Chapter 19

OBJECTIVES
After studying Chapter 19, the reader should be able to:

1. Diagnose torque converter and torque converter
clutch problems.
2. Explain the conditions when a torque converter
should be reused or rebuilt.
3. Describe the procedure used to rebuild a torque
converter.
4. Complete the ASE tasks related to torque
converter inspection.
Automatic Transmissions and Transaxles, Fourth Edition © 2010 Pearson Higher Education, Inc.
By Tom Birch and Chuck Rockwood Pearson Prentice Hall - Upper Saddle River, NJ 07458
INTRODUCTION
• A torque converter is considered to be part of the

transmission.
• It should be serviced or replaced when a transmission is
overhauled.
• A torque converter is always replaced with a new or rebuilt
unit if it has an internal failure.
– Most shops do not rebuild torque converters.
– There are companies that specialize in torque converter overhaul.
• A torque converter does not usually wear out and require
replacement.
• Many shops flush and check the torque converter during
every transmission overhaul.
INTRODUCTION
FIGURE 19-1 This cutaway view shows

where debris and foreign material will tend to
collect inside of the outer rim of a torque
converter. (Courtesy of Chrysler Corporation)
TORQUE CONVERTER CHECKS
• The torque converter should be checked to make

sure it is in usable condition when the transmission
is removed.
• These checks include the visual condition, stator
one-way clutch operation, turbine end play,
internal interference, lock-up clutch operation,
and external leakage.
• Visual Checks
– The first checks performed
are visual.
– A technician often performs a
visual inspection as the
torque converter is removed
from the transmission.
FIGURE 19-2 Converter inspection begins with visual

checks to ensure that the pilot, drive lugs, ring gear (if
used), hub, and pump drive tangs are in good condition.
FIGURE 19-3 A bad starter ring gear can be changed by cutting the
welds using a hack saw or grinder and driving the old gear off. The
new gear must be secured by welding following the procedure
recommended by the manufacturer.(Courtesy of Chrysler
Corporation)
• Stator One-Way Clutch

Check
– There are several ways to
check a stator one-way
clutch.
– The stator clutch must lock in
one direction and slip or
freewheel in the other.
– To check a one-way clutch,
you should:
FIGURE 19-4 A stator clutch can be checked by

reaching into the hub so your finger contacts the
splines. You should be able to rotate the splines in one
direction but not the other.
TECH TIP
• Grip the stator splines

using long, thin, flat-jaw
snap-ring pliers in order to
rotate the stator.
FIGURE 19-5 A stator clutch can be checked by

gripping the splines using snap-ring pliers. Rotate the
splines quickly; in only one direction, you should feel
the weight of the stator.
• End-Play Check
– Thrust washers at the stator
and turbine control internal
end play.
FIGURE 19-6 The major wear points inside a torque

converter are these thrust surfaces. Internal end play
increases as these surfaces wear.
FIGURE 19-7 The special tool is locked into

the turbine. Moving the tool handle up and
down allows the end play to be read on the dial
indicator.
FIGURE 19-8 The torque converter is placed onto the end-

play fixture. After setting the dial indicator to zero (0), the
handle is moved downward to lift the turbine and read the
end play. (Courtesy of TCRS Inc.)
TECH TIP
• Turbine or stator clutch end

play can be checked by
gripping the splines with a
pair of snap-ring pliers or
your fingers.
FIGURE 19-9 A quick end-play check can be made by

gripping the turbine or stator splines and trying to move
the turbine or stator in and out.
• Internal Interference Checks

– The thrust washers inside a torque converter can wear to
the point where the impeller, turbine, or stator can rub
against each other.
– The normal wear pattern caused by the dynamic fluid
pressure moves the turbine toward the front of the torque
converter and the stator toward the rear.
– Torque converter interference should be checked twice:
Once with the turbine and stator toward the front and
again with them toward the rear.
– To check a converter for internal interference, you should:
FIGURE 19-10 An internal interference check. The pump body with

stator support (a) and clutch with turbine shaft (b) have been installed
and are rotated to feel and listen for internal contact. The assembly is
then turned upside down and the checks are repeated. Internal contact
in either position indicates a faulty converter.
• Torque Converter Clutch Checks

– Two styles of testers are available for checking torque
converter clutches.
– One type uses adapters that replace the turbine shaft and
allow a vacuum to be exerted on the front side of the
clutch plate assembly.
– If this chamber can hold a vacuum, the center seal and
the clutch lining (which forms the outer seal) are good.
– The second tester style uses adapters that attach to the
turbine, which uses air pressure to apply the clutch
FIGURE 19-11 A torque converter lock-up

dyno. It tests the TCC to make sure that it
will lock up properly. (Courtesy of TCRS
Inc.)
• Leak Checks
– A torque converter can leak at
the welds, fittings, or plugs.
– Leaking fluid will show up at
the bottom of the torque
converter housing and can be
mistaken for a front seal leak.
– The difference is the location
of wetness on the torque
converter.
FIGURE 19-12 This torque converter leak-test fixture

has adapters to fit hubs of different diameters (a). A
different tester is shown with a converter installed (b).
(a courtesy of Kent-Moore)
• To check a torque converter

for leaks, you should:
FIGURE 19-13 A leak test fixture has been placed on

the torque converter. It will be inflated with air pressure,
and then soapy water will be sprayed on it to identify
any leaks.
TECH TIP
• Very small pinhole leaks

can be sealed by peening
the hole closed.
• This is done using a punch
and hammer and striking
the area immediately
around the hole.
FIGURE 19-14 Pinhole leaks in a converter can be

sealed using a punch and hammer. A series of punch
marks around the hole should displace metal to close
off the hole.
TORQUE CONVERTER CLEANING
• Torque converters are very difficult to clean because of their

internal shape.
• Most shops use rebuilt torque converters to ensure a
completely clean unit without any concerns of internal wear
or damage.
• A torque converter cleaner is an effective but expensive
piece of equipment.
– It pumps cleaning solvent under pressure through the torque
converter in a reverse direction, and at the same time, the device
rotates the turbine in order to create a fluid flow that loosens the
debris so it can be flushed out.
• The cleaning operation usually runs until the solvent leaving
the torque converter runs clear, about 5 to 15 minutes.
• Drilling a Torque Converter

– It is possible to drill a torque converter to provide a drain
opening.
– This requires installing a plug to seal the opening.
– Drilling a torque converter is not generally recommended.
• Cooler Cleaning
– Cooler cleaners are designed to clean the radiator oil
cooler by forcing cleaning solution or fluid through the
cooler lines.
– This can also be done with a simple fluid pump
TECH TIP
• When drilling a torque

converter, it is important not
to drill into any of the
internal components.
• Drill only deep enough to
penetrate the cover and
preferably, into the impeller
area
FIGURE 19-15 A hole can be drilled into the torque

converter so that it can be drained. This hole should be
tapped to accept a small pipe plug.
FIGURE 19-16 This cooler line flusher pumps FIGURE 19-17 A cooler flusher is connected to the
heated flushing solution through the cooler lines cooler lines so a cleaning agent can be forced in
and cooler. A flow meter is used to ensure that the the reverse direction through the cooler unit until it
cooler is flowing properly and not plugged. is clean.
(Courtesy of G-Tec)
TECH TIP
• Flush kits consisting of an

aerosol can of flushing
solution with adapters to
connect to the cooler are
available.
FIGURE 19-18 A cooler can be back-flushed using an

aerosol flushing kit. (Courtesy of Life Automotive
Products Inc.)
TORQUE CONVERTER REBUILDING
• A torque converter is rebuilt by cutting it open,

cleaning and inspecting the parts, replacing any
worn or damaged parts, and welding it back
together.
• Expensive specialized equipment is required to
rebuild a torque converter.
• The equipment operator should have some
machining and metalworking skills.
• These requirements limit torque converter
rebuilding to companies that specialize in torque
converter rebuilding or the larger transmission
shops.
• Rebuilding a torque converter consists of the following

operations:
– Inspect the exterior for damage.
– Cut the torque converter open on a specially equipped lathe.
– Inspect the interior components for wear or damage.
– Thoroughly clean the interior parts.
– Disassemble and inspect the stator one-way clutch.
– Replace all worn or damaged parts.
– Prelubricate the internal bearing surfaces.
– Adjust the internal end play.
– Carefully reassemble and weld the two sections together.
– Leak check all welds.
– Balance the assembly.
• Disassembling a Torque
Converter
– Since a torque converter is
welded together, the weld
must be cut to open the
torque converter.
– The torque converter is
mounted in a metal-cutting
lathe for the cutting operation.
FIGURE 19-19 This worn converter hub has been

removed to allow replacement (a). A new hub has been
installed and welded in place using a special welder (b).
FIGURE 19-20 To rebuild a converter, first cut it open on a machine lathe (a). A carbide tool is used to cut
the weld so the converter can be split apart (b).
• Cleaning
– A hot spray washer is used to
clean the disassembled
torque converter parts.
FIGURE 19-21 After being cut open, the usable

components are placed in a spray washer for thorough
cleaning.
• Subassembly Repair
– With the torque converter disassembled, the following items are
checked and repaired as necessary:
• Torque converter hub: removed and replaced
• Starter ring gear: removed and replaced
• Crankshaft pilot: welded to build up material and machined back to original size
• Drive lugs/studs: removed and replaced
• Turbine drive hub: removed and replaced
• Thrust washers: removed, lubricated, and replaced or upgraded to Torrington
bearings
• Support bushings: removed and replaced
• Impeller fins: spot welded to lock in place
• Stator clutch: disassembled, inspected, lubricated, and reassembled
• Stator clutch outer race: pinned to lock into the stator
• Clutch lining: relined
• Damper springs or assemblies: removed and replaced
FIGURE 19-22 A new starter ring gear has been

installed and tack welded. After ensuring that it
is straight, it will be welded securely.
FIGURE 19-23 This torque converter piston

bonder is used to bond new lining onto a torque
converter clutch piston. (Courtesy of TCRS Inc.)
• Torque Converter Reassembly

– Torque converter reassembly requires several operations:
• Check the height of the stacked components to ensure that the
assembled unit is not too long or too short.
• Check and adjust the internal clearance to ensure there is correct end
play. Adjustment is done by changing or shimming the thrust washers.
• Make sure the bowl and impeller housings are correctly aligned so there
is a minimum of hub runout, and tack weld them securely into position.
• Weld the housing in an automatic wire welder to provide a continuous,
leak-free weld.
FIGURE 19-24 This fixture is used to ensure that the

converter will have the correct overall length after assembly.
Shims are added internally to correct end play if necessary.
FIGURE 19-25 This converter is assembled, and the two housings are tack welded together (a).
Checks made at this time ensure that the hub is centered and true with the front of the converter
(b).
FIGURE 19-26 The assembled converter is

welded together on an automatic welder.
• Post-assembly Checks
– After the torque converter has
been welded back together, it
is pressure checked for no
leaks
FIGURE 19-27 This converter is pressure tested for

leaks in this special fixture. Soap will be sprayed on it,
and bubbles will show any leaks.
FIGURE 19-28 This converter is balanced

using a special balancer. Small weights will
be spot welded onto it to correct any
unbalance.
SUMMARY
1. When a transmission is rebuilt, the torque

converter is serviced, rebuilt, or replaced.
2. If a torque converter is to be reused, it should be
visually inspected for leaks, the one-way clutch
operation checked, and internal end play should
be measured.
3. Torque converters are rebuilt by disassembling
them. They are then inspected, cleaned, parts
replaced as necessary, adjusted, and
reassembled.
REVIEW QUESTIONS
1. Torque converters should be checked for:
a. _________
b. _________
c. _________
d. _________
e. _________
f. _________
2. The six areas of a torque converter that are visually
checked are:
a. Housing for _________
b. Drive lugs or _________ for damage
c. Pilot for damage or _________
d. Hub for signs of seal or _________ wear
e. _________ drive tangs or lugs for wear or damage
f. Starter _________ gear for wear or damage
REVIEW QUESTIONS
3. If the stator one-way clutch can be easily turned in both
directions, it is said to be _________.
4. A customer concern about poor fuel economy or higher-
than normal engine speed could be the result of a
_________ stator clutch.
5. As a rule of thumb, the torque converter should have no
more than _________ end play.
6. A check for a leaking torque converter is to _________ it
and spray it with soapy water.
7. Transmission coolers are flushed out by forcing _________
through the cooler in a reverse direction.
8. Torque converters are welded together and must be
_________ to be rebuilt.
CHAPTER QUIZ
1. Student A says that a dirty torque converter can

ruin a transmission rebuild. Student B says that
most used torque converters are worn out. Who is
correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
1. Student A says that a dirty torque converter can

ruin a transmission rebuild. Student B says that
most used torque converters are worn out. Who is
correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
2. The visual checks to be made on a torque

converter include the condition of the
a) drive lugs or studs.
b) hub and pump drive tangs.
c) pilot.
d) All of these
CHAPTER QUIZ
2. The visual checks to be made on a torque

converter include the condition of the
a) drive lugs or studs.
b) hub and pump drive tangs.
c) pilot.
d) All of these
CHAPTER QUIZ
3. Student A says that it should not be possible to

turn the stator splines in either direction with one’s
finger. Student B says that normally these splines
can be turned both ways by gripping them with a
pair of snap-ring pliers. Who is correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
3. Student A says that it should not be possible to

turn the stator splines in either direction with one’s
finger. Student B says that normally these splines
can be turned both ways by gripping them with a
pair of snap-ring pliers. Who is correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
4. Student A says that a torque converter with a bad

stator oneway clutch should be replaced with a
new torque converter. Student B says a torque
converter can be rebuilt and the oneway clutch
repaired. Who is correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
4. Student A says that a torque converter with a bad

stator oneway clutch should be replaced with a
new torque converter. Student B says a torque
converter can be rebuilt and the oneway clutch
repaired. Who is correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
5. Student A says that excessive end play in a torque

converter is caused by a worn-out stator. Student
B says that torque converter end play can be
accurately checked with a pair of snapring pliers.
Who is correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
5. Student A says that excessive end play in a torque

converter is caused by a worn-out stator. Student
B says that torque converter end play can be
accurately checked with a pair of snapring pliers.
Who is correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
6. Student A says that a good rule of thumb for the

maximum allowable amount of torque converter
end play is 0.050 in. Student B says that any
torque converter with less than 0.040 in. of end
play should be replaced or rebuilt. Who is correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
6. Student A says that a good rule of thumb for the

maximum allowable amount of torque converter
end play is 0.050 in. Student B says that any
torque converter with less than 0.040 in. of end
play should be replaced or rebuilt. Who is correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
7. Student A says that a stator support and a turbine

shaft are needed in order to check a torque
converter for internal interference. Student B says
that this is a simple check in which one merely
rotates parts in the torque converter while listening
and feeling for internal rubbing. Who is correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
7. Student A says that a stator support and a turbine

shaft are needed in order to check a torque
converter for internal interference. Student B says
that this is a simple check in which one merely
rotates parts in the torque converter while listening
and feeling for internal rubbing. Who is correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
8. Student A says that if the torque converter clutch

lining breaks up, it probably plugs the cooler.
Student B says that a failed torque converter
clutch can cause too little internal end play. Who is
correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
8. Student A says that if the torque converter clutch

lining breaks up, it probably plugs the cooler.
Student B says that a failed torque converter
clutch can cause too little internal end play. Who is
correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
9. Student A says that during a leak check the torque

converter is filled with oil to a pressure of about 80
psi. Student B says that a very small leak at a
torque converter weld can be stopped using a
hammer and punch. Who is correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
9. Student A says that during a leak check the torque

converter is filled with oil to a pressure of about 80
psi. Student B says that a very small leak at a
torque converter weld can be stopped using a
hammer and punch. Who is correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ

converter should be
a) balanced.
b) painted.
c) cleaned.
d) All of these
CHAPTER QUIZ

converter should be
a) balanced.
b) painted.
c) cleaned.
d) All of these
CHAPTER QUIZ
11. Student A says that a torque converter can be

drained adequately by merely turning it so the hub
is downward over a container. Student B says that
one can clean a torque converter quite well by
running a solvent hose into it and turning on the
parts washer. Who is correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
11. Student A says that a torque converter can be

drained adequately by merely turning it so the hub
is downward over a container. Student B says that
one can clean a torque converter quite well by
running a solvent hose into it and turning on the
parts washer. Who is correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
12. Student A says that after a torque converter is

flushed with solvent, it should be filled with ATF
and then as much of the ATF/solvent mix as
possible should be drained. Student B says that it
is possible to completely drain the torque converter
by drilling a hole in it. Who is correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
12. Student A says that after a torque converter is

flushed with solvent, it should be filled with ATF
and then as much of the ATF/solvent mix as
possible should be drained. Student B says that it
is possible to completely drain the torque converter
by drilling a hole in it. Who is correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
13. During a rebuild, a torque converter

a) is taken apart and cleaned.
b) has the stator clutch disassembled and checked.
c) is adjusted to the correct internal end play.
d) All of these
CHAPTER QUIZ
13. During a rebuild, a torque converter

a) is taken apart and cleaned.
b) has the stator clutch disassembled and checked.
c) is adjusted to the correct internal end play.
d) All of these
CHAPTER QUIZ
14. Student A says that special equipment is required

to rebuild a torque converter. Student B says that
the only sure way to get all of the dirt and debris
out of a torque converter is to rebuild it. Who is
correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B
CHAPTER QUIZ
14. Student A says that special equipment is required

to rebuild a torque converter. Student B says that
the only sure way to get all of the dirt and debris
out of a torque converter is to rebuild it. Who is
correct?
a) Student A
b) Student B
c) Both A and B
d) Neither A nor B

Chapter 19

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OBJECTIVES

After studying Chapter 19, the reader should be able to:

• A torque converter is considered to be part of the

FIGURE 19-1 This cutaway view shows

• The torque converter should be checked to make

FIGURE 19-2 Converter inspection begins with visual

• Stator One-Way Clutch

FIGURE 19-4 A stator clutch can be checked by

• Grip the stator splines

FIGURE 19-5 A stator clutch can be checked by

FIGURE 19-6 The major wear points inside a torque

FIGURE 19-7 The special tool is locked into

FIGURE 19-8 The torque converter is placed onto the end-

• Turbine or stator clutch end

FIGURE 19-9 A quick end-play check can be made by

• Internal Interference Checks

FIGURE 19-10 An internal interference check. The pump body with

• Torque Converter Clutch Checks

FIGURE 19-11 A torque converter lock-up

FIGURE 19-12 This torque converter leak-test fixture

• To check a torque converter

FIGURE 19-13 A leak test fixture has been placed on

• Very small pinhole leaks

FIGURE 19-14 Pinhole leaks in a converter can be

• Torque converters are very difficult to clean because of their

• Drilling a Torque Converter

• When drilling a torque

FIGURE 19-15 A hole can be drilled into the torque

• Flush kits consisting of an

FIGURE 19-18 A cooler can be back-flushed using an

• A torque converter is rebuilt by cutting it open,

• Rebuilding a torque converter consists of the following

FIGURE 19-19 This worn converter hub has been

FIGURE 19-21 After being cut open, the usable

FIGURE 19-22 A new starter ring gear has been

FIGURE 19-23 This torque converter piston

• Torque Converter Reassembly

FIGURE 19-24 This fixture is used to ensure that the

FIGURE 19-26 The assembled converter is

FIGURE 19-27 This converter is pressure tested for

FIGURE 19-28 This converter is balanced

1. When a transmission is rebuilt, the torque

1. Student A says that a dirty torque converter can

1. Student A says that a dirty torque converter can

2. The visual checks to be made on a torque

2. The visual checks to be made on a torque

3. Student A says that it should not be possible to

3. Student A says that it should not be possible to

4. Student A says that a torque converter with a bad

4. Student A says that a torque converter with a bad

5. Student A says that excessive end play in a torque

5. Student A says that excessive end play in a torque

6. Student A says that a good rule of thumb for the

6. Student A says that a good rule of thumb for the

7. Student A says that a stator support and a turbine

7. Student A says that a stator support and a turbine

8. Student A says that if the torque converter clutch

8. Student A says that if the torque converter clutch

9. Student A says that during a leak check the torque

9. Student A says that during a leak check the torque

10. When a transmission is rebuilt, the torque

10. When a transmission is rebuilt, the torque

11. Student A says that a torque converter can be