1
INTRODUCTIONAISIN WARNER 50-42LE
PublishedJuly, 2004
We wish to thank Lory's transmission partsfor supplying the transmission to make
this book possible
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 textillustrations, tables and charts.
AUTOMATIC TRANSMISSION SERVICE GROUP9200 S. DADELAND BLVD. SUITE 720
MIAMI, FLORIDA 33156(305) 670-4161
The information and part numbers contained in this booklet havebeen carefully compiled from industry sources known for their
reliability, but ATSG does not guarantee its accuracy.
Copyright © ATSG 2004
DALE ENGLANDFIELD SERVICE CONSULTANT
ED KRUSETECHNICAL CONSULTANT
WAYNE COLONNATECHNICAL SUPERVISOR
PETER LUBANTECHNICAL CONSULTANT
JIM DIALTECHNICAL CONSULTANT
GREGORY LIPNICKTECHNICAL CONSULTANT
JERRY GOTTTECHNICAL CONSULTANT
JON GLATSTEINTECHNICAL CONSULTANT
DAVID CHALKERTECHNICAL CONSULTANT
STANTON ANDERSONTECHNICAL CONSULTANT
ROLAND ALVAREZTECHNICAL CONSULTANT
MIKE SOUZATECHNICAL CONSULTANT
GERALD CAMPBELLTECHNICAL CONSULTANT
The Aisin Warner 50-42LE transmission first appeared in the Volvo 850, in model year 1992. Saab and Daewoo also implemented the 50-42LE in some of their models. This manual was produced using a 1995 model Volvo transmission for the photos. There are a few subtle differences between the Volvo, Saab and Daewoo versions and these differences are mentioned in the rebuilding process. Overall, the transmissions in all of these vehicle applications operate exactly the same. This manual will cover much needed information for diagnosis, service, repair and rebuild, including electrical information and hydraulic passage identification.
INDEX
Copyright © ATSG 2004
2
AUTOMATIC TRANSMISSION SERVICE GROUP9200 S. DADELAND BLVD. SUITE 720
MIAMI, FLORIDA 33156(305) 670-4161
AISIN WARNER 50-42LE
50-42LE IDENTIFICATION TAG INFORMATION................................................................................................. 3CUT-AWAY VIEW, CLUTCH AND SOLENOID APPLICATION............................................................................ 4GEAR RATIOS AND SPECIFICATIONS.................................................................................................................. 5COMPONENT RESISTANCE CHARTS.................................................................................................................... 6TRANSMISSION RANGE SWITCH CHECK........................................................................................................... 7VOLVO TCM WIRE SCHEMATIC............................................................................................................................ 8SAAB TCM WIRE SCHEMATIC............................................................................................................................... 9DAEWOO TCM WIRE SCHEMATIC........................................................................................................................ 10VOLVO TROUBLE CODES AND RETRIEVAL....................................................................................................... 11SAAB TROUBLE CODES AND RETRIEVAL.......................................................................................................... 15DAEWOO TROUBLE CODES AND RETRIEVAL................................................................................................... 16
VALVE BODY MAPPING AND PASSAGE IDENTIFICATION............................................................................. 17VALVE BODY MAPPING CIRCUIT DIAGRAM..................................................................................................... 34
OIL CIRCUIT DIAGRAMS "PARK" POSITION................................................................................................................................................ 35 "REVERSE" POSITION........................................................................................................................................ 36 "D" POSITION 1ST GEAR................................................................................................................................... 37 "D" POSITION 2ND GEAR................................................................................................................................... 38 "D" POSITION 3RD GEAR.................................................................................................................................. 39 "D" POSITION 4TH GEAR.................................................................................................................................. 40 "D" POSITION 4TH GEAR TCC ON................................................................................................................... 41 "D3" POSITION 3RD GEAR................................................................................................................................ 42 "D1" POSITION MANUAL 1ST GEAR................................................................................................................ 43
TRANSMISSION DISASSEMBLY............................................................................................................................. 44SUB-ASSEMBLIES SECTION PUMP........................................................................................................................................................................ 56 B2 COAST BRAKE HUB AND F1 SPRAG............................................................................................................ 62 C3 UNDERDRIVE CLUTCH DRUM..................................................................................................................... 64 F3 UNDERDRIVE SPRAG...................................................................................................................................... 66 UNDERDRIVE PLANETARY AND PINION GEAR ASSY.................................................................................. 68 F2 FREEWHEEL (LOW SPRAG)......................................................................................................................... 72 COUNTER DRIVE GEAR...................................................................................................................................... 74 C1-C2 DRUM......................................................................................................................................................... 76 REAR COVER......................................................................................................................................................... 79 VALVE BODY.......................................................................................................................................................... 81 CHECK BALL LOCATIONS................................................................................................................................... 89 B3 BRAKE ASSEMBLY........................................................................................................................................... 92
TRANSMISSION RE-ASSEMBLY............................................................................................................................. 92CASE AIR CHECKS................................................................................................................................................. 104
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TRANSMISSIONIDENTIFICATION
VOLVOAISIN AW CO LTDMADE IN JAPAN
SERIAL NO
50-42LE1208 573
92 WF 8 1243
YEAROF MANUFACTURE
MONTHOF MANUFACTURE
(A= JANUARY)
50-42LE
TRANSMISSIONMANUFACTURED
FOR VOLVO
MANUFACTURINGNUMBER
(Starts with 0001 each month)
VOLVOPART NUMBER
I.D. TAG
Figure 1
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CLUTCH/BAND AND SOLENOIDAPPLICATION CHART
S1 = SHIFT SOLENOID "A"S2 = SHIFT SOLENOID "B"
C1 = FORWARD CLUTCHC2 = DIRECT CLUTCHC3 = UNDERDRIVE CLUTCH
B1 = OVERRUN CLUTCHB2 = INTERMEDIATE CLUTCHB3 = LOW & REVERSE CLUTCHB4 = UNDERDRIVE BRAKE BAND
F1 = INTERMEDIATE SPRAGF2 = LOW SPRAGF3 = UNDERDRIVE SPRAG
SHIFT POSITION
S1 S2 C1 C2 C3 B1 B2 B3 B4 F1 F2 F3
P PARK OFF ON ON
R REVERSE
UNDER 4 MPH
REVERSE INHIBITVSS OVER 4 MPH
OFF ON
ONON ON
ON ON ON
ON
N NEUTRAL OFF ON ON
ON
OND
FIRST OFF ON
SECOND
ON
ONON ON ON ON ON ON
THIRD ON OFF ON ON ON ON ON
FOURTH OFF OFF ON ON ON ON
3
FIRST OFF ON ON ON ON ON
SECOND ONON ON ON ON ON ON ON
THIRD ON OFF ON ON ON ON ON
*2SECOND
THIRD
ON ON ON ON ON ON ON ON
ON OFF ON ON ON ON ON
1FIRST OFF ON ON ON ON ON ON
SECOND ON ON ON ON ON ON ON ON
*SAAB ONLY
ON
Figure 2
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Figure 3
SPECIFICATIONS
GEAR RATIOS:
1st Gear2nd Gear
3rd Gear
4th Gear
Reverse
FLUID TYPE :
ATF - Type.................................................................Dexron ll E ATF - Type..................................Volvo part number 1381166-6
FLUID CAPACITY:
Dry Fill..........................................................5.1 liters (5.4 US qts)Torque converter..........................................2.5 liters (2.6 US qts)
LINE PRESSURE SPECIFICATIONS:
Base line pressure in Drive..................................................57-65 psi.Stall line pressure in Drive.................................................150-190psi.Base line pressure in Reverse..............................................85-100psi.Stall line pressure in Reverse.............................................280-290psi.
LINE PRESSUREPORT
(not used on all models)
VOLVO DAEWOO
3.95 : 1
0.98 : 11.37 : 1
2.06 : 1
3.61 : 1
4.271 : 1
1.062 : 1
1.477 : 1
2.228 : 1
3.900 : 1
GEAR
AUTOMATIC TRANSMISSION SERVICE GROUP
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COMPONENT RESISTANCE CHARTS
26
232221
24 25
16 17
12 13
987
4 5 6
321
SAAB CONNECTORNUMBER H16-3
1
9
2
10
3
11
4
12
5
13
6
14
7
15
8
16
1 2 3 4 5 6
7 8 9 10 11 12
DAEWOO CONNECTORNUMBER C110
VOLVO CONNECTORNUMBER 3/71
COMPONENT OHMS TERMINALS
SOLENOID 1
SOLENOID 2
LOCK UPSOLENOID
STH SOLENOID(Line Pressure )
OIL TEMPSENSOR
11-15
11-15
11-15
2-6
900 @ 68°F (20°C)
75 @ 212°F (100°C)
21 & GND
22 & GND
23 & GND
24 & 25
12 & 13
VOLVO
COMPONENT OHMS TERMINALS
SOLENOID 1
SOLENOID 2
LOCK UPSOLENOID
ST SOLENOID(Line Pressure )
OIL TEMPSENSOR
11-15
11-15
11-15
2-6
900 @ 68°F (20°C)
75 @ 212°F (100°C)
1 & GND
9 & GND
10 & GND
11 & 3
12 & 4
SAAB
COMPONENT OHMS TERMINALS
SOLENOID 1
SOLENOID 2LOCK UP
SOLENOID STH SOLENOID(Line Pressure )
OIL TEMPSENSOR
11-15
11-15
11-15
2-6
900 @ 68°F (20°C)
75 @ 212°F (100°C)
6 & GND
12 & GND
11 & GND
4 & 10
3 & 9
DAEWOO
TURBINE SENSOR 300-600
OUTPUT SENSOR 300-600
16 & 17
NOT ROUTEDTHRU CONNECTOR
TURBINE SENSOR 300-600
OUTPUT SENSOR 300-600
5 & 13
14 & 6
TURBINE SENSOR 300-600OUTPUT SENSOR 300-600
5 & 1314 & 6
Figure 4
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RANGE
PARK
PIN/SWITCH COMBINATIONSVOLVO
TRANSMISSION RANGE SWITCH OR GEARPOSITION SENSOR CHECK
REVERSE
D
NEUTRAL
3
L
PIN 1 (A) PIN 2 (B) PIN 3 (C) PIN 4 (PA)
OPEN
OPEN
CLOSED
CLOSED
CLOSED
RANGE
PARK
DAEWOO
REVERSE
D
NEUTRAL
3
L
PIN 4 PIN 8
RANGE
PARK
PIN/SWITCH COMBINATIONSSAAB
REVERSE
D
NEUTRAL
3
2
PIN 1 (A) PIN 3 (B) PIN 2 (C) PIN 4 (PA)
OPEN
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
OPEN
OPEN
OPEN
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
OPEN
CLOSED
OPEN
CLOSED
OPEN
26
232221
24 25
16 17
12 13
987
4 5 6
321
VOLVO CONNECTORNUMBER 3/71
CONNECT POSITIVE LEAD TO THE SPECIFIED PINAND THE GROUND LEAD TO THE CASE.
OPEN = O.L. CLOSED = CONTINUITY
1
CLOSED
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
OPEN
OPEN
OPEN
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
OPEN
CLOSED
OPEN
CLOSED
OPEN
OPEN OPEN CLOSED CLOSED
SAAB CONNECTORNUMBER H10-1
1 2 3 4 5
6 7 8 9 10
CONNECT POSITIVE LEAD TO THE PIN 8AND THE GROUND LEAD TO THE SPECIFIED PIN
OPEN = O.L. CLOSED = CONTINUITY
DAEWOO CONNECTOR
1
2
3
4
5
6
7
8
9
10
11
PIN 9 PIN 10 PIN 11 PIN 1 PIN 2
CONNECT POSITIVE LEAD TO PIN 4AND THE GROUND LEAD TO THE SPECIFIED PIN.CONTINUITY MUST BE PRESENT BETWEEN THE
PINS CONNECTED IN THE CHART ABOVE.
Figure 5
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111111
2121
2020 30301010
111111
2121
2020 10103030
VOLVO TCM WIRE SCHEMATIC
TCMCONNECTOR
B
TCMCONNECTOR
A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
TCMCONNECTOR
A
TCMCONNECTOR
B
Battery voltagefrom ignition
Direct Batteryvoltage
Ground
Ground
25
CONNECTORNUMBER 3/71
24 STHPRES.
SOLENOID
23
SLLOCK-UP
SOLENOID
S2SOLENOID
22
S1SOLENOID
21
13
12 OILTEMP
4
GEAR POSITIONSENSOR
3
2
1
TURBINESENSOR
17
16
PA
CB
A 5
6
7
9
BL
5050
S15
l
BACK-UPLAMP SW.
BACK-UPLAMP SW.
STARTINH SW.
KICKDOWNSWITCH
BRAKE LIGHTSWITCH
BATTERY VOLTAGE
ENGINECONTROLLER
2
3
4
12
20
24
28
DIAGNOSTICOUTPUT
(IND)INDICATORLIGHT
(TQ) ENGINELOAD
(P/N) GEAR POSITIONS
(VTH) THROTTLE POSITION
(SPM) SPEEDOMETER
FROM ENGINE CONTROLLER
MODESWITCH
(MS2 SPORT)
(MS1 WINTER)
(TC1) TORQUE-LIMITING
(TC2) TORQUE-LIMITING
(TCM) TORQUE-LIMIT ACKNOWLEDGE
(BK)
(KD)
(15)
(PG)
(S2)
(S1)
(STHG)
(STH)
(SG)
(OTG)
(OT)
(30)
(SL)
(PA)
(C)
(B)
(A)
(NC1G)
(NC1)
VOLVOTCM
Figure 6
TCM is located in the ControlModule box in the engine compartment
closest to the passenger side fender.
VSSSENSOR
95&up
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123456789101112131415161718
35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
11
CONNECTORNUMBER H16-3
3 STPRES.
SOLENOID
10
SLLOCK-UP
SOLENOID
S2SOLENOID
9
S1SOLENOID
1
12
4 OILTEMP
6
14
TURBINESENSOR
13
5
OUTPUTSENSOR
(S1)
(S2)
(TCS)
(TCS)
TRACTIONCONTROLMODULE
ENGINECONTROLMODULE
CHECK ENGINE LIGHT REQUEST
CHECKGEARBOX
LIGHT
WINTERLIGHT
BRAKESWITCH
SAAB TCM WIRE SCHEMATIC
CONNECTORNUMBER H10-1
B+
B+
A
B
C
PA
SELECTORPOSITION SENSOR
1
INSTRUMENTPANEL
2
3
4
(Idle compensation)
(Torque limit)
B+B+
8
SPORTSWITCH
WINTERSWITCH
GROUND
DLC
SPORTLIGHT
TPS
B+
KICKDOWNSWITCH
ENGINE RPM
GROUND
GROUND
SAAB TCM
SAAB TCM CONNECTOR
Figure 7
TCM is located behindthe glove box.
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DAEWOO TCM WIRE SCHEMATIC
7 8
34 35
5 6
32 3330 31
1611 12
3
26 27
1 2
24 25 28 29
4
9 10 14 1513 17 18 19 20 21 2322
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
DAEWOOTCM
DAEWOO TCM CONNECTOR
IGNITION B+
DIRECT B+
GROUND
GROUND
10
4 STHPRES.
SOLENOID
11
SLLOCK-UP
SOLENOID
S2SOLENOID
12
S1SOLENOID
6
3
9 OILTEMP
1
7
TURBINESENSOR
8
2
OUTPUTSENSOR
STH
STHG
S2
S1
SL
CONNECTORNUMBER C110
ENGINECONTROLMODULE
DLC
TPS
TORQUE REDUCTION
SERIAL DATA
ENGINE RPM
B+
P
R
TRANS RANGESWITCH
8
10
9
11
4
3
N
D
L
1
2
POWERMODE LIGHT
B+
HOLDMODELIGHT
BRAKESWITCH
B+
POWERMODE
SWITCH
HOLDMODE
SWITCH
Figure 8
TCM is located below dash near steering column.
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VOLVO "850" 50-40LEDIAGNOSTIC TROUBLE CODE RETRIEVAL
1992-1995 MODELS ONLYTROUBLE CODE RETRIEVAL
Faults are recorded in the Transmission Control Module (TCM) memory, in the form of Diagnostic Trouble Codes (DTC). Codes can be displayed manually using the LED Indicator on the Volvo diagnostic unit. The diagnostic unit is located at the right front of the engine compartment, as shown in Figure 9. The diagnostic unit is equipped with an LED Indicator, Function Selector Cable and Activation Button, as shown in Figure 10. Diagnostic unit output socket number 1 is used to retrieve TCM diagnostic codes, as shown in Figure 10. Use the following procedure to retrieve (DTC's).
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Turn the ignition switch to the "OFF" position.
Remove the Function Selector Cable from it's storage cavity, and install it into diagnostic unit output socket number 1, as shown in Figure 10.
Turn the ignition switch to the "ON" position.
Depress the Activation Button and keep depressed for more than one second, but not more than three seconds. Refer to Figure 10.
Observe the LED Indicator on the diagnostic unit, and count the number of flashes to determine the first Diagnostic Trouble Code stored in the TCM memory. All codes contain three digits (Example: 2-1-3). Since all codes have three digits, each code requires three series of flashes on the LED Indicator. Example is shown in Figure 10.
Since only one DTC can be retrieved with one push of the button, depress the Activation Button again to determine if any additional DTC's have been stored in the TCM memory.
Read and record all Diagnostic Trouble Codes, pushing the activation button as many times as necessary, until the first code returns to the display.Note: The Transmission Control Module is capable of storing a maximum of five DTC's, so these faults must be corrected and their DTC's cleared before any additional DTC's can be displayed. Refer to Figure 11 for a Diagnostic Trouble Code description and interpretation.
CLEARING TROUBLE CODES
All Diagnostic Trouble Codes must be displayed at least once before it is possible to clear the codes from the TCM memory. Only after the first DTC has returned to the display, will it be possible to clear the codes. Use the following procedure:
(1)
(2)
(4)
Ensure that the Function Selector Cable is still located in diagnostic unit output socket number 1, as shown in Figure 10, and the ignition switch is in the "ON" position.
Depress the activation button, and hold down for at least ten seconds, and watch for LED indicator response. The LED indicator should go out three seconds after the button is released.
Depress the activation button, and hold down for at least an additional ten seconds, and watch for LED indicator response. The LED indicator should go out when the button is released.
Ensure that the Diagnostic Trouble Codes have been cleared by pressing once on the activation button again for more than one second, but less than three seconds, and observe LED indicator. If the code 1-1-1 is displayed on the LED indicator, the DTC's have been cleared.
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Figure 10
1
5
63
2
2
1
7
77
AA
BB
55
1122
3366
RETRIEVING TROUBLE CODES
} }3 SECONDS 3 SECONDS
EXAMPLE OF TROUBLE CODE 2-1-3
2 1 3
FUNCTION SELECTORCABLE
LEDINDICATOR
Once the Function Selector Cable has been inserted in correct socket, depress button once and keep depressed for more than one second, but not more than three seconds. Diagnostic Trouble Codes are read by observing and counting LED flashes to determine the Diagnostic Trouble Code.
DIAGNOSTIC UNIT LOCATION
Figure 9
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Figure 11
DTC DESCRIPTIONWARNINGLAMP **
1-1-1
1-1-2
1-1-3
1-1-4
1-2-1
1-2-2
1-2-3
1-2-4
1-3-1
1-3-2
1-3-4
1-4-1
1-4-2
1-4-3
2-1-1
2-1-2
2-1-3
2-2-1
2-2-2
2-2-3
2-3-1
2-3-2
2-3-3
2-3-5
2-4-5
3-1-1
3-1-2
3-1-3
3-2-2
3-2-3
3-3-1
3-3-2
3-3-3
NO
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
NO
NO
NO
YES *
NO FAULTS RECORDED
SHORT CIRCUIT TO BATTERY VOLTAGE IN SHIFT SOLENOID S1 CIRCUIT
SHORT CIRCUIT TO BATTERY VOLTAGE IN SHIFT SOLENOID S2 CIRCUIT
SHORT CIRCUIT TO BATTERY VOLTAGE IN LOCK-UP SOLENOID CIRCUIT
THROTTLE POSITION SENSOR SIGNAL TOO HIGH
THROTTLE POSITION SENSOR SIGNAL TOO LOW
IRREGULAR THROTTLE POSITION SENSOR SIGNAL
SPEEDOMETER SIGNAL ABSENT
RPM SIGNAL ABSENT
RPM SIGNAL FAULTY
INCORRECT SIGNAL FROM GEAR POSITION SENSOR
INCORRECT GEAR RATIO
LOCK-UP SLIPS OR IS NOT ENGAGED
INCORRECT SPEEDOMETER SIGNAL
HIGH TRANSMISSION OIL TEMPERATURE
BREAK OR SHORT IN TORQUE LIMITING CIRCUIT
FAULT IN TRANSMISSION CONTROL MODULE
FAULT IN TRANSMISSION CONTROL MODULE
FAULT IN TRANSMISSION CONTROL MODULE
INCORRECT LOAD SIGNAL
SHORT CIRCUIT IN TRANSMISSION TEMPERATURE SENSOR CIRCUIT
BREAK (OPEN) IN TRANSMISSION TEMPERATURE SENSOR CIRCUIT
SHORT CIRCUIT TO GROUND IN KICKDOWN SWITCH CIRCUIT
BREAK IN MODE SELECTOR CIRCUIT
SHORT CIRCUIT TO GROUND IN SHIFT SOLENOID S1 CIRCUIT
SHORT CIRCUIT TO GROUND IN SHIFT SOLENOID S2 CIRCUIT
SHORT CIRCUIT TO GROUND IN LOCK-UP SOLENOID CIRCUIT
BREAK (OPEN) IN SHIFT SOLENOID S1 CIRCUIT
BREAK (OPEN) IN SHIFT SOLENOID S2 CIRCUIT
BREAK (OPEN) IN LOCK-UP SOLENOID CIRCUIT
SHORT CIRCUIT TO BATTERY VOLTAGE IN EPC SOLENOID CIRCUIT
SHORT CIRCUIT TO GROUND IN MODE SELECTOR CIRCUIT
BREAK OR SHORT CIRCUIT TO GROUND IN EPC SOLENOID CIRCUIT
When a fault occurs the code is stored and the "WARNING" lamp in the instrument panel comes on. If the fault is intermittent and ceases, the warning lamp will go out, but the DTC will remain.Only for as long as the temperature remains high.
**
*
13
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Figure 12
VOLVODTC CODE DESCRIPTION
1-2-1
1-2-2
1-2-3
2-2-1
2-3-2
3-1-1
3-1-3
3-2-1
SPEEDOMETER SIGNAL ABSENT
RPM SIGNAL ABSENT
INCORRECT SIGNAL FROM GEAR POSITION SENSOR
INCORRECT 1st GEAR RATIO
SHORT CIRCUIT TO GROUND IN SHIFT SOLENOID S1 CIRCUIT
SHORT CIRCUIT TO GROUND IN SHIFT SOLENOID S2 CIRCUIT
BREAK (OPEN) IN SHIFT SOLENOID S1 CIRCUIT
SHORT CIRCUIT TO BATTERY VOLTAGE IN EPC SOLENOID CIRCUIT
OBD-llDTC
1-3-2 FAULT IN TRANSMISSION CONTROL MODULE (STH SHORT CIRCUIT)
P0750
P0750
P0745
P0745
P0755
P07552-2-2 BREAK (OPEN) IN SHIFT SOLENOID S2 CIRCUIT
2-1-3 THROTTLE POSITION SENSOR SIGNAL TOO HIGHP0120
2-2-3 THROTTLE POSITION SENSOR SIGNAL TOO LOWP0120
P0500
P0715
P0731
3-2-2 INCORRECT 2nd GEAR RATIOP0732
3-2-3 INCORRECT 3rd GEAR RATIOP0733
3-2-4 INCORRECT 4th GEAR RATIOP0734
P0705
OBD-ll CONNECTOR
OBD-llConnector Location:
In front of shifteror in front of console
by gas pedal
VOLVO 96 & UP OBD-ll CODE DEFINITIONS
NOTE: Codes may be retrieved in OBD-ll Generic mode
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Figure 13
CODE DESCRIPTION
GEAR SELECTOR POSITION SENSOR, SIGNAL INCORRECT
OBD-llDTC
P0705
BATTERY VOLTAGE TOO LOW OR TO HIGHP1500
TPS SIGNAL FROM ENGINE / TCS INCORRECTP1785/6
P1787/8 TPS SIGNAL FROM ENGINE / TCS SHORT
P1789 DRIVE SIGNAL TO ENGINE MANAGEMENT SHORT OR OPEN
P1790 KICKDOWN SWITCH SHORT TO GROUND
P1812 OIL TEMPERATURE SHORT TO GROUND
P1813 OIL TEMPERATURE SHORT TO B+ OR OPEN
P1813 OIL TEMPERATURE SHORT TO B+ OR OPEN
P1817 TURBINE SHAFT SPEED SENSOR NO SIGNAL
P1822 OUTPUT SHAFT SPEED SENSOR NO SIGNAL
P1830 GEAR RATIO ERROR (SLIP CODE)
P1831 DOWNSHIFTING MECHANICAL FAULT
P1832 SHIFTING TIME MECHANICAL FAULT
P1832 SHIFTING TIME MECHANICAL FAULT
P1842 TORQUE LIMIT SIGNAL TO ECM SHORT OR OPEN
P1847 PRESSURE CONTROL SOLENOID CIRCUIT (ST) SHORT OR OPEN
P1848 PRESSURE CONTROL SOLENOID CIRCUIT (ST) SHORT TO B+
P1849 PRESSURE CONTROL SOLENOID (ST) SHORT
P1852 SOLENOID S1 SHORT TO GROUND
P1853 SOLENOID S1 SHORT TO B+ OR OPEN
P1857 SOLENOID S2 SHORT TO GROUND
P1858 SOLENOID S2 SHORT TO B+ OR OPEN
P1862 SOLENOID SL SHORT TO GROUND
P1863 SOLENOID SL SHORT TO B+ OR OPEN
OBD-ll CONNECTOR
OBD-llConnector Location:
Below dash atbase of steering column
SAAB OBD-ll CODE DEFINITIONS
15
NOTE: Codes may be retrieved in OBD-ll Generic mode
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Technical Service Information
16
Figure 14
Copyright © 2004 ATSG
CODE DESCRIPTION
INTERNAL CONTROL MODULE FAILURE (RAM FAILURE)
OBD-llDTC
P0604
OBD-ll CONNECTOR
OBD-llConnector Location:
Below dash at theright of steering column
DAEWOO OBD-ll CODE DEFINITIONS
TRANS RANGE SENSOR CIRCUIT MALFUNCTIONP0705
TRANS FLUID TEMP SENSOR CIRCUIT - LOW INPUTP0712
TRANS FLUID TEMP SENSOR CIRCUIT - HIGH INPUTP0713
TURBINE SPEED SENSOR CIRCUIT - NO SIGNALP0717
OUTPUT SPEED SENSOR CIRCUIT - NO SIGNALP0722
ENGINE SPEED SENSOR CIRCUIT - NO SIGNALP0727
TORQUE CONVERTER CLUTCH (SL) STUCK OFFP0741
TORQUE CONVERTER CLUTCH (SL) STUCK ONP0742
TORQUE CONVERTER CLUTCH (SL) CIRCUIT ELECTRICALP0743
PRESSURE CONTROL SOLENOID (STH) CIRCUIT ELECTRICALP0748
S1 SOLENOID PERFORMANCEP0751
S1 SOLENOID CIRCUIT ELECTRICALP0753
S2 SOLENOID PERFORMANCEP0756
S2 SOLENOID CIRCUIT ELECTRICALP0758
ENGINE COOLANT TEMP SIGNAL MALFUNCTIONP1701
TORQUE CONTROL SIGNAL MALFUNCTIONP1702
P1790 INTERNAL CONTROL MODULE FAILURE (CHECK SUM FAILURE)
P1791 THROTTLE POSITION SENSOR SIGNAL MALFUNCTION
NOTE: Codes may be retrieved in OBD-ll Generic mode
VALVE BODY MAPPINGAND PASSAGE IDENTIFICATION
500U
LOWER VALVE BODYFRONT SIDE
535U
532U
539U
538U
506U
541U
518U
533U 523U
551U
528U
53
4U
53
6U
53
7U
54
7U
52
9U
50
2U
550U
51
2U
54
0U
50
8U
52
6U
50
9U
52
5U 5
49
U
52
0U
52
1U
50
7U
50
4U
511
U
51
0U
50
3U
54
2U
51
3U
51
4U
51
7U
51
5U
51
6U
54
4U
52
2U
54
3U
54
8U
54
6U
51
9U
50
5U
52
4U
527U
54
5U
531U 5
30U
501U
CB4
CB2
CB6
X
LOW COASTMODULATOR VALVE (B3)
51
9U
52
0U
52
1U
54
9U
50
1L
PARTIAL HYDRAULICSCHEMATIC FOR THE
LOW COAST MODULATOR VALVE
520U
HOW TO USE THIS MANUAL:
All castings and spacer plates have been numbered so they can be identifiedin the Valve Body Mapping oil circuit diagram. Example: 520U passage is located
in the Lower Valve Body Upper side (500U series). This passage can now be locatedin the partial oil circuit diagram and matched up to the passage in the
Lower Valve Body Upper side as shown above.
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
17
Copyright © 2004 ATSG
Figure 15
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Copyright © 2004 ATSG
100 UUPPER VALVE BODY
FRONT SIDE
5555 001199
100 LUPPER VALVE BODY
LOWER SIDE
200 UPPER SPACER
PLATE
GASKET
GASKET
300U CENTER VALVE
BODY UPPER SIDE
300L CENTER VALVE
BODY LOWER SIDE
GASKET
GASKET
400 LOWER SPACER
PLATE
500U LOWER VALVE
BODY UPPER SIDE
500LLOWER VALVE
BODY LOWER SIDE
50-40 SERIES VALVE BODY COMPONENTSFOR PASSAGE I.D.
COVER ANDGASKET
18
Figure 16
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Copyright © 2004 ATSG
50-40 SERIES SOLENOIDLOCATION AND I.D.
99
992222
2211
9911
1155 22
B1
9B
19
Shift SolenoidNumber 2
(S2)
Shift SolenoidNumber 1
(S1)
Pressure ControlSolenoid
(STH)
TCC Solenoid(SL)
19Figure 17
99
992222
2211
9911
1155 22
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Copyright © 2004 ATSG
100 U
UPPER VALVE BODYFRONT SIDE
105U
103U
101U
107U
106U
104U
108U
102Uexhaustnext to
bolt hole
20Figure 18
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Copyright © 2004 ATSG
100 L
UPPER VALVE BODYLOWER SIDE
101L
116L
103L
118L
120L 119L 115L
105L
113L
112L
108L
127L
110L
106L
126L
129L
114L
128L
12
5L
10
7L
111L
12
3L
12
2L
11
7L
10
2L
10
4L
12
4L
12
1L
10
9L
21Figure 19
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Copyright © 2004 ATSG
200 UPPER SPACER PLATE
220
224
202.030"
233.030"
PLATE I.D.
W1 & W2 are two different spacer plate configurations
221.051"
219
218
217
215 210
206
208
204.030"
207.040"
222
205214
242
213
236212
203211246
201
234225
226W1
250W2
249W2
235
237
238
243 241
240
239
229
228
227
233
230
232231
248.032"
226W1249W2250W2
= This hole used on W1 spacer plates only
= This hole used on W2 spacer plates only
= This hole used on W2 spacer plates only
247.032"
245
244
209
21
6
223
24
2
W 1
22Figure 20
5555
00
1199
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Copyright © 2004 ATSG
300U
CENTER VALVE BODYFRONT SIDE
31
9U
31
8U
30
4U
31
7U
31
6U
33
5U
30
5U
32
2U
32
1U
31
4U
34
0U
33
9U
32
5U
33
7U
34
1U3
34
U
30
7U
30
6U
30
9U
30
8U
32
6U
31
2U
31
3U
33
3U
33
6U
33
8U
32
7U
30
1U
30
2U
345U303U
343U
310U
314U
332U
347U
328U
348U-W2
348U-W2 THIS PASSAGE IS USED WITH W2 PLATE ONLY
349U-W2 THIS PASSAGE IS USED WITH W2 PLATE ONLY
329U
33
1U
32
4U
346U
FIL
TE
R
34
3U
31
5U
34
2U
34
1U
311
U 33
0U
32
3U
34
9U
-W2
COVER
FILTER
23Figure 21
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Copyright © 2004 ATSG
300L
CENTER VALVE BODYREAR SIDE
337L
336L
327L
329L
334L
343L
326L
328L
346L
30
1L
30
2L
30
3L
33
2L
30
4L
311
L
32
5L
32
2L
32
0L
31
0L
32
1L
33
8L
31
4L
34
2L
341L
345L
323L
339L
316L
318L
319L335L
315L
340L
344L313L
CB5CB7
CB3
CB8
CB9
CB10
CB1
312L
309L
330L
305L
328L
324L
308L
307L
306L
31
7L
33
3L
33
1L
CHECK VALVEAND SPRING
RELIEFVALVE AND
SPRING
CHECKVALVE
24Figure 22
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Copyright © 2004 ATSG
400
442.042"
424.039"
479.032"
441
472473
428427
478486
429
469
423*425
426
423* = USED ON CHECK VALVE VERSIONS ONLY
485474
475435434
433432.078”
431
439
412416
415
406421
.059”
409
438
422449
408
437.039"
407411414
440.050"
417418
419.043"
420
404
401402467
446.039"
455403
464
45
7 46
8
48
4
445444482483
461463
459458
450
452460
470
471 466.059"
465.039"
436
413462
430
443
481
477
480
476
410
451.086"
456
405
487453
454.032"
488.040"
447.039"
448.039"
490
489
LOWER SPACER PLATE
25Figure 23
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Copyright © 2004 ATSG
500U
LOWER VALVE BODYFRONT SIDE
535U
532U
539U
538U
506U
541U
518U
533U 523U
55
1U
52
8U
53
4U
53
6U
53
7U
54
7U
52
9U
50
2U
55
0U
51
2U
54
0U
50
8U
52
6U
50
9U
52
5U 5
49
U
52
0U
52
1U
50
7U
50
4U
511
U
51
0U
50
3U
54
2U
51
3U
51
4U
51
7U
51
5U
51
6U
54
4U
52
2U
54
3U
54
8U
54
6U
51
9U
50
5U
52
4U
52
7U
54
5U
53
1U 5
30
U
501U
CB4
CB2
CB6
RELIEF VALVEAND SPRING
CHECK VALVEAND SPRING
26Figure 24
22 2211AA
33 9911
5500
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Copyright © 2004 ATSG
500L
LOWER VALVE BODYLOWER SIDE
510L511L
509L
507L
508L
505L
502L
503L
504L506L
501L
512L
27Figure 25
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Copyright © 2004 ATSG
600F
MID-CASE FRONT SIDE
601F
603F
602F
611F
605F
604F
609F
610F
606F
607F
B4 ACCUMULATORASSEMBLY
PIPE #5*
TO PIPE #4 *HOLE NOT THEREON LATE MODELS
PIPE #4 IS ONLY USED ON EARLY MODELS WITH LINE PRESSURE TAP
PIPE #5 IS ONLY USED ON EARLY MODELS WITH LINE PRESSURE TAP
.034"ORIFICE
28Figure 26
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Copyright © 2004 ATSG
600R
MID-CASE REAR SIDE
605R
603R
606R
604R
607RTO PIPE #3
601RFROM PIPE #2
608RFROM PIPE #3
602RTO PIPE #2
PIPE #3
PIPE #4 AND 5 ARE USED FOR EARLY MODELSWITH LINE PRESSURE TEST PORT ONLY
PIPE #2
PIPE #4 *CONNECTS PUMP
PASSAGE TO PIPE#5
29Figure 27
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Copyright © 2004 ATSG
600V
MID-CASEVALVE BODY SIDE
617V
612V
615V
604V
605V
616V
611V
608V
603V
613V
601V
614V
609V
610V
606V
607VTO PRESSURE
TAP
602V(COOLER OUT)
TEMPSENSOR
30Figure 28
9151
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Copyright © 2004 ATSG
700U
BELLHOUSINGREAR VIEW
AIRVENT
703UFROMPIPE#1
701U
PIPE#1
702UTO PIPE#1
704U
705U*
705U* THERE IS A SEALING RING IN THIS LOCATION THAT HASA .055" GAP THAT PROVIDES A CONTROLLED LEAK INTO THE BEARING
31Figure 29
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Copyright © 2004 ATSG
DIFFERENTIAL LUBE
.034"ORIFICE
60
1V
PIPE #2
PIPE #1
701U
60
1F
60
1F
60
1F
60
1R
60
2R
702U
704U
2 -.042"ORIFICES IN PLUG
705U*
703U
PIPE #1
705U* THERE IS A SEALING RING IN THIS LOCATION THAT HASA .055" GAP THAT PROVIDES A CONTROLLED LEAK INTO THE BEARING
32Figure 30
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
Copyright © 2004 ATSG
800U
REAR COVERFRONT VIEW
802U
804U
805U
803U
801U
C1ACCUMULATOR
33Figure 31
X
X
XX
X
X
X
X X
X
X
MANUAL VALVE
P R N D 3 L
2-3 SHIFT VALVE
3-4 SHIFT VALVE
1-2 SHIFT VALVE
NEUTRAL CONTROL VALVE (Blocked)
CLUTCH MODULATOR VALVE
TCC SOLENOID REGULATOR VALVE
PRESSURE REGULATOR VALVE
SECONDARY REGULATOR VALVE
LOCK-UP CONTROL VALVE
LOW COASTMODULATOR VALVE (B3)
B1 ACCUMULATORVALVE
ACCUMULATORCONTROL
VALVE
B2 ACCUMULATOR VALVE
B2ACCUMULATOR
C2 ACCU-MULATOR
C2 ACCU-MULATOR
VALVE
C3 ACCUMULATORVALVE
OUTPUT SUCTION TCCRELEASE SIDE
TCCAPPLY SIDE
THE RETURNLINE IS LOCATED
IN THE FRONT PAN
C3ACCUMULATOR
.038" ORIFICE
.058" CROSS-DRILLED HOLE
30
6U
30
8U
30
9U3
10
U3
38
U
32
5L
30
6L
30
8L
32
1L
32
4L
30
8L
33
0L
32
2L
31
0L
30
9L
31
9L
32
1L
32
2L
32
3L
32
2L
32
3L
52
2U
30
9L
30
7L
31
4L
31
5L
31
6L
31
7L
31
8L
31
9L
32
0L
31
6U
50
3U
50
9U
51
0U
50
8U
51
2U
50
8U
51
3U
540U541U
542U
51
4U
51
7U
51
6U
51
8U
51
5U
52
2U
54
4U
54
6U
54
8U
54
3U
50
4U
511
U
50
6U
50
7U
50
3U
50
3U
50
3U
50
3U
50
6U
52
5U
50
2L
31
8U
32
0L
311
U
34
1U
34
2U
317U
31
2U
31
3U
33
3U
33
4U
33
6U
33
9U
33
4U
34
1U
33
7U
33
3U
32
7U
31
2U
31
4U
32
5U
32
6U
33
0U
33
0U
33
0U
32
1U
32
2U
32
1U
30
7U
33
5U
20
2.0
30
"2
07
.04
0"
22
6W
12
49
W2
32
3U
VOID
C-3
B-1
C-3
ATFCOOLER
602F
611F
60
3V
61
6V
40
14
02
40
34
43
45
04
51
.08
6"
45
24
88
.04
0"
40
44
10
41
54
49
41
6.0
35
"4
13
411
41
44
12
43
84
06
40
94
37
.03
9"
43
64
08
40
74
21
.05
9”
42
24
18
48
74
19
.04
2"
42
3**
42
54
26
42
74
20
42
4.0
39
"4
28
42
94
30
43
14
33
43
44
35
CB
3
CB
4C
B6
CB
5
43
2.0
78
"4
17
43
94
41
44
0.0
50
"4
42
.04
2"
30
2L
30
3L
32
8L
30
3U
30
3U
34
3U
34
5U
34
4U
30
4U
311
L3
12
L
31
4U
34
8W
2
34
9W
2
32
4U
33
0U
31
9U
30
4U
33
0U
31
5U
30
4U
32
8U
32
8U
32
9U
33
1U
32
9U
33
2U
52
5U
609V
60
8F
Pu
mp
610V
Rearlube
606F
615V
617V
609F
THRUPUMP
THRUPUMP/TURBINE
30
4L
33
3L
32
6L
32
9L
33
0L
30
1U
CO
VE
R
30
2U
50
1U
52
7U
52
8U
50
2U
52
9U
53
4U
53
5U
505L503L
53
7U
54
7U
53
6U
53
0U
53
8U
55
1U
53
2U
51
9U
52
0U
52
4U
52
6U
54
0U
50
7L
50
8L
509L
510L511L
512L
52
1U
54
9U
50
1L
603F
SUMP
X
X
PUMP
TORQUECONVERTER
CB
1
CB
2
CB
8C
B9
CB
10
31
3L
30
1L
X
339L
472 473
340L 341L 342L 343L 344L 345L
347UCB7
475 476 477 480 481.047"
482 483 484 485 486479.032"
478
545U
474
DIFFERENTIAL LUBE
.034"ORIFICE
60
1V
PIPE #2
PIPE #1
701U
60
1F
60
1F
60
1F
60
1R
60
2R
702U
704U
2 -.042"ORIFICES IN PLUG
705U*
703U
PIPE #1
.058” ORIFICE
9B
19B
1
S1"OFF"
VIEWED FROM THEWORM TRACK SIDE
VIEWED FROM THEWORM TRACK SIDE
n.c.
n.c.
S2"ON"
STH (epc)
SL"OFF"
n.o.
X
XX
X
X
XX
X
X101U (side)
.035" balance orifice thru valve
.039" balance orifice thru valve
PRESSURE CONTROLSOLENOID REG. VALVE
C1 ACCUMULATOR
LEGEND
PARK POSITIONVALVE BODY MAPPING
LINE PRESSURE
EPC PRESSURE
TO SUMP
SOLENOID 1 PRESSURE
COOLER PRESSURE
CONNECTED CIRCUIT
W1- W2 SPACERPLATE DIFFERENCES
SECONDARY REG. PRESSURE
CLUTCH PACKS
B1 BRAKE
B2 BRAKE
B3 BRAKE
C2 CLUTCH
C1 CLUTCH
C3 CLUTCH
B4 BRAKE BAND"ON"
B4 SERVO
B4 ACCUMULATORPISTON
(UNDERDRIVE CLUTCH)
(FORWARD CLUTCH)
(DIRECT CLUTCH)
(LOW/REV. BRAKE)
(INT. BRAKE)
(OVERRUN BRAKE)
10
1L
10
2L 104L
10
3L
103U102U
20
12
33
23
52
50
W2
23
02
31
23
22
13
21
4
10
7L
10
9L
111
L1
04
L1
03
L11
8L
12
0L
11
2L
11
3L
11
4L
12
8L
11
5L
11
6L
11
7L
11
9L
12
9L
12
1L
12
2L
10
8L
11
0L
12
3L
12
4L
12
5L
12
6L
12
7L
10
7U
10
8U
10
4U
10
5U
10
6U
30
4U
23
3.0
30
"2
04
.03
0"
20
62
08
20
92
10
20
52
15
21
62
39
24
02
41
24
22
46
24
42
45
24
7.0
32
"2
48
.03
2"
21
72
36
21
82
11
20
32
37
23
82
12
21
92
20
24
2
24
32
22
22
32
24
22
52
27
22
82
29
23
42
21
.05
1"
10
5L
11
9L
10
6L
*
**
SEE NOTE IN THE PASSAGE IDENTIFICATION
THIS HOLE IS USED ONLYON CHECK VALVE VERSIONS
B-4
A-2
PIPE#3
607F4
05
44
44
45
45
34
54
.03
2"
45
54
46
.03
9"
44
7.0
39
"4
48
.03
9"
604V
605V
608V
50
2L
606V
614V
61
2V
Centrallube
606R 802U
80
4U
604R
605R801U
802U
604F
605F
603R
607R
608R
607V Pressureport
30
5U
34
0U
34
3U
34
5U
52
3U
55
0U
53
3U
50
4L
611V
613V
602V
X
X
X
X
X
30
5L
32
7L
32
8L
33
1L
33
2L
X
X
456 457 458
531U
346L 334L 335L
346U
336L 337L338L
539U
506L
459.070"
460 461 462 463 464 465.039"
466.059"
468 469 467 489 490 470 471
X
X
X
503L
529U
S1"OFF"
VIEWED FROM THEWORM TRACK SIDE
n.c.
STH (epc)
SL"OFF"
X
X
XX
X
X
X
X X
X
X
.039" balance orifice thru valve
PRESSURE CONTROLSOLENOID REG. VALVE
MANUAL VALVE
2-3 SHIFT VALVE
3-4 SHIFT VALVE
1-2 SHIFT VALVE
NEUTRAL CONTROL VALVE (Blocked)
CLUTCH MODULATOR VALVE
TCC SOLENOID REGULATOR VALVE
PRESSURE REGULATOR VALVE
SECONDARY REGULATOR VALVE
LOCK-UP CONTROL VALVE
C1 ACCUMULATOR
LOW COASTMODULATOR VALVE (B3)
B1 ACCUMULATORVALVE
ACCUMULATORCONTROL
VALVE
B2 ACCUMULATOR VALVE
B2ACCUMULATOR
C2 ACCU-MULATOR
C2 ACCU-MULATOR
VALVE
C3 ACCUMULATORVALVE
OUTPUT SUCTION
TCCRELEASE SIDE
TCCAPPLY SIDE
THE RETURNLINE IS LOCATED
IN THE FRONT PAN
CLUTCH PACKS
B1 BRAKE
B2 BRAKE
B3 BRAKE
C2 CLUTCH
C1 CLUTCH
C3 CLUTCH(UNDERDRIVE CLUTCH)
(FORWARD CLUTCH)
(DIRECT CLUTCH)
(LOW/REV. BRAKE)
(INT. BRAKE)
(OVERRUN BRAKE)
C3ACCUMULATOR
.038" ORIFICE
.058" CROSS-DRILLED HOLE
.03
0"
.03
0"
22
6W
1
.05
1"
VOID
C-3
B-1
C-3
ATFCOOLER
X
X
B4 BRAKE BAND"ON"
B4 SERVO
B4 ACCUMULATORPISTON
B-4
A-2
.03
2"
.08
6"
.04
0"
.03
5"
.03
9"
.04
2"
**.0
39
"
CB
3
CB
6
.07
8"
Rearlube
Centrallube
Pressureport
503L
SUMP
X
X
PUMP
TORQUECONVERTER
CB
1
CB
2
CB
8C
B9
CB
10
.059"
X
.047"
X
XCOOLERRELIEF
X
0. 32"
X
X
X
X
503L
.04
0"
X
XX
X.032”
Differentiallube
.05
9”
. 2"03
B19
B19
n.c.
S2"ON"
n.o.
X
X
X
X
X
X
.035" balance orifice thru valve
P R N D 3 L
50-42LE
24
9W
2
.03
9"
CB
4
CB
5
.05
0"
.04
2"
W2
W2
X
X
.039"
.070"
.03
9"
.03
9"
X
X
.03
0"
CB
7
PARK/NEUTRALPOSITION
LEGEND
LINE PRESSURE
EPC PRESSURE
SECONDARY REG.PRESSURE
TO SUMP
SOLENOID PRESSURE
COOLER PRESSURE
CONNECTED CIRCUIT
W1- W2 SPACERPLATE DIFFERENCES
** THIS HOLE IS USED ONLYON CHECK VALVE VERSIONS
ACCUMULATOR BACK PRESH.
.058” ORIFICE
S1"OFF"
VIEWED FROM THEWORM TRACK SIDE
n.c.
STH (epc)
SL"OFF"
X
X
XX
X
X
X
X X
X
X
.039" balance orifice thru valve
PRESSURE CONTROLSOLENOID REG. VALVE
MANUAL VALVE
2-3 SHIFT VALVE
3-4 SHIFT VALVE
1-2 SHIFT VALVE
NEUTRAL CONTROL VALVE (Blocked)
CLUTCH MODULATOR VALVE
TCC SOLENOID REGULATOR VALVE
PRESSURE REGULATOR VALVE
SECONDARY REGULATOR VALVE
LOCK-UP CONTROL VALVE
C1 ACCUMULATOR
LOW COASTMODULATOR VALVE (B3)
LEGEND
B1 ACCUMULATORVALVE
ACCUMULATORCONTROL
VALVE
B2 ACCUMULATOR VALVE
B2ACCUMULATOR
C2 ACCU-MULATOR
C2 ACCU-MULATOR
VALVE
C3 ACCUMULATORVALVE
OUTPUT SUCTION
TCCRELEASE SIDE
TCCAPPLY SIDE
THE RETURNLINE IS LOCATED
IN THE FRONT PAN
CLUTCH PACKS
B1 BRAKE
B2 BRAKE
C1 CLUTCH
C3 CLUTCH(UNDERDRIVE CLUTCH)
(FORWARD CLUTCH)
(INT. BRAKE)
(OVERRUN BRAKE)
C3ACCUMULATOR
.038" ORIFICE
.058" CROSS-DRILLED HOLE
.03
0"
.03
0"
22
6W
1
.05
1"
VOID
C-3
B-1
C-3
ATFCOOLER
X
X
B4 BRAKE BAND"ON"
B4 SERVO
B4 ACCUMULATORPISTON
B-4
A-2
.03
2"
.08
6"
.04
0"
.03
5"
.03
9"
.04
2"
**.0
39
"
CB
3
CB
6
.07
8"
Rearlube
Centrallube
Pressureport
503L
SUMP
X
X
PUMP
TORQUECONVERTER
CB
1
CB
2
CB
8C
B9
CB
10
.059"
X
.047"
X
XCOOLERRELIEF
X
.032"
X
X
X
X
503L
.04
0"
X
XX
X.032”
Differentiallube
.05
9”
. 203 "
B91
B91
n.c.
S2"ON"
n.o.
X
X
X
X
X
X
.035" balance orifice thru valve
P R N D 3 L
50-42LE
249
W2
.039"
CB
4
CB
5
.050"
.042"
W2
W2
X
X
.039"
.070"
.039"
.039"
X
X
.030"
CB
7
REVERSE
B3 BRAKE(LOW/REV. BRAKE)
C2 CLUTCH(DIRECT CLUTCH)
LEGEND
LINE PRESSURE
EPC PRESSURE
SECONDARY REG.PRESSURE
TO SUMP
SOLENOID 1AND 2 PRESSURE
COOLER PRESSURE
CONNECTED CIRCUIT
W1- W2 SPACERPLATE DIFFERENCES
** THIS HOLE IS USED ONLYON CHECK VALVE VERSIONS
ACCUMULATOR BACK PRESH.
.058” ORIFICE
S1"OFF"
VIEWED FROM THEWORM TRACK SIDE
n.c.
STH (epc)
SL"OFF"
X
X
XX
X
X
X
X X
X
X
.039" balance orifice thru valve
PRESSURE CONTROLSOLENOID REG. VALVE
MANUAL VALVE
2-3 SHIFT VALVE
3-4 SHIFT VALVE
1-2 SHIFT VALVE
NEUTRAL CONTROL VALVE (Blocked)
CLUTCH MODULATOR VALVE
TCC SOLENOID REGULATOR VALVE
PRESSURE REGULATOR VALVE
SECONDARY REGULATOR VALVE
LOCK-UP CONTROL VALVE
C1 ACCUMULATOR
LOW COASTMODULATOR VALVE (B3)
LEGEND
B1 ACCUMULATORVALVE
ACCUMULATORCONTROL
VALVE
B2 ACCUMULATOR VALVE
B2ACCUMULATOR
C2 ACCU-MULATOR
C2 ACCU-MULATOR
VALVE
C3 ACCUMULATORVALVE
OUTPUT SUCTION
TCCRELEASE SIDE
TCCAPPLY SIDE
THE RETURNLINE IS LOCATED
IN THE FRONT PAN
CLUTCH PACKS
B1 BRAKE
B2 BRAKE
C3 CLUTCH(UNDERDRIVE CLUTCH)
(INT. BRAKE)
(OVERRUN BRAKE)
C3ACCUMULATOR
.038" ORIFICE
.058" CROSS-DRILLED HOLE
.03
0"
.03
0"
22
6W
1
.05
1"
VOID
C-3
B-1
C-3
ATFCOOLER
X
X
B4 BRAKE BAND"ON"
B4 SERVO
B4 ACCUMULATORPISTON
B-4
A-2
.03
2"
.08
6"
.04
0"
.03
5"
.03
9"
.04
2"
**.0
39
"
CB
3
CB
6
.07
8"
Rearlube
Centrallube
Pressureport
503L
SUMP
X
X
PUMP
TORQUECONVERTER
CB
1
CB
2
CB
8C
B9
CB
10
.059"
X
.047"
X
XCOOLERRELIEF
X
0. 32"
X
X
X
X
503L
.04
0"
X
XX
X.032”
Differentiallube
.05
9”
. 2"03
B19
B19
n.c.
S2"ON"
n.o.
X
X
X
X
X
X
.035" balance orifice thru valve
P R N D 3 L
50-42LE
24
9W
2
.03
9"
CB
4
CB
5
.05
0"
.04
2"
W2
W2
X
X
.039"
.070"
.03
9"
.03
9"
X
X
.03
0"
CB
7
DRIVE POSITION1st GEAR
B3 BRAKE(LOW/REV. BRAKE)
C2 CLUTCH(DIRECT CLUTCH)
LEGEND
LINE PRESSURE
EPC PRESSURE
SECONDARY REG.PRESSURE
TO SUMP
SOLENOID PRESSURE
COOLER PRESSURE
CONNECTED CIRCUIT
W1- W2 SPACERPLATE DIFFERENCES
** THIS HOLE IS USED ONLYON CHECK VALVE VERSIONS
ACCUMULATOR BACK PRESH.
C1 CLUTCH(FORWARD CLUTCH)
.058” ORIFICE
S1"ON"
VIEWED FROM THEWORM TRACK SIDE
n.c.
STH (epc)
SL"OFF"
X
X
XX
X
X
X
X X
X
X
.039" balance orifice thru valve
PRESSURE CONTROLSOLENOID REG. VALVE
MANUAL VALVE
2-3 SHIFT VALVE
3-4 SHIFT VALVE
1-2 SHIFT VALVE
NEUTRAL CONTROL VALVE (Blocked)
CLUTCH MODULATOR VALVE
TCC SOLENOID REGULATOR VALVE
PRESSURE REGULATOR VALVE
SECONDARY REGULATOR VALVE
LOCK-UP CONTROL VALVE
C1 ACCUMULATOR
LOW COASTMODULATOR VALVE (B3)
LEGEND
B1 ACCUMULATORVALVE
ACCUMULATORCONTROL
VALVE
B2 ACCUMULATOR VALVE
B2ACCUMULATOR
C2 ACCU-MULATOR
C2 ACCU-MULATOR
VALVE
C3 ACCUMULATORVALVE
OUTPUT SUCTION
TCCRELEASE SIDE
TCCAPPLY SIDE
THE RETURNLINE IS LOCATED
IN THE FRONT PAN
CLUTCH PACKS
C3 CLUTCH(UNDERDRIVE CLUTCH)
C3ACCUMULATOR
.038" ORIFICE
.058" CROSS-DRILLED HOLE
.03
0"
.03
0"
22
6W
1
.05
1"
VOID
C-3
C-3
ATFCOOLER
X
X
B4 BRAKE BAND"ON"
B4 SERVO
B4 ACCUMULATORPISTON
B-4
A-2
.03
2"
.08
6"
.04
0"
.03
5"
.03
9"
.04
2"
**.0
39
"
CB
3
CB
6
.07
8"
Rearlube
Centrallube
Pressureport
503L
SUMP
X
X
PUMP
TORQUECONVERTER
B-1
CB
1
CB
2
CB
8C
B9
CB
10
.059"
X
.047"
X
XCOOLERRELIEF
X
.032"
X
X
X
X
503L
.04
0"
X
XX
X.032”
Differentiallube
.05
9”
. 2"03
B19
B19
n.c.
S2"ON"
n.o.
X
X
X
X
X
X
.035" balance orifice thru valve
P R N D 3 L
50-42LE
24
9W
2
.03
9"
CB
4
CB
5
.05
0"
.04
2"
W2
W2
X
X
.039"
.070"
.03
9"
.03
9"
X
X
.03
0"
CB
7
DRIVE POSITION2nd GEAR
B3 BRAKE(LOW/REV. BRAKE)
C2 CLUTCH(DIRECT CLUTCH)
LEGEND
LINE PRESSURE
EPC PRESSURE
SECONDARY REG.PRESSURE
TO SUMP
SOLENOID PRESSURE
COOLER PRESSURE
CONNECTED CIRCUIT
W1- W2 SPACERPLATE DIFFERENCES
** THIS HOLE IS USED ONLYON CHECK VALVE VERSIONS
ACCUMULATOR BACK PRESH.
C1 CLUTCH(FORWARD CLUTCH)
B1 BRAKE(OVERRUN BRAKE)
B2 BRAKE(INT. BRAKE)
.058” ORIFICE
S1"ON"
VIEWED FROM THEWORM TRACK SIDE
n.c.
STH (epc)
SL"OFF"
X
X
XX
X
X
X
X X
X
X
.039" balance orifice thru valve
PRESSURE CONTROLSOLENOID REG. VALVE
MANUAL VALVE
2-3 SHIFT VALVE
3-4 SHIFT VALVE
1-2 SHIFT VALVE
NEUTRAL CONTROL VALVE (Blocked)
CLUTCH MODULATOR VALVE
TCC SOLENOID REGULATOR VALVE
PRESSURE REGULATOR VALVE
SECONDARY REGULATOR VALVE
LOCK-UP CONTROL VALVE
C1 ACCUMULATOR
LOW COASTMODULATOR VALVE (B3)
LEGEND
B1 ACCUMULATORVALVE
ACCUMULATORCONTROL
VALVE
B2 ACCUMULATOR VALVE
B2ACCUMULATOR
C2 ACCU-MULATOR
C2 ACCU-MULATOR
VALVE
C3 ACCUMULATORVALVE
OUTPUT SUCTION
TCCRELEASE SIDE
TCCAPPLY SIDE
THE RETURNLINE IS LOCATED
IN THE FRONT PAN
CLUTCH PACKS
C3ACCUMULATOR
.038" ORIFICE
.058" CROSS-DRILLED HOLE
.03
0"
.03
0"
22
6W
1
.05
1"
VOID
C-3
C-3
ATFCOOLER
X
X
B4 BRAKE BAND"OFF"
B4 SERVO
B4 ACCUMULATORPISTON
B-4
A-2
.03
2"
.08
6"
.04
0"
.03
5"
.03
9"
.04
2"
**.0
39
"
CB
3
CB
6
.07
8"
Rearlube
Centrallube
Pressureport
503L
SUMP
X
X
PUMP
TORQUECONVERTER
B-1
CB
1
CB
2
CB
8C
B9
CB
10
.059"
X
.047"
X
XCOOLERRELIEF
X
0. 32"
X
X
X
X
503L
.04
0"
X
XX
X.032”
Differentiallube
.05
9”
. 2"03
B19
B19
n.c.
S2"OFF"
n.o.
X
X
X
X
X
X
.035" balance orifice thru valve
P R N D 3 L
50-42LE
24
9W
2
.03
9"
CB
4
CB
5
.05
0"
.04
2"
W2
W2
X
X
.039"
.070"
.03
9"
.03
9"
X
X
.03
0"
CB
7
DRIVE POSITION3rd GEAR
B3 BRAKE(LOW/REV. BRAKE)
C2 CLUTCH(DIRECT CLUTCH)
LEGEND
LINE PRESSURE
EPC PRESSURE
SECONDARY REG.PRESSURE
TO SUMP
SOLENOID PRESSURE
COOLER PRESSURE
CONNECTED CIRCUIT
W1- W2 SPACERPLATE DIFFERENCES
** THIS HOLE IS USED ONLYON CHECK VALVE VERSIONS
ACCUMULATOR BACK PRESH.
C1 CLUTCH(FORWARD CLUTCH)
B1 BRAKE(OVERRUN BRAKE)
B2 BRAKE(INT. BRAKE)
C3 CLUTCH(UNDERDRIVE CLUTCH)
.058” ORIFICE
S1"OFF"
VIEWED FROM THEWORM TRACK SIDE
n.c.
STH (epc)
SL"OFF"
X
X
XX
X
X
X
X X
X
X
.039" balance orifice thru valve
PRESSURE CONTROLSOLENOID REG. VALVE
MANUAL VALVE
2-3 SHIFT VALVE
3-4 SHIFT VALVE
1-2 SHIFT VALVE
NEUTRAL CONTROL VALVE (Blocked)
CLUTCH MODULATOR VALVE
TCC SOLENOID REGULATOR VALVE
PRESSURE REGULATOR VALVE
SECONDARY REGULATOR VALVE
LOCK-UP CONTROL VALVE
C1 ACCUMULATOR
LOW COASTMODULATOR VALVE (B3)
LEGEND
B1 ACCUMULATORVALVE
ACCUMULATORCONTROL
VALVE
B2 ACCUMULATOR VALVE
B2ACCUMULATOR
C2 ACCU-MULATOR
C2 ACCU-MULATOR
VALVE
C3 ACCUMULATORVALVE
OUTPUT SUCTION
TCCRELEASE SIDE
TCCAPPLY SIDE
THE RETURNLINE IS LOCATED
IN THE FRONT PAN
CLUTCH PACKS
C3ACCUMULATOR
.038" ORIFICE
.058" CROSS-DRILLED HOLE
.03
0"
.03
0"
22
6W
1
.05
1"
VOID
C-3
C-3
ATFCOOLER
X
X
B4 BRAKE BAND"OFF"
B4 SERVO
B4 ACCUMULATORPISTON
B-4
A-2
.03
2"
.08
6"
.04
0"
.03
5"
.03
9"
.04
2"
**.0
39
"
CB
3
CB
6
.07
8"
Rearlube
Centrallube
Pressureport
503L
SUMP
X
X
PUMP
TORQUECONVERTER
B-1
CB
1
CB
2
CB
8C
B9
CB
10
X
.047"
X
XCOOLERRELIEF
X
03. 2"
X
X
X
X
503L
.04
0"
X
XX
X.032”
Differentiallube
.05
9”
.0 2"3
B1
9B
19
n.c.
S2"OFF"
n.o.
X
X
X
X
X
X
.035" balance orifice thru valve
P R N D 3 L
50-42LE
24
9W
2
.03
9"
CB
4
CB
5
.05
0"
.04
2"
W2
W2
X
X
.039"
.070"
.03
9"
.03
9"
X
X
.03
0"
CB
7
DRIVE POSITION4th GEAR
B3 BRAKE(LOW/REV. BRAKE)
LEGEND
LINE PRESSURE
EPC PRESSURE
SECONDARY REG.PRESSURE
TO SUMP
SOLENOID PRESSURE
COOLER PRESSURE
CONNECTED CIRCUIT
W1- W2 SPACERPLATE DIFFERENCES
** THIS HOLE IS USED ONLYON CHECK VALVE VERSIONS
ACCUMULATOR BACK PRESH.
C1 CLUTCH(FORWARD CLUTCH)
B1 BRAKE(OVERRUN BRAKE)
B2 BRAKE(INT. BRAKE)
C3 CLUTCH(UNDERDRIVE CLUTCH)
C2 CLUTCH(DIRECT CLUTCH)
.059"
.058” ORIFICE
S1"OFF"
VIEWED FROM THEWORM TRACK SIDE
n.c.
STH (epc)
SL"ON"
X
X
XX
X
X
X
X X
X
X
.039" balance orifice thru valve
PRESSURE CONTROLSOLENOID REG. VALVE
MANUAL VALVE
2-3 SHIFT VALVE
3-4 SHIFT VALVE
1-2 SHIFT VALVE
NEUTRAL CONTROL VALVE (Blocked)
CLUTCH MODULATOR VALVE
TCC SOLENOID REGULATOR VALVE
PRESSURE REGULATOR VALVE
SECONDARY REGULATOR VALVE
LOCK-UP CONTROL VALVE
C1 ACCUMULATOR
LOW COASTMODULATOR VALVE (B3)
LEGEND
B1 ACCUMULATORVALVE
ACCUMULATORCONTROL
VALVE
B2 ACCUMULATOR VALVE
B2ACCUMULATOR
C2 ACCU-MULATOR
C2 ACCU-MULATOR
VALVE
C3 ACCUMULATORVALVE
OUTPUT SUCTION
TCCRELEASE SIDE
TCCAPPLY SIDE
THE RETURNLINE IS LOCATED
IN THE FRONT PAN
CLUTCH PACKS
C3ACCUMULATOR
.038" ORIFICE
.058" CROSS-DRILLED HOLE
.03
0"
.03
0"
22
6W
1
.05
1"
VOID
C-3
C-3
ATFCOOLER
X
X
B4 BRAKE BAND"OFF"
B4 SERVO
B4 ACCUMULATORPISTON
B-4
A-2
.03
2"
.08
6"
.04
0"
.03
5"
.03
9"
.04
2"
**.0
39
"
CB
3
CB
6
.07
8"
Rearlube
Centrallube
Pressureport
503L
SUMP
X
X
PUMP
TORQUECONVERTER
B-1
CB
1
CB
2
CB
8C
B9
CB
10
.059"
X
.047"
XX
XXCOOLERRELIEF
X
0. 32"
X
X
X
X
503L
.04
0"
X
XX
X.032”
Differentiallube
.05
9”
. 2"03
B1
9B
19
n.c.
S2"OFF"
n.o.
X
X
X
X
X
.035" balance orifice thru valve
P R N D 3 L
50-42LE
24
9W
2
.03
9"
CB
4
CB
5
.05
0"
.04
2"
W2
W2
X
X
.039"
.070"
.03
9"
.03
9"
X
X
.03
0"
CB
7
DRIVE POSITION4th GEAR TCC "ON"
B3 BRAKE(LOW/REV. BRAKE)
LEGEND
LINE PRESSURE
EPC PRESSURE
SECONDARY REG.PRESSURE
TO SUMP
SOLENOID PRESSURE
COOLER PRESSURE
CONNECTED CIRCUIT
W1- W2 SPACERPLATE DIFFERENCES
** THIS HOLE IS USED ONLYON CHECK VALVE VERSIONS
ACCUMULATOR BACK PRESH.
C1 CLUTCH(FORWARD CLUTCH)
B1 BRAKE(OVERRUN BRAKE)
B2 BRAKE(INT. BRAKE)
C3 CLUTCH(UNDERDRIVE CLUTCH)
C2 CLUTCH(DIRECT CLUTCH)
.058” ORIFICE
S1"ON"
VIEWED FROM THEWORM TRACK SIDE
n.c.
STH (epc)
SL"OFF"
X
X
XX
X
X
X
X X
X
X
.039" balance orifice thru valve
PRESSURE CONTROLSOLENOID REG. VALVE
MANUAL VALVE
2-3 SHIFT VALVE
3-4 SHIFT VALVE
1-2 SHIFT VALVE
NEUTRAL CONTROL VALVE (Blocked)
CLUTCH MODULATOR VALVE
TCC SOLENOID REGULATOR VALVE
PRESSURE REGULATOR VALVE
SECONDARY REGULATOR VALVE
LOCK-UP CONTROL VALVE
C1 ACCUMULATOR
LOW COASTMODULATOR VALVE (B3)
LEGEND
B1 ACCUMULATORVALVE
ACCUMULATORCONTROL
VALVE
B2 ACCUMULATOR VALVE
B2ACCUMULATOR
C2 ACCU-MULATOR
C2 ACCU-MULATOR
VALVE
C3 ACCUMULATORVALVE
OUTPUT SUCTION
TCCRELEASE SIDE
TCCAPPLY SIDE
THE RETURNLINE IS LOCATED
IN THE FRONT PAN
CLUTCH PACKS
C3ACCUMULATOR
.038" ORIFICE
.058" ORIFICE
.058" CROSS-DRILLED HOLE
.03
0"
.03
0"
22
6W
1
.05
1"
VOID
C-3
C-3
ATFCOOLER
X
X
B4 BRAKE BAND"OFF"
B4 SERVO
B4 ACCUMULATORPISTON
B-4
A-2
.03
2"
.08
6"
.04
0"
.03
5"
.03
9"
.04
2"
**.0
39
"
CB
3
CB
6
.07
8"
Rearlube
Centrallube
Pressureport
503L
SUMP
X
X
PUMP
TORQUECONVERTER
B-1
CB
1
CB
2
CB
8C
B9
CB
10
.059"
X
.047"
X
XCOOLERRELIEF
X
.032"
X
X
X
X
503L
.04
0"
X
XX
X.032”
Differentiallube
.05
9”
. 20 "3
B19
B19
n.c.
S2"OFF"
n.o.
X
X
X
X
X
X
.035" balance orifice thru valve
P R N D 3 L
50-42LE
24
9W
2
.03
9"
CB
4
CB
5
.050"
.042"
W2
W2
X
X
.039"
.070"
.03
9"
.03
9"
X
X
.03
0"
CB
7
MANUAL "3" POSITION3rd GEAR
B3 BRAKE(LOW/REV. BRAKE)
C2 CLUTCH(DIRECT CLUTCH)
LEGEND
LINE PRESSURE
EPC PRESSURE
SECONDARY REG.PRESSURE
TO SUMP
SOLENOID PRESSURE
COOLER PRESSURE
CONNECTED CIRCUIT
W1- W2 SPACERPLATE DIFFERENCES
** THIS HOLE IS USED ONLYON CHECK VALVE VERSIONS
ACCUMULATOR BACK PRESH.
C1 CLUTCH(FORWARD CLUTCH)
B1 BRAKE(OVERRUN BRAKE)
B2 BRAKE(INT. BRAKE)
C3 CLUTCH(UNDERDRIVE CLUTCH)
LOW COAST MOD. PRESH.
S1"OFF"
VIEWED FROM THEWORM TRACK SIDE
n.c.
STH (epc)
SL"OFF"
X
X
XX
X
X
X
X X
X
X
.039" balance orifice thru valve
PRESSURE CONTROLSOLENOID REG. VALVE
MANUAL VALVE
2-3 SHIFT VALVE
3-4 SHIFT VALVE
1-2 SHIFT VALVE
NEUTRAL CONTROL VALVE (Blocked)
CLUTCH MODULATOR VALVE
TCC SOLENOID REGULATOR VALVE
PRESSURE REGULATOR VALVE
SECONDARY REGULATOR VALVE
LOCK-UP CONTROL VALVE
C1 ACCUMULATOR
LOW COASTMODULATOR VALVE (B3)
LEGEND
B1 ACCUMULATORVALVE
ACCUMULATORCONTROL
VALVE
B2 ACCUMULATOR VALVE
B2ACCUMULATOR
C2 ACCU-MULATOR
C2 ACCU-MULATOR
VALVE
C3 ACCUMULATORVALVE
OUTPUT SUCTION
TCCRELEASE SIDE
TCCAPPLY SIDE
THE RETURNLINE IS LOCATED
IN THE FRONT PAN
CLUTCH PACKS
C3ACCUMULATOR
.038" ORIFICE
.058" CROSS-DRILLED HOLE
.03
0"
.03
0"
22
6W
1
.05
1"
VOID
C-3
C-3
ATFCOOLER
X
X
B4 BRAKE BAND"ON"
B4 SERVO
B4 ACCUMULATORPISTON
B-4
A-2
.03
2"
.08
6"
.04
0"
.03
5"
.03
9"
.04
2"
**.0
39
"
CB
3
CB
6
.07
8"
Rearlube
Centrallube
Pressureport
503L
SUMP
X
X
PUMP
TORQUECONVERTER
B-1
CB
1
CB
2
CB
8C
B9
CB
10
.059"
X
.047"
X
XCOOLERRELIEF
X
03. 2"
X
X
X
X
503L
.04
0"
X
XX
X.032”
Differentiallube
.05
9”
.0 2"3
B19
B19
n.c.
S2"ON"
n.o.
X
X
X
X
X
X
.035" balance orifice thru valve
P R N D 3 L
50-42LE
24
9W
2
.03
9"
CB
4
CB
5
.05
0"
.04
2"
W2
W2
X
X
.039"
.070"
.03
9"
.03
9"
X
X
.03
0"
CB
7
MANUAL "1" POSITION1st GEAR
C2 CLUTCH(DIRECT CLUTCH)
LEGEND
LINE PRESSURE
EPC PRESSURE
SECONDARY REG.PRESSURE
TO SUMP
SOLENOID PRESSURE
COOLER PRESSURE
CONNECTED CIRCUIT
W1- W2 SPACERPLATE DIFFERENCES
** THIS HOLE IS USED ONLYON CHECK VALVE VERSIONS
ACCUMULATOR BACK PRESH.
C1 CLUTCH(FORWARD CLUTCH)
B1 BRAKE(OVERRUN BRAKE)
B2 BRAKE(INT. BRAKE)
C3 CLUTCH(UNDERDRIVE CLUTCH)
LOW COAST MOD. PRESH.
B3 BRAKE(LOW/REV. BRAKE)
.058” ORIFICE
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
44
Copyright © 2004 ATSG
1. Place the transmission on a suitable work bench. 2. Remove the 8, 12 mm headed pump to case retaining bolts as shown in Figure 42 . 3. Using a suitable pump puller, remove the pump from the bellhousing as shown in Figure 43 and set it aside for further disassembly. 4. Once the pump is removed, remove the B2- Second Coast Brake Hub assembly as shown in Figure 44. 5. Remove the 5, 12 mm headed bellhousing to main case bolts as shown in Figure 45. NOTE: See Figure 45 for bolt lengths.
Figure 42
TRANSMISSION DISASSEMBLY
Figure 43
Figure 44
Continued on Page 45
B2- Second Coast Brake Hub
Bolt lengths
8 Pump to case retaining bolts 28mm long
5 bellhousing to case retaining bolts A = 30mm longB = 35mm longC = 35mm longD = 30mm longE = 45mm long
Figure 45
B
C
D
E
A
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
45
6. Remove the 6 , 12mm headed bellhousing to main case bolts as shown in figure 46. Note: Bolts are 30mm long. 7. Stand the transmission up on its back cover and remove the remaining 5, 12mm headed bellhousing to main case bolts as shown in Figure 47. Note: Bolts are 30mm long. 8. Using a rubber mallet, tap the bellhousing evenly in the direction of the arrows shown in Figure 48 and set it off to the side. 9. Remove the differential carrier shown in Figure 49.
TRANSMISSION DISASSEMBLYCONTINUED
Figure 47
Figure 46
Figure 48
Differential carrier
Figure 49
Continued on Page 46
Copyright © 2004 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
46
Copyright © 2004 ATSG
10. Remove the 10 mm headed filter retaining bolt, shown in Figure 50, and discard the filter. Note: The bolt length is 13mm. 11. Remove the 27 torx headed output shaft speed sensor bolt and remove the sensor as shown in Figure 51. Note: The bolt length is 13mm long. 12. Remove the 2, 10mm headed oil deflector plate retaining bolts and the 2, 10mm headed case plate retaining bolts as shown in Figure 52. Note the bolt lengths are 13mm long. 13. Remove the 2, 10mm headed detent spring retaining bolts, detent spring and park rod guide as shown in Figure 53. Refer to Figure 54 to see this assembly removed from the Case. Note the bolt lengths are 15.5mm long.
Figure 50
TRANSMISSION DISASSEMBLYCONTINUED
Figure 51
See bolt legend in Figure 45 for lengths
Filter
Output speed sensor
Oil deflector plate
Case plate
Figure 52
Figure 53
Park rod guide Detent spring
REMOVED
Figure 54
Continued on Page 47
Filter retaining bolt
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
47
Copyright © 2004 ATSG
Figure 55
14. Remove the park pawl pin and return spring. Remove the park pawl as shown in Figure 55. Refer to Figure 56 to see this assembly removed from the case. 15. Remove the two B4 accumulator retaining plate bolts and plate, using a 30 torx bit, as shown in Figure 57. The bolt on the left anchors the sleeve and parking rod return spring, as shown in the close-up in Figure 58. Note: The bolt on the left is 22mm long. The bolt on the right is 13.5mm long. CAUTION: B4 accumulator is spring loaded in your direction. 16. Remove the B4 accumulator cap, as shown in Figure 59.
TRANSMISSION DISASSEMBLYCONTINUED
Continued on Page 48
REMOVED
Park pawl return spring
Park pawlPark pawl pin
Figure 56
Pin in pic
Park pawl pinand return spring
Park pawl
Figure 57
B4 accumulator retaining plate
B4 accumulator cap
Figure 59
B4 accumulator retaining plate
Parking rod return spring and sleeve
Figure 58
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
48
17. Remove the B4 accumulator piston and spring as shown in Figure 60. Refer to Figure 61 to see this assembly removed from the case. 18. Remove the park lock pin from the case. Remove the Underdrive planetary thrust washer and bearing as shown in Figure 62 and Figure 63. 19. Remove the Underdrive planetary geartrain, by pulling it straight forward, and set it aside for later disassembly, as shown in Figure 64.
TRANSMISSION DISASSEMBLYCONTINUED
Figure 60
B4 accumulator piston and spring
B4 accumulator piston and spring
Figure 61
Figure 62
Park lock pin
Underdrive planetary thrustwasher and bearing
Underdrive planetary thrustwasher and bearing
Figure 63
Figure 64
Underdrive planetary assembly
Continued on Page 49
Copyright © 2004 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
49
Copyright © 2004 ATSG
F3 Freewheel
14. Remove the Underdrive clutch drum by grasping the sun gear and turning it counter clockwise while pulling it forward as shown in Figure 65. 15. Place the Underdrive drum on the bench and remove the bearing from the rear of the drum as shown in Figure 66. 16. Grasp the B4 Underdrive Brake Band, in the area of the arrow as shown in Figure 67, and pull it forward to remove it from the case. 17. Remove the snap ring and pull the F3 freewheel forward as shown in Figure 68. 18. Remove the Anti-rattle clip as shown in Figure 69.
TRANSMISSION DISASSEMBLYCONTINUED
Continued on Page 50
Underdrive clutch drum
Remove the bearing from the rear ofthe Underdrive drum
Figure 65
Figure 66
Figure 67
Sun gear ETATOR
B4 Underdrive Brake Band
Snapring
Anti-rattle cliplocation (installed)
Figure 68
Figure 69
Anti-rattle clip
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
50
19. Remove the two 10mm headed bolts that are identified with an "A", shown in Figure 70. Note: the bolt lengths are 16mm. 20. Remove the remaining seven 12 mm headed bolts as shown in Figure 70. Note: the bolt lengths are as follows: B= 25mm, C= 48mm and D= 45mm. Using a hammer gently tap the rear cover off of the case. 21. Remove the 27 torx headed turbine sensor bolt and sensor. Note: the bolt length is 13mm. Remove the C1-C2 drum thrust bearing and washer. Remove the C1-C2 drum as shown in Figure 71. Refer to Figure 72 to see a closeup of the C1-C2 washer and bearing. 22. Remove the C2 hub and sun gear assembly as shown in Figure 73. 23. Refer to Figure 74 for a view of the C2 hub with the front and rear bearings.
TRANSMISSION DISASSEMBLYCONTINUED
Continued on Page 51
Figure 70
Figure
A
A
B
B
C
D
C
D
D
Figure 71
Turbine Sensor
C1-C2 Drum
C1-C2 DrumThrust bearing
and washer
C1-C2 Drum Thrust bearingand washer removed
Figure 73
Figure 72
Copyright © 2004 ATSG
C2 Hub and sun gear
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
51
Copyright © 2004 ATSG
24. Refer to Figure 74 for the bearing placements on the C2 hub. Remove the C1 hub as shown in Figure 75. 25. Remove the front and rear bearings from the C1 hub as shown in Figure 76. 26. Remove the rear planetary thrust washer and planetary assembly as shown in Figure 77. 27. Remove the rear ring gear bearing as shown in Figure 78.
TRANSMISSION DISASSEMBLYCONTINUED
Continued on Page 52
Figure 75
Figure 74
C2 hub front bearingC2 hub rear bearing
C1 hub
Figure 76
C1 hub front bearingC1 hub rear thrustwasher
Rear planetarythrust washer
Planetary assembly
Figure 77
Figure 78
Rear ring gear
Bearing
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
52
28. Remove the snap ring retaining the B3 brake in the case. Pull the ring gear forward to remove the B3 brake assembly, as shown in Figure 79. 29. Place the ring gear on the bench and remove the B3 brake frictions and steels up off of the ring gear as shown in Figure 80. 30. Turn the ring gear over and remove the inner thrust washer and bearing shown in Figure 81. 31. Remove the B3 brake lower pressure plate from the case as shown in Figure 82. 32. Remove the retaining snap ring and B3 piston return spring as shown in Figure 83.
TRANSMISSION DISASSEMBLYCONTINUED
Figure 79
Figure 80
Figure 81
Figure 82
Figure 83
B3 brake return spring
Continued on Page 53
Copyright © 2004 ATSG
Remove the snap ring retaining the B3 brakeand remove the ring gear with the B3 brake
Remove B3 brake assembly from the ring gear
Remove the inner thrustwasher and bearing
Remove B3 brake lower pressure plate
Retaining snap ring
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
53
33. Remove the B3 piston from the case as shown in Figure 84. 34. Remove the snap ring retaining the Counter drive gear into the case as shown in Figure 85. Refer to Figure 86 to see the Counter drive gear removed from the case. 35. Turn the transaxle to the side and remove the temperature sensor with a 19mm wrench. 36. Using a 40 torx bit, remove the 9 pan retaining bolts as shown in Figure 87. Note: the bolts are 15mm long. 37. Remove the four solenoid connectors shown in Figure 88 and move the internal wire harness away from the valve body retaining bolts. Note: The wire colors are listed below each solenoid.
TRANSMISSION DISASSEMBLYCONTINUED
Continued on Page 54
B3 brake piston
Figure 84
Figure 86
Tempsensor
Remove the 9 pan bolts
Figure 85 Figure 87
Snap ring
Remove Counter drive gear thru rear
of the case half
S2black
STHtan/blue
SLred
S1white
Figure 88
Snap ring
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
54
38. Remove the 10 mm headed valve body to case retaining bolts as shown in Figure 89. Note: bolt lengths are as follows, A = 16mm long, 50mm long and C = 55mm long. 39. Remove the 13mm headed nut retaining the manual lever and remove the lever. Remove the two 17mm headed transmission range switch to case retaining bolts. Note: the bolt lengths are as follows, A = 21mm long and B = 32mm long. Remove the two 14mm headed connector retaining bolts. Note : the bolt lengths are 20 mm long. See Figure 90. 40. Lift the transmission range switch up off of the manual shaft and remove the internal wire harness to case connector retainer, as shown in Figure 91. Once the retainer is removed push the internal wire harness thru the case and set the entire assembly to the side. 41. Refer to Figure 92 for a close- up view of the internal wire harness to case retainer.
TRANSMISSION DISASSEMBLYCONTINUED
Figure 89
Figure 90
Figure 92
Continued on Page 55
Remove the inner thrustwasher and bearing
A
A
B
B
B
B
C
C
CInternal wire harness to case retainer
Figure 91
Internal wire harness to case retainer
A
B
Manual lever
Transmissionrangeswitch
Figure 81Manual shaft
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
55
Copyright © 2004 ATSG
42. Rotate the Manual shaft until the tab on the park rod aligns with the slot in the in the manual shaft. Lift the park rod up and pull it forward to remove it from the case as shown in Figure 93. 43. Push the manual shaft down thru the case to remove it as shown in Figure 94. 44. Refer to Figure 95 to view the manual shaft and the park rod removed from the case. 45. Remove the snap ring retaining the B4 servo assembly into the case, as shown in Figure 96. 46. Refer to Figure 97, to view the B4 servo and it's related parts.
TRANSMISSION DISASSEMBLYCONTINUED
B4 servo assembly
Figure 93
Figure 94 Figure 96
Figure 97
B4 servo assembly removedManual shaft
Park rod
Manual shaft
Push the Manualshaft this direction
Push the parkrod this direction
Manual shaft
Park rod
Figure 95
Copyright © 2004 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
56
47. Remove the snap ring and B2 clutch assembly as shown in Figure 98. 48. Remove the snap ring and pressure plate above the B1 clutch as shown in Figure 99. Caution: The pressure plate is spring loaded in the direction facing you. 49. Remove the return spring assembly as shown in Figure 100. 50. Remove the remaining B1 clutch assembly as shown in Figure 101. 51. Remove the pump to B2 second coast brake hub thrust washer as shown in Figure 102.
SUB-ASSEMBLIES"PUMP"
Figure 98
Figure 99
Figure 100
Figure 101
Figure 102
Thrust washer
Continued on Page 57
Copyright © 2004 ATSGB1 upper pressure plate
Return spring assembly
Remove B1 clutch assemblyB2 clutch assembly
Cautionspring loaded
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
57
52. Using a suitable press, remove the snap ring and B1 return spring assembly, as shown in Figure 103. 53. Refer to Figure 104 for piston identification. 54. Apply compressed air to the passage shown in Figure 105 and remove the B2 piston. Caution: Using compressed air may cause the piston to jump out of the housing. 55. Apply compressed air to the passage shown in Figure 106 and remove the B1 piston. 56. Using a 30 torx bit, remove the 14 bolts that retain the piston housing to the pump. Note: The bolt length for the smaller diameter bolt is 16mm long. The remaining bolts are 13mm long. Inspect stator bushings and replace as necessary. See Figure 107. Continued on Page 58
B1 return spring
Figure 103
Figure 105
Figure 104
Figure 106
B1 piston
Figure 107
Apply airpressure
SUB-ASSEMBLIES"PUMP" CONTINUED
B2 piston
RemoveB2 piston
Apply airpressure
RemoveB1 piston
Pistonhousing
Snap ring
Smallerdiameter bolt16mm long
Statorbushings
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
58
57. Remove the pump plate as shown, in Figure 108, and check for wear or scoring. 58. Using a straight edge, check the pump gear to pump face clearance, as shown in Figure 109. Clearance must be between .001"-.003." The maximum clearance is .004." Using a feeler gage check the outer pump gear to pump body clearance. Clearance must be between .003" and .006." The maximum is .008." 59. Inspect the outer pump gear and the torque converter lug area for wear, as shown in Figure 110. 60. Inspect the pump body for wear, and remove the pump o-ring as shown in Figure 111. 61. Check the pump bushing for wear and replace the front seal, as shown in Figure 112.
Figure 108
Figure 110
Figure 112
Continued on Page 59
Pump bushing
Figure 111
Pump body check
Figure 109
.003"
Pump gear clearance check
Straight edge
Feeler gage
Pump gear check
Pump plate
.00
3"
SUB-ASSEMBLIES"PUMP" CONTINUED
Pump seal
Pump o-ring
Smallerdiameter bolt16mm long
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
59
62. Assemble the pump gears into the pump body with the dot on the pump gears facing down, as shown in Figure 113. Lubricate the gears with a small amount of ATF. 62. Assemble the pump plate on over the two alignment pins shown in Figure 114. 63. Assemble the piston housing / stator shaft thru the pump body over the alignment pins as shown in Figure 115. Using a 30 torx bit, install the thirteen 13mm long retaining bolts and torque to 89-124 in.lb. Torque the 16mm long bolt to 53-62 in.lb. 64. Replace the inner and outer B1 and B2 piston o-rings as shown in Figure 116. 65. Lubricate the piston o-rings and install the pistons into the housing shown in Figure 117.
Pump assembly
Figure 116
Figure 117Figure 115
Copyright © 2004 ATSG
Dot on pump gears face down
Alignment pin
Alignment pin
B1 piston B2 piston
Inner o-ring
Outer o-ring Outer o-ring
Inner o-ring
Figure 113
Figure 114
Pump plate
SUB-ASSEMBLIES"PUMP" CONTINUED
Continued on Page 60
30 torx
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
60
66. Using a suitable press, depress the B1 return spring and assemble the retaining snap ring, as shown in Figure 118. 67. Assemble the B2 second coast brake hub thrust washer as shown in Figure 119. 68. Assemble the two B1 steel plates and two B1 clutch plates into the housing as shown in Figure 121. Refer to the exploded view in Figure 120 for assembly purposes. 69. Assemble the return spring assembly into the housing as shown in Figure 122.
SUB-ASSEMBLIES"PUMP" CONTINUED
Figure 118
Figure 119
Figure 121
Figure 122
Thrust washer
Continued on Page 61
Assemble B1 clutch assembly
B1 return springSnap ring
B1 clutch assembly
Steel platethickness .072"
Pressure platethickness .137"
Snap ring
Clutch platethickness .070"
Return spring assembly
Copyright © 2004 ATSG
Figure 120
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
61
70. Assemble the B1 upper pressure plate on top of the spring retainer as shown in Figure 123. Press it down and assemble the retaining snap ring. Check B1 clutch clearance using a feeler gage. Clearance should be between .030"-.040." 71. Assemble the B2 clutch assembly into the housing starting with the .145" thick pressure plate, as shown in Figure 124, ending with the snap ring. Check the clearance between the top pressure plate and the top B2 clutch plate. The clearance should be between .025"- .030." 72. Using a rubber tip blow gun, air check the B1 and B2 clutch assemblies , thru the two ports, as shown in Figure 126. 73. Install pump o-ring as shown in Figure 127.Figure 123
Figure 125
Figure 124Figure 126
Figure 127
SUB-ASSEMBLIES"PUMP" CONTINUED
B1 upper pressure plate
Cautionspring loaded
.030" to .040"clearance
.035"
B2 clutch assembly
B2 clutch assembly
Pressure platethickness .145"
Snap ring
Clutch platethickness .068"
Pressure platethickness .145"
Steel plate thickness .100"
.025" to .030"clearance
.030"
B1 air check B2 air check
Pump o-ring
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
62
74. Remove the inner race rotating it clockwise as shown in Figure 128. 75. Turn the inner race upside down to check for wear in the area where the sprag rides. Replace as necessary. See Figure 129. 76. Remove the sprag and end bearings from the outer race, as shown in Figure 130, and check for wear in the area where the sprag rides. Replace as necessary. 78. Inspect the sprag elements for wear as shown in Figure 131. Replace as necessary. 79. Refer to Figure 132 for a view of the complete assembly disassembled.
Figure 128
Figure 130
Figure 132
Continued on Page 63
Figure 131
Figure 129
Check for wear here
Inner race thrust washer
Sprag and end bearings
SUB-ASSEMBLIES"B2 COAST BRAKE HUB AND SPRAG"
Inner sprag race
Outer race
Sprag elements
I.D. rib
Inner racethrust washer
Inner race
Sprag andend bearings
Outer race
Rear thrustwasher
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
63
80. Assemble the sprag, I.D. rib facing down, and end bearings into the outer race, as shown in Figure 133. Use the illustration in Figure 131 to identify the I.D. rib. 81. Assemble the inner thrust washer into the inner sprag race as shown in Figure 134. 82. Assemble the inner sprag race into the sprag and outer race. The inner race must freewheel clockwise and lock counterclockwise when holding the outer race. See Figure 135. 83. Turn the complete assembly over and assemble the rear thrust washer into the outer race shown in Figure 136. 84. Assemble the complete B2 coast brake hub assembly into the already completed pump assembly and set aside for final assembly into the case. See Figure 137.
Figure 136
Figure 137Figure 135
Copyright © 2004 ATSG
Install the sprag and end bearingsthe I.D. rib should face down
Inner race
Figure 133
Figure 134
Thrust washer
Outer race
Turn inner race
Hold outer race
Freewheel
Rear thrust washer
Outer race
SUB-ASSEMBLIES"B2 COAST BRAKE HUB AND SPRAG Contd."
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
64
85. Remove the snap ring and the C3 clutch assembly from the C3 drum as shown below in Figure 138. 86. Remove the snap ring, C3 return spring assy. and C3 piston as shown in Figure 139. 87. Inspect the bushing in the front of the C3 drum and replace as necessary. See Figure 140. 88. Turn the C3 drum over and inspect the rear bushing in the drum. Inspect the sprag race as shown in Figure 141. Replace as necessary. 89. Inspect the check ball assembly for debris and replace the inner and outer o-rings on the C3 piston. See Figure 142.
SUB-ASSEMBLIES"C3 UNDERDRIVE CLUTCH DRUM"
Figure 138
Figure 139
Figure 141
Figure 142
Snap ring
Continued on Page 65
C3 drumSnap ring
Copyright © 2004 ATSG
Figure 140
Inspect bushing
Inspect bushing
Inspect sprag race
C3 piston
Inner o-ring
Outer o-ring
Check ball
Return spring
C3 piston
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
65
90. Lubricate the inside of the C3 drum in the areas shown in Figure 143. 91. Install the C3 piston into the C3 drum as shown in Figure 144. 92. Install the return spring into the C3 piston and install the retaining snap ring as shown in Figure 145. 93. Install the C3 clutch assembly into the C3 drum as shown in Figure 147, using Figure 146 as a guide. Install the .020" bottom steel first, then install the cushion plate in the direction shown in Figure 146. Install the remaining clutch plates, steel plates, pressure plate and snap ring. Using a feeler gage check clutch clearance between the pressure plate and the top clutch plate. The clearance should be .032" - .038."Figure 143
Figure 145
Figure 144Figure 146
Figure 147
Lubricate
C3 piston
Snap ring
Return spring
C3 clutch assembly
SUB-ASSEMBLIES"C3 UNDERDRIVE CLUTCH DRUM Contd."
Snap ring
Pressure platethickness .150"
4 clutch platesthickness .068"
Bottom steel platethickness .020"
4 steel platesthickness .072"Cushion plate
Install
.032" to .038"clearance
.035"
Copyright © 2004 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
66
94. Remove the retainer from the top of the outer sprag race as shown in Figure 148. 95. Remove the F3 sprag and end bearings from the outer race as shown in Figure 149. 96. Inspect the end bearings for wear as shown in Figure 150. Replace as necessary. 97. Inspect the sprag elements for wear as shown in Figure 151, and replace as necessary. 98. Inspect the area where the sprag rides, in the outer race, for wear or scoring. Replace as necessary. See Figure 152.
Figure 148
Figure 150
Figure 152
Continued on Page 67
Figure 151
Figure 149
SUB-ASSEMBLIES"F3 UNDER DRIVE SPRAG"
Check for wear
Check the sprag elements for wearF3 sprag assembly
Retainer
F3 sprag and end bearings
Sprag and end bearings
I.D. rib
Check for wear
Outer sprag race
Copyright © 2004 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
67
99. Install the F3 sprag and end bearings into the outer race as shown in. Refer to Figure 151 for the orientation of the I.D. rib. Ensure that the two lugs on the outer race are in the 5 o'clock position, as shown in Figure 153.100. Snap the retainer back into the groove shown in Figure 154.101. Assemble the F3 sprag onto the C3 drum and verify the proper rotation. Rotate the outer race while holding the C3 drum. The outer race should freewheel in the counter clockwise direction, as shown in Figure 155.
Figure 155
Copyright © 2004 ATSG
Install the sprag and end bearingsthe I.D. rib should face up
Retainer
Figure 153
Figure 154
Outer race
Hold drum
Freewheel
Rotate the outer race
Two lugs
SUB-ASSEMBLIES"F3 UNDERDRIVE SPRAG"
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
68
102. Using a hammer and punch, remove the stakes from the lock nut. Place the park gear into a vice and remove the lock nut with a 36mm socket. See Figure 156.103. Compress the two tabs inward and pull the ring gear rearward to remove it from the back of the counter driven gear. Refer to Figures 157 and 158.104. Support the counter driven gear in a suitable press and push the C3 underdrive planetary thru the counter driven gear. See Figure 159.105. Refer to Figure 160 for a view of the complete assembly dis-assembled and for assembly purposes.
SUB-ASSEMBLIES"UNDERDRIVE PLANETARY AND
DIFFERENTIAL PINION GEAR ASSY."
Figure 156
Figure 157
Figure 159
Figure 160
Snap ring
Continued on Page 69Figure 158
CLOSE-UP
C3- underdriveplanetary assy.
Counter driven gear
Ring gear
Lock nut
Removestakes
Snap ring tabs
C3- underdriveplanetary assy.
Ring gearPinion gear
Bearing
Park gear
Counter drivengear
Bearingrace
Crush sleeve
Copyright © 2004 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
69
106. Inspect the C3 underdrive planetary pinions and check the planetary washers for wear, replace as necessary. See Figure 161.107. Inspect the inner planetary bearing as shown in Figure 162.108. Inspect the rear tapered bearing as shown in Figure 163 and replace as necessary. Note: To remove the bearing assy., remove the cage and individual rollers. Remove the race with a two jaw bearing puller. Press a new bearing onto the planetary shaft.109. Install a new crush sleeve onto the shaft. See Figure 164.110. Inspect the counter driven gear races and front bearing as shown in Figure 165, and replace as necessary.
Figure 161
Figure 163
Figure 162
Figure 164
Figure 165
Planetary pinions
Rear taperedbearing
Copyright © 2004 ATSG
SUB-ASSEMBLIES"UNDERDRIVE PLANETARY AND
DIFFERENTIAL PINION GEAR ASSY. Contd."
Continued on Page 70Inner bearing
Crush sleeve
Front bearing
Counter driven gearbearing races
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
70
111. Install the counter driven gear onto the C3 planetary shaft as shown in Figure 166.112. Using a suitable press, install the front tapered bearing as shown in Figure 167.113. Install the pinion gear as shown in Figure 168.114. Using a suitable press, install the bearing race as shown in Figure 169.115. Assemble the park gear into a vise or suitable holding fixture and snug down a new lock nut with a 36mm socket. See Figure 170. Note: Do not tighten until the next step!
Figure 166
Figure 168
Figure 170
Continued on Page 71
Figure 169
Figure 167
Front bearing
Pinion gear
Copyright © 2004 ATSGLock nut
SUB-ASSEMBLIES"UNDERDRIVE PLANETARY AND
DIFFERENTIAL PINION GEAR ASSY."
Bearing race
Counter driven gear
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
71
116. Tighten the lock nut until the turning torque is between 5-12 in.lb. See Figure 171. Note: To check turning torque, hold the counter driven gear with the left hand and check the turning torque with an inch pound torque wrench with the right hand.117. Using a punch, stake the nut on both sides of the shaft, as shown in Figure 172.118. Using needle nose pliers, compress the tabs of the snap ring towards the ring gear and push it into the back of the counter driven gear shown in Figure 173.119. Push the ring gear into the counter driven gear until it snaps into it's groove. See Figure 174 and the close-up in Figure 175.
Figure 153
Figure 174
Snap ring
Ring gear
Figure 172
Copyright © 2004 ATSGLock nutStake with
punch
Figure 171
CLOSE-UP
Snap ring tabs
Figure 175Figure 173
Copyright © 2004 ATSG
Snap ring
SUB-ASSEMBLIES"UNDERDRIVE PLANETARY AND
DIFFERENTIAL PINION GEAR ASSY. Contd."
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
72
120. Remove the inner race from the F2 freewheel assembly as shown in Figure 176.121. Remove the snap ring and upper end bearing as shown in Figure 177.122. Lift the sprag and lower end bearing from the outer race as shown in Figure 178.123. Remove the thrust washer from the outer race. See Figure 179.124. See Figure 180 for a view of the complete assy. dis-assembled.
Figure 179
Thrust washer
Figure 177 Figure 180
Figure 178
Sprag andlower end bearing
SUB-ASSEMBLIESF2 FREEWHEEL (LOW SPRAG)
Snap ringUpper end
bearing
Sprag and end bearings
Thrust washer
Inner race
Snap ringOuter race
Continued on Page 73
Figure 176
Inner race
Turninner race
Snap ringUpper end
bearing
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
73
125. Inspect the outer race for wear or scoring, in the area where the sprag rides and replace as as necessary. See Figure 181.126. Assemble the thrust washer and the lower end bearing as shown in Figure 182.127. Inspect the sprag elements and replace as necessary. See Figure 183.128. Assemble the sprag, using Figure 183 for assy. purposes. Note: I.D. rib faces up. Assemble the upper end bearing and snap ring as shown in Figure 184.129. Inspect the inner race for wear, and assemble the inner race into the F2 freewheel assembly and check for proper rotation. Note: The inner race freewheels counter clockwise and locks clockwise when holding the outer race .See Figure 185.
Figure 181
Figure 183
Figure 182 Figure 184
Figure 185
Outer race
Copyright © 2004 ATSG
Lower end bearingThrust washer
I.D. rib
SUB-ASSEMBLIESF2 FREEWHEEL (LOW SPRAG) Contd.
Holdouter race
Sprag
Freewheel
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
74
130. Using a hammer and punch remove the stakes on the lock nut. Place the Counter drive gear in a suitable holding fixture or vice and remove the 60mm nut. See Figure 186.131. Remove the bearing race using a suitable two jaw puller. This will remove the front bearing along with the race. See Figure 187.132. Remove the crush sleeve shown in Figure 188.133. Using a suitable two jaw bearing puller, remove the rear bearing shown in Figure 189.134. Refer to Figure 190 for a view of the complete assembly dis-assembled.
Figure 186
Figure 188
Figure 190
Continued on Page 75
Figure 189
Figure 187
Copyright © 2004 ATSG
SUB-ASSEMBLIES"COUNTER DRIVE GEAR"
Lower bearing
Counter drive gear
StakeStake
Front bearing
Snap ringgroove
Crush sleeve
Bearing race
Front bearing
Rear bearing
Lock nut
Crush sleeve
Bearing race
Counter drive gear
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
75
135. Press the rear bearing onto the counter drive gear and place a new crush sleeve on the top of the rear bearing as shown in Figure 191.136. Assemble the bearing race on top of the rear bearing as shown in Figure 192.137. Press the Front bearing onto the counter drive gear shaft as shown in Figure 193.138. Place a new lock nut on to the counter drive gear and snug it down. See Figure 194.139. Place the counter drive gear into a suitable holding fixture or vice and tighten the lock nut down until turning torque is approximately 3-7 in.lb. See Figure 195. Refer to Figure 186 and stake the lock nut in two places.
Figure 194Figure 192
Figure 191
Figure 195Figure 193
Copyright © 2004 ATSG
Front bearing
Crush sleeveCrush sleeve
Crush sleeveRear bearing
Bearing raceLock nut
1 02
9
3
8
4
7
56
10Hold bearingrace
SUB-ASSEMBLIES"COUNTER DRIVE GEAR Contd."
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
76
140. Remove the snap ring and C1 clutch assembly as shown in Figure 196.141. Remove the snap ring and C2 clutch assembly as shown in Figure 197.142. Using a suitable press, remove the snap ring and return spring as shown in Figure 198.143. Remove the C1 and C2 pistons from the drum as shown in Figure 199. 144. Refer to Figure 200 for a view of the complete assembly dis-assembled.
Figure 199
Figure 197 Figure 200
Figure 198
SUB-ASSEMBLIES"C1 / C2 DRUM"
Snap ring and return spring
C1/C2 drum
Continued on Page 77
Figure 196
Inner raceSnap ringC1 clutch assy.
Snap ringC2 clutch assy.
Return spring Snap ring
C1 piston
C2 piston
C1 piston
C1 clutch
C2 clutch
C2 piston
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
77
145. Inspect the rear of the C1/C2 drum where the weld is to ensure there are no visible cracks. Replace the sealing ring shown in Figure 201. Note: This drum is notorious for cracking.146. Inspect the check ball in the C1 piston for debris and replace the inner and outer piston o-rings as shown in Figure 202.147. Lubricate the inner and outer o-rings, and the area where they ride in the drum, and install the C1 piston. See Figure 203.148. Inspect the check ball in the C2 piston for debris and replace the inner and outer piston o-rings as shown in Figure 204.149. Lubricate the inner and outer o-rings, and the area where they ride in the drum, and install the C2 piston. See Figure 205.Figure 201
Figure 203
Figure 202 Figure 204
Figure 205
Weld
Copyright © 2004 ATSG
Inner o-ring
C1 piston
Sealing ring
Outer o-ring
Inner o-ringC2 piston
Outer o-ringCheck ball
Check ball
SUB-ASSEMBLIES"C1 / C2 DRUM Contd."
Continued on Page 78
Inner raceSnap ringC1 clutch assy.
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
78
150. Install the return spring and snap ring as shown in Figure 206.151. Install the C2 clutch assembly into the drum as shown in Figure 208. Use Figure 207 as an assembly guide. Install a .072" steel plate into drum first, then install the remaining C2 clutch plates and steels ending with the pressure plate and snap ring. Clutch clearance should be between .025" to .035."152. Install the C1 clutch assembly into the drum as shown in Figure 210. Use Figure 209 as an assembly guide. Install a .072" steel plate into drum first, then install the remaining C1 clutch plates and steels ending with the pressure plate and snap ring. Clutch clearance should be between .035" to .045." Note: The C1 and C2 clutch plates are slightly waved.
Figure 206
Figure 208
Figure 210
Figure 209
Figure 207
Copyright © 2004 ATSG
Return spring Snap ring
Snap ringC2 clutch assy.
SUB-ASSEMBLIES"C1 / C2 DRUM Contd."
C1 clutch assembly
C2 clutch assembly
Pressure platethickness .150"
4 clutch platesthickness .068"
4 steel platesthickness .072" Snap ring
4 clutch platesthickness .068"
Pressure platethickness .153"
4 steel platesthickness .072"
Snap ring
.035"
.025"
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
79
153. Remove the bearing race and the two 30 torx bolts retaining the C1 accumulator cover. Caution: The cover is spring loaded. Note: The bolt lengths are 14mm. Once the cover is off, remove the spring and piston from the cover. See Figure 211.154. See Figure 212 for a view of the accumulator assembly completely dis-assembled.155. Inspect the needle bearing in the rear cover and replace the three sealing rings as shown in Figure 213. Note: The early design rear cover has an aluminum sleeve which requires steel sealing rings. ATSG recommends the late design, which is the steel sleeve.156. Lubricate the rear cover shown in Figure 214, replace the C1 accumulator piston o-ring and install it into the rear cover. See Figure 215.
Figure 214Figure 212
Figure 211
Figure 215Figure 213
Copyright © 2004 ATSG
Needle bearing
C1 accumulatorcover
Crush sleeveBearing race
Lock nut
SUB-ASSEMBLIES"REAR COVER"
C1 accumulatorpiston
O-ring
Cover andbolts
Spring
Steel sleeve uses3 Teflon sealing rings
Lubricate
C1 accumulatorpiston
Bolts
Continued on Page 80
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
80
157. Install the C1 accumulator spring over the accumulator piston as shown in Figure 216.158. Assemble the C1 accumulator cover into the rear cover and torque the 30 torx bit bolts to 70-100 in. lb. See Figure 217. 159. Install the Bearing race, using some assembly grease. See Figure 218. 160. Place the C1 / C2 drum onto the rear cover and air check the clutches using 80-100psi. of air pressure. See Figure 219. Refer to Figure 220 to identify the air check ports.
Figure 217
Figure 218
Figure 216
C1 accumulatorspring
Bearing race
"A"
SUB-ASSEMBLIES"REAR COVER Contd."
C1 accumulatorcover
Bolts
"B"
"C"
"D"
Figure 219
Figure 220
"A"= C1 clutch
C1/C2 AIR CHECKS
"B"= C2 clutch
"C"= lube"D"= C1 clutch
Note: When air checking the C1 clutch thru the D port, you must cover the A port and vice-versa. The C1 accumulator will stroke when the C1 clutch is applied.
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
81
VALVE BODY EXPLODED VIEWSAND IDENTIFICATION OF COMPONENTS
Refer to Figure 221 for Solenoid identification and locations on the valve body.
Refer to Figure 222 for valve identification and locations in the "Upper" valve body.
Refer to Figure 223 for valve identification and locations in the "Center" valve body, "Front" side.
Refer to Figure 224 for valve identification and locations in the "Center" valve body, "Rear" side.
Refer to Figure 225 for valve identification and locations in the "Lower" valve body, "Front" side.
Refer to Figure 226 for valve identification and locations in the "Lower" valve body, "Rear" side.
Refer to Figure 227 for illustrations of the typical spacer plates.
Refer to Figure 228 for the check valve and check ball locations in the "Lower" valve body.
Refer to Figure 229 for the screen locations in the "Center" valve body, "Upper" valve body side.
Refer to Figure 230 for the check valve and check ball locations in the "Center" valve body, "Lower" valve body side.
Refer to Figure 231 for bolt identification and locations for the "Lower" valve body.
SUB-ASSEMBLIES
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
82
99
992222
2211
9911
1155 22
B1
9B
19
Shift SolenoidNumber 1
Shift SolenoidNumber 2
Pressure ControlSolenoid
TCC Solenoid
Figure 221
SOLENOID IDENTIFICATIONAND BOLT LOCATIONS
8mm Head10mm long
8mm Head35mm long
8mm Head10mm long
8mm Head35mm long
Pressure controlsolenoid retainer
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
83
1. UPPER VALVE BODY CASTING2. PRESSURE CONTROL SOLENOID REGULATOR VALVE3. PRESSURE CONTROL SOLENOID REGULATOR VALVE SPRING4. PRESSURE CONTROL SOLENOID REGULATOR VALVE BORE PLUG5. PRESSURE CONTROL SOLENOID REGULATOR VALVE BORE PLUG RETAINER
2
1
3
4
5
Figure 222
UPPER VALVE BODYVALVE IDENTIFICATION AND BOLT LOCATIONS
8mm Head45mm long
8mm Head50mm long
8mm Head50mm long
8mm Head64.5mm long
12. 1-2 SHIFT VALVE SPRING13. 1-2 SHIFT VALVE BORE PLUG14. 1-2 SHIFT VALVE RETAINER15. NEUTRAL CONTROL VALVE16. NEUTRAL CONTROL VALVE RETAINER17. PRIMARY REGULATOR VALVE18. PRIMARY REGULATOR VALVE SPRING19. PLUNGER20. PLUNGER SLEEVE21. PLUNGER SLEEVE RETAINER
1. CENTER VALVE BODY CASTING2. MANUAL VALVE3. 2-3 SHIFT VALVE4. 2-3 SHIFT VALVE SPRING5. 2-3 SHIFT VALVE BORE PLUG6. 2-3 SHIFT VALVE RETAINER7. 3-4 SHIFT VALVE8. 3-4 SHIFT VALVE SPRING9. 3-4 SHIFT VALVE BORE PLUG
10. 3-4 SHIFT VALVE RETAINER11. 1-2 SHIFT VALVE
CENTER VALVE BODY "FRONT" SIDEVALVE IDENTIFICATION AND LOCATIONS
5555
00
1199
1
2
3
45
6
9
13
17
1819
20
16
14
10
21
15
12
11
7
8
RetainerLocations
Figure 223
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
84
8mm Head16mm long
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
85
1. CENTER VALVE BODY CASTING2. CLUTCH MODULATOR VALVE3. CLUTCH MODULATOR VALVE SPRING4. CLUTCH MODULATOR VALVE BORE PLUG5. CLUTCH MODULATOR VALVE RETAINER
6. TCC SOLENOID REGULATOR VALVE7. TCC SOLENOID REGULATOR VALVE SPRING8. TCC SOLENOID REGULATOR VALVE BORE PLUG9. TCC SOLENOID REGULATOR VALVE RETAINER
Figure 224
CENTER VALVE BODY "REAR" SIDEVALVE IDENTIFICATION AND LOCATIONS
555500 1199
6
7 8
9
5
43
2
1
RetainerLocations
RetainerLocations
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
86
1. LOWER VALVE BODY2. C3 ACCUMULATOR PISTON3. C3 ACCUMULATOR PISTON SPRING4. C3 ACCUMULATOR VALVE5. C3 ACCUMULATOR VALVE SPRING6. B1 ACCUMULATOR VALVE7. B1 ACCUMULATOR VALVE SPRING8. LOW COAST MODULATOR VALVE (B3)
9. LOW COAST MODULATOR VALVE SPRING (B3)
10. LOCK-UP CONTROL VALVE11. LOCK-UP CONTROL VALVE SPRING12. PLUNGER13. PLUNGER SLEEVE14. LOCK-UP CONTROL VALVE RETAINER 15. COVER PLATE GASKET16. COVER PLATE 17. COVER PLATE BOLTS (7)
Figure 225
LOWER VALVE BODY "FRONT" SIDEVALVE IDENTIFICATION AND LOCATIONS
RetainerLocations
1
3
2
15
1617
4
5
7
6
89
10
11
12
14
13
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
87
1. LOWER VALVE BODY2. C2 ACCUMULATOR PISTON3. C2 ACCUMULATOR SPRING (INNER)4. C2 ACCUMULATOR SPRING (OUTER)5. C2 ACCUMULATOR VALVE6. C2 ACCUMULATOR VALVE SPRING7. B2 ACCUMULATOR PISTON8. B2 ACCUMULATOR SPRING (INBOARD)9. B2 ACCUMULATOR SPRING (OUTBOARD)
10. B2 ACCUMULATOR VALVE
11. B2 ACCUMULATOR SPRING12. ACCUMULATOR CONTROL VALVE13. ACCUMULATOR CONTROL VALVE SPRING14. SECONDARY REGULATOR VALVE15. SECONDARY REGULATOR VALVE SPRING16. SECONDARY REGULATOR VALVE BORE PLUG17. SECONDARY REGULATOR VALVE RETAINER18. COVER PLATE GASKET19. COVER PLATE20. COVER PLATE BOLTS (7)
Figure 226
LOWER VALVE BODY "REAR" SIDEVALVE IDENTIFICATION AND LOCATIONS
1
43
2 18
1920
6
5
97
8
10
1112
13
17
1614
15
RetainerLocations
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
88
"TYPICAL" SPACER PLATES AND GASKETS
CENTER VALVE BODYTO UPPER VALVE BODY
SPACER PLATE AND GASKETS
LOWER VALVE BODYTO CASE SPACER PLATE AND GASKETS
Figure 227
W 1 W 1
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
89
LARGE FILTERSCREEN
Figure 229
VOLVO/SAAB AW50-42LE"CENTER" VALVE BODY, "UPPER" VALVE BODY SIDE
3 SMALLFILTER
SCREENS
Figure 228
CHECK VALVEAND SPRING
PRESSURE RELIEFVALVE AND SPRING
"LOWER" VALVE BODY
REQUIRES THREE OR FOURRUBBER CHECKBALLS
5.0mm (.197") IN DIAMETER
NOT USED ON ALL MODELS
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
90
VOLVO/SAAB AW50-42LE"CENTER" VALVE BODY, "LOWER" VALVE BODY SIDE
If the spacer plate has only onesmall hole over either locationDO NOT install a checkball.
If the spacer plate has one largeand one small hole over location
INSTALL a checkball.
CHECK VALVEASSEMBLY
(Early Models Only)
This checkball can go ineither location indicated
by the arrows.
CHECK VALVEAND SPRING
BYPASS VALVEAND SPRING
REQUIRES SEVEN RUBBER CHECKBALLS5.0 mm (.197") DIAMETER
Figure 230
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
91
Figure 231
22 2211AA
33 9911
5500
LOWER VALVE BODYLOWER SIDE BOLT LOCATIONS
8mm Head35mm long
8mm Head35mm long
8mm Head64.5mm long
8mm Head35mm long
8mm Head64.5mm long
8mm Head64.5mm long
8mm Head64.5mm long
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
92
161. Refer to Figure 232 to see a view of the completed counter drive gear assembly.162. Assemble the counter drive gear thru the rear of the mid case and assemble the snap ring with the taper facing up. Replace the axle seal as shown in Figure 233.163. Lubricate the inside of the mid case where the B3 brake piston rides , replace the inner and outer o-rings, and assemble the piston into the case as shown in Figure 234.164. Assemble the B3 return spring into the case over the B3 piston and install the retaining snap ring as shown in Figure 235.165. Install the B3 brake lower pressure plate as shown in Figure 236.
TRANSMISSION REASSEMBLY
Figure 232
Figure 233
Figure 235
Figure 83
B3 brake return spring
Continued on Page 93
Retaining snap ringSnap ring
Snap ringtaper faces up
Assemble Counter drive gear thru rear
of the case half
B3 brake piston
Taper faces up
Replace axleseal
Figure 234
Figure 236
Install B3 brake lowerpressure plate .150" thick
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
166. Assemble the inner thrust washer and bearing into the rear ring gear assembly with assembly lube to hold them in place. See Figure 237.167. Assemble the rear ring gear into the case half over the splines of the counter drive gear as shown in Figure 238.168. Install the B3 brake assembly into the case half starting with a .070" clutch plate and ending with the .150" pressure plate and the snap ring. Check the clutch clearance using a feeler gage as shown in Figure 240. Clutch clearance should be between .040"-.050."Refer to Figure 239 as an assembly guide for the B3 brake. Install the rear ring gear internal bearing black side up.169. Inspect the planetary pinion washers as shown in Figure 241. Replace as necessary.
TRANSMISSION REASSEMBLYCONTINUED
Continued on Page 94
Figure 237
Figure 239
Assemble the inner thrustwasher and bearing
Figure 238
B3 brake assembly
Snap ring
Pressure platethickness .150"
5 steel platesthickness .072"
6 clutch platesthickness .070"
Rear ring gear
Figure 240
B3 brake assemblyand snap ring
Bearingblack side up
.045
Figure 241
93
Check planetary pinion washers
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
94
170. Inspect the bushings in the planetary as shown in Figure 242. Replace as necessary.171. Install the planetary assembly into the rear ring gear as shown in Figure 243. Install the rear planetary thrust washer.172. Install the C1 hub rear thrust washer and the C1 hub front bearing with assembly lube to hold them in place. See Figure 244.173. Install the C2 hub rear and front bearing with assembly lube to hold them in place as shown in Figure 245. 174. Index the C2 hub into the C2 clutch plates as shown in Figure 246.
TRANSMISSION REASSEMBLYCONTINUED
Figure 242
Figure 244Continued on Page 95
Rear planetarythrust washer
Planetary assembly
C1 hub front bearingC1 hub rear thrustwasher
Figure 245
C2 hub front bearingC2 hub rear bearing
Figure 243 Figure 246
Inspect bushings
C2 hub
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
95
175. Index the C1 hub into the C1 clutches shown in Figure 247.176. Carefully, take the C1/C2 drum and slide it into the planetary assembly turning it slightly. Note: Do this with the case half standing up on the bench. Install the C1/C2 thrust washer and bearing into the rear of the drum. Apply a thin coat of sealant to the surface where the rear cover mating surface is. Replace the four rubber seals in the case half. See Figure 248. 177. Refer to Figure 249 for a close up view of the C1/C2 thrust bearing and race.178. Assemble the rear cover onto the case half and install and torque the bolts into the correct locations using the chart listed below. See Figure 250. A= 16mm long. Torque to 70-100 in.lb. B= 25mm long. Torque to 15-22 ft.lb. C= 48mm long. Torque to 15-22ft.lb. D= 45mm long. Torque to 15-22 ft.lb.
TRANSMISSION REASSEMBLYCONTINUED
Figure 248
C1-C2 DrumThrust bearing
and washer
C1-C2 Drum Thrust bearingand washer removed
Figure 250
Figure
A
A
B
B
C
D
C
D
D
Figure 247
Figure 249
Copyright © 2004 ATSG
Apply sealant
Continued on Page 96
C1/C2 drum
C1 hub
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
96
179. Turn the case over to where it is resting on the rear cover, and replace the two C3 underdrive sealing rings as shown in Figure 251.180. Install the anti-rattle clip into the case half as shown in Figure 252.181. Install the F3 freewheel and snap ring into the case. Install a new rubber seal into the case. See Figure 253.182. Replace the o-rings on the cap and B4 servo assembly as shown in Figure 254.183. Lubricate and install the servo piston, cap and retaining snap ring. See Figure 255.
TRANSMISSION REASSEMBLYCONTINUED
Figure 251
Figure 252
B3 brake return spring
Continued on Page 97
Retaining snap ring
Figure 255
Anti-rattle clip
F3 Freewheel Snap ring
Anti-rattle cliplocation (installed)
B4 servo assembly
B4 servo assembly removed
Copyright © 2004 ATSG
Figure 254
Figure 253
Sealing rings
Inspect thecaged needle
bearing
Seal
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
184. Install the B4 underdrive brake band as shown in Figure 256.185. Install the bearing into the rear of the C3 underdrive drum with the black side facing out. See Figure 257.186. Grasp the underdrive clutch drum by the sun gear and install it into the F3 freewheel and over the sealing rings by turning it counter- clockwise. See Figure 258.187. Grasp the underdrive planetary assembly by the pinion gear and assemble it into the under- drive clutch, by turning it to the left and right to index it into the underdrive clutches. See Figure 259.188. Install the underdrive planetary thrust washer and bearing as shown in Figure 260.
TRANSMISSION REASSEMBLYCONTINUED
Figure 258
97
Underdrive clutch drum
Sun gearETATOR
Underdrive planetary assembly
Underdrive planetary thrustwasher and bearing
Figure 256
Figure 257
B4 UnderdriveBrake Band
Install the bearing into the rear ofthe Underdrive drum
Continued on Page 98
Figure 259
Figure 260
Copyright © 2004 ATSG
Black side
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
98
189. Install a new linkage seal and assemble the manual shaft into the case as shown below in Figure 262.Use Figure 261 as an assembly guide.190. Slide the parking rod into the case and rotate the manual shaft until the slot lines up with the park rod. See Figure 263.191. Install new o-rings on the B4 accumulator cap and piston as shown in Figure 264.192. Lubricate and install the B4 accumulator piston and spring (spring first). Install the park lock pin into the case. See Figure 265.
TRANSMISSION REASSEMBLYCONTINUED
Continued on Page 99
Figure 265
Figure 264
B4 accumulator piston and spring
B4 accumulator piston spring and cap
Figure 263
Manual shaft
Park rod
Manual shaft
Park rod
Figure 261
Manual shaft
Linkage seal
Figure 262
Park lock pin
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
99
193. Lubricate the o-ring on the B4 accumulator cap and install it into the case. See Figure 266.194. Install the B4 accumulator retaining plate, parking rod return spring, sleeve and bolts as shown in Figure 268. Use Figure 267 as an assembly guide. Caution: the B4 accumulator piston is spring loaded. Tighten down the bolts evenly so the cap does not get cocked. Note: The bolt on the left is 22mm long and the bolt on the left is 13.5mm long. Torque both bolts to 71-106 in.lb.195. Assemble the park pawl, return spring and park pawl pin into the case as shown in Figure 270. Use Figure 269 as an assembly guide.
TRANSMISSION REASSEMBLYCONTINUED
REMOVED
Park pawl return spring
Park pawlPark pawl pin
Figure 270
Pin in pic
Park pawl pinand return spring
Park pawl
Figure 269
B4 accumulator cap
B4 accumulator retaining plate
Parking rod return spring and sleeve
B4 accumulator retaining plate
Figure 266
Figure 267
Figure 268
Copyright © 2004 ATSG
Continued on Page 100
AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
100
196. Install the detent spring and park rod guide as shown in Figure 272. Use Figure 271 as an assembly guide . Install the two retaining bolts and torque to 71-106 in. lb. Note: the bolt lengths are 15.5mm long.197. Install the oil deflector plate, case plate and the four retaining bolts. Torque to 71-106ft.lb. See Figure 273. Note: the bolt lengths are 13mm long.198. Install a new gasket on both sides of the filter as shown in Figure 274.199. Install the new filter onto the case as shown in Figure 275. Install the filter retaining bolt and torque to 71-106 in. lb. Note the bolt length is 13mm long.
TRANSMISSION REASSEMBLYCONTINUED
Continued on Page 101
Figure 275
Figure 274
Figure 272
See bolt legend in Figure 45 for lengths
Detent spring Park rod guide
REMOVED
Figure 271
Figure 273
Oil deflector plate
Case plate
Gasket
Filter
Filter retaining bolt
101AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
200. Inspect the bearing race shown in Figure 276. Replace as necessary. Install new seal in case. Note: Below the bearing race is the selective shim which sets the pre-load for the diff- erential bearings. 201. Inspect the lower differential bearing as shown in Figure 277. Replace as necessary.202. Inspect the upper differential bearing and the spider gear assembly as shown in Figure 278. Replace as necessary.203. Lubricate bearings and install the differential assembly into the case half as shown below in Figure 279. 204. Remove the four 10mm headed bolts retaining the side cover, reseal and re-install the bolts. Remove the three 10mm headed oil deflector retaining bolts as shown in Figure 280.
TRANSMISSION REASSEMBLYCONTINUED
Bearing race
Figure 280
Continued on Page 102
Selective shim
Figure 276
Figure 277
Figure 278
Copyright © 2004 ATSG
Side cover
Spider gearassembly
Upper bearing
Lower bearing
Figure 279
Differential assembly
Oil deflector
Seal
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205. Turn the oil deflector upside down and clean the three magnets. See Figure 281.206. Install the oil deflector back into the case. Apply a small amount of loctite to the three 12mm long retaining bolts and torque to 71- 106 in.lb. See Figure 282.207. Inspect the upper bearing race and the roller bearing as shown in Figure 283. Replace as necessary.208. Replace the sealing ring shown in Figure 284. Note: There is a .055" gap in between the sealing ring ends, this is normal.209. Replace the axle seal as shown in Figure 285.
TRANSMISSION REASSEMBLYCONTINUED
Continued on Page 103
Figure 285
Figure 284
Figure 282
Figure 283
Oil deflector
Oil deflector
Figure 281
Axle seal
Sealing ring
103AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information
210. Apply a thin coat of sealant between the case half and the bell housing and assemble the bell housing onto the case half. See Figure 286.211. Install the five bolts shown in Figure 287. Note: The bolt lengths are 30mm long. Torque to 17-26 ft.lb.212. Install the six bolts shown in Figure 288. Note: The bolt lengths are 30mm long. Torque to 17-26 ft.lb.213. Install the five bolts as shown in Figure 289. Refer to the chart for the correct bolt lengths and torque the bolts to 17-26 ft.lb.
TRANSMISSION REASSEMBLYCONTINUED
Continued on Page 104Figure 286
Figure 287
Figure 288
Sealant
Figure 289
B
C
D
E
A
Bolt lengths
5 bellhousing to case retaining bolts A = 30mm longB = 35mm longC = 35mm longD = 30mm longE = 45mm long
Copyright © 2004 ATSG
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Technical Service Information
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Copyright © 2004 ATSG
214. Stand the transmission horizontally on the bench as shown in Figure 290.215. Ensure that the B2 second coast brake hub is fully indexed into the clutch plates on the back of the pump as shown in Figure 291. Lubricate the pump o-ring.216. Install the pump assembly into the case and gently tap it into the case. Once the pump is seated into the case, install the eight pump to case retaining bolts and torque to 15-22ft.lb. Note: The bolt lengths are 28mm long. See Figure 292.217. Turn the transmission to the side and air check each clutch and brake to ensure proper apply. Install two new apply seals. See Figure 293.
TRANSMISSION REASSEMBLYCONTINUED
Continued on Page 105
Transmission in horizontalposition on the bench
Figure 291
Figure 290
Figure 292
B4 Servoand accumulator
B2 Brake
B3 Brake
B1 Brake
C3 Clutch
C1 Clutchand accumulator
passage
C2 Clutch
NOTE: When air checking the C1 clutch thruC1 port 1, you must cover C1 port 2 and vice-versa.
C1 port 1
C1 port 2
Figure 293
Case air checks
B2 second coast brake hub
Install two newapply seals
AUTOMATIC TRANSMISSION SERVICE GROUP
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TRANSMISSION REASSEMBLYCONTINUED
Figure 294
Continued on Page 106
Remove the inner thrustwasher and bearing
Internal wire harness to case retainer
Figure 81Manual shaft
218. Install a new o-ring on the plastic part of the wiring harness, install it back thru the case, and place the retainer in the groove as shown in Figure 294.
220. Install the two connector retaining bolts and torque to 14-22 ft.lb. Note: the bolt lengths are 20mm long. Install the manual lever and the retaining nut and torque to 7-10 ft.lb. See Figure 296.221. Install the valve body on to the case and align the manual valve link into the manual shaft as shown in Figure 297.
219. Install the transmission range switch over the manual shaft and align the flats on the shaft with the dotted line on the transmission range switch as shown in Figure 295. Torque bolts A and B to 14-22ft.lb. Note: the bolt lengths are as follows, A = 21mm long and B = 32mm long.
Manual lever
Transmissionrange switch
Figure 295
Figure 296
Flats on themanual shaft
A
B
Figure 297
1-P1-P
THE END OF THE MANUAL VALVE IS FLUSH WITH THE END OF THE VALVE
BODY CASTING, WHEN THE SELECTORIS IN THE "PARK POSITION"
MANUAL VALVELINK
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TRANSMISSION REASSEMBLYCONTINUED
Figure 298
Copyright © 2004 ATSG
A
A
B
B
B
B
C
C
C
222. Install the 10 mm headed valve body to case retaining bolts as shown in Figure 298.Torque to 7-11 ft.lb. Note: bolt lengths are as follows, A = 16mm long, 50mm long and C = 55mm long.223. Install the four solenoid connectors shown in Figure 299. Note: The internal wire colors are listed below each solenoid.224. Apply a thin coat of sealant to the case half and install the side pan. Install the nine pan bolts and torque to 7-11ft.lb. Note: the bolt lengths are 15mm long. Install the temperature sensor. See Figure 300.
S2black
STHtan/blue
SLred
S1white
Tempsensor
Remove the 9 pan bolts
Figure 299
Figure 300
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