figure 167 104 AUTOMATIC TRANSMISSION SERVICE GROUP . Install valve body checkballs into their proper locations in the lower channel plate. Lay both front and rear valve body assemblies on a flat work surface exactly as they are layed out in Figure 166. as shown in Figure 167. Install the lower channel plate with checkballs over the guide pins. 22.Technical Service Information VALVE BODY ASSEMBLY (CONT'D) 19. Install spacer plate over guide pins. Install two new screens into the spacer plate in locations shown in Figure 166. as shown in Figure 166. 20. 23.

Technical Service Information
"5L40-E" CHECK BALL LOCATIONS
No. 2 No. 3 No. 4 No. 5 No. 6
SPRING ILLUS. NO. 302

No. 7

No. 1 No. 8

No. 9

No. 10 No. 12 No. 11 (5L40-E Only)

"4L40-E" CHECK BALL LOCATIONS
No. 2 No. 3 No. 4 No. 5 No. 6

SPRING ILLUS. NO. 302

No. 7

No. 1 No. 8

No. 9

No. 10 No. 12 Copyright © 2002 ATSG

Figure 168

AUTOMATIC TRANSMISSION SERVICE GROUP

105

Technical Service Information
LARGE ACCUMULATOR PISTON "O" RING SEAL

300

301

SMALL ACCUMULATOR PISTON "O" RING SEAL

Copyright © 2002 ATSG

Figure 170

303 302

COMPLETED ACCUMULATOR PISTON ASSEMBLY

ENSURE MANUAL VALVE SLIDER IS ENGAGED PROPERLY 50

ACCUMULATOR HOUSING

50 300 301 302 303

VALVE BODY TO TOP CHANNEL PLATE (SEE BOLT CHART) TOP CHANNEL PL ATE TO VALVE BODY (SEE BOLT CHART) TOP CHANNEL PL ATE ASSEMBLY NUMBER 7 CHECKBALL SPRING TOP CHANNEL PL ATE TO BOTTOM CHANNEL PLATE GASKET

Copyright © 2002 ATSG

Copyright © 2002 ATSG

Figure 169

Figure 171

106

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information
VALVE BODY ASSEMBLY (CONT'D)
24. Ensure that the manual valve slider is engaged properly with the lower channel plate casting, as shown in Figure 169. Note: Manual valve must slide freely. 25. Install the top channel plate to bottom channel plate gasket over the guide pins, as shown in Figure 169. 26. Install the number 7 checkball spring (302) in the location shown in Figure 169. 27. Install the top channel plate casting over guide pins, as shown in Figure 169. 28. Install the 7 top channel plate to valve body bolts in the locations shown in Figure 169, and finger tighten only at this time. Note: Refer to bolt chart for identification of valve body bolts and their length. 29. Install the 2 valve body to top channel plate bolts from the bottom, as shown in Figure 169, and finger tighten only at this time. Note: Refer to bolt chart for identification of valve body bolts and their length. 30. Now you can torque the 9 valve body bolts you have just installed to 11 Nm (8 ft.lb.), and then remove the J-39068 guide pins. Note: Once again, ensure that manual valve moves freely. 31. Install new "O" ring seals onto all four of the accumulator pistons, as shown in Figure 170. Note: All accumulator pistons are the same. All large "O" ring seals are the same. All small "O"ring seals are the same. All accumulator housings are the same. All accumulator springs are the same. 32. Install the completed accumulator pistons into the accumulator housings (See Figure 171). 33. Install all completed accumulator assemblies onto the valve body assembly, using three bolts per accumulator, as shown in Figure 172. 34. Torque all four of the accumulator housings to 11 Nm (8 ft.lb.). 35. Set the completed valve body assembly, as shown in Figure 173, aside for final assembly.
318

317

313

313 ACCUMULATOR SPRINGS (ALL THE SAME) 317 COMPLETED ACCUMULATOR HOUSING AND PISTON 318 ACCUMULATOR HOUSING RETAINING BOLTS (3 REQUIRED PER)

Copyright © 2002 ATSG

Figure 172

COMPLETED VALVE BODY ASSEMBLY

Copyright © 2002 ATSG

Figure 173

AUTOMATIC TRANSMISSION SERVICE GROUP

107

Install pre-assembled center support assembly as shown in Figure 176. Install thrust bearing on the back side of the low sprag assembly and retain with a small amount of Trans-Jel® (See Figure 177). Note: We have illustrated both the 4L40-E and the 5L40-E in Figure 174. along with the thrust bearing. Install pre-assembled planetary carrier system. Install the low sprag assembly until fully seated by rotating back and forth to engage the low/ reverse clutch plates (See Figure 177).Technical Service Information TRANSMISSION ASSEMBLY INTERNAL COMPONENTS 1. and rotate the output shaft back and forth to engage the 2nd clutch plates and the 2nd coast clutch plates. Note: We have illustrated both the 4L40-E and the 5L40-E in Figure 175. 3. as shown in Figure 175. 2. Continued on Page 109 4L40-E ONLY 5L40-E ONLY 4L40-E ONLY 5L40-E ONLY 22 23 22 21 23 21 22 PL ANETARY CARRIER TO OUTPUT SHAFT THRUST BEARING 23 OUTPUT SHAFT AND INTERNAL RING GEAR ASSEMBLY 21 PL ANETARY CARRIER ASSEMBLY Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 174 Figure 175 108 AUTOMATIC TRANSMISSION SERVICE GROUP . as shown in Figure 174. 4. by rotating down into position. Install the pre-assembled planetary internal ring gear and output shaft. 5.

as shown in Figure 178. CLUTCH HOUSING SNAP RING (SELECTIVE) 15 INTERMEDIATE/OVERDRIVE CLUTCH HOUSING ASSEMBLY Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 177 Figure 178 AUTOMATIC TRANSMISSION SERVICE GROUP 109 .Technical Service Information TRANSMISSION ASSEMBLY (CONT'D) 18 INTERNAL COMPONENTS 6.D. Install pre-assembled intermediate/overdrive clutch housing. Continued on Page 110 18 CENTER SUPPORT ASSEMBLY Copyright © 2002 ATSG Figure 176 14 16 15 17 16 LOW SPRAG ASSEMBLY 17 LOW SPRAG TO CENTER SUPPORT THRUST WASHER 14 INTERM/O. "Do Not" install the snap ring yet. This snap ring is "Selective" and we must measure to determine correct thickness. 7. Rotate the output shaft back and forth until it is fully seated and engaged on the low sprag race.

as shown in Figures 179 and 180. Note: Record this as Dimension "M1".045") to 1.095 mm (.141") 1.029") to .80mm (.70 to 3.50mm (.Technical Service Information DETERMINE DIMENSION "M" 3 4 5 6 7 8 9 TRANSMISSION ASSEMBLY (CONT'D) INTERNAL COMPONENTS (CONT'D) 8.60 to 3.033") 3.041") to 1. 9.05 mm (.157") 0.145") 1.25 mm (.80 to 4.153") 0.15 mm (. as shown in Figures 179 and 180.145" to . Note: Record this as Dimension "M2".60mm (.249in 6 AUTO POWER-O FF mm ELECTRONIC DIGITAL C ALIPER 0 1 2 3 4 5 6 7 8 9 10 20 30 40 1 1 2 3 4 5 6 7 8 9 "M1" "M2" mm/in 0 50 60 70 80 90 AUTO POWER-O FF AUTO POWER-O FF 2 1 2 3 4 5 6 7 8 9 3 IN 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 00.049") 3.40 to 3.90mm (.70mm (.00mm (.05 mm (.85 mm (.149") 1. Measure the distance from the pump gasket surface.037") 3.137" to .153" to .35 mm (.037") to 1.90 to 4. to the top of the intermediate/overdrive housing.15 mm (.045") 3. to the bottom of the snap ring groove in the case.25 mm (.054") 3.085 mm (.141" to .049") to 1.133" to .95 mm (. 120 130 5 IN 1 2 3 4 5 6 7 8 9 Pump Gasket Surface 140 150 mm/in 0 04. Measure the distance from the pump gasket surface.149" to .137") Figure 181 110 AUTOMATIC TRANSMISSION SERVICE GROUP .75 mm (.945 4 5 6 in 100 110 120 130 140 150 mm ELECTRONIC DIGITAL C ALIPER Intermediate/Overdrive Clutch Housing Figure 179 Figure 180 INTERMEDIATE AND OVERDRIVE CLUTCH HOUSING SNAP RING CHART DIMENSION "M" SNAP RING THICKNESS SHOULD BE: 0.033") to .50 to 3.041") 3.

After you have both dimensions recorded. Dimension "M1" = 4.Technical Service Information INTERNAL COMPONENTS (CONT'D) 10.141"-. Refer to the chart in Figure 181 to determine the thickness of the proper snap ring. 13. 3. 12. Note: This snap ring is "Very" strong and requires J-45126 snap ring pliers to avoid any possible injury.043".206". CLUTCH HOUSING SNAP RING (SELECTIVE) Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 182 Figure 183 AUTOMATIC TRANSMISSION SERVICE GROUP 111 . subtract "M1" from "M2". Dimension "M2" = 4.D.043" 5.145" thickness snap ring required. Subtract "M1" from "M2" = . Now you can install the proper size snap ring using the J-45126 snap ring pliers. 4. 11. Note: This will be Dimension "M". Continued on Page 112 Snap Ring Pliers J-45126 Are "Required" To Remove Or Replace This Snap Ring Snap Ring Pliers J-45126 are long handled for leverage and locking J-45126 14 Measure Snap Ring Thickness 14 INTERM/O. Dimension "M" = .249". as shown in Figure 183. to ensure that your snap ring is the proper thickness. Measure thickness of your snap ring exactly as shown in Figure 182. 2. EXAMPLE: 1. Dimension "M" from the chart in Figure 181 shows a .

18. 16. if not already done. Install direct clutch hub thrust washer (9) into direct clutch hub.D. by rotating back and forth until fully seated. CLUTCH HUB AND INTERMEDIATE SPRAG ASSEMBLY Copyright © 2002 ATSG 9 DIRECT CLUTCH HUB THRUST WASHER 10 DIRECT CLUTCH HUB AND SHAFT ASSEMBLY Copyright © 2002 ATSG Figure 184 Figure 185 112 AUTOMATIC TRANSMISSION SERVICE GROUP . as shown in Figure 185. as shown in Figure 185. Install overdrive clutch hub and intermediate sprag assembly. Install the pre-assembled forward sprag and sun gear shaft assembly into the transmission. 17. if not already done. by rotating back and forth until fully seated. by rotating back and forth until fully seated and both overdrive and 2nd clutches are engaged. Install thrust washer (11) onto the overdrive clutch hub and intermediate sprag assembly as shown in Figure 184. CLUTCH HUB THRUST WASHER 12 O. and retain with small amount of Trans-Jel®.Technical Service Information TRANSMISSION ASSEMBLY (CONT'D) INTERNAL COMPONENTS (CONT'D) 14. Continued on Page 113 11 9 10 12 11 DIRECT CLUTCH HUB TO O. Install the direct clutch hub assembly into the transmission. as shown in Figure 186. 15. and retain with small amount of Trans-Jel®. as shown in Figure 184.D.

Install the reverse clutch housing on forward and coast clutch housing by rotating back and forth to engage the reverse clutch plates. Continued on Page 114 6 8 7 8 FORWARD SPRAG ASSEMBLY AND INPUT SUN GEAR SHAFT 6 DIRECT AND REVERSE CLUTCH HOUSING ASSEMBLY 7 FORWARD AND COAST CLUTCH HOUSING ASSEMBLY Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 186 Figure 187 AUTOMATIC TRANSMISSION SERVICE GROUP 113 . until fully seated and splines engaged on forward clutch housing (See Figure 187).Technical Service Information INTERNAL COMPONENTS (CONT'D) 19.

Front end clearance should be: 0.. Remove "H" gage from case.02 mm (.Technical Service Information TRANSMISSION ASSEMBLY (CONT'D) INTERNAL COMPONENTS (CONT'D) 20. 23. as shown in Figure 189. Install the "H" gage on top surface of the case. Install the pre-assembled forward/coast clutch housing and reverse clutch housing as assembly as shown in Figure 188. 25. 22. 24.040"). by rotating back and forth to engage the three sets of clutches. loosen adjusting knob and allow gage rod to rest on washer surface of reverse clutch housing (See Figure 189). turn it over and install on surface of converter housing as it is shown in Figure 190.030" . Refer to chart in Figure 190 for the different thickness thrust washers that are available. Measure with feeler gage between the gage rod and the current "Selective" thrust washer being used. Continued on Page 115 Forward And Reverse Drums Installed As Assembly Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 188 Figure 189 114 AUTOMATIC TRANSMISSION SERVICE GROUP . Change the selective thrust washer as necessary to achieve the proper front end clearance. 21. as shown in Figure 190.1.76 .

105") (.135"-.20 mm 3.030" TO .149"-.79-3.142"-.120"-.106"-.140") (.04 mm 3.76 mm 3.71-2.113"-.040" 230 22 6 2.099"-.40 mm 3.89-3.43-3.127"-.53-2. Continued on Page 116 CHECKING FRONT END CLEARANCE CLEARANCE SHOULD BE . Ensure that the converter housing to case "O" ring seal is in place on the converter housing.119") (.Technical Service Information THRUST WASHERS AVAILABLE 2.125") (.61-3. If not.86 mm 2.133") (.1 832 HYDRAMATIC STRASBURG FRANCE 96 022 022 832 HYDRAMATIC STRASBURG FRANCE 96 *0139781RVO* GM 230 CONVERTER HOUSING TO MAIN CASE "O" RING SEAL Copyright © 2002 ATSG GM *0139781RVO* 22 6 2. install it now as shown in Figure 191 and retain with small amount of Trans-Jel®.25-3.112") (.148") (.68 mm 2.05-3.58 mm 3.1 Figure 190 Figure 191 AUTOMATIC TRANSMISSION SERVICE GROUP nat 6 6 Copyright © 2002 ATSG 1/8 6 6 1/8 nat 115 .155") INTERNAL COMPONENTS (CONT'D) 26.94 mm (.

2 3 46 4 CONVERTER HOUSING TORQUE SEQUENCE 2 7 4 5 6 2 BELL HOUSING RETAINING BOLTS (7 REQUIRED) 3 BELL HOUSING AND PUMP ASSEMBLY 4 BELL HOUSING TO CASE SEAL 3 1 Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 192 Figure 193 116 AUTOMATIC TRANSMISSION SERVICE GROUP . Install the turbine shaft "O" ring seal using a small screwdriver. 28. and lubricate with small amount of Trans-Jel®. using the molded guide pins. as shown in Figure 192. 29.Technical Service Information TRANSMISSION ASSEMBLY (CONT'D) INTERNAL COMPONENTS (CONT'D) 27.). as shown in Figure 195. 31. Refer to the bolt chart to identify proper bolts. 30. Install complete converter housing assembly onto case.lb. Retain with a small amount of Trans-Jel®. as shown in Figure 193. Install the molded pump to case gasket (46) onto the back side of pump cover. 32. as shown in Figure 192. 33. Install the seven converter housing to case bolts. if necessary. as shown in Figure 194. Torque the seven bolts to 22 Nm (16 ft. as shown in Figure 192. Use the torque sequence in a cris-cross pattern.

2 42 RT 0 1 1 PA 6 NO. CA AD 8 P0 VO 2 117 . as shown in Figure 196.Technical Service Information INTERNAL COMPONENTS (CONT'D) 34. Install the valve body to case seal assemblies. 35. as shown in Figure 196. 7 8 9 AL 9 C RI 3 ATI G SE 01 AM UR E DR BO C HY AS FRANM _ TC _ IN STRE GM L. TEC KPA K FIT Z-A LL Continued on Page 118 Copyright © 2002 ATSG Figure 195 Sn ap -O n 39 38 38 CENTER SUPPORT SEAL AND SLEEVE ASSEMBLY 39 OVERDRIVE CLUTCH SEAL AND SLEEVE ASSEMBLY Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 194 Figure 196 AUTOMATIC TRANSMISSION SERVICE GROUP M 3 5 87 28 3 NO. Rotate the transmission in fixture so that the bottom pan side is facing up.

8 mm spacer. and hand tighten only at this time.lb.).lb. as shown in Figure 198. Torque all ten valve body bolts. 6. 2. 7.Technical Service Information 45 TRANSMISSION ASSEMBLY (CONT'D) BOTTOM PAN COMPONENTS 1. 44 44 INPUT SHAFT SPEED SENSOR 45 INPUT SPEED SENSOR RETAINING BOLT Copyright © 2002 ATSG Figure 197 43 42 Continued on Page 120 41 41 OUTPUT SPEED SENSOR SPACER 42 OUTPUT SHAFT SPEED SENSOR 43 OUTPUT SPEED SENSOR RETAINING BOLT Copyright © 2002 ATSG Figure 198 118 AUTOMATIC TRANSMISSION SERVICE GROUP .8 mm spacer between inside detent lever and the detent spring. Install the proper bolts installed in the locations shown in Figure 199 and 201. as shown in Figure 197. Install the pre-assembled valve body assembly onto case. Remove the 0. 3. as shown in Figure 199. 8. Torque the input shaft speed sensor bolt down to 11 Nm (8 ft. 5. Install the output shaft speed sensor.lb. Note: Refer to the bolt chart to identify the proper bolt. 9. as shown in Figure 200. Install a 0. Note: Refer to the bolt chart to identify the proper valve body bolts. 4. in the exact sequence shown in Figure 201. down to 11 Nm (8 ft. Note: Refer to the bolt chart to identify the proper bolt.).). Torque the output shaft speed sensor bolt down to 11 Nm (8ft. Install the input shaft speed sensor.

5 6 7 119 .Technical Service Information 49 53 30 7 51 L-2 96 02 05 66 96 02 04 73 30 7 49 REAR VALVE BODY TO CASE M6 X 1. CAL 8 P0 VO Detent Lever Refer to "Bolt Chart" for identification. 3 A 96020566 8 30 96020473 L-2 B 30 7 L-1 C 2 8 78 9 10 9 Copyright © 2002 ATSG Figure 201 AUTOMATIC TRANSMISSION SERVICE GROUP 96022748 96022748 GM MA 5 32 87 3 . 28 42 T NO 1 02 PAR 1 9 6IAL NO.00 X 50 (4 TOTAL) 51 FRONT VALVE BODY TO CASE M6 X 1.8 mm Spacer Figure 200 Copyright © 2002 ATSG Figure 199 VALVE BODY TORQUING SEQUENCE 1 4 Refer to "Bolt Chart" for identification.00 X 50 (4 TOTAL) 53 DETENT SPRING TO CASE M6 X 1.00 X 68 (1) Detent Spring 0. IC 78 AT SER 39 AM RG DR OU CE 01 HY SBFRAN _ TCM RA _ ST DE IN .

install the retaining clip. Ensure that the bottom pan magnet is in proper position in the oil pan (See Figure 205). IC 78 AT G RIA SE 39 RAM UR CE 01 HYDASBO AN FR TCM _ _ R _ ST E IN MAD L. as shown in Figure 205. Ensure that internal wiring harness is not rubbing on any part of the oil pan. Install the bottom transmission pan onto the transmission. Install a new bottom pan gasket onto the transmission case.). Note: Notice that spacer is used only on "Some" models.Technical Service Information TRANSMISSION ASSEMBLY (CONT'D) BOTTOM PAN COMPONENTS (CONT'D) 10. 15. 3 28 42 RT NO 02 1 PA 1 9 6 L NO. Install the case connector through the case bore and while holding the connector. Install the bottom pan filter. Install two new "O" ring seals onto the case connector. as shown in Figure 202. 19.lb. Install the TFT Sensor into the TFT Sensor bracket (See Figure 202). as shown in Figure 205. 16. as shown in Figure 205. CA 30 7 Figure 202 120 AUTOMATIC TRANSMISSION SERVICE GROUP 960 205 66 Internal Wiring Harness Colors May Vary GM 8 P0 VO Internal Mode Switch Copyright © 2002 ATSG . Install the 20 bottom oil pan bolts. and lube with a small amount of Trans-Jel®. Route the internal harness and connect all the components that are listed in Figure 202. as you put it on the case. Continued on Page 122 2 Connector "O" Ring Seals TFT Sensor (Part Of Harness) Internal Wiring Harness Assembly Input Shaft Speed Sensor (Yellow And White) Pressure Control Solenoid (Green And White) TCC/PWM Solenoid (White And Yellow) TFT Sensor Retaining Bracket 1-2 Shift Solenoid (A) (White And Black) Output Shaft Speed Sensor (Orange And White) 960 204 73 2-3 Shift Solenoid (B) (White And Blue) 4-5 Shift Solenoid (C) (White And Gray) 5 32 87 . 17. as shown in Figure 204. 11. as shown in Figure 203. 13. 12. 14. and torque to 11 Nm (8 ft. 18. filter seals and the filter spacer.

28 42 T NO 02 1 PAR 1 9 6IAL NO. IC 78 IAL AT SER 39 AM RG DR OU CE 01 HY SB AN RA IN FR TCM _ CAL 8 P0 _ VO 96 02 05 66 GM 5 32 87 3 .Technical Service Information 55 54 54 TRANSMISSION CASE CONNECTOR RETAINER 55 TRANSMISSION CASE CONNECTOR Copyright © 2002 ATSG 65 62 Figure 203 59 Y N AN A TR RM FIL E S G IB IN E AD M 58 61 60 57 Y N AN RA LT RM FI E S G IB IN E AD M 96 02 04 73 96 02 30 7 04 73 57 BOTTOM PAN OIL FILTER SEALS 58 BOTTOM PAN OIL FILTER SPACER (SOME MODELS) 59 BOTTOM PAN OIL FILTER ASSEMBLY 60 61 62 65 BOTTOM OIL PAN GASKET BOTTOM OIL PAN MAGNET BOTTOM OIL PAN BOTTOM OIL PAN BOLTS (20 REQUIRED) Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 204 Figure 205 30 7 AUTOMATIC TRANSMISSION SERVICE GROUP 96 02 05 66 GM ST DE MA . 5 32 87 3 . 28 42 T NO 1 02 PAR 1 9 6 NO. IC 78 AT SER 39 AM RG DR OU CE 01 HY SBFRAN _ TCM RA _ ST DE IN MA . CAL 8 P0 VO 121 .

07 mm (.703" to .95 to 2. OUTPUT SHAFT BEARING THRUST WASHER (SELECTIVE) OUTPUT SHAFT TO EXTENSION HO USING THRUST BEARING EXTENSION HOUSING ASSEMBLY EXTENSION HOUSING YOKE METAL CLAD SEAL ASSEMBLY Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 206 Figure 207 OUTPUT SHAFT END PLAY CHART IF DIMENSION "B" IS: THRUST WASHER THICKNESS SHOULD BE: 15.108" to .67 to 16.87 to 17.67 to 17.688") 17.35 to 1.65 mm (.27 to 16.057") 1. Install extension housing yoke seal into the extension housing.076" to .065") 1.045" to .25 mm (.648" to . 27 0 1 2 3 4 5 6 7 8 9 10 20 30 1 IN 1 2 3 4 5 6 7 8 9 28 mm/in 0 40 50 60 70 80 AUTO POWER-O FF 01.704") 17.680") 17.629" to .096") 2.672") 17.068" to .093" to .696" to .664" to .696") 17.112") 122 AUTOMATIC TRANSMISSION SERVICE GROUP .15 to 2.87 mm (.089") 2.27 to 17.061" to .104") 2.47 to 16.640") 16.47 mm (.688" to . as shown in Figure 206.041") 1.27 mm (.55 to 2.45 mm (.711") Figure 208 0. as shown in Figure 207.27 mm (.037" to . Rotate transmission in fixture so that output shaft is facing up.47 to 17.084" to .05 mm (.65 mm (. using the proper seal driver.55 to 1.15 to 1.640" to .664") 16.656" to .67 mm (.656") 16.45 mm (.073") 1.049") 1.95 to 1.07 to 17.47 mm (.081") 2.85 mm (.053" to .35 to 2.75 to 2.672" to .170 2 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 3 26 90 100 110 120 130 4 1 2 3 4 5 6 7 8 9 5 1 2 3 4 5 6 7 8 9 29 140 150 mm 6 in ELECTRONIC DIGITAL C ALIPER 31 26 27 28 29 31 EXTENSION HOUSING FR ONT CAGED NEEDLE BEARING ASM.67 mm (.100" to .99 to 16.87 to 18.Technical Service Information EXTERNAL COMPONENTS TRANSMISSION ASSEMBLY (CONT'D) 2.680" to .85 mm (.25 mm (.648") 16. 1.07 mm (.05 mm (.87 mm (.75 to 1.

Note: Record this as Dimension "B2". 7. Install the output shaft to extension housing thrust bearing (28). 9. as shown in Figure 207. Install the pre-assembled extension housing onto the case. Note: Refer to bolt chart for identification of extension housing bolts. 96 G 02 M 30 1 7 29 25 27 Continued on Page 124 25 EXTENSION HOUSING TO MAIN CASE GASKET 27 OUTPUT SHAFT BEARING THRUST WASHER (SELECTIVE) 29 EXTENSION HOUSING ASSEMBLY Copyright © 2002 ATSG Figure 209 AUTOMATIC TRANSMISSION SERVICE GROUP 123 . 15. as shown in Figure 209. 5. Measure the thickness of the gaging bar as they vary in thickness (See Figure 207). 13. Refer to the output shaft end-play chart shown in Figure 208 to determine proper "Selective" output shaft bearing thrust washer. by hand pressing into the bore. Note: Record this as Dimension "B1". as shown in Figure 209. as shown in Figure 209.). Place gaging bar across case extension housing gasket surface. Install the seven extension housing bolts. as shown in Figure 209. Replace the caged needle bearings in extension housing as necessary using the proper pullers and drivers. Install output shaft bearing thrust washer onto the output shaft. 11. Subtract Dimension "B2" from "B1". 12. as shown in Figure 207. 8. as shown in Figure 206.Technical Service Information EXTERNAL COMPONENTS TRANSMISSION ASSEMBLY (CONT'D) 36 3. Measure from the gaging bar to the face of the output shaft. 14. Install a new extension housing gasket on the case surface. 10.lb. The output shaft bearing thrust washer (27) is "Selective" and measurements are required to determine proper thickness to set rear end-play. 4. Note: Record this as Dimension "B". 6. Torque the seven extension housing bolts down to 22 Nm (16 ft.

5 X 10 7 Copyright © 2002 ATSG Copyright © 2002 ATSG Figure 211 Figure 212 124 AUTOMATIC TRANSMISSION SERVICE GROUP . 19.) (See Figure 211). 22. 35.lb. Torque the drive shaft yoke flange nut down to 57 Nm (42 ft.Technical Service Information TRANSMISSION ASSEMBLY "O" Ring Groove EXTERNAL COMPONENTS (CONT'D) 16. as shown in Figure 211. Lubricate turbine shaft "O" ring with a small amount of Trans-Jel®. if you have not already done so. 33. Install a new turbine shaft "O" ring. Install the yoke washer and screw the nut onto output shaft. as shown in Figure 210. 20. as shown in Figure 212. Copyright © 2002 ATSG Figure 210 35 34 33 32 TEC KPA K FIT Z-A LL 32. 18. and lubricate with a small amount of Trans-Jel®. Install the transmission yoke onto the output shaft. 23. 34. DRIVESHAFT YOKE DRIVESHAFT YOKE "O" RING SEAL DRIVESHAFT YOKE WASHER DRIVESHAFT YOKE RETAINING NUT 96 G 02 M 30 1 M22 X 1. Place the transmission in the Park position to engage the parking pawl. as shown in Figure 211. 17. Install a new "O" ring into the inside groove of the transmission yoke assembly. Rotate the transmission in fixture so that the bottom pan is facing down (See Figure 212). 21.

Remove the transmission assembly from the work bench with a lifting device. Refer to Figure 214. Ensure that it is fully seated and engaged with the oil pump gear. as shown in Figure 213. 1 3 CONGRATULATIONS. Install the torque converter carefully into the transmission. 26.Technical Service Information EXTERNAL COMPONENTS (CONT'D) 24. Remove the fixture from transmission. 25. YOU ARE FINISHED! 1 TORQUE CONVERTER ASSEMBLY 3 TRANSMISSION ASSEMBLY Copyright © 2002 ATSG Figure 213 HOLDING FIXTURE J-8763-02 GM ATIC AM G HYDR BOUR 96 AS STR ANCE FR 022 832 RVO* 9781 *013 Copyright © 2002 ATSG Figure 214 AUTOMATIC TRANSMISSION SERVICE GROUP 2/99 18/14 18:5 71 0199 VO GM P08 1423 875 960 228 32 81 997 013 125 .

Technical Service Information BOLT CHART (A) 10 mm Hex Head (B) E8 Reverse Torx Head (C) 30 Torx Head (D) 30 Torx Head (E) 30 Torx Head (F) 10 mm Hex Head (G) 10 mm Hex Head (H) 20 Torx Head 20 mm Length 30 mm Length 38 mm Length 50 mm Length 30 mm Length 10 mm Length 10 mm Length All Bolts Drawn Actual Size 68 mm Length (J) 40 Torx Head (K) 15 mm Hex Head (L) 15 mm Hex Head (M) 30 Torx Head (N) 40 Torx Head 25 mm Length 35 mm Length 35 mm Length 40 mm Length 40 mm Length Copyright © 2002 ATSG Figure 215 126 AUTOMATIC TRANSMISSION SERVICE GROUP .

lb.00 X 50 Valve Body Detent Spring To Main Case 53 1 M6 X 1.7 X 10 M6 X 1.00 X 68 Line Pressure Test Plug To Case 40 1 M10 X 1.00 X 50 Front Valve Body To Main Case 51 4 M6 X 1. 42 ft. 16 ft.25 X 35 M4 X 0.lb.lb.00 X 68 Valve Body Detent Spring To Channel Plate 53 1 M6 X 1.lb.lb. 16 ft.lb. 8 ft.lb.Technical Service Information TORQUE SPECIFICATIONS DESCRIPTION (K) Converter Housing To Main Case (H) Converter Seal To Converter Housing (M) Pump Cover To Converter Housing (N) Pump Cover To Converter Housing Drain Plug To Bottom Pan (G) Bottom Pan To Case (L) Extension Housing To Main Case (J) Parking Pawl Actuator Bracket Drive Shaft Yoke To Output Shaft Nut (F) Input Speed Sensor To Main Case (E) Output Speed Sensor To Main Case (D) (C) (C) (B) (B) (A) (A) REF NO.00 X 20 M6 X 1.5 X 10 M6 X 1. 8 ft. 31 in.lb.lb. 8 ft.lb.25 X 40 M14 X 1. Accumulator Housings To Valve Body 318 12 M6 X 1.00 X 38 Rear Valve Body To Main Case 49 4 M6 X 1.25 X 25 M22 X 1. 15 ft. 8 ft.00 X 30 Channel Plate To Valve Body 300 7 M6 X 1. 8 ft.lb.00 X 8 Fluid Level Fill/Check Plug To Case 36 1 M18 X 1.00 X 38 Valve Body To Top Channel Plate 50 2 M6 X 1.5 X 12 Reference Number refers to the callout number on the exploded views. 8 ft. 8 ft. 8 ft.lb. 15 ft.00 X 16 M8 X 1. 16 ft. Copyright © 2002 ATSG Figure 216 AUTOMATIC TRANSMISSION SERVICE GROUP 127 . 8 ft.lb.lb.lb. 8 ft.lb.lb.lb.lb.25 X 35 M8 X 1.5 X 10 M6 X 1.lb. 8 ft.00 X 40 M8 X 1.6 N·m 11 N·m 22 N·m 20 N·m 11 N·m 22 N·m 22 N·m 57 N·m 11 N·m 11 N·m 11 N·m 11 N·m 11 N·m 11 N·m 11 N·m 11 N·m 11 N·m 11 N·m 20 N·m ENGLISH 16 ft. 8 ft. QTY 2 7 228 2 240 6 241 5 63 1 65 20 35 7 609 2 34 1 45 43 1 1 SIZE M8 X 1.00 X 30 METRIC 22 N·m 3.

FLORIDA 33143 Phone (305) 666-3544 Phone (305) 666-4208 Fax (305) 666-8238 Copyright © 2002 ATSG 128 AUTOMATIC TRANSMISSION SERVICE GROUP .Technical Service Information We wish to thank the following for supplying the actual transmission that have made these illustrations possible. INDEPENDENT TRANSMISSION SERVICE AND MARIO ARISTIDES 5846 SW 68TH STREET SOUTH MIAMI.