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SPRING 2006 VOL. 7 ISSUE 1

News and Tips for the Rebuilder from Transtar Industries, Inc.

TranstarBuilding Success for the Rebuilder

While conditions in the transmission rebuilding industry change with the addition of more and newertransmissions, fewer repair orders overall, and the advent of OE exchange remanufactured units, there is onething that will never changeTranstar Industries commitment to supporting the rebuilder.

Building our business by helping you build yours is more than just words, its a promise by every member ofour organization to provide you with the products, service and knowledge that will help you stay on top.

In this time of change, independent and franchise transmission shops must do what they do bestrebuild

transmissions with the skill that only experienced, educated professionals possess. How can Transtar help?

We offer the broadest product line in the business. Transtar stocks over 15,000 OE qualitytransmission products every day so you can be assured that when you call us, weve got what you need

We offer the highest quality products from the best manufacturers. Transtar partners with the mostrespected manufacturers in the industry to provide OE quality transmission parts that meet the highestquality standardsyours. We offer the best names in the business so youll be proud to put your nameon every rebuild that leaves your shop.

We know the value of continuing education. Transtar is involved with and supports ATSG and ATRAthrough sponsorship of seminars and knowledge sharing with ATSG and ATRA experts so your

rebuilders have access to the latest information and education affecting our industry. Theres nosubstitute for up-to-date information.

We are expanding to serve you better. Transtar is adding delivery routes and locations so we can getto you faster. We know that you expect to receive your parts in a timely manner, and were constantlyworking to improve delivery times and local accessibility to our full product line.

We know the value of service. Transtar is proud to have the most dedicated sales force in thetransmission industry. Our sales reps are knowledgeable, dependable, and committed to making iteasy for you to get the products you need. We want to be your first callevery timeand ourrepresentatives will bend over backward to prove it. Please call your Transtar rep today and give us thopportunity to continue to prove how much we value your business.

As the premier provider of transmission products for over 30 years, Transtar Industries is the one company youcan count on to help you conquer market challenges, stay on the cutting edge of product and technologydevelopments, and succeed for years to come.

Together, we can make 2006 another great year for our industry.

Michael A. SotakPresident and COO

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Authorized Distributor

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TRANSTAR LAUNCHES CUSTOMER-CENTERED WEB SITE

Transtar Industries, Inc. announced the launch of its re-designed web site on Februa9, 2006, www.transtarindustries.com. The key objective in re-designing the companweb site is to make it easier than ever for customers to find and use the information thneed to run their businesses successfully. Our new site, makes it simple for custometo find information on products, promotions, technical and product informatioseminars, and catalogs, gives users immediate access to the information tha

important to them.

There are several new features to the site that make doing business with TranstIndustries especially easy for customers:

Electronic Catalog. Transtars popular electronic catalog (e-cat) is now available for download directly fromthe web site. Customers no longer have to request the e-cat on disk from Transtar, they can simply go out tothe web site and download it onto their hard drives.

UPS shipment tracking. Customers can track their orders by clicking on the UPS Track Shipments icon atthe bottom of the home page.

Promotions section. This new section features all current promotions, making it easy for customers to findthe latest specials and new product introductions.

Online credit application. New customers can now access Transtar Industries credit application online. Theapplication can be downloaded from the web site, completed, then faxed or e-mailed back to Transtar for approval

International section. For the first time, international customers will find content that addresses their specineeds, like shipping methods and transit times to major cities around the globe, payment options, andinternational division contacts.

Technical section. The new Technical section of the web site features TransTalk product bulletins and produapplication updates that cover product news and transmission information created by Transtars product experVisitors to the site can download any of the product bulletins or updates archived in this section.

Locationspage. All Transtar branch locations are listed here, along with a map of locations, contactinformation for each branch, maps to each location, and a location finder.

Subscribe function. Visitors to the Transtar web site can now elect to subscribe to receive newsletters,promotional flyers, and technical and product updates via e-mail or regular mail.

Manufacturers page. The new Manufacturers page on the web site features an interactive transmissionwhose sections light up when a user mouses over the list of manufacturers featured to indicate what part(s) oa transmission they manufacture. There is also a link to each manufacturers web site from this page.

The new site will be updated frequently to keep the content fresh and our customers coming back. Check back regulato see the latest information.

Use your American Express Card at Transtar Industrieand earn double Membership Rewards Points

It Pays to Order from Transtar!Use Your American Express Card at Transtar fromMarch 1 April 30, 2006 and Double Your Rewards!

Transtar Industries, Inc. is the one-stop transmission parts supplier forall your transmission needs. For over 30 years, Transtar has been theautomotive transmission repair industrys most trusted source for OEquality parts, outstanding service, product support, and on-time deliveWith locations throughout the U.S., Puerto Rico and Canada, one-stoptransmission parts shopping starts here!

Earn DOUBLE Membership Rewards Points on all your Transtar purchases from March 1 April 30, 2006 whenyou use your eligible, enrolled American Express Card. Only available to U.S. Membership Rewards enrollees

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4

Got Gears?(Here come the 6-speeds)

It seems like only yesterday that 5-speed automatics werethe talk of the town. Although Nissan released theRE5R01A in 1991, it really never made it to the stateswhereas ZF, the cutting edge guys from Germany, didmake it here in 1991 with the 5HP30.

The bulk of the 5-speeds however, did not show up until thelate 1990s including the Ford 5R55E, the Toyota (Lexus)A650E and the GM Straussburg 5L40E to name a few.

A 5-speed could have merely begun as a 4-speed but withupdated computer strategy or it could have been a brandnew box.

(But that was then and this is now.)

Based on the premise that more is better the automotivetransmission engineering community has determined that6-speeds are just peachy and have released several. Thefocus of this article will be on the ZF6HP26, Fords 6R60and the GM 6L80(E).

Although the basic design of these models stem from ZF,which launched their version first, Ford and GM did changecertain components to fit their criteria. From a complexitystandpoint these transmissions are not overwhelming andanyone that has rebuilt an AODE will certainly recognizethe planetary arrangement and power flow.

Engineers were able to achieve 6-speeds with using onlyfive clutch packs, no bands and with the exception of GM,no one-way clutches. The clutch-to-clutch shifting isprovided by seven or eight solenoids depending onmanufacturer and there is, of course, a lock-up converter.Most of the components are normal automatictransmission design stuff, however, the electrical controlscontinue to evolve and the units do have adaptive learncomputer strategy which provides the ability to changeparameters according to driving habits.

Externally, the 6-speed models will vary in appearance

based on manufacturer, model, engine size, and whetherits a 2-wheel drive or a 4-wheel drive vehicle. The electricalhookups are somewhat similar including the multiwirecase connector. Torque converters will vary as well.

Terminology differs between ZF, Ford and GM, which willtend to complicate matters when ordering parts orobtaining and applying diagnostic information. A simpleitem such as the primary input clutch is called the Aclutch by ZF, the forward clutch by Ford and the 1-2-3-4clutch by GM.

The following is an overview of the internal components:

Pump The 6HP26 and 6R60 pumps are basically tsame. They are gear type pumps using a regular body acover. Instead of a converter bushing there is a cagbearing to ride on the converter hub.

The 6L80E is typically GM meaning that it is a variabdisplacement rotor/vane type pump. The rotor/slicomponents fit into a pocket in the bell housing aspecific valves fit in the pump cover.GM uses a converter bushing. Themost unique feature of the pump isthat the sealing ring side of thepump cover is splined at the end.Fig. 1The splines serve to anchorthe front planetary sun gear toprovide reduction. The front planetis what sets the 6-speed apart froman AODE.

Clutch Packs There are three rotating clutch packs atwo stationary brakes consisting of normal componen(i.e. frictions, steels, pistons, etc.)

Input Clutch The first rotating clutch to discuss, whichdirectly behind the pump, is the main input clutch (i.e. clutch, forward clutch, 1-2-3-4 clutch.)

Whats unique about this clutch is that the front planet

splined to the housing and is driven by the planet, ndirectly by the input shaft. The A clutch is always drivenreduction mode by the planet. GM differs from ZF and Foin that the reverse clutch is integral in the A cluthousing whereas ZF and Ford uses two separahousings. Fig. 2The ZF andFord models use a hub fromthe A housing to the reverseclutch. All three modelsfunction the same concerningpower flow. The A clutchdrives the forward sun gear(AODE term).

Reverse Clutch The next rotating clutch in the stack would normally be considered the reverse clutch reverse/3rd clutch. The ZF, Ford and GM lingo for thclutch is B clutch, direct clutch, or 3-5 clutcrespectively.

As previously stated ZF and Ford use a separate housing fthis clutch pack whereas the GM version locates the 3-5 clutinto the 1-2-3-4 (A clutch) housing. ZF and Ford models ufrictions and steels, which look similar throughout ttransmission, whereas GM offers more of a variety. The clutch drives the reverse sun gear (AODE term).

By Mike RilTechnical Services Direc

Fig. 1

Fig. 2

ZF/FORDGM

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High Clutch The last rotating clutch in the line up wouldbe comparable to a high gear clutch in an AODE. ZF, Fordand GM call this clutch assembly the E clutch, overdriveclutch, and 4-5-6 clutch, respectively.

The E clutch housing is what the turbine (input) shaft issplined to and is driven directly by the torque converter. Aunique feature of the E clutch is that the front planet ring

gear is attached to the housing which drives the frontplanet carrier.

Although ZF, Ford, and GM E clutch assemblies arebasically the same, GM does differ on one component, thehub. To eliminate noise/vibration during apply GM added adampener to the inside of the hub. Fig. 3The dampenerhas a friction ring oneach side, whichabsorbs vibration. TheE clutch drives therear planet carrier, asdoes the AODE direct

clutch.

2nd Brake The first of the stationary brakes to coverwould normally be applied for 2ndgear. The OE terms forthese brakes are ZF, (C clutch), Ford, (intermediateclutch), and GM, (2-6 clutch). The C clutch splines to theB clutch housing (ZF & Ford) or 3-5 hub (GM) and whenapplied will stop the housing/hub from turning. The hub issplined to the reverse sun gear (AODE term). When theC clutch is applied the reverse sun gear is held stationaryforcing the rear planet to walk around it. The C clutch islocated on the front side of the center support.

Low/Reverse Brake The last friction pack on the list isanother stationary brake, which is applied in manual lowand reverse. ZF refers to this brake as the D clutchwhereas Ford and GM call it the low-reverse clutch.

The D clutch is located on the backside of the centersupport and the frictions are splined to the rear planet.When applied, the D clutch holds the planet stationary toprovide reverse or low.

ZF and Ford differ from GM concerning low gear (1st). The6L80E has a low sprag (of course) in conjunction with theD clutch. On ZF and Ford applications the rear planet is

held only by the D clutch whereas the GM model uses thesprag to hold the planet stationary. Although the D clutchis applied in 1stgear initially on the 6L80E, it releases priorto the 1-2 upshift to provide a non-synchronous (clean)shift. A clutch-clutch shift can always exhibit overlap orspin-up.

Connecting Hubs The hubs that connect clutch packsto planetary components are stamped steel and thearrangement is fairly straightforward. As was previouslydiscussed, the only unique feature is the GM E clutchhub, which has the dampener.

Planetaries The front (input) planetary set is direcbehind the pump and the sun gear is splined to the coveThe ring gear is attached to the E clutch housing and tplanet is splined to the A clutch housing. It is merelysimple planetary set and only has one mode. The planis effective in 1stthrough 5thgears.

The rear (output) planetary set is a compound planeta

(Ravigneaux) type with a forward andreverse sun gear like AODE. The ZFand Ford rear planet differs from GMin that the friction plate spline doesntexist on GM. The GM planet has aninternal spline, which meshes withthe low sprag outer race. Fig. 4TheZF and Ford long pinions are onepiece whereas the GM pinions aretwo-piece.

Lastly, the ZF and Fooutput ring gear is a wi

one-piece design whereGM has two narrow gearsdifferent diameters. Fig. 5

Center Support The main difference in center suppois that the GM support has the low sprag inner race spliand the ZF and Ford doesnt. Use caution during assembdue to the tube seals in the case. There are four of thewith different lengths.

Valve Body The valve bodies are, of course, a piecework with a noticeable amount of stuff. There are sevevalves, springs, etc along with a ton of electrical. ZF a

Ford valve bodies have seven solenoids and one exopening just for luck. GM didnt wait. The 6L80E has eigsolenoids to start.

They all have an elaborate MLPS (internal mode switcand electrical connector combination. Dont break it. Telectrical case connector has a release tab for removThere is also a valve body to pump suction/pressure sethat must be removed before the pump comes out.

Oil Pan Fig. 6The quick lubeguys will love

this. AlthoughGM and Ford intheir infinitewisdom usesa tin pan andremovable filter, ZF doesnt. Nope! ZF has an all-plaspan with integral filter, which will make fluid/filter changreally cheap. Filling the trans or checking the fluid levealso a real chore not to mention the cost of the fluid. Uthe right stuff.

Fig. 3

Fig. 4

Fig. 6

Fig. 5

Continued on next pa

ZF/FORD

ZF FOR

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6

WHY?

Why? I think Ive asked myself that question more andmore in the last few years than ever before. The more Itear down and see these new transmissions the more Iask WHY. Actually it is more like what the heck were youthinking.

This time it concerns the people at Ford and the 5R55Ntransmission. For instance, since Ive been in thisbusiness it was always that the flywheel (flex plate) was

bolted to the crankshaft and the torque converter wasbolted to the flywheel. I guess that wasnt good enoughfor the 5R55N transmission because now there is a flexplate that bolts to the converter (an alignment tool

required) and the flex plate bolts to the flywheel that boltsto the crank. Confusing? It was for me, so I ordered theflex plate, flywheel, torque converter and alignment tool.($$$) I wanted to know why a tool was needed and howthe tool actually worked. The OTC OEM tool is big $$$but thanks to the aftermarket there are now lessexpensive alternatives.

There are four tools including the OEM version that Iknow of at this time. The OTC (OEM) is made of steel,

two of the aftermarket ones are made of aluminum and

look similar to the OTC styThe fourth one is made of plasand is its own design, not lthe OTC version. They all seeto work ok and are leexpensive than the OTC style

Transtar is going to carry the OEM, OTC style, Transnumber T-0519for the customers who want OEM a

one of the aluminum aftermarket versions, Transnumber T-0519N for those who want to save a febucks. The tool is needed to align the flex plate to tconverter. The 5R55S/W transmission does not nethe tool, only the 5R55N, at least at this time.

While on the subjectof this family of units(A4LD, 4R44/55E,5R55E, 5R55N, and5R55S/W) there is

another tool to beaware of. This tool isfor the servo pin borethat seems to bewearing out and causing many problems. This toallows you to bore the case and sleeve the worn boThis will save money by not buying a new case. Tservo pin bore repair kit for the A4LD/E is Transnumber T-9212 and for the 5R55N/S/W order pnumber T-9213. Replacement sleeves are aavailable; contact your sales person for all the kit a

sleeve part numbers.

By Dave Hritsk

Technical Services Coordinat

Listed at right is an application chart,which may help with diagnosis.

There are few certainties in thisbusiness but one for sure change!Why? Mercedes just released a 7-speed and there is talk of 8-speeds.

Break out the chauffeurs license!

Got Gears? - Continued from previous page

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NEW PARTS & PRODUCTS

This 4F27E rear cover hasbeen modified to fit Ford andMazda applications. Mazdauses a cover with aluminumring lands that wear outprematurely. This cover is the

Ford style with steel ring lands,Transtar Part Number 88995-R.Directions are included for easyinstallation.

Dont forget Transtar carriesa complete line of hardparts, from OEM new to ourcontinually expanding lineof remanufactured hardparts including our newestadditions for the 5R110Wtransmission.

Transtar has recently addedone-way clutches for theMercedes 722.6 transmission,part numbers 55960E and55960F, plus other late modelapplications such as partnumber 91960 and 91930 forthe JF506E transmission andpart numbers 41960M, 41960P,41960R for the 5L40Etransmission.

Transtar carries the standarpump gear kit for the A604transmission, part numbeK72201. The oversized pumgear kit, part numberK72201-OS

will also be available soon.

Transtar continues to expand itsline of valve body component fixes,remanufactured valve bodies, andvalve body kits including theTransLab kit for the A4BF3,Hyundai 2000-Up transmission,Transtar part number 63D03. Wehave added a valve body reamerholding fixture, Transtar partnumber T-9120, to support certain

VB Reamers during the repair process.

A new Overhaul Kit has been added fothe RE5R05A, 2003-up transmissionTranstar part numberK93900.

2006 SHOWS/CONVENTIONS:

ATRA POWERTRAIN EXPO 2006 10/5/06 - 10/8/06 Sponored by ATRA & Gears Magazine Orlando, FLAAPEX SHOW 10/31/06 - 11/3/06 Sponsored by AAPEX & MEMA Las Vegas, N

2006 SEMINAR SCHEDULE

ATRA CHAPTER SEMINARS

4/8/06 Bloomington, MN4/15/06 Salt Lake City, UT4/22/06 Florence, AL5/13/06 Denver, CO5/13/06 Fremont, CA5/20/06 Anchorage, AK

5/20/06 Los Angeles, CA6/10/06 Vancouver, BC6/17/06 Coeur dAlene, ID8/5/06 Albuquerque, NM9/9/06 Billings, MT9/16/06 Chicago, IL10/14/06 Portland, OR10/21/06 Council Bluffs, IA

TRANSTAR SPONSORED ATSG SEMINARS

5/6/06 Atlanta, GA5/20/06 Phoenix, AZ8/12/06 St. Louis, MO8/26/06 Cleveland, OH

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8

IN THIS ISSUE:

7350 YOUNG DRIVE

CLEVELAND, OHIO 44146

Weve created this newsletter for customers

and friends of Transtar Industries, Inc.

We encourage you to send or e-mail us

your comments! Thank you.

SPRING 2006 VOL. 7 ISSUE 1

Printed in U.S.A. 2006 Transtar Industries, Inc., 7350 Young Drive, Cleveland, OH 44146 USA. All rights reserved.

CONTACT YOUR TRANSTAR REPRESENTATIVE FOR MORE INFORMATION!

BULK RATE

U.S. POSTAGE

PAIDPERMIT

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TRANS MISSIONS

MAIN OFFICE & INTERNATIONAL DIVISION

7350 Young Drive, Cleveland, Ohio 44146 U.S.A.

Toll Free: 800-359-3339

Telephone: 440-232-5100

Cleveland Sales Fax: 440-232-0632

Web: www.transtarindustries.com

E-mail: infodesk@transtarindustries.com

Atlanta, GA800-241-8524Anaheim, CA800-231-9000Baltimore, MD800-878-4249Birmingham, AL800-322-1026Boston Area800-446-9888

Chicago, IL800-214-8710

Phoenix, AZ800-835-1234Portland, OR800-345-7500Sacramento, CA800-446-2600San Francisco,CA800-991-0117Sarasota, FL800-899-9623

Seattle, WA866-254-1198

Cincinnati, OH800-543-2723Cleveland, OH800-321-8830Dallas, TX800-527-4821Denver, CO800-525-9096Detroit, MI800-356-1590

East Brunswick, NJ800-654-3442

SPX Filtran . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

American Express Promotion . . . . . . . . . . . . . . . . . 3

Got Gears - by Mike Riley . . . . . . . . . . . . . . . . . . . . 4

Why? - by Dave Hritsko . . . . . . . . . . . . . . . . . . . . . 6

New Parts & Products . . . . . . . . . . . . . . . . . . . . . . 7

2006 Seminar Schedule . . . . . . . . . . . . . . . . . . . . 7

Ft. Lauderdale, FL866-795-6666Houston, TX800-882-8844Long Island, NY800-445-1170Minneapolis, MN800-214-8710New Orleans, LA800-525-2512

Philadelphia, PA866-750-8860

St. Louis, MO800-446-71Spokane, WA800-876-22Van Nuys, CA800-231-90Bayamon, PR800-981-33Toronto, Can888-869-02

Transtar agrees to sponsor 2006 ATRA Powertrain

Industry Reception

Transtar Industries is pleased to announce that wehave agreed to sponsor the 2006 ATRA PowertrainIndustry Reception at 7:00 on Friday, October 6,2006 at Disneys Coronado Springs Resort inOrlando, FL. Transtar supports the educationalefforts of ATRA to help shop owners and rebuildershave the most up to date information, stated TomOLaughlin Vice President of Sales and Marketing

for Transtar. The Transtar Powertrain Reception isone of the ways we faciliate the sharing ofknowledge between transmission shops, suppliers,and manufacturers in a relaxed setting. Mark yourcalendars and plan to join us in Orlando for anothergreat event.

2005 Powertrain Expo attendees enjoy hors d'oeuvres, drink

entertainment and networking during the Friday night openi

reception sponsored by Transtar Industries.